HEIDENHAIN TNC 415 User manual

RGB ELEKTRONIKA AGACIAK CIACIEK
SPÓŁKA JAWNA
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Poland
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www.rgbelektronika.pl
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236 484 10
23648410, 236484 10, 236 48410, 236 484 10
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January 98 208 732 21 · 6.5 · 1/98 · S · Printed in Germany · Subject to change without notice
(208 732 E2)
Technical Manual
TNC 407
TNC 415
TNC 425
Valid for the NC software types
259 96 (TNC 415 A)
259 97 (TNC 415 E)
243 02 (TNC 407)
up to version 09
and
259 93 (TNC 415 B/TNC 425)
259 94 (TNC 415 F/TNC 425 E)
243 03 (TNC 407)
up to version 12
and
280 54 (TNC 415 B/TNC 425)
280 56 (TNC 415 F/TNC 425 E)
280 58 (TNC 407)
up to version 06

01.98 TNC 407/TNC 415/TNC 425
Preface
This Technical Manual is intended for manufacturers and distributors of machine tools.
It contains all the necessary information for the assembly, electrical installation, start-up and
PLC-programming for the HEIDENHAIN contouring controls.
When hardware or software is improved in these HEIDENHAIN contouring controls you will
receive a free delivery of updated information. Please arrange and insert this updated information
in your manual without delay. This will ensure that your manual always remains at the current
revision level.
You can use extracts from this manual for your machine documentation. An enlargement of the
manual format (17 cm x 24 cm) by a factor of 1.225 will produce pages in DIN A4 format.
No documentation can be perfect. Like all living things it must grow and change. Among other
things, it lives from your impulses and suggestions for improvement. Please help us by letting
us know your ideas.
DR. JOHANNES HEIDENHAIN GmbH
Department PE
PO Box 1260
D-83292 Traunreut
Germany

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11
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Contents Technical Manual TNC 407, TNC 415 B, TNC 425
Update Information
Introduction
Mounting and Electrical Installation
Machine Integration
Machine Parameters
Markers and Words
PLC Programming
Data interfaces
Original Equipment Manufacturer’s (OEM) Cycles
Positioning Module
TNC 425
Appendix

01/98 TNC 407/TNC 415/TNC 425 Update Information No. 20 1-1
Update Information No. 20
New NC software
In May 1996 the following new NC software versions were released:
TNC 407 280 58x 06
280 590 06
TNC 415B / TNC 425 280 54x 06
280 550 06
TNC 415F / TNC 425E 280 56x 06
280 570 06
Hardware
New Design for TNC 407
A new hardware design was introduced with the new TNC 410, TNC 426 and TNC 430 controls.
This changed design can also be used for the TNC 407. The visual display unit and keyboard unit
with the new design are gray in color and require a larger front-panel cutout.
The new BC 120 visual display unit is connected to the TNC 407 with a new cable
(Id. Nr. 312 878 ..) and adapter (Id. Nr. 313 434 02). The matching TE 400 B keyboard unit has the
Id Nr. 313 038 02. A matching gray MB 420 machine operating panel (Id. Nr. 293 757 12) is also
available.
Documentation
No replacement pages will be issued for this Technical Manual. You will find the updated
documentation on the CD-ROM entitled “TNCguide OEM” (Id. Nr. 208 935 92), available from
January 1998. Please contact HEIDENHAIN if you have not yet received this CD-ROM.

01.98 TNC 407/TNC 415/TNC 425 2-1
Introduction – Contents 2
1 Hardware concept 2-2
2 Technical data TNC 407/TNC 415 B/TNC 425 2-3
3 Software 2-7
3.1 NC-Software 2-7
3.1.1 NC-Software number 2-7
3.1.2 Software types 2-7
3.1.3 Software option 2-8
3.1.4 Software/Hardware 2-9
3.2 PLC-Software 2-11
3.3 EPROM sockets 2-11
3.3.1 TNC 415 A/TNC 415 E 2-11
3.3.2 TNC 415 B/TNC 415 F and TNC 425 A/TNC 425 E 2-12
3.3.3 TNC 407 2-13
3.4 Software replacement 2-13
3.5 Releases 2-14
3.5.1 Software types 243 05, 259 91 and 243 07 2-14
3.5.2 Software types 259 96, 259 97 and 243 02 2-14
3.5.3 Software types 259 93, 259 94 and 243 03 2-18
3.5.4 Software types 280 54, 280 56 and 280 58 2-23

2-2 TNC 407/TNC 415/TNC 425 1 Hardware concept 01.98
1 Hardware concept
The HEIDENHAIN-contouring controls TNC 407 and TNC 415 are designed for use with drilling and
milling machines.
The HEIDENHAIN-TNCs consist of several units. The principal subassembly is the logic unit. The logic
unit is joined to the other units and the TNC accessories by connecting cables.
Encoders
Noml. value outputs
PLC I/0 unit
Visual display unit
TNC keyboard unit
Touch probe
Electronic handwheel
Data interfaces
NC PLC
Common
data area
Machine operating panel
PLC outputs
PLC inputs
• • •• • •
• • •• • •
The logic unit contains the electronics for both the NC and the PLC sections of the control.
The common data area contains the machine parameters and the PLC markers and words. The
machine parameters define the hardware configuration of the machine (ranges of travel, acceleration,
number of axes etc.). The PLC markers and words are used for the exchange of information between
the NC and the PLC.

01.98 TNC 407/TNC 415/TNC 425 2 Technical data TNC 407/TNC 415 B/TNC 425 2-3
2 Technical data TNC 407/TNC 415 B/TNC 425
TNC 407 TNC 415B/TNC 425
Axes 3, 4 or 5 plus spindle S1)
(NC axes and PLC axes can be defined as desired)
Program input In HEIDENHAIN Plain Language and to DIN/ISO
Memory for 6000 blocks approx. 12 000 blocks approx.
part program
Positions Nominal positions in Cartesian or polar coordinates,
dimensions absolute and incremental
Input and display to 1 µm to 0.1 µm
resolution
Interpolation
Linear interpolation 3 of 5 axes 5 of 5 axes
Circular interpolation 2 of 5 axes 3 of 5 axes 1)
Helix Yes
Rigid Tapping Yes1)
Block processing time2) 25 ms 4 ms
Look Ahead •Defined rounding of discontinuous contour transitions (e.g. 3D surfaces)
•Collision viewing with the SL cycle for "open" contours
•Advance calculation of geometry for feed-rate adjustment
Free contour In HEIDENHAIN Plain Language with graphic support
programming FK
Coordinate Shift and/or rotate coordinate system, mirroring, reduce and enlarge -
transformations also axis-specific
Tilting the – Yes1)
working plane
Subprogram Program section repeats, subprograms, program calls
functions
Fixed cycles Pecking, tapping, slot cutting, rectangular and circular pockets,
SL cycles (milling cycles whose contour descriptions are stored in
subprograms); the machine tool manufacturer can also integrate
customized macros1)
1) These functions must be implemented by the OEM.
2) 3D-straight line without radius compensation

2-4 TNC 407/TNC 415/TNC 425 2 Technical data TNC 407/TNC 415 B/TNC 425 01.98
TNC 407 TNC 415 B/TNC 425
Q-Parameters Mathematical functions (=, +, -, x, ÷, sin α, cos α, angle αfrom sin α
and cos α, a, a2+ b2, tan α, arcsin, arctan, arccos, an, en, ln,
log, absolute value of a number, the constant π, negation, truncate places
before or after the decimal point)
logical comparisons (=,≠, >, <),
Parenthetical calculations
Program test By graphic simulation of the part program
Parallel operation Yes, no graphics Yes, with graphics
File management up to 100 files: programs in HEIDENHAIN and DIN/ISO format, also tool 1),
PLC datum shift, pallet tables1) and text files
Tool compensation Tool length, tool radius in machining plane
– Three-dimensional tool
compensation with surface
normal vectors
Central tool file Various tool tables for 254 tools max. each, with flexible pocket coding,
tool life monitoring and sister tool organization1)
Data interfaces V.24/RS 232 C and V.11/RS 422
•"Blockwise transfer": programs that exceed the control capacity can be
downloaded block by block and simultaneously executed.
•Extended data interface with LSV/2 protocol for external TNC operation
across the data interface
Baud rate 38400; 19200; 9600; 4800; 2400; 1200; 600; 300; 150; 110
Keyboard TE 400 with integral QWERTY keyboard
Screen BC 110 14" colour monitor 640 x 490 pixels
Logic unit LE 407 LE 415B / LE 425
Axis control Feed pre-control or operation with servo lag
–TNC 425: additional digital speed control
Cycle times
Contour interpolation 6 ms 3 ms
Fine interpolation – TNC 415 B: 0.6 ms (contour)
TNC 425:0.6 ms (speed)
Position control 0.1 µm
resolution
1) These functions must be implemented by the OEM.

01.98 TNC 407/TNC 415/TNC 425 2 Technical data TNC 407/TNC 415 B/TNC 425 2-5
TNC 407 TNC 415 B/TNC 425
Integral PLC
PLC inputs 56 + 1 "Control is ready" input; (Option: + 64*)per PL)
PLC outputs 31 + 1 "Control is ready" output "; (Option: + 31*)per PL)
.Two PL 410 max. can be connected
Option: analog inputs
±10 V 4 per PL 4101)or PA
Option: Inputs for
thermistors
4 per PL 4101)or PA
PLC program memory Approx. 8000 logic commands
PLC cycle time 24 ms 20 ms
Error compensation •linear axis error compensation
•non-linear axis error compensation
•compensation of reversal spikes in circular movements
•compensation of thermal expansion
•backlash compensation
•stiction compensation
•offset compensation
Position encoders HEIDENHAIN incremental linear and angle encoders (preferably with
distance-coded reference marks)
also HEIDENHAIN incremental rotary encoders
Reference mark Following a power interruption, automatic reference value input if
evaluation reference marks are traversed
Max. traverse ± 100 000 mm
Max. traversing 300 m/min
speed
Feed-rate and 0 to 150% with two potentiometers at the control panel
spindle override
Accessories
Electronic handwheel 1 x HR 330 Portable handwheel
or 1 x HR 130 Integral handwheel
or up to 3 x HR 150 Integral handwheel with adapter HRA 110
Diskette unit FE 401
Touch trigger 3D probe TS 120/TS 511
Measuring 3D probe — TM 110
Touch probe for tool TT 110
inspection
*) PL 410 B: Active analog inputs reduce the number of PLC inputs by 8 and the number of PLC outputs by 2.

2-6 TNC 407/TNC 415/TNC 425 2 Technical data TNC 407/TNC 415 B/TNC 425 01.98
TNC 407 TNC 415 B/TNC 425
Digitizing •With TS 120 touch trigger 3D probe
with optional software •With TM 110 measuring touch probe
module in TNC
Export versions TNC 415F / TNC 425E:
Linear interpolation 4 of 5 axes,
input/display resolution 1 µm
Power consumption
NC 24 W approx. 36 W approx.
PLC 6 W approx.
PL 410 B 25 W approx.
BC 110 B 70 W max.
Ambient
temperature
Operation 0 to 45°C
Storage –30 to 70°C
Weights
Logic unit 8.0 kg 10.0 kg
TE 400 2.4 kg
BC 110 B 11.0 kg
PL 410 B 3.1 kg

01.98 TNC 407/TNC 415/TNC 425 3 Software 2-7
3 Software
The logic unit contains separate software for the NC section and the PLC section. The software is
identified by an 8-figure number.
After switching on the control, the NC, PLC and Software-Options software numbers are displayed on
the screen. The software number can also be directly requested with the aid of the MOD function.
3.1 NC-Software
3.1.1 NC-Software number
The 8-figure NC software number identifies the type of control, the dialog language (language of the
country) and the version of the software.
Software type
259 96 0 01
National language
Software version
0 = German
1 = Czech
2 = French
3 = Italian
4 = Spanish
6 = Swedish
7 = Danish
8 = Finnish
9 = Dutch
In addition to the above-listed languages, the TNC can always use English, which may be selected via
the machine parameter MP7230.
3.1.2 Software types
Due to restrictions on the export of the TNC 415 B, HEIDENHAIN can also deliver a special export
version. This export version is differentiated from the standard control through the installed software
type. With this software type, the control offers different features in respect of linear interpolation and
the entry/display resolutions.
Linear interpolation Entry/Display
Resolution
TNC 415 B (Standard) 5 of 5 axes up to 0.1 µm
TNC 415 F (Export) 4 of 5 axes up to 1 µm
The TNC 407 does not fall under the export restrictions, therefore no export version is necessary.

2-8 TNC 407/TNC 415/TNC 425 3 Software 01.98
New functions will be introduced only in the following software types:
TNC 415B / TNC 425: 280 54
TNC 415F / TNC 425 E: 280 56
TNC 407: 280 58
These software types are therefore supplied as standard.
3.1.3 Software option
HEIDENHAIN offers the "Digitising with TS 120" function as a software option (see chapter "Machine
integration"). An additional software protection module is installed in controls supplied with this
software option. The Id.-Nr. of the logic unit indicates another version. If the software module is
installed, the option is indicated on the screen under the NC and PLC software numbers.
Logic units that have already been delivered can be retrofitted with the software protection module.
Please contact HEIDENHAIN if you wish to buy this option for your existing control. The proper
component model must be ordered for a specific hardware model.
Digitizing with TS 120:
Id.-Nr. of the installation kit Id.-Nr. of software module NC software
TNC 407 265 313 01 243 02, 243 03, 280 58
TNC 415A 265 314 01 246 051 01 259 96
TNC 415B
TNC 425
286 405 01 280 54
Digitizing with TM 110:
Id.-Nr. of the installation kit Id.-Nr. of software module NC software
TNC 415B
TNC 425
286 405 02 246 051 03 280 54

01.98 TNC 407/TNC 415/TNC 425 3 Software 2-9
3.1.4 Software/Hardware
Various hardware versions of the logic units LE 407 and LE 415 have until now been delivered (please
refer to the chapter 3 ”Mounting and electrical installation” section 1). The new software types are not
compatible with all hardware versions. The valid combinations are shown in the following tables.
TNC 415A / TNC 415E:
Software T
yp
e
Id.-Nr. LE 243 05 259 91 259 96 259 97
251 481 78 415 E ---X
251 481 79 415 A - - X -
251 481 88 415 E - X - X
251 481 89 415 A X - X -
251 481 98 415 E - X - -
251 481 99 415 A X - - -
258 993 78 415 E - - - X
258 993 79 415 A - - X -
258 993 88 415 E - X - X
258 993 89 415 A X - X -
258 993 98 415 E - X - X
258 993 99 415 A X - X -
264 429 78 415 E - - - X
264 429 79 415 A - - X -
264 429 98 415 E - X - X
264 429 99 415 A X - X -
TNC 415B / TNC 415F: TNC 425 / TNC 425E:
Id.-Nr.: 267 223 xy Id.-Nr.: 267 214 xy
x = Identifier for hardware change
y = Version
3 = Export version with software module "Digitizing with TS 120"
4 = Standard version with software module "Digitizing with TS 120"
7 = Standard version with software module "Digitizing with TS 120"
8 = Export version without option
9 = Standard version without option

2-10 TNC 407/TNC 415/TNC 425 3 Software 01.98
TNC 407:
Software Type
Id.-Nr. of the LE 243 07 243 02 243 03 280 58
256 113 99 X - - -
255 444 79 - X X X
255 444 89 X X X X
255 444 99 X X X X
261 092 79 - X X X
261 092 89 X X X X
261 092 99 X X X X
264 430 24 X X X X
264 430 29 X X X X
264 430 79 - X X X
264 430 99 X X X X

01.98 TNC 407/TNC 415/TNC 425 3 Software 2-11
3.2 PLC-Software
The PLC software is produced by the manufacturer of the machine. Either HEIDENHAIN or the
manufacturer of the machine can store this software in EPROMs. HEIDENHAIN assigns PLC software
numbers to the machine manufacturers on request. HEIDENHAIN can archive the specific PLC
programs in a data bank, so that the installation of the correct PLC program is assured if a control has
to be exchanged.
The PLC EPROM must be written in the format of the corresponding software type!
Beginning with software types 280 54, 280 56 and 280 58, either a 1 MB or a 2 MB
EPROM can be used for the PLC.
3.3 EPROM sockets
3.3.1 TNC 415 A/TNC 415 E
Sockets on processor board:
IC 1 IC 2
NC IC 5 NC IC 6 NC
IC 3
NC IC 4 NC
IC 8
PLC
IC 7
Language
1 MB
1 MB
1 MB 1 MB
1 MB 1 MBNC 1 MB 1 MB
Sockets on CLP board:
IC 9
Boot
IC S
SW-Module

2-12 TNC 407/TNC 415/TNC 425 3 Software 01.98
3.3.2 TNC 415 B/TNC 415 F and TNC 425 A/TNC 425 E
Sockets on processor board:
IC 1 IC 2
NC IC 5 NC IC 6 NC
IC 3
NC IC 4 NC
IC 8
PLC
IC 7
Language
1 MB
1 MB
1 MB 1 MB
2 MB 2 MBNC 1 MB 1 MB
Set jumper to 2M
or
Sockets on processor board:
IC 1 IC 2
NC IC 5 NC IC 6 NC
IC 8
PLC
IC 7
Language
1 MB
1 MB
4 MB 4 MBNC 1 MB 1 MB
Set jumper to 4M
Sockets on CLP board:
IC 9
Boot
IC S
SW-Modul

01.98 TNC 407/TNC 415/TNC 425 3 Software 2-13
3.3.3 TNC 407
Sockets on processor board:
IC 5
PLC 1MB
IC S
SW-Module
IC 3
Language 1MB
IC 4
Language 1MB
IC 12MB
IC 2
NC 2MB
3.4 Software replacement
Before replacing the software on a TNC the data of all file types, the machine parameter list, the non-
linear axis error compensation table and the PLC program (if in the RAM) must be backed up.
You can use the TNC BACKUP routine to do this. In the "Machine Parameter Editor" mode (code
number 95 148) press the MOD key to display the menu for configuring the data interface. The
"BACKUP DATA" and "RESTORE DATA" soft keys will be offered.
Use "BACKUP DATA" to transmit all operating parameters and the data of all file types across the data
interface and store them in the $BACKUP.ANC file. When software replacement is complete, use
"RESTORE DATA" to download the data to the TNC again.

2-14 TNC 407/TNC 415/TNC 425 3 Software 01.98
3.5 Releases
New NC software versions are released by HEIDENHAIN at irregular intervals.
3.5.1 Software types 243 05, 259 91 and 243 07
Standard version TNC 415 A
NC-Software-Version Release
243 05x 02 2/90
243 05x 03 4/90
243 05x 04 5/90
243 05x 05 8/90
243 05x 08 9/90
243 05x 10 2/91
243 05x 11 4/91
243 05x 12 5/91
243 05x 13 6/91
243 05x 14 11/91
243 05x 15 3/92
243 05x 16 7/93
Export version TNC 415 E
NC-Software-Version Release
259 91x 08 11/90
259 91x 10 2/91
259 91x 11 4/91
259 91x 12 5/91
259 91x 13 6/91
259 91x 14 11/91
259 91x 15 3/92
259 91x 16 7/93
TNC 407
243 07x 03 7/90
243 07x 05 10/90
243 07x 07 2/91
243 07x 08 4/91
243 07x 09 5/91
243 07x 10 6/91
243 07x 11 11/91
243 07x 12 3/92
243 07x 13 7/93
New releases of these software types will be
made only to correct errors.
3.5.2 Software types 259 96, 259 97 and 243 02
TNC 415 A: 259 96x 01
TNC 415 E: 259 97x 01
TNC 407: 243 02x 01 Release 8/91
New functions:
– Digitising with TS 120
– Rigid tapping
– Input resolution and display step 0.0001 mm for TNC 415 A
– Re-approaching the contour
– Compensation of reversal spikes in circular movements
– New format for PLC-EPROM
– Machine parameter editor
– FN15: PRINT
– New machine parameter for setting screen colours