MANUALplus 620
The Control for CNC andCycle Lathes

03/2019

MANUALplus 620
with 15.6-inch touchscreen andmachine operating panel

Windows 7, Windows 8, and Windows 10 are trademarks ofMicrosoft Corporation
Options are functions that are integrated into the control and thatallow you to tailor the feature range of the MANUALplus 620 toyour actual requirements, including retroactively if necessary.
Some options need to be adapted by the machine tool builder.
The features and specifications described here apply to thefollowing control and NC software versions:
MANUALplus 620 with NC software version
548431-06 (no export license required)This brochure supersedes all previous editions, which thereby
become invalid. Subject to change without notice.

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Contents

The MANUALplus 620...
Compact and versatile

4

Intuitive and user-friendly

6

Universally applicable

8

Easy machining with cycles (option)

10

Well thought out, simple, and flexible

14

Describing and importing contours

18

Realistic testing before machining

20

Expandable for complex tasks

22

Rapid availability of tool data and cutting data

28

Reliable machining

30

Open for communication

31

What accessories are there? Workpiece measurement– Setup, presetting, and measuring with touch trigger probes

35

Where can it be used?

– MANUALplus 620, the control for CNC and cycle lathes
What does it look like?

– The MANUALplus 620 in dialog with the user
What can it do?

– The right programming mode for every task

– Preprogrammed machining steps– From single parts to series– Simple programming with smart.Turn (option)– NC program at the stroke of a key with TURN PLUS (option)– Interactive Contour Programming (ICP) (option)– Graphic simulation– Full-surface machining including the C axis and Y axis (option)– Turning, drilling, and milling in one setup (option)– Working in a tilted plane with the B axis (option)– The tool database and technology database of the MANUALplus 620– Intelligent supervision with Load Monitoring (option)– Rapid availability of all information– Connected Machining– The DataPilot MP 620 programming station

Tool measurement

36

Overview

37– Measuring the length, radius, and wear directly in the machine... At a glance– User functions– Options– Accessories– Specifications

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Compact and versatile– MANUALplus 620, the control for CNC and cycle lathes

The MANUALplus 620 is a compact andversatile contouring control that isparticularly well suited for cycle-controlled
lathes. The MANUALplus 620 optimallycombines the ease of use of conventional
lathes with the advantages of CNCcontrolled machines.
Regardless of whether you are
manufacturing single parts or batches orwhether your workpieces are simple orcomplex, the control adapts to the needsof your company. The MANUALplus 620
is characterized by its simple operationand programming. It is easy to learn andrequires minimum training time.

MANUALplus 620 for cycle lathes
On the MANUALplus 620, rework or simple
tasks can be done in the same way as on aconventional lathe. You move the axes in
the familiar way by turning the handwheels.
For difficult cuts such as tapers, undercuts,or threads, you can utilize the cycles of the
MANUALplus 620. This makes getting
started with automated production very
easy even for conventional lathe operators
without previous knowledge of NC
technology.

MANUALplus 620 for cycle lathes

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For small and medium-size production
runs, you have the benefit of cycle
programming. When machining the first
workpiece, you can record the machining
cycles and thereby save valuable time
starting immediately with the second
workpiece.
For increased requirements and complex
machining tasks, you will profit from theprogramming mode smart.Turn.

MANUALplus 620 for CNC lathes
Regardless of whether you are turning
simple parts or complex workpieces, the
MANUALplus 620 provides you with thebenefits of graphical contour input andconvenient programming with smart.Turn.
Programming with variables, controlling
special machine components, or using
externally created programs, etc. is no
problem: simply switch to DIN PLUS. In
this programming mode, you will find thesolution to your specialized tasks.

The MANUALplus 620 is designed forboth CNC and cycle lathes and is suitablefor horizontal and vertical machines. The
MANUALplus 620 supports lathes withsimple tool holders and lathes with tool
turrets. The tool carrier of horizontal lathes
can be located in front of or behind theworkpiece.

Compatibility
You can also run existing NC programsfrom old HEIDENHAIN lathe controls on
the MANUALplus 620. With a convenient
import filter, you can easily transfer older
programs (e.g., from the CNC PILOT 4290)
to the new control for continued use.

The MANUALplus 620 supports lathes
with main and counter spindle, one slide(X and Z axis), C axis or positionable spindle,
and driven tools as well as machines with
Y and B axes.

Milling operation with the Y axis on a CNC lathe

5Intuitive and user-friendly– State-of-the-art multitouch operation and clear-cut display

The screen
The MANUALplus 620 is equipped with apractical 15.6-inch touchscreen designed
for harsh shop conditions. It is splash-proof,
scratch-resistant, and features an IP54
protection rating. The screen can be operated
with gestures like those commonly usedon your smartphone or tablet.
The MANUALplus 620 gives you a clear
view of all the information you need inorder to program, operate, and check thecontrol and machine, including NC blocks,
informational texts, error messages, etc.
While you are inputting the program, therequired parameters are explained throughhelp graphics. In the simulation, all
movements of the tool are displayed inrealistic detail. During program run, the
MANUALplus 620 shows you complete
information on the tool position, speed,
and load of the drives, as well as thecurrent machine status.
The keyboard
The MANUALplus 620 needs very few
keys, and their functions are clearly
indicated by easily understood symbols.
The numeric keypad is used both for
inputting data and for selecting functions.
The menu window graphically displays theavailable functions. You can use soft keys
to modify the selected functions, confirm
position and technology values, and control
the data input.
For easy entry of program names, tool
texts, comments, etc., an ASCII keyboard
can be displayed.

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Ergonomic and sturdy design
The optimized stainless-steel operating
panel of the MANUALplus 620 features a
special protective coating and is thus
particularly resistant to contamination andwear. The labeling of the ergonomicallyformed keys can withstand extreme shop
conditions. With the handy control knobs,
you can make fine adjustments to the feed
rate and spindle speed.
Intuitive touchscreen operation
The conventional means of operating the
MANUALplus 620 has proven itself overmany years. Users around the world
operate their MANUALplus 620 controls
using its dialog keys, navigation keys, andsoft keys.
In a touchscreen version, the
MANUALplus 620 now supports you witha particularly innovative and user-friendly
operating interface. It combines the provenadvantages of the HEIDENHAIN controls
with a new type of operation by tapping,swiping, and dragging.
Practical touchscreen
The touchscreen is ideally suited to a shop
environment. It can still be operated evenwhen exposed to cooling lubricant, oil, etc..
If you wish to clean your screen, you cansimply select the “Touchscreen Cleaning”
mode to lock it. The touchscreen can also
be operated with different types of work
gloves.

PLC soft keys for machine functions
Operating modes
Display of the machine status. The display
is configurable. You can select the suitabledisplay field for each of the 16 segments
and save different display fields for the
automatic and manual modes.

Straightforward input forms for cycle
programming, smart.Turn programming, or
DIN PLUS programming. Help graphics
illustrate the inputs during NC programming

Self-explanatory soft keys for the current
operating mode
Operating panel with the option of switching
between a numerical keypad and a small
ASCII keyboard, function keys for switching
the dashboard, HEROS system menu,
calculator, help keys, and much morebesides
Machine operating panel with override
potentiometerGestures for multitouch operation
The screen of the MANULplus 620 can be
operated with gestures like those commonlyused on your smartphone or tablet. For
example, you can zoom in and out with
two fingers, while swiping allows you toquickly navigate through soft-key rows,
programs, and menus.

SymbolGestureTap
Double tap
Long press
Swipe

Drag

Two-finger dragSpreadPinch

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Universally applicable– The right programming mode for every task

With its various programming operating
modes—cycle programming, smart.Turn,and DIN PLUS—the MANUALplus 620
always provides the right support for yourtasks.

Regardless of whether you want to perform
rework or machine a single part on a cycle
lathe, the cycles of the MANUALplus 620
will simplify your tasks. For manufacturingbatches, you can create a cycle program bysaving your cycles while machining the first

Manual• Simple, non-repetitive machining tasks• Rework• Thread repair

workpiece. And for more demanding tasks,
the effective smart.Turn programming modeis there to help you create NC programswith speed and ease.

Teach-in• Manual-oriented machining of small andmedium-size production runs
• Graphic description of complex contours

Machining with cycles

Machining with cycles

Define the cycle

Define the cycleSimulate the cycle

Simulate the cycleMachine the workpiece

Machine the workpieceSave the cycleFinished cycle program

Manual cycle

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Teach-in cycle

For work on CNC lathes, creating programswith smart.Turn is recommended. This
programming mode from HEIDENHAIN isbased on input forms and allows you tocreate structured and easy-to-read NC
programs. In these programs, you caneven store all of the setup informationneeded for machining the workpiece.

smart.Turn• Convenient smart.Turn programming• Graphic contour description• Numerous machining units• Compatible with cycle programs• Clearly structured and easy-to-readprograms• All required data contained in therespective working block

And if you program with variables, need tohandle special requirements, or want touse externally created NC programs, thenDIN PLUS will give you the right support.

DIN PLUS• Familiar DIN programming• Graphic contour description• Numerous fixed cycles• Variable programming and subprograms• Resolving smart.Turn units into DIN
commands• Compatible with externally created DIN
programs

smart.Turn

DIN PLUS

Create smart.Turn program

External programming

Simulate smart.Turn program

Resolve a smart.Turn unit

Finished smart.Turn program

Edit the DIN program










Simulate the DIN program

Finished DIN program

smart.Turn cycle

DIN PLUS cycle

9Easy machining with cycles (option)– Preprogrammed machining steps

With the MANUALplus 620, you canperform simple operations such as turning
or facing by means of a handwheel, just as
with a conventional lathe. All standard
machining operations, such as area clearance,
slot milling, recess turning, undercutting,parting, thread cutting, boring, drilling, andmilling are stored in the MANUALplus 620
as cycles. You simply enter the positions,dimensions, and specifications, and thecontrol will automatically run the machining
program.
Manual workpiece machining
The MANUALplus 620 simplifies manual
turning with numerous functions, without
requiring you to learn complicated procedures. This enables you, for example, to­adjust the feed rate and spindle speed
steplessly during machining, to machinewith preset tools, or to part with constantcutting speed.
Workpiece machining with cycles
For simple, non-recurring tasks, rework,thread repair, or small production runs, thecycles of the MANUALplus 620 simplify
your work.
Help graphics and dialogs illustrate the few
entries that are needed for the cycles.
Before cutting, use the simulation to makesure that the machining operation will run
as planned.

Thread cutting—three times faster with a cycle

Turning cylinders manually:
You work as usual with the handwheels and the position display on thescreen.

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Turning tapers automatically:
You enter the dimensions, and the MANUALplus 620 will move the saddle
and cross-slide automatically.

Fewer calculations
The MANUALplus 620 automaticallycalculates the number of cuts for roughing,recessing, recess turning, and thread
cutting. For pecking, it determines therequired number of infeeds. When turninga taper, you can enter either the starting
point and end point or the starting point
and the taper angle—whichever is shownon your drawing.

Technology data as suggested values
The MANUALplus 620 saves the cutting
data according to the criteria of workpiecematerial, tool material, and machining
mode. Because you have already entered
the cutting material in the tool definition,
you need only enter the material of yourworkpiece. This provides the cycle with allof the data required for suggesting the
cutting data.

Continuous availability of tool data
The MANUALplus 620 uses a tool database.
Tool data such as cutting radius, tool angle,
and point angle must only be enteredonce, and you can determine the setting
dimensions via touch-off, for example. The
MANUALplus 620 saves the data. The nexttime you use the tool, you simply call thetool number; the MANUALplus 620
automatically adjusts for the correct toolsize, and you can immediately work todimension.

Presets
You can define the workpiece datum bytouching the workpiece with the tool or byentering the datum coordinates.

When turning a contour, the­MANUALplus 620 automatically compensates for the deviations from the cutting-­edge radius. This increases the precisionof your workpiece.

Approach the tool change point once andstore this position. Afterwards, a simple
cycle call suffices to return to the toolchange point.
Protective zone for the spindle
For every tool movement in the negative
Z direction, the MANUALplus 620 checks
whether the programmed protective
zone will be violated. If so, it stops the
movement and responds with an error
message.

Running a cycle to cut a thread automatically:
Call the appropriate fixed cycle and enter the dimensions.
The MANUALplus 620 will perform all of the work steps automatically.

11Easy machining with cycles (option)– From single parts to series

The first workpiece
Machine the workpiece cycle for cycle in theusual way, and save the machining steps.
When you have finished machining, you thensave the created cycle program. By thismeans, you can create the working plan for
the workpiece. The MANUALplus 620
displays the individual machining steps inthe proper sequence on the screen.
Repeating individual cycles
After you have saved the cycles for a part,you can always go back later to edit ordelete the steps used to machine it, or toinsert new steps.
You can save a great deal of time with the
MANUALplus 620 when using this feature
to produce a family of parts, for example.
Saving your work for the next partYou can save all of the cycles and rerun
them automatically. For each additional
machined part, you save time and cost.

1. Transverse turning

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2. Longitudinal turning

Cycles for turning
You will always find the appropriate cycle inthe cycle menus of the MANUALplus 620.
Help graphics and dialogs explain the work
step, the required dimensions, and any
additional entries. After entering thesevalues, you can graphically inspect the
cutting process and let the operation run
automatically.

Turning—cutting and finishing
Longitudinal/transverse cutting for simple
contours

Longitudinal/transverse cutting withplunging

Longitudinal/transverse ICP cutting forany contours

Longitudinal/transverse ICP contourparallel cutting
Threads and undercuts
Single- or multi-start longitudinal,
taper, or API threads

Recessing and recess turning—cutting and finishing
Radial/axial recessing for simple contours

Undercuts as per DIN 76,
DIN 509 E, or DIN 509 F
Longitudinal/transverse recess turningfor simple contours
Undercuts and parting

3. Finishing

Undercut form H, form K,or form U

Radial/axial ICP recessing for any
contours

Parting

Longitudinal/transverse ICP recess
turning for any contours

4. Threading with
undercut and chamfer

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Well thought out, simple, and flexible– Easy programming with smart.Turn (option)

Has the safety clearance been correctly
entered, is the speed limit taken into account,and how are the oversizes defined? All ofthese items need to be considered not onlyby the beginner but also by the experienced
NC programmer when creating conventional
DIN programs.
The smart.Turn principle
The working block—called a unit—plays apivotal role in smart.Turn programs. A unit
completely describes and unambiguously
defines a single working step. The unit
includes the tool call, the technology data,
the cycle call, the approach and departure
strategies, and global data such as thesafety clearance, etc. All of these parameters
are summarized in a clearly structured
dialog box.
The smart.Turn principle gives you thereassurance that the working block is definedcorrectly and completely. In the NC program,smart.Turn lists the unit’s DIN PLUS
commands. This gives you an overview ofall working-block details at any time.

Programming made easy
With smart.Turn, you program with the aidof simple and intuitive fillable forms. The
overview form provides you with an overview
of the selected unit, while subforms provide
information on the details of a working block.
Clearly arranged help graphics illustrate allof the required inputs. If alternative inputs
are available, then smart.Turn displaysthem in a list, from which you can thenmake a selection.
Global program parameters, such as
oversizes, safety clearances, coolants, etc.,
are defined once in the start unit. Then
smart.Turn transfers these parameters to
the other units.
The smart.Turn programming mode
supports units for roughing, finishing,recessing, recess turning, thread cutting,boring, drilling, tapping, and milling,
as well as special units for program start,
program end, moving the C axis in/out,
subprograms, and program-section
repeats.
By the way, you do not need to stop the
manufacturing process to program withsmart.Turn. You can create and test thesmart.Turn program while the program is
actually running.

Overview form in smart.Turn

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Subform in smart.Turn

Structured and easy-to-read
Programs created with smart.Turn arecharacterized by their clear structure andeasy understandability. The smart.Turn tool
uses section codes that clearly distinguishbetween the program head with the setup
information, the turret assignment, theworkpiece description, and the actualmachining operation.
The smart.Turn method not only ensuresthat the program is easy to read; it also
makes it possible to save all of theinformation required for producing theworkpiece in the NC program.

Programming contours
Simple contours can be defined with just a
few entries in the cycle. Complex contours
are described with ICP graphical interactive
programming. Workpiece descriptions thatare available in DXF format can be easily
imported.
Contour follow-up
When you define the workpiece blank,
smart.Turn works with contour follow-up.
This means that the MANUALplus 620
calculates the newly created workpieceblank after every cut. The machining cycles
are thereby always conformed to thecurrent state of the workpiece blank. The
contour follow-up helps you to avoid air
cuts and to optimize approach paths, eventhrough space where workpiece material
has been removed.
Technology data as suggested values
The MANUALplus 620 saves the cutting
data according to the criteria of workpiecematerial, tool material, and machining mode.
Because you specify the cutting material in
the tool definition, you need only still enter
the material of your workpiece. This provides
smart.Turn with all of the data it needs inorder to set default values for the cutting
data.

Contour selection in ICP

Programming in DIN PLUS
The smart.Turn tool offers units for all
machining tasks, as well as units for special
functions.
However, if you wish to control special
machine components or use the variable
programming function or other complex
functions that are not provided by smart.Turn,
then use DIN PLUS. It provides powerfulmachining cycles, program branches, andprogramming with variables. Within aprogram, you can switch back and forth
between the smart.Turn and DIN PLUS
programming modes.
Because the units are based on DIN PLUS,
you can “resolve” a unit into blocks at any
time in order to modify and optimize theresulting DIN PLUS program section.
Of course, the MANUALplus 620 also allows
you to create a DIN program, or to importand use externally created programs.

Resolving a DIN PLUS unit

15

Well thought out, simple, and flexible– NC program at the stroke of a key with TURN PLUS (option)

With TURN PLUS, you can create NC
programs in very little time. After you havedescribed the contour of the workpieceblank and finished part, you need only
select the material and clamping devices.
TURN PLUS takes care of the rest
automatically: it generates the working
plan, selects the machining strategy,
selects the tools and cutting data, andgenerates the NC blocks.
The result is a comprehensively
commented smart.Turn program withworking blocks (units). This gives you
leeway for optimization and safety when
you first use the NC program.
TURNPLUS can do all this for boring, drilling,
and milling operations with the C or Y axison the front face and lateral surfaces aswell as on rear-face surfaces in machineswith counter spindles.

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The NC program at a keystroke
If short programming times are important,
you can generate all of the working steps
with only a single keystroke. Based on theentered contour and the information fromthe technology database, TURN PLUS
creates the working plan and selects suitablemachining strategies, tools, and cutting
data, all on its own. This only takes a few
seconds. You can monitor each individual
step in the control graphic. TURN PLUS
uses a reasonable sequence of possible
operations, such as “first roughingtransverse, then roughing longitudinal” or“finishing outside, then finishing inside.”
However, you can also adapt this sequence
on your own to suit various tasks. In thisway, the MANUALplus 620 can also
harness your company’s know-how during
automatic working plan generation.

Automatic program generation for thecomplete contour
The MANUALplus 620 can also automaticallygenerate the NC program for complex
workpieces that need to be machined on
the front face, rear face, and lateral surfaces.
After defining the geometry, you canbenefit from time savings of approximately
90 %—time otherwise needed for the
programming of the machining operations.
Automatic program generation for thesecond setup
TURN PLUS knows the contour of theclamping devices and takes it into accountwhen it generates the working plan. It thus
automatically limits the tool path to a safe
distance from the clamping device. Oncethe program for the first setup is completed,
you can “rechuck” using interactive graphics.
The control then automatically generates
the program for the second setup without
the workpiece geometry needing to be
re-entered.

Inclined contours are no problem
The control faces unique demands whenit comes to automatically generating the
NC program for inclined contours. Often,
the angle at which the contour falls off is
steeper than the tool tip angle. In this case,the control automatically selects a different
tool and performs the machining operationin the opposite direction or as a recess.
In any case, the result is an executable
NC program.

Defining the machining sequence
In the TURN PLUS dialog, you can define astandard machining sequence. You canstore various machining sequences, suchas for chuck parts, shaft machining, etc.
From the global main types of machining,such as “roughing,” “finishing,” or “drilling,”
to details such as defining a tool for a
specific operation, the automatic working
plan generation (AWG) feature can beadapted to the user’s requirements.

Technology
Material
Velocity
Feed rate

Tools

Go from programming to the first cut in the shortest possible time with TURN PLUS

17

Describing and importing contours– Interactive Contour Programming (ICP) (option)

For jobs that cannot be machined with thestandard cycles due to the complexity of theworkpiece or the lack of certain dimensions
in the workpiece drawing, you need ICP.
You describe the contour elements directlyas they appear in the workpiece drawing.
Or—if the drawing is available in DXF
format—you simply import the contour.
Contour programming with ICP
You define an ICP contour by entering thecontour elements one after the other in thegraphic editor. When selecting the contour
elements, you specify the direction of theline or the direction of rotation of thecircular arc. This way, the MANUALplus 620
requires very little information about thecontour element.
When entering the data, you decide
whether the coordinates are to be absoluteor incremental, and whether lines aredefined by their end point or length andcircular arcs by their center point or radius.
You also specify whether the path to thenext contour element should be tangential
or non-tangential.
The MANUALplus 620 calculates missing
coordinates, intersections, center points,
etc., provided that they are mathematicallydefined. If the entered data permit multiple
mathematically possible solutions, then
you can view the alternative proposals andselect the one you prefer. You can also add
to or modify existing contours.

18

Superimposing form elements
The ICP editor recognizes the chamfer,rounding, and undercut form elements(DIN 76, DIN 509 E, DIN 509 F, etc.). You
can enter these form elements during thecourse of the sequential contour definition.
However, it is often easier to first define
the “rough” contour and then superimpose
the form elements. This is done by selecting
the corner on which the form element is tobe placed and then inserting the element.

ICP contours for smart.Turn and DIN PLUS
In smart.Turn, you have various possibilities
for describing the contour to be machined.
You can describe simple contours rightwithin the unit, or you can use ICP for
complex turning or milling contours as wellas linear or circular drilling and milling
patterns. The contour defined with ICP isincorporated into the smart.Turn program.
Within the unit, you enter a reference tothe contour section to be machined.

ICP contours for cycle programs
In turning or milling operations, standard
contours are defined in the cycle. Complex
contours are described with ICP, and thisICP contour is then called in an ICP cycle
for roughing, recessing, recess turning, or
milling.

If you are working in DIN PLUS mode, you
can likewise use ICP to describe theturning and milling contours, as well as thelinear and circular patterns. In the contourrelated cycles, you enter a reference to thecontour section to be machined.

The ICP editor can be called directly during
cycle programming.

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  DXF import of contours (option)
Why should you painstakingly enter
contour elements if the data already exists
in the CAD system? ICP makes it possible
to import contours in DXF format directly
into the MANUALplus 620. Not only do you
save time that would otherwise be spenton programming and testing, but you also
ensure that the finished contour corresponds
exactly to the design engineer’s specification.
DXF contours can describe workpieceblanks, finished parts, contour trains, andmilling contours. They must be present as
two-dimensional elements in a separate
layer (i.e., without dimension lines, wraparound edges, etc.).
First, you download the DXF file to the
MANUALplus 620 over the network or
through a USB flash drive. Since the DXF
format is fundamentally different from the
ICP format, the contour is converted from
DXF to the ICP format during the import.
This contour is then treated as a normal
ICP contour, and is available for smart.Turn,DIN PLUS, or cycle programming.

19

Realistic testing before machining– Graphic simulation

Timely detection of errors is very important
for the production or repair of single parts.
With its graphic simulation feature, the
MANUALplus 620 supports you in checking
the program for errors—with exactness
and with the real dimensions of the contour
and cutting edge.
Graphic simulation
Before actual machining, you can use thegraphic simulation to inspect• the machining sequence,• the proportioning of cuts,• the finished contour,• the approach and departure behavior.
In the graphic simulation, you can display
the cutting edge. You can view the cuttingedge radius, width, and position rendered
true to scale. This helps you recognize
machining details or collision risks ahead oftime.
Wire-frame or cutting-path graphics,
machining simulation
The MANUALplus 620 supports various
views of the tool paths and machining
process. You can choose the type ofverification best suited to the tool or
machining process used.

Wire-frame graphics

20

The wire-frame graphics is particularly
convenient if you only need a quick
overview of the proportioning of cuts. The
wire-frame graphics illustrate the path of
the theoretical cutting point.
More accurate contour verification isprovided by the cutting-path graphics,
which account for the exact geometry of
the tool tip. You immediately see whether
material was left behind, the contour isdamaged, or the overlaps are too large.
The cutting-path graphics are particularly
helpful for recessing, boring, drilling, or
milling operations in which the tool shape
has a decisive influence on the final result.
The machining simulation (material removal
graphic) realistically demonstrates the cutting
process. The workpiece blank is shown asa filled-in surface. The MANUALplus 620
simulates every tool movement at its
programmed cutting speed and removes
the “machined” material.

Finished part in a 3-D graphic

Cutting-path graphics

Configuring the views
If your lathe is equipped with driven tools
and a positionable spindle, a C axis, or a
Y axis, then the MANUALplus 620 also
simulates machining operations on the front
face and lateral surface, or on the XY andYZ planes. You can select the combinationof windows best suited for the job. This
gives you everything you need for a precise
inspection of your boring, drilling, andmilling operations.
The MANUALplus 620 depicts C-axis
machining on the lateral surface on an“unrolled” plane surface.
3-D simulation
With the high-resolution and intricately
realistic 3-D simulation, you can precisely
evaluate the production results fromturning, drilling, or milling processes priorto actual machining. Milling and turning
operations are shown in different colors.

Machining the front face

The view, which is freely rotatable about
all axes, permits visual inspection of theworkpiece blank and finished part from all
angles. Thanks to intuitive mouse andkeyboard operation, you can navigate andzoom onto every programmed detail—including, of course, with C-axis contours
on the cylindrical surface or front face, andwith Y-axis contours in the tilted plane. In
this way, the 3-D simulation makes it possible
for you to detect even the smallest errors
prior to machining.
Calculating the machining time
If your customer needs an offer in a hurry,
and you require exact information withinvery little time, the MANUALplus 620 is avaluable aid with its machining time calculator.
During simulation of the smart.Turn or
DIN PLUS program, the MANUALplus 620
calculates the time required per piece forthe programmed machining work.
Along with the total time, the table displays
the machining time and idle time of eachcycle or each tool used. And this can help
with more than just cost calculations, since
you can also tell at a glance whether there
are ways to further optimize the machining
process.

Calculation of machining time21

Expandable for complex tasks– Full-surface machining including the C axis and Y axis (option)

The MANUALplus 620 provides a solution
for any machining task and any machine
configuration: it performs complex machining
tasks with a C or Y axis. It also controls fullsurface cutting on dual-spindle machines.
Likewise, for C-axis, Y-axis, and full-surface
machining, you can select from the DIN PLUS,
smart.Turn or Teach-in programming modes.
C axis or positionable spindle*
For more complex tasks, the
MANUALplus 620 can be expanded toadditionally support a C axis or positionablespindle and a driven tool. The driven tool
makes it possible to drill off-center and totap holes while the spindle is at rest. The
C axis or positionable spindle permits boring,
drilling, and milling operations on the front
face and lateral surface of the workpiece.
For the programming and inspection ofthese machining sections, the workpiece isshown in the front face view and in theunrolled lateral surface view.

Y axis*With the Y-axis option of the
MANUALplus 620, you can machineslots or pockets with plane floors andperpendicular slot walls. By defining thespindle angle, you can determine theposition of the milling contours on theworkpiece. For programming andverification of these machining sections,
the workpiece is shown in the side andfront face views. The Y axis is supported
in the smart.Turn and DIN programming
modes.
Dual-spindle option
For full-surface lathes, the MANUALplus 620
provides the following control features:• Counter spindle with second C axis
• Movable tailstock (W axis)
These features are complemented byadditional functions such as coordinatetransformation, spindle synchronization,and traversing to a stop surface.
*	The machine and MANUALplus 620 must be
adapted to this function by the machine tool builder.

Graphic contour programming for C-axis machining (boring, drilling,
and milling)

22

First clamping

Coordinate transformation
Contours of workpiece blanks and finishedparts can be mirrored about the X axis or
shifted in relation to the workpiece datum.
Spindle synchronization
Counter spindles are electronically coupled
and rotate synchronously. This makes it
possible to transfer the workpiece fromone spindle to the other while they arerotating, thereby saving time otherwise
spent braking and starting the spindles.
The MANUALplus 620 detects any angularoffset and compensates for it during
subsequent milling on the counter spindle.
Traversing to a fixed stop
To ensure that the workpiece is firmly
pressed onto the opposite spindle surface,
the control monitors the nominal and actual
positions while the longitudinal axis is inmotion and thereby detects the fixed stop.
The MANUALplus 620 monitors the
motor torque and uses it to achieve theprogrammed contact force.

Eccentric turning and non-circularturning*
The MANUALplus 620 offers convenient
cycles for eccentric turning and for the
manufacture of oval and polygonal parts.
In this case—besides the actual contour
machining—additional traversing movementsof the X and Y axes are superimposed insynchronism with the rotational movementof the spindle. The manufacture of cams
and non-circular parts is possible without
additional machine elements.

Hobbing of external gears
Cycle G808 HOBBING allows you to machineexternal cylindrical gears or helical gears in
any angle. During hobbing, the rotation of
the tool and the spindle are synchronized.
In addition, the gear hob moves along theworkpiece in axial direction. Cycle G808

automatically controls these complex
movements and allows you to easily andpractically enter all of the relevant values.
You can use gear parameters directly fromyour drawing, and the cycle will then use
them to calculate the sequence of motion.

* The machine and the control must be adapted to thisfunction by the machine tool builder.

S1/C1

S3/C2

S1/C1

W

Full-surface machining: counter spindle (S3) with C axis (C2) on secondary
axis (W) and driven tool (S2)Spindle 1 (S1) with C axis (C1) and driven tool (S2)Rear-face machining on the counter spindle after automatic workpiecetransfer

23

Expandable for complex tasks– Turning, drilling, and milling in one setup (option)

You can use the MANUALplus 620* toturn, drill, and mill your workpiece on thefront face or lateral surface in a single
setup. In addition, the control offers
numerous functions and practical cycles.

Drilling, deep-hole drilling, tapping
The MANUALplus 620 drills, pecks, andtaps individual holes with the C or Y axis.
Using parameters, you can easily program
infeed reductions for spot drilling and forthe drilling of through-holes.

* Optional, the machine and MANUALplus 620 must
be adapted to this function by the machine toolbuilder.

Drilling and milling patterns
If holes, slots, or ICP milling cycles arelocated at regular intervals along a straightline or circular arc, the MANUALplus 620
greatly simplifies your work: you can create
these patterns on the front face or lateralsurface with just a few key strokes.
Thread milling
On lathes equipped with a C or Y axis, you
can take advantage of thread milling
because the MANUALplus 620 supports
special thread-milling tools.
Milling slots and simple figures
Slot milling is very simple with the
MANUALplus 620. You define the positionand depth of the slot as well as the cutting
values, and the milling cycles will take careof the rest automatically.
For simple contours such as circles,
rectangles, and equilateral polygons,
defining the figure and position likewise
requires only a few keystrokes.

Drilling

Deep-hole drilling

Tapping

Thread milling

Drilling or tapping

24

Cycles for drilling

Contour and pocket milling
The milling cycles of the MANUALplus 620
support both contour and pocket milling.
You determine all of the essential details,
such as the machining direction, milling
direction, approach and departure behavior,infeeds, etc. The MANUALplus 620
automatically compensates for the tool
radius. You can mill the pocket in twostages—first roughing, and then finishing.
The result is high accuracy and goodsurface quality.
In smart.Turn and DIN programming, the
MANUALplus 620 supports various infeed
strategies. You can choose between direct,
reciprocating, or helical infeed, or infeed at
the predrilling position.
Face milling
The face milling cycle machines individual
surfaces, equilateral polygons, or a circle—
even off-center.
Helical slot milling
The helical slot milling cycle is useful formachining lubrication grooves. You specify
all of the important parameters such as
pitch and milling at multiple infeeds, etc.

Slot milling

Engraving cycles
Do you want to inscribe your workpieces?
That’s no problem with the MANUALplus
620. The smart.Turn engraving units require
only a few parameters in order to engrave
characters of any size on the front face orlateral surface, or on the XY or YZ plane.
On the front face of the workpiece, you
can arrange the characters along a line oran arc. On the lateral surface, and whenengraving with the Y axis, you can define
the angle at which the characters are to bearranged. With the time function, you canengrave the current time and date on yourworkpiece.
Of course, the engraving cycles are alsoavailable as DIN PLUS cycles.
Deburring
The MANUALplus 620 supports special
units or DIN PLUS cycles for deburring. You
enjoy the benefit of being able to program
this operation with only a few parameters.
Trochoidal milling
The trochoidal milling method allows you
to efficiently machine pockets in different
shapes (circle, rectangle, and polygon), as
well as any desired slot. With this technique,roughing is performed with circular
movements that are superimposed onto
a linear forward motion. Trochoidal milling
enables high removal rates and reduceschatter.

Figure milling (circles, rectangles,
equilateral polygons)

ICP contour milling

Face milling (single surfaces,
flat surface, polygon)

Helical slot milling

Cycles for milling

Front face and lateral-surface milling25

Expandable for complex tasks– Working in a tilted plane with the B axis (option)

The B axis makes it possible to performboring, drilling, and milling operations intilted planes. At first glance, the programming
work for such operations seems very
complex and compute-intensive. But with
the MANUALplus 620, you simply tilt thecoordinate system to the required positionand program the machining operation as
usual in the main plane. The machine willthen execute the machining operation in
the tilted working plane.
The B axis also provides benefits in turning
operations. By tilting the B axis and rotating
the tool, you can bring it into positions
that enable you to use a single tool toperform machining in the longitudinal andtransverse directions on the main andcounter spindles. You can thereby reduce
the number of tools needed as well as
forgo certain tool changes.

Programming
The usual separation of the contour
description from the machining operationon the MANUALplus 620 also applies toboring, drilling, and milling operations in atilted plane.
First, you rotate and shift the coordinate
system so that it lies in the tilted plane.
Then you describe the hole pattern or the
milling contour as you would in the YZ plane.
The hole pattern and figure definitions of
the MANUALplus 620 are available. Thismeans that, for linear or circular patterns,
as well as for simple figures (circles,
rectangles, equilateral polygons, etc.), only
a few more entries are needed in order todescribe the pattern or figure in the tilted
plane.

Simulation
In the Side View window, the simulationshows the hole pattern and milling contour
perpendicularly to the tilted plane, andtherefore without distortion. This ensuresthe easy verification of programmed holepatterns and milling contours. You can also
verify the tool movements in the Side View
window. If you want to check the machining
operation in the tilted plane with respect tothe turning contour or the front face, then
add the Lathe Window or Front Window.
In the position display (below the simulation
window), the MANUALplus 620 displays theangle of the tilted plane and the tilt angle of
the B axis. Do you want to view the active
coordinate system? No problem—with asimple keystroke, the MANUALplus 620
shows the current datum and the directionof the active coordinate system.

* The machine and MANUALplus 620 must be adapted
to this function

Machining in the tilted plane

26

Flexible use of tools*
If your machine is equipped with a B axis,
then you can use your tools much more
efficiently than before. Whereas onconventional lathes you need four different
tools for longitudinal and transverse turning
on main and counter spindles, you canperform these tasks with just a single tool
when you employ a B axis.
You simply tilt the B axis and rotate the tool
to the normal position or to the position formachining from behind the workpiece—
whichever is required for longitudinal ortransverse turning on the main or counterspindle. All you need is a single call: the
MANUALplus 620 calculates the tool
lengths, the tool angle, and the other tool
data for you.

Tool-use flexibility is increased significantly
when multiple tools are mounted in one
holder. For example, with a roughing,finishing, and recessing tool you canperform essential portions of turning andrecessing operations on a main spindle andcounter spindle—without changing thetool. And programming is very easy. You
simply indicate which tooth of the tool to
use and then define the tilting angle andthe tool position. This is sufficient because
the MANUALplus 620 already contains therest position and the data of each tool
tooth in its database.
This type of flexibility reduces the numberof your tools, and you save on machining
time by reducing the number of toolchanges.
* The machine and MANUALplus 620 must be adapted
to this function

Facing and ...

... longitudinal turning with the same tool ...

... and with multiple tools on one holder.

27

Fast availability of tool data and cutting data
– The tool database and technology database of the
MANUALplus 620

Tool database
The standard tool database of the
MANUALplus 620 stores 250 tools. The
tool database can be expanded to contain999 tools (option).
The MANUALplus 620 differentiates
between various types of turning, drilling,
and milling tools. The data that are input
vary depending on the tool type. In this way,
you can be sure that all of the importantparameters are specified despite reduced
data input.
The tool data are entered through dialog
prompts in which you enter parameterssuch as the cutting-edge radius, tool angle,
point angle, cutting material, and tool
description. The data to be input is explainedby context-sensitive help graphics.
Tool list
The MANUALplus 620 shows all of thetools in a straightforward tool list. Various
sorting criteria help you to quickly find thedesired tool.
This list not only gives you a good overview
of your tools—it is also the basis fortransferring tool data during manualmachining and during the creation of NC
programs.

Wear compensation
The MANUALplus 620 offers a simple
means of compensating for tool wear inboth the X and the Z axes. You enter thecompensation values during or after
workpiece machining.
Tool measurement
The MANUALplus 620 offers various
possibilities for the measurement of tools
directly on the machine:• By touching the workpiece• With the aid of an optical gauge* (option):
the tool is manually traversed to thecrosshairs of the optical measuring device,and the value is saved with a keystroke• With a tool touch probe* (option): the tool
moves in the direction of measurement.
The tool setting dimension is ascertained
and adopted when the tool touch probe
releases a trigger signal, e.g. the TT 160
touch trigger probe with cuboid probe
contact.
You can determine the tool data with greatease, reliability, and precision during tool
measurement with an optical gauge or tool
touch probe.
* The machine and MANUALplus 620 must be adapted
to this function by the machine tool builder.

Tool management in the tool list

28

Tool editor

Turret assignment
If your lathe is equipped with a tool turret, you
can view the programmed turret assignment
at any time. The MANUALplus 620 displays
all of the important tool parameters.
If you want to change the tool assignmentor the tools in the turret, you can additionallydisplay the tool database entries in thelower window. Now you need only selectthe desired turret pocket and choose thecorrect tool from the database. At thestroke of a key, you can apply the tool data
to the turret assignment entry.
Tool life monitoring (option)
With smart.Turn and DIN PLUS programs,
in addition to the simple tool life monitoring
feature you can also use the “Tool Life
Monitoring with Sister Tool” option. The
MANUALplus 620 then automaticallyinserts a replacement tool as soon as theactive tool is worn out. The MANUALplus 620
does not stop the program run until thelast tool of the tool change sequence isworn out.

Tool selection for turret assignment

Technology data (option)
With the MANUALplus 620, you need toenter the cutting data only once. The control
saves the data in accordance with thecriteria of the workpiece material, cutting
material, and machining mode. Thanks tothis three-dimensional table, the control
always knows the correct feed rate and thecorrect cutting speed.
The MANUALplus 620 determines themachining mode based on the cycle or theunit. The cutting material is entered during thetool description. Now you need only define
the workpiece material at the beginningof the cycle program or the smart.Turn
program, and the MANUALplus 620 will
provide the correct suggested values foryour machining operation. You can use thesuggested cutting parameters or adjust
them if required.
In its standard version, you can store thecutting data for nine workpiece-material /tool-material combinations in the technology
database of the MANUALplus 620. It canbe expanded to a total of 62 combinations(option). Each workpiece-material / toolmaterial combination includes the cutting
speed, the main and secondary feed rates,
and the infeed for 16 machining modes.

Input of cutting values in the technology editor

29

Reliable machining– Intelligent supervision with Load Monitoring (option)

Load Monitoring – detecting tool wear
and breakage during machining*
Load Monitoring tracks the machine’s
spindle and motor loads while comparing
them with the load values of a reference
operation. The MANUALplus 620 cangraphically display the load values in a
separate window.

You can set two limit values that trigger
different error reactions. After the first limit
value is exceeded, the current tool is
flagged as worn out, and the control
automatically exchanges it on the next tool
call with a previously defined replacement
tool. After the second limit value is exceeded,
the MANUALplus 620 assumes that there
is an impermissible load (e.g., tool breakage)and stops the machining process. This
improves process reliability during machining,particularly during unmanned shifts.
*	The machine and MANUALplus 620 must be
adapted to this function by the machine tool builder.

Graphic display of the load values

30

Batch mode
The batch mode function allows you to run
multiple main programs automatically. You
can also define the part programs and therespective number of parts in a program list.
The MANUALplus 620 can then execute
this list on its own and without you having
to select and start programs in between.
Batch mode is particularly suitable fordifferent operations with the same raw
material supplied by bar loaders or robots.

Open for communication– Rapid availability of all information

Do you have questions about a programming
step, but your User’s Manual is not at hand?
No problem: the MANUALplus 620
numerical control and DataPilot MP 620
programming station feature TURNguide,a convenient help system that can display
the user documentation in a separate
window.
You can activate TURNguide by simply
pressing the Info soft key.
Typically, TURNguide directly displays theinformation in the correct context (contextsensitive help). This means that you
immediately receive the information thatyou need. This function is particularly
helpful for the programming of cycles. The
respective operating method is explained
as soon as you press the Info soft key inthe opened dialog.

You can download the documentation in thedesired language from the HEIDENHAIN
homepage to the corresponding language
directory on your control.
The following manuals are available in thehelp system:• MANUALplus 620 User’s Manual• smart.Turn and DIN Programming User’s
Manual• DataPilot MP 620 User’s Manual(included only in the programming
station)TURNguide integrated into the control, e.g., on the MANUALplus 620 ...
… or at the programming station.

31

Open for communication– Uniformly digital job management with Connected Machining

The networked MANUALplus 620
You can integrate the MANUALplus 620 withthe functions of Connected Machining into
your corporate network and, via the control,
connect the shop to PCs, programming
stations, and other data storage devices in
the following departments:• Design• Programming• Simulation• Production planning• Production

Standard range of functions
For you to be able to use the data that you
transfer to the MANUALplus 620 over a
standard network connection, the
MANUALplus 620 offers attractive
applications, even as part of its standard
range of functions. A CAD viewer, PDF
viewer, or the web browser Mozilla Firefox
make the simplest form of Connected
Machining possible: access to
manufacturing process data right at thecontrol.

Even in its standard version, the
MANUALplus 620 features a Gigabit
Ethernet interface of the latest generation.
The MANUALplus 620 communicates with
NFS servers and Windows networks in
TCP/IP protocol without requiring additional
software. The fast data transfer at rates of
up to 1000 Mbps ensures very shorttransfer times. The MANUALplus 620
therefore meets the ideal technologicalrequirements for Connected Machining,
the networking of the control in theworkshop with all production-related areas
in your company.

The operation of web-based documentation
software or ERP systems is just as much
possible in this case as is the access toyour e-mail inbox. The following further fileformats can also be opened directly on the
MANUALplus 620:
• Text files ending with .txt or .ini
• Graphic files ending with .gif, .bmp, .jpg,
or .png• Table files ending with .xls or .csv
• HTML files

Data transfer with Connected Machining
An additional solution for uniformly digital
job management as part of Connected
Machining is the free TNCremo software
for PCs. With it, you can• transfer remotely stored part programsand tool tables in both directions, evenvia Ethernet, and• make backups.
With the powerful TNCremoPlus PC
software, you can also transfer the screen
contents of the control to your PC using
the live-screen function.

Company network
CAD/CAMsystem

DataPilot MP 620
Ethernet
interface

iTNC 530
Ethernet
interface

TNC 320
Ethernet
interface

MANUALplus 620
Ethernet
interface
Data transfer on the control

32

USB interface
Of course, for data transfer you can also
use one of the USB ports. By using USB
removable memory media (such as flash
drives), you can quickly and easily exchange
DXF contours, ICP contour descriptions,
NC programs, tool parameters, etc.,
between systems that are not linked toeach other.
All programs at a glance
After you have entered the path of thepartner terminal, your own MANUALplus 620
programs will appear on the left side of
the screen, with your partner’s programs
appearing on the right. Now select the
programs that you want to transfer andpress the send or receive button. The datais transferred very quickly and reliably.
Transferring programs
Data transfer is easiest and most convenientwhen you integrate the systems into yourcompany network.

Exchanging tool data
You can also transfer already acquired tool
data. This is important not only for data
backup but is also an advantage when you
use the DataPilot PC programming station.
The benefits are that there is no redundantdata acquisition and that your files arealways up to date.
Detailed data for the optimal organizationof the production process
HEIDENHAIN DNC1) enables, among otherthings, the connection of MANUALplus 620
controls to inventory management systems
and production activity control systems.
Automatic feedback messages about
active production processes, for example,
can be set up over this interface.
1)

One aspect of Connected Machining is theStateMonitor2) PC software, which gives
you access to the status of the current
machining operations. You can use thesoftware with any device that has a web
browser. This allows you to use StateMonitor
not only on your control or PC but also on
your smartphone or tablet. In a well-designed
display, you can quickly gain an overview of
the current machine status or see whether
any machine messages are pending. This
allows you to react immediately and takeappropriate action. You can also easily
configure StateMonitor to send you an
e-mail for specific events, such as at theend of a program, for a machine stop, orfor a servicing message.
2)

Option 18 required

The machine must be adapted to this function by themachine tool builder.

When transferring NC programs, the
MANUALplus 620 even takes into accountthe files related to the cycle program,smart.Turn program, or DIN PLUS program,
such as contour descriptions, DIN macros,or subprograms.

33

Open for communication– The DataPilot MP 620 programming station

DataPilot MP 620 is the PC programming
station for the MANUALplus 620 and theorganizational system for the shop anddesign office.
That is why DataPilot MP 620 is the ideal
supplement to the MANUALplus 620 for
program creation and archiving, and forbasic and advanced training.
Creating programs
Programming, testing, and optimization ofsmart.Turn or DIN PLUS programs with theprogramming station significantly reducemachine idle time. This does not evenrequire an adjustment in thinking, because,with DataPilot, programming and testing
are performed in the same manner as on
the lathe. DataPilot is based on the same
software that is in the control. This also

gives you the assurance that a program
created with DataPilot can be run on themachine immediately.
Archiving programs
Even though the MANUALplus 620 featuresa large memory capacity, you should also
back up your programs on an external
system. The MANUALplus features a USB
port and an Ethernet interface. This gives
you everything you need to integrate the
MANUALplus 620 into your existing
network or to connect the DataPilot PC
directly to the control.
Convenient program transfer functions
support both programming and archivingon the DataPilot PC.

Training with DataPilot MP 620
Because DataPilot MP 620 is based on thesame software as the MANUALplus 620,
it is also ideally suited for training purposes.
Programming and program testing on the
DataPilot PC are performed in exactly thesame way as on the machine. DataPilot
even simulates setup functions such as
defining the workpiece datum, tool
measurement, or running individual cycles
or smart.Turn or DINPLUS programs. This
gives trainees the confidence they willneed for working on the actual machine.
System requirements
The DataPilot software can run on PCs
with the Windows 7, 8, 8.1, or 10 (64-bit)
operating systems.

Trainer

Printers

Trainees

34

MachineWorkpiece measurement–	Setup, presetting, and measuring with touch trigger probes

Inspecting workpieces for propermachining and dimensional accuracy
The MANUALplus 620 features measuring
cycles for checking the geometry of themachined workpieces. For the measuring
cycles, you simply insert a 3-D touch probefrom HEIDENHAIN into the turret insteadof a tool:• Check whether all of the machining
operations have been properly performed• Determine infeeds for finishing• Detect and compensate for tool wear
• Inspect workpiece geometry and sortparts
• Log measured data
• Ascertain the machining error trend

Workpiece touch probes from HEIDENHAIN
help you to reduce costs in the shop and inseries production: together with the
MANUALplus 620’s probing cycles, touchprobes can automatically perform setup,measuring, and inspection functions.
The stylus of a TS touch trigger probe isdeflected upon contact with a workpiecesurface. At that moment the TS generates
a trigger signal that, depending on themodel, is transmitted to the control either
by cable, radio transmission, or an infrared
beam.
HEIDENHAIN touch probes* for workpiecemeasurement are available in various
versions. The ball tips, which are made ofruby, are available in different diameterswith various stylus lengths.
*	The touch probes must be interfaced to the
MANUALplus 620 by the machine tool builder.

Touch probes with cable connection for
signal transmission for machines withmanual tool change, as well as for grinding
machines and lathes:
TS 260 – new generation, axial or radialcable connection
TS 248 – like the TS 260, but with reduced
deflection forces
Touch probes with radio or infrared signaltransmission for machines with anautomatic tool changer:
TS 460 – new generation standard touchprobe for radio and infrared transmission,
with compact dimensions
TS 740 – high probing accuracy andrepeatability, low probing force, with infraredtransmission

Further information:
Detailed descriptions about touchprobes are available on the Internet atwww.heidenhain.de or in the brochure
Touch Probes for Machine Tools.

TS 46035

Tool measurement– Measuring the length, radius, and wear directly in the machine

Exact measurement of the tool dimensions
is a decisive factor in ensuring a consistently
high level of production quality. The TT tool
touch probes from HEIDENHAIN serve thispurpose.
TT 160 – new generation, signal transmission
to the NC over a cable
TT 460 – new generation, signal transmission
over radio and infrared beam to thetransceiver

The TT 160 and TT 460 are 3-D touch
trigger probes for the measurement andinspection of tools. The disk-shaped probe
contact of the TT is deflected during thephysical probing of a tool. During probing,
the TT generates a trigger signal that istransmitted to the control for further
processing. The trigger signal is generated
by means of a wear-free and highly reliable
optical sensor.

The SE 660 is a common transceiver fortool and workpiece touch probes with radioor infrared transmission.

SE 660Further information:
Detailed descriptions about touchprobes are available on the Internet atwww.heidenhain.de or in the brochure
Touch Probes for Machine Tools.

36

TT 160With their rugged design and high protection
rating, these tool touch probes can beinstalled directly within the machine tool’s
work envelope, thereby enabling tool
measurement directly within the machine.
You can thus determine the tool dimensions
quickly, easily and, above all, very precisely.
The TT tool touch probes from HEIDENHAIN
are the ideal addition for improving theefficiency and quality of your production
system.

OptionUser functions

Standard

Overview– User functions

Basic version: X and Z axis, main spindle
Driven tool and auxiliary axes (U, V, W)
0-6
55+0-6 C axis and driven tool
70+0-6 Y axis
54+0-6 B axis
94+0-6 Parallel axes U, V, W (display function and compensation)
132+0-6 Counter spindle•
Digital current and speed control

Configuration•

Operating modes		
Manual operation••
11

Teach-in mode
Program run

Setup functions

Programming
		Cycle programming

8

•

•
•
•
•
•
•

Manual slide movement through axis-direction keys, an intermediate switch, or electronic
handwheels
Graphical support for entering and running cycles without storage of the machining steps indirect alternation with manual machine operation
Thread reworking (thread repair) in a second workpiece setup
Sequential arrangement of fixed cycles, with each cycle being run immediately after input orgraphically simulated and subsequently saved

98

Each in Single-Block mode and Full-Sequence mode
DIN PLUS programs
smart.Turn programs
Cycle programs

17
17
17

Workpiece datum setting
Definition of tool-change position
Definition of protection zone
Definition of machine dimensions
Manual programs
Tool measurement by touching the workpiece
Tool measurement with a TT tool touch probe
Tool measurement with an optical gauge
Workpiece measurement with a TS workpiece touch probe

8
8
8
8
8
8
8
8
8+55
8+55
8+55
8+55
8+55
8+55
8
8
8
8+9

Turning cycles for simple or complex contours, and contours described with ICP
Contour-parallel turning cycles
Recessing cycles for simple or complex contours, and contours described with ICP
Repetitions with recessing cycles
Recess turning cycles for simple or complex contours, and contours described with ICP
Undercut and parting cycles
Engraving cycles
Threading cycles for single or multi-start longitudinal, taper, or API threads, and threads withvariable pitch
Cycles for axial and radial drilling, deep drilling, and tapping operations with the C axis
Thread milling with the C axis
Axial and radial milling cycles for slots, figures, single surfaces, and centric polygon surfaces,
and for complex contours described with ICP for machining with the C axis
Helical slot milling (multi-start) with the C axis
Deburring of ICP contours
Linear and circular patterns for boring, drilling, and milling operations with the C axis
Context-sensitive help graphics
Transfer of cutting values from the technology database
Use of DIN macros in cycle programs
Conversion of cycle programs to smart.Turn programs

37

Interactive Contour
Programming (ICP)

Contour definition with linear and circular contour elements
Immediate display of entered contour elements
Calculation of missing coordinates, intersections, etc.
Graphic display of all solutions for selection by the user if more than one solution is possible
Chamfers, rounding arcs, and undercuts available as form elements
Input of form elements immediately during contour creation or through later superimposition
Changes to existing contours can be programmed
Machining attributes available for individual contour elements
C-axis machining on the front face and lateral surface:• Description of individual holes and hole patterns (only in smart.Turn)• Description of figures and figure patterns for milling (only in smart.Turn)• Creation of freely definable milling contours
9+70 Y-axis machining on the XY and ZY planes (only in smart.Turn):• Description of individual holes and hole patterns• Description of figures and figure patterns for milling operations• Creation of freely definable milling contours
8/9+55+ Programming of the rear face for full-surface machining with the C and Y axes
70+132
8/9+42 DXF import: importing of contours for turning and milling operations

smart.Turn
programming

The basis is the “unit,” which is the complete description of a machining block (geometry,technology, and cycle data)
Dialog boxes divided into overview and detail forms
9
Fast navigation between the forms and the input groups via the "smart" keys
9
Context-sensitive help graphics
9
Start unit with global settings
9
Transfer of global values from the start unit
9
Transfer of cutting values from the technology database
9
Units for all turning and recessing operations for simple contours and ICP contours
9
9+55/70 Units for boring, drilling, and milling operations with the C or Y axis for holes, milling contours,
and drilling and milling patterns that are simple or that have been programmed with ICP
9+55/70 Units for trochoidal milling operations for pockets and slots
9+55+ Hobbing unit for the machining of gear teeth
135
9+55 Special units for activating/deactivating the C axis, as well as for subprograms and section
repeats
9+55/70 Verification graphics for the workpiece blank and finished part, as well as for C- and Y-axis
contours
Turret assignment and other setup information in the smart.Turn program
9
Parallel programming
9
Parallel simulation
9

TURN PLUS

38

OptionUser functions

Standard

Overview– User functions

8/9
8/9
8/9
8/9
8/9
8/9
8/9
8/9
8/9+55

9

63

Automatic smart.Turn program generation with• Automatic tool selection• Automatic turret assignment• Automatic calculation of cutting data
• Automatic generation of the machining sequence in all working planes,
also for C-axis machining (with option 55) and Y-axis machining (with option 70)• Automatic cutting limit through chucking equipment• Automatic generation of rechucking work blocks for turning with opposing spindles• Automatic generation of work blocks for rear-face machining (with option 132)

Programming		DIN PLUS
programming

•
•
•
•
•
•
•
•
•
•
•
•
•

Simulation

OptionStandard

User functions

Programming in DIN 66025 format
Expanded command format (IF ... THEN ... ELSE ...)
Simplified geometry programming (calculation of missing data)
Powerful fixed cycles for area clearance, recessing, recess turning, and thread machining
Powerful fixed cycles for boring, drilling, and milling with the C axis
55
Powerful fixed cycles for boring, drilling, and milling with the Y axis
70
Subprograms
Technology functions for full-surface machining:• Traversing to a fixed stop
• Controlled parting• Spindle synchronization
131/132• Mirroring and converting132• Mechatronic tailstock
Programming with variables
Contour description with ICP
8/9
Program verification graphics for workpiece blank and finished partTurret assignment and other setup information in the DIN PLUS program
Conversion of smart.Turn units into DIN PLUS command sequences9
Parallel programming
Parallel simulation

•
•
•
•
•
•
•
•

B axis machining•

Monitoring function

54
132

54
54
135
135

Eccentric machining

Machining time analysis

55

•
•
•

Graphic simulation of the cycle process, or of the cycle program, smart.Turn program,or DIN PLUS program
Depiction of the tool paths as pencil-trace or cutting-path graphics; special identificationof the rapid traverse paths
Machining simulation (2-D material-removal graphic)
Side or front face view, or 2-D view of lateral surface for verification of C-axis machining
Display of programmed contours
View of the tilted plane (B-axis machining)
View of front face and YZ plane for verification of Y-axis machining
Three-dimensional display of the workpiece blank and finished part
Simulation of mirrored contours for rear-face machining
Shifting and magnifying functions
Block scan in the simulation
Machining with the B axis
Tilting the working plane
Rotating the machining position of the tool
Cycles for eccentric turning and for the manufacture of oval and polygonal contours
Superimpositioning of traversing movements of the X and Y axes synchronously to therotational motion of the spindle
Calculation of machining times and idle times
Consideration of the switching commands triggered by the CNC
Representation of time per individual cycle or per tool change

151

Load Monitoring—detecting tool wear and breakage during machining

39

Tool database

•
•
•
•
•

OptionUser functions

Standard

Overview– User functions

10

•
•
•
•

10

8/9

Technology database

8/9
8/9
8/9
10
User administration•

Conversational languages •40

For 250 tools
For 999 tools
Tool description can be entered for every tool
Automatic inspection of the tool-tip position relative to the contour
Compensation of the tool-tip position in the X/Y/Z plane
Fine compensation of tool via handwheel with application of compensation values in thetool table
Automatic tool-tip and cutter radius compensation
Tool monitoring for the service life of the indexable insert or of the number of produced
workpieces
Tool monitoring with an automatic tool change after expiration of tool life
Management of multipoint tools (multiple inserts or reference points)
Support of quick-change tool systems
Access to cutting data after definition of workpiece material, cutting material, and machining
mode. The MANUALplus 620 distinguishes between 16 machining modes. Each
workpiece-material / tool-material combination includes the cutting speed, the main andsecondary feed rates, and the infeed for 16 machining modes.
Automatic determination of the machining modes from the cycle or the machining unit
The cutting data are entered in the cycle or in the unit as suggested values
Nine workpiece-material / tool-material combinations (144 entries)
62 workpiece-material / tool-material combinations (992 entries)
Configurable linkage of permissions to user roles• Logging on to the control with a user account• User-specific HOME folder for simplified data management• Role-based access to the control and network data
English, German, Czech, French, Italian, Spanish, Portuguese, Dutch, Swedish, Danish,
Finnish, Norwegian, Slovenian, Slovak, Polish, Hungarian, Russian (Cyrillic), Romanian, Turkish,
Chinese (traditional and simplified), Korean

Overview– Options

OptionnumberOptionAs of NC
software
54843x-ID

Comment

0
1
2
3
4
5
6

Additional Axis

01
01
01
01
01
01
01

354540-01
353904-01
353905-01
367867-01
367868-01
370291-01
307292-01

Additional control loops 1 to 7

8

Teach-In

01632226-01

Cycle programming• Contour description with ICP• Cycle programming• Technology database with nine workpiece-material / tool-material
combinations

9

smart.Turn

01632227-01

smart.Turn• Contour description with ICP• Programming with smart.Turn• Technology database with nine workpiece-material / tool-material
combinations

10

Tools and Technology

01632228-01

Tools and technology• Tool database expanded to 999 entries• Technology database expanded to 62 workpiece-material /tool-material combinations• Tool life monitoring with exchange tools

11

Thread Recutting

01

632229-01

Threads• Thread recutting• Handwheel superimpositioning during thread cutting

17

Touch Probe Functions 01

632230-01

Tool measurement and workpiece measurement• Determining tool-setting dimensions with a tool touch probe• Determining tool-setting dimensions with an optical gauge• Automatic workpiece measurement with a workpiece touch probe

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM component

24

Gantry Axes

01

634621-01

Gantry axes via master-slave torque control

42

DXF Import

01

632231-01

DXF import: importing of DXF contours

46

Python OEM Process

01579650-01

Python application on the MANUALplus 620

49

Double Speed Axes

01

632223-01

Short control-loop cycle times for direct drives

54

B-Axis Machining

01825742-01

B axis: tilting the working plane, rotating the machining position of the tool55

C‑Axis Machining

01633944-01

C-axis machining

63

TURN PLUS

01825743-01

TURN PLUS: automatic generation of smart.Turn programs

41

Overview– Options– Accessories
OptionnumberOptionAs of NC
software
54843x-ID

Comment

70

Y-Axis Machining

01

661881-01

Y-axis machining

77

4 Additional Axes

03

634613-01

4 additional control loops

94

Parallel Axes

01

679676-01

Support of parallel axes (U, V, W)
Combined display of principal axes and secondary axes

131

Spindle Synchronism

01

806270-01

Synchronization (of two or more spindles)

132

Counter Spindle

01806275-01

Counter spindle (spindle synchronism, rear-face machining)

135

Synchronizing
Functions

03

1085731-01 Advanced synchronization of axes and spindles

137

State Reporting

06

1232242-01 State Reporting Interface (SRI): provision of operating conditions

143

Load Adapt. Control

01

800545-01

LAC: load-dependent adaptation of the control parameters

151

Load Monitoring

03

1111843-01

Monitoring of the tool load

Accessories

Electronic handwheels• HR 180 panel-mounted handwheels with connection at position inputs, plus
• One HR 130 serial, panel-mounted handwheel or an HR 510 , HR 520 , or HR 550 portableserial handwheel

Tool measurement

3-D touch trigger probes:• TT 160 with a cuboid probe contact and cable connection• TT 460 with a cuboid probe contact and radio or infrared transmission

Workpiece measurement• TS 260 touch trigger probe with cable connection, or• TS 460 touch trigger probe with radio or infrared transmission, or• TS 740 touch trigger probe with infrared transmission

DataPilot CP 640, MP 620

Programming station for PC for programming, archiving, and training for the MANUALplus 620• Full version with license for single station or multiple stations• Demo version (free of charge)

Software for PCs• TeleService software for remote diagnostics, monitoring, and operation• TNCremo software for data transfer—free of charge• TNCremoPlus software for data transfer with live-screen function

42

Overview– Specifications

Specifications

Components

MC main computer with integrated 15.6-inch screen (1366 × 768 pixels) for
multi-touch operation; operating panel can be shown
CC or UEC controller unit
Machine operating panel with 36 exchangeable snap-on keys as well as spindle
and feed rate override potentiometers

Operating system

HEROS 5 real-time operating system for machine control

NC program memory

1.8 GB (on CFR compact flash memory card)

Input resolution and display step

X axis: 0.5 µm, diameter: 1 µm
U, V, W, Y, Z axes: 1 µm
B, C1/C2 axes: 0.001°

Interpolation

Straight line: in two principal axes (max. ±100 m), optional in three principal axes
Circle: in two axes (radius max. 999 m), optional additional linear interpolation in
the third axis
C1/C2 axis: interpolation of X and Z linear axes with the C1/C2 axis (option)
B axis: interpolation of the X, Z, Y, B, C axes (max. four axes)

Feed rate

mm/min or mm/revolution
Constant surface speed
Max. feed rate (60 000/pole pair number × spindle pitch) with fPWM = 5000 Hz

Main spindle

Maximum of 60 000 rpm (with option 49: max. 120 000 rpm) for motors with
one pole pair

Axis feedback control

Integrated digital drive control for synchronous and asynchronous motors
Position loop resolution: signal period of the position encoder/1024
Cycle time of position controller: 0.2 ms
Cycle time of speed controller: 0.2 ms
Cycle time of current controller: minimum 0.05 ms

Error compensation

Linear and nonlinear axis error, backlash, reversal spikes during circular movements
Static friction

Data interfaces

1000BASE-T Gigabit Ethernet interface
MC 7410T: 5 x USB (1 x front USB 2.0; 4 x back panel USB 3.0)
MC 8420T: 4 x back panel USB 3.0

Diagnostics

Fast and simple troubleshooting through integrated diagnostic aids

Ambient temperature

Operation: in electrical cabinet: 5 °C to 40 °C
in operating panel: 0 °C to 50 °C
Storage: –20 °C to 60 °C

43

Mastering nanometer accuracy

DR. JOHANNES HEIDENHAIN GmbH
Dr.-Johannes-Heidenhain-Straße 583301 Traunreut, Germany +49 8669 31-0
 +49 8669 32-5061
info@heidenhain.dewww.heidenhain.com
1082181-25 · 3 · 03/2019 · F&W · Printed in Germany

HEIDENHAIN
worldwide