TNC 640 HSCIFor 1xx Inverter Systems
The Contouring Control for
Milling Machines, Milling-Turning
Machines, and Machining
Centers
Information for the
Machine Tool Builder

02/2020

TNC contouring control with drive system from HEIDENHAIN
General information

TNC 640• Contouring control for milling machines, milling-turning
machines, and machining centers• Axes: up to 24 control loops (22 control loops with functionalsafety (FS)), of which up to 4 can be configured as spindles• For operation with HEIDENHAIN inverter systems and ideally
HEIDENHAIN motors• Uniformly digital with HSCI interface and EnDat interface• Version with touchscreen for multitouch operation• Solid state disk (SSDR)• Programming in HEIDENHAIN Klartext or G-code (ISO)• Comprehensive cycle package for milling and turning operations• Constant surface speed for turning operations• Tool radius compensation• Touch probe cycles• Free contour programming (FK)• Special function for fast 3-D machining• Short block processing time (0.5 ms)
System test

Controls, power modules, motors, and encoders from
HEIDENHAIN are usually integrated as components into complete
systems. In such cases, comprehensive testing of the complete
system is required, irrespective of the specifications of theindividual devices.

Parts subject towear

Controls from HEIDENHAIN contain parts subject to wear, such asa hard disk, backup battery and fan.

Standards

Standards (ISO, EN, etc.) apply only where explicitly stated in thebrochure.

Note

Microsoft, Windows 8, Windows 10, and Internet Explorer are
registered trademarks of Microsoft Corporation. Intel, Intel Core,
and Celeron are registered trademarks of Intel Corporation.

Validity

The features and specifications described here apply to thefollowing control and NC software versions:
TNC 640 with NC software versions
340590-10 (export license required)
340591-10 (no export license required)This brochure supersedes all previous editions, which thereby
become invalid. Subject to change without notice.

Requirements

Some of these specifications require particular machine
configurations. Please also note that, for some functions, a special
PLC program must be created by the manufacturer.

Functional safety(FS)

If no explicit distinction is made between standard and FS
components (FS = functional safety), then the data and otherinformation apply to both versions (e.g., TE 745, TE 745 FS).

Use of thisbrochure

The purpose of this brochure is to help you select suitablecomponents from HEIDENHAIN. Further documents are requiredfor project planning (see "Technical documentation", Page 127).

2

Contents

TNC contouring control with drive system from HEIDENHAIN

2

Overview tables

4

HSCI control components

16

Accessories

33

Cable overview

51

Technical description

57

Data transfer and communication

92

Mounting information

96

Overall dimensions

98

General information

127

Other HEIDENHAIN controls

129

Subject index

130

Please refer to the page references in the tables with thespecifications.

3Overview tables
Components

Control systems
Main computer

Storage medium

15-inch design

19-inch design 24-inch design Page

For operating panel

MC 8512MC 7522MC 8532

For electrical cabinet

MC 6541, MC 6542, or MC 6641

MC 85x2
MC 75x2
MC 6x42
MC 306SSDR solid state disk

MC 6x41

HDR hard disk

MC 366

16

–
18

–

NC software license

On SIK component

Monitor

BF 750

BF 860–27

Keyboard

TE 730 or TE 735

TE 745

TE 36027

Machine operating panel

MB 720 (integrated in TE 735)

Integrated in
TE 745Integrated in
TE 36028

MB 721 (for MC 8512)

Controller unit

PLB 600x (HSCI adapter for OEM machine operating panel)34

6 control loops

CC 610622

8 control loops

CC 610822

10 control loops

CC 611022

12 control loops

CC 6106 + CC 6106

22

14 control loops

CC 6108 + CC 6106

22

16 control loops

CC 6108 + CC 6108

22

18 control loops

CC 6106 + CC 6106 + CC 6106 or CC 6110 + CC 6108

22

20 control loops

CC 6110 + CC 6110

22

PSL 130 / PSL 135

33

PL 6000 consisting of PLB 62xx basic module (system PL) or PLB 61xx
(expansion PL) and I/O modules

31

On UEC23

On UMC25

CMA-H for analog axes/spindles in the HSCI system

35

Power supply*)
PLC inputs/
outputs1)

18

With HSCI interface

Additional modules1)

Modules for fieldbus systems
Compact inverters and modular inverters*)

UEC 11123

UMC 11125

5 control loops

UEC 11223

6 control loops

UEC 113

Inverter systems
Inverters withintegrated
controller unit

4 control loops

Connecting cables

51*) For more information, refer to the Inverter Systems for HEIDENHAIN Controls brochure1) May be necessary depending on the configuration

Please note: The MC main computer does not have any PLC inputs/outputs. Therefore one PL 6000, UEC, or UMC is necessary foreach control. They feature safety-relevant inputs/outputs as well as the connections for touch probes.

4Accessories

Accessory
Electronic handwheels

Workpiece touch probes

Tool touch probes

TNC 640• HR 510 FS portable handwheel, or• HR 520 FS portable handwheel with display, or• HR 550 FS portable wireless handwheel with display, or• HR 130 panel-mounted handwheel• TS 260 touch trigger probe with cable connection, or• TS 460 touch trigger probe with radio and infrared transmission, or• TS 740 touch trigger probe with infrared transmission• TT 160 touch trigger probe with cable connection, or• TT 460 touch trigger probe with radio and infrared transmission

Page
38

36

37

Programming station1)

Control software for PCs for programming, archiving, and training• Single-station license with original control keyboard• Single-station license with virtual keyboard• Network license with virtual keyboard• Demo version with virtual keyboard or PC keyboard—free of charge

Auxiliary axis control

PNC 61043

Industrial PC

ITC 755: additional operating station with touchscreen and ASCII keyboard
ITC 750/ITC 860: additional operating station; separate TE 7xx necessary
IPC 6641: industrial PC for Windows
IPC 6490/IPC 8420: industrial PC for PNC 610

41

Camera system

VS 101 camera system for monitoring the working space46

Snap-on keys

For controls and handwheels

471) For more information, refer to the Programming Station for TNC Controls brochure

Accessories / Software

TNC 640Page

PLCdesign1)

PLC development software

88

KinematicsDesign1)

Software for creation of kinematic models

80

M3D Converter4)

Software for creation of high-resolution collision objects in M3D format

80

TNCremo2), TNCremoPlus2)

Data transfer software (TNCremoPlus with “live” screen)

93

ConfigDesign1)

Software for configuring the machine parameters

84

CycleDesign1)

Software for creating cycle structures

91

TNCkeygen1)

Software for enabling SIK options for a limited time, and for single-day access to the
OEM area18

TNCscope1)

Software for data recording

85

TNCopt1)

Software for putting digital control loops into service

85

IOconfig1)

Software for configuring PLC I/O and fieldbus components

32

TeleService1)3)

Software for remote diagnostics, monitoring, and operation

86

RemoTools SDK1)

Function library for developing customized applications for communication with
HEIDENHAIN controls

94

virtualTNC1)3)

Control component for virtual machines

94

TNCtest1)

Software for creation and execution of an acceptance test

86

TNCanalyzer1)

Software for the analysis and evaluation of service files

861) Available to registered customers for download from the Internet

2) Available to all customers (without registration) for download from the Internet
3) Software release module required4) Included in the KinematicsDesign installation package with version 3.1 or later (software release module required)

5

Specifications

Specifications

TNC 640

Page

Axes

Max. of 24 control loops (22 control loops with functional safety (FS)), of which
up to 4 can be configured as spindles

63

Rotary axes

Max. 3

Synchronized axes✓

PLC axes✓

Main spindles

Milling: max. 4; second, third, and fourth spindle can be controlled alternately
with the first
Turning: max. 2
Milling spindle or lathe spindle activated via NC command

69

Speed

Max. 60 000 rpm (with software option 49, max. 120 000 rpm)*

69

Operating mode switchover✓

69

Position-controlled spindle✓

69

Oriented spindle stop✓69

Gear shifting✓69

NC program memory

MC 6x41: ≈ 144 GB on HDR hard disk
MC 6542, MC 75x2, MC 85x2: ≈ 21 GB on SSDR solid state disk

16
63

Input resolution and display step
Linear axes

Down to 0.01 µm

Rotary axes

Down to 0.000 01°

Functional safety (FS)With FS components, SPLC, and SKERN

For applications with up to59• SIL 2 as per EN 61508• Category 3, PL d as per EN ISO 13849-1: 2008

Interpolation
Straight line

In 4 axes; in max. 6 axes with software option 9

Circular

In 2 axes; in 3 axes with software option 8

Helical✓
71

Axis feedback control
With following error✓

With feedforward✓

Axis clamping✓

Maximum feed rate

63
60000 rpm
No. of motor pole pairs

at fPWM = 5000 Hz*

6

For motors with a single pole pair.

63
Screw pitch [mm]Specifications

TNC 640

Page

Cycle times of main computer

MC

72

Block processing

0.5 ms73

Cycle times of controller unit

CC/UEC/UMC

72

Path interpolation

3 ms

72

Fine interpolation

Single-speed: 0.2 ms
Double-speed: 0.1 ms (software option 49)

Position controller

Single-speed: 0.2 ms
Double-speed: 0.1 ms (software option 49)

Speed controller

Single-speed: 0.2 ms
Double-speed: 0.1 ms (software option 49)

Current controller

fPWM
3333 Hz
4000 Hz
5000 Hz
6666 Hz with software option 49
8 000 Hz with software option 49
10 000 Hz with software option 49

Permissible temperature range

Operation:
In electrical cabinet: 5 °C to 40 °C
In operating panel: 0 °C to 50 °C
Storage: –20 °C to 60 °C

TINT
150 µs125 µs100 µs
75 µs with software option 49
62.5 µs with software option 49
50 µs with software option 49

7

Interfacing to the machineInterfacing to the machine

TNC 640

Page

Error compensation✓

81

Linear axis error✓

81

Nonlinear axis error✓

81

Backlash✓81

Reversal spikes during circular
movement✓

81

Hysteresis✓

81

Thermal expansion✓

81

Static friction✓

81

Sliding friction✓

81

Integrated PLC✓

87Program format

Statement list

87

Program input at the control✓

87

Program input via PC✓

87

Symbolic PLC-NC interface✓

87

PLC memory> 1 GB87

PLC cycle time

9 ms to 30 ms (adjustable)

87

PLC inputs/outputs

For the maximum configuration of the PLC system, see Page 58

31,
23

PLC inputs, DC 24 V

Via PL, UEC, UMC

31

PLC outputs, DC 24 V

Via PL, UEC, UMC

31

Analog inputs ±10 V

Via PL

31

Inputs for PT 100 thermistors

Via PL

31

Analog outputs ±10 V

Via PL31

PLC functions✓

87

Small PLC window✓

88

PLC soft keys✓

88

PLC positioning✓

88

PLC basic program✓

90

Integration of applications

89

High-level language programming Use of the Python programming language in conjunction with the PLC(software option 46)

89

User interfaces can be customdesigned

8Creation of individualized user interfaces by the machine manufacturer with the89
Python programming language. Programs up to a memory limit of 10 MB are enabledin standard mode. More can be enabled via software option 46.

Interfacing to the machine

TNC 640

Page
84

Commissioning anddiagnostic aids
DriveDiag

Software for diagnosis of digital drive systems

84

TNCoptSoftware for putting digital control loops into service

85

ConfigDesign

Software for creating the machine configuration

84

KinematicsDesign

Software for creating the machine kinematics, initialization of DCM

80

Integrated oscilloscope✓

84

Trace function✓

85

API DATA function✓

85

Table function✓85

OLM (online monitor)

✓

85

Log

✓

85

TNCscope✓

85

Bus diagnostics✓

86

Data interfaces✓

Ethernet

2 x 1000BASE-T

92

USB

Rear: 4 x USB 3.0
Front: may vary based on the component description

92

V.24/RS-232-C

✓

92
92

Protocols
Standard data transmission✓

92

Blockwise data transfer

✓

92

LSV2

✓

92

Encoder inputs

CC 6106

CC 6108

CC 6110

UEC 111

UMC 111

UEC 112

UEC 11370

Position

6

8

10

4

-

5

6

70

Incremental

1 VPP

70

Absolute

EnDat 2.2

70

Speed

6

8

10

4

4

5

6

70

Incremental

1 VPP

70

Absolute

EnDat 2.2

70

Nominal-value outputs

CC 6106

CC 6108

CC 6110

UEC 111

UMC 111

UEC 112

UEC 113

PWM

6

8

10

-

-

-

-

Motor connections

-

-

-

4

4

5

6

70

9

Short description✓✓
Program entry✓✓

TNC 640
OptionUser function

Standard

User functions

Basic version: 3 axes plus closed-loop spindle
0-7 A total of 14 additional NC axes or 13 additional NC axes plus second spindle
77
78
Digital current and speed control

42

HEIDENHAIN Klartext
According to ISO
Direct loading of contours or machining positions from DXF files and saving as Klartext contouring
programs, or as point tables

Position values✓✓✓

Nominal positions for lines and arcs in Cartesian coordinates or polar coordinates
Incremental or absolute dimensions
Display and entry in mm or inches

Tool compensation✓✓

Tool radius in the working plane and tool length
Radius-compensated contour look ahead for up to 99 blocks (M120)
Three-dimensional tool-radius compensation for changing tool data without having to recalculate an
existing program

9

Tool tables✓Multiple tool tables with any number of tools

Cutting data✓

Automatic calculation of spindle speed, cutting speed, feed per tooth, and feed per revolution

Constant contour
speed

✓
✓

Relative to the path of the tool center
Relative to the tool’s cutting edge

Parallel operation✓

Creating a program with graphical support while another program is being run

3-D machining

✓

9
9
9
92

Motion control with smoothed jerk
3-D tool compensation via surface-normal vectors
Using the electronic handwheel to change the angle of the swivel head during program run
without affecting the position of the tool point (TCPM = Tool Center Point Management)
Keeping the tool normal to the contour
Tool radius compensation normal to the tool direction
Manual traverse in the active tool-axis system
3-D radius compensation depending on the tool’s contact angle

Rotary tablemachining88Programming of cylindrical contours as if in two axes
Feed rate in mm/min

Turning

50
50
50
50
50
50
50
50
50
50

Program-controlled switchover between milling and turning
Constant surface speed
Tool radius compensation
Cycles for roughing, finishing, recessing, thread turning, and recess turning
Blank form updated in contour cycles
Turning-specific contour elements for recesses and undercuts
Orientation of the turning tool for outside or inside machining
Inclined turning
Speed limiting
Eccentric turning (also requires software option 135)50
50

Straight line
Chamfer
Circular path
Circle center
Circle radius
Tangentially connecting circular arc
Corner rounding
RecessUndercutContour elements

10

✓
✓
✓
✓
✓
✓
✓

9
9

TNC 640
OptionStandard

User function

Contour approach and ✓departure✓

Via straight line: tangential or perpendicular
Via circular arc

Adaptive feed control

45

AFC: Adaptive Feed Control adjusts the contouring feed rate to the current spindle power

Collision monitoring

40
40
40

Dynamic Collision Monitoring (DCM)
Graphic depiction of the active collision objects (high-resolution M3D format)
Tool carrier monitoring

FK free contour
programming✓

FK free contour programming in HEIDENHAIN Klartext format with graphical support forworkpiece drawings not dimensioned for NC

Program jumps✓✓✓

Subprograms
Program section repeat
Calling any program as a subprogram

Fixed cycles

✓
✓

✓

✓
✓
✓
✓
✓
✓
✓
✓
Coordinatetransformations✓

Q parameters
Programming withvariables

✓
✓
✓
✓
✓
✓

Programming aids

CAD viewer

✓
✓
✓
✓

Drilling, tapping with a floating tap holder, rigid tapping
Peck drilling, reaming, boring, counterboring, centering
50 Area clearance cycles, longitudinal and transverse, paraxial and contour parallel
50 Recessing cycles, radial/axial
50 Radial/axial recess turning cycles (combined recessing and roughing motion)
Milling internal and external threads
50 Turning internal and external threads
50+ Hobbing
135
96 Interpolation turning (not with functional safety (FS))
Clearing level and oblique surfaces
Multi-operation machining of straight and circular slots
Multio-peration machining of rectangular and circular pockets
Point patterns for circles, lines, and DataMatrix codes
Contour train, contour pocket
Contour slot with trochoidal milling
OEM cycles (special cycles developed by the machine tool builder) can be integrated
Engraving cycle: engrave text or numbers in a straight line or on an arc
8
44

Shifting, rotating, mirroring, scaling (axis specific)
Tilting the working plane, PLANE function
Manually definable: shifts, rotations, and handwheel superimpositioning can be manually defined
via global program settings
Mathematical functions =, +, –, *, /, sin α, cos α, tan α, arc sin, arc cos, arc tan, an, en, In, log,
square root of a, square root of (a2 + b2)
Logical operations (=, = /, <, >)Calculating with parentheses
Absolute value of a number, constant π, negation, truncation of digits before or after the decimal
point
Functions for calculation of circles
Functions for text processing✓✓

Calculator
Complete list of all current error messages
Context-sensitive help function for error messages
TNCguide: the integrated help system. User information directly available on the TNC 640; contextsensitive calling possible
Graphic support for programming cycles
Comment and structure blocks in the NC program✓

Display of standardized CAD file formats on the TNC

11

TNC 640
OptionStandard

User function

Teach-In✓

Actual positions can be transferred directly into the NC program

Test graphics
Depictions✓✓✓

Graphical simulation before a program run, even while another program is running
Plan view / projection in 3 planes / 3-D view, also in tilted working plane
Detail zoom

3-D line graphics✓

For verification of programs created offline

Programming graphics ✓In the Programming and Editing mode, the contours of entered NC blocks are rendered (2-D
pencil-trace graphics), even while another NC program is running

Program-run graphics
Display modes✓✓

Graphic simulation during real-time machining
Plan view / projection in 3 planes / 3-D view

Machining time✓✓

Calculation of machining time in the Test Run operating mode
Display of the current machining time in the Program Run operating modes

Returning to thecontour✓✓Mid-program startup at any block in the program, and approach of the calculated nominal position
for continued machining
Program interruption, contour departure and approach

Preset management✓

One table for saving any reference points (presets)

Datum tables✓Multiple datum tables for storing workpiece-specific datums

Pallet tables✓

Workpiece-oriented execution of pallet tables (with any number of entries for the selection of
pallets, NC program, and datums)

Parallel secondary
axes

✓
✓

Compensation of movement in the secondary axes U, V, W through the principal axes X, Y, Z
Movements of parallel axes included in the position display of the associated principal axis (sumdisplay)
Defining the principal and secondary axes in the NC program makes it possible to run programs on
different machine configurations✓
Touch probe cycles

Conversational
languages

12

✓
✓
✓
✓
✓

48

Calibrating the touch probe
Compensation of workpiece misalignment, manual or automatic
Reference point setting, manual or automatic
Automatic tool and workpiece measurement
Automatic measurement and optimization of machine kinematics
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

Software options

SoftwareoptionnumberSoftware option

With NC
software34059x- or
later

ID

Comment

Page

0

Additional Axis 101354540-01

Additional control loop 1

201Additional Axis 201353904-01

Additional control loop 2202Additional Axis 301353905-01

Additional control loop 3"Enablingfurther
controlloops"

3

Additional Axis 401367867-01

Additional control loop 4"Enablingfurther
controlloops"

4

Additional Axis 501367868-01

Additional control loop 5205Additional Axis 601370291-01

Additional control loop 6206Additional Axis 701370292-01

Additional control loop 7207Additional Axis 801370293-01

Additional control loop 8208Advanced Function
Set 1

01

617920-01

Rotary table machining• Programming of cylindrical contours as if in two axes
• Feed rate in mm/min

63

Coordinate transformation• Tilting the working plane, PLANE function

64

Interpolation• Circular in 3 axes with tilted working plane
9

Advanced Function
Set 2

01

617921-01

3-D machining64• 3-D tool compensation via surface normal vectors• Using the electronic handwheel to change the angle ofthe swivel head during program run without affecting
the position of the tool point (TCPM = Tool Center
Point Management)• Keeping the tool normal to the contour• Tool radius compensation normal to the tool direction• Manual traverse in the active tool-axis system
Interpolation• Linear in more than 4 axes (export license required)

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM
component

9440

DCM Collision

01
02526452-01

Dynamic collision monitoring (DCM)

7942

CAD Import

08526450-01

Importing of contours from 2-D and 3-D models, e.g.,
STEP, IGES, DXF

44

Global PGM Settings

05

576057-01

Global program settings

65

45

Adaptive Feed Control
(AFC)

02

579648-01

Adaptive feed control

74

46

Python OEM Process

01579650-01

Execute Python applications

89

48

KinematicsOpt

01630916-01

Touch-probe cycles for the automated measurement ofrotary axes

82

49

Double-Speed Axes

01

632223-01

Short control-loop cycle times for direct drive motors

72

13Software
optionnumberSoftware option

With NC
software34059x- or
later

ID

Comment

Page

50

Turning

01634608-01

Turning functions• Tool management for turning• Tool-tip radius compensation• Switching between milling and turning modes ofoperation• Lathe-specific contour elements• Package of turning cycles

66

52

KinematicsComp

05661879-01

Spatial compensation of errors in rotary andlinear axes (export license required)83

56 - 61

OPC UA NC Server 1
to 6

10

1291434-01 Connection of an OPC UA application
to1291434-06

95

77

4 Additional Axes

01

634613-01

4 additional control loops

2078

8 Additional Axes

01

634614-01

8 additional control loops

20

92

3D-ToolComp

07679678-01

3-D radius compensation based on the contact angle(only with the Advanced Function Set 2 software option)

83

93

Extended ToolManagement01676938-01

Expanded tool management:• Tooling list
(list of all tools of the NC program)• T usage sequence(sequence of all tools inserted during the program)

96

Adv. Spindle Interp.

05751653-01

Additional functions for an interpolated spindle• Interpolation turning, coupling• Interpolation turning, contour finishing

101 - 130

OEM Software
Option02579651-01
to579651-30

Software options of the machine manufacturer

131

Spindle Synchronism

05806270-01

Synchronization of two or more spindles

94

133

Remote Desktop
Manager

01894423-01

Display and remote operation of external computer units(e.g., a Windows PC)

94

135

Synchronizing
Functions

041085731-01 Expanded synchronization of axes and spindles

65

136

Visual Setup Control

06

1099457-01 VSC: camera-based monitoring of the setup situation

65

137

State Reporting

09

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

86

141

Cross Talk Comp.

02

800542-01

CTC: compensation of axis couplings

77

142

Pos. Adapt. Control

02800544-01

PAC: position-dependent adaptation of control
parameters

77

143

Load Adapt. Control

02800545-01

LAC: load-dependent adaptation of control parameters

76

144

Motion Adapt. Control

02800546-01

MAC: motion-dependent adaptation of control
parameters

76

145

Active Chatter Control

02800547-01

ACC: active suppression of chatter

75

14

Software
optionnumberSoftware option

With NC
software34059x- or
later

ID

Comment

Page

146

Active Vibration
Damping

04800548-01

AVD: active vibration damping

77

154

Batch Process
Manager

051219521-01 Planning and executing multiple machining operations

65

155

Component
Monitoring

09

1226833-01 Monitoring for component overloading and wear

80

156

Grinding

101237232-01 Grinding function• Jig grinding• Switching between normal operation and dressingmode• Reciprocating stroke• Grinding cycles• Tool management for grinding and dressing

68

157

Gear Cutting

09

1237235-01 Functions for the machining of gear teeth

67

158

Advanced Function Set 09
Turning1237237-01 Extended turning cycles and functions

67

167

Optimized Contour
Milling

1289547-01 OCM: optimized contour milling

75

10

15

HSCI control components
Main computers

Main computer

The MC main computers feature:• Processor• RAM memory• HSCI interface to the controller unit and to other control
components• HDL interface to the BF monitor(with electrical cabinet versions)• 4 x USB 3.0 interface, e.g. to the TE 7x5 keyboard unit
To be ordered separately, and installed in the main computer by
the OEM:• HDR or SSDR storage medium with the NC software• The System Identification Key (SIK) component for enabling
control loops and software options.
The following HSCI components are necessary for operation of
the TNC 640:
• MC main computer• Controller unit
• PLB 62xx PLC I/O unit (system PL; integrated in UxC)
• MB 72x machine operating panel (integrated in TE 7x5) or
PLB 600x HSCI adapter for connection of an OEM machine
operating panel

Interfaces

For use by end users, the MC is equipped with theUSB 3.0 ,V.24/RS-232-C and Ethernet interfaces. Connection
to PROFIBUS DP or PROFINET IO is possible either via
additional modules or by means of a combined PROFIBUS DP /PROFINET IO module.

Power supply

The DC 24 V supply voltage to the main computer and other
HSCI components is provided by the PSL 13x power supply unit
with the supply voltage 24 V-NC or by the power supply of a UEC
compact inverter. For the entire HSCI system, this DC 24 V-NC
supply voltage is required to be safely separated voltage (PELV).
It must not be connected to the DC 24 V supply voltage for PLC
components (e.g., holding brakes).

Export version

Because the complete NC software is on the storage medium,no export version is required for the main computer itself. Only
the easily replaceable storage medium and SIK component areavailable as export versions.

Gen 3 labels

The Gen 3 labels identify in which systems the control
components can be used.
Gen 3 ready: These components can be used in systems withGen 3 drives (UVR 3xx, UM 3xx, CC 3xx) and in systems with a
1xx inverter system (UVR 1xx, UE 2xx, UR 2xx, CC 61xx).

16

Versions

Various versions of the MC main computer are available:• Installation in the electrical cabinet:
The MC 6x4x are installed in the electrical cabinet. The
operating panel requires HSCI, USB, and HDL cables as control
lines• Installation in the operating panel:
The MC 7522 (with operating keys), as well as the MC 85x2
(with touchscreen), are installed directly into the operating panel.
With the exception of the power supply line, only one HSCI
connecting cable to the electrical cabinet is needed. These MCs
are supported with NC software 34059x-04 or later

MC 654x

MC 6x41

MC 8512 with main computer installed on
the back*

Installation Storage
type
mediumProcessor

MC 6541

ElectricalcabinetHDR

MC 6542

ElectricalcabinetMC 6641RAM
memoryMC 8532 with main computer installed on
the backPowerconsumption*

Mass

ID

Intel Core i7-3
4 GB
1.7 GHz, dual-core≈ 48 W≈ 4.0 kg

1081185-xx

SSDRIntel Core i7-3
4 GB
1.7 GHz, dual-core≈ 48 W≈ 4.0 kg

1081188-xx

Electricalcabinet

HDRIntel Core i7-3
4 GB
2.1 GHz, quad-core≈ 75 W≈ 4.0 kg811550-xx

MC 7522

Operating
panel

SSDR

Intel Core i7-3,
4 GB
1.7 GHz, dual-core≈ 60 W≈ 6.5 kg

1071597-xx

MC 8512

Operating
panel

SSDR

Intel Core i7-3
4 GB
1.7 GHz, dual-core≈ 75 W≈ 7.5 kg

1243919-xx

MC 8532

Operating
panel

SSDR

Intel Core i7-3
4 GB
1.7 GHz, dual-core≈ 75 W≈ 7.5 kg

1189190-xx

MC 366

Operating
panel

SSDR

Intel Core i7-3,
8 GB
1.7 GHz, dual-core≈ 75 W≈ 7.5 kg

1246689-xx

Test conditions: Windows 7 (64-bit) operating system, 100 % processor loading, no load on interfaces, nofieldbus module

17Software options

Software options allow the performance of the TNC 640 to beadapted to one’s actual needs at a later time. The software options
are described on page 13. They are enabled by entering keywords
based on the SIK number and are saved in the SIK component.
Please provide the SIK number when ordering new options.

Storage medium

The storage medium must be ordered separately. It is removable
memory and contains the NC software. Depending on the main
computer, an HDR hard disk or an SSDR solid state disk is used asa storage medium.
HDR hard disk
Free capacity
For main computer
Export license required
No export license required
SSDR solid state disk
Free capacity
For main computer
Export license required
No export license required

144 GBMC 6541, MC 6641
ID 617779-10
ID 617779-60
21 GB
MC 6542, MC 7522,
MC 85x2
ID 810288-10
ID 810288-60

HDR hard disk

SSDR solid state disk

SIK component

The SIK component contains the NC software license forenabling control loops and software options. It gives the main
computer an unambiguous ID code—the SIK number. The SIK
component is ordered and shipped separately. It must be inserted
into a slot provided for it in the MC main computer.
The SIK component with the NC software license exists indifferent versions based on the enabled control loops and software
options. Additional control loops can be enabled later by entering a
keyword. HEIDENHAIN provides the keyword, which is based on
the SIK number.
When ordering, please provide the SIK number of your control.
When the keywords are entered in the control, they are saved in
the SIK component, thereby enabling and activating the software
options. Should servicing become necessary, the SIK component
must be inserted into the replacement control in order to enable allof the required software options.

Master keyword(general key)

18

For putting the TNC 640 into service, there is a master keyword
that enables all software options once for 90 days. After thisperiod, the software options can be activated only with the correct
keywords. The general key is activated via a soft key.

SIK component

TNCkeygen(accessory)

TNCkeygen is a collection of PC software tools for generating
enabling keys for HEIDENHAIN controls for a limited period oftime.
With OEM Key Generator, you can generate enabling keys
for software options by entering the SIK number, the software
option to be enabled, the enabling period, and an OEM-specificpassword. The enabling period is limited to 10 to 90 days. Eachsoftware option can be enabled only once. Options are enabledindependently of the master keyword.
The OEM daily key generator generates an enabling key for theprotected OEM area, thus granting the user access on the day it isgenerated.
NC software license
2 x CC 6108

CC 6106 +CC 6108

2 x CC 6106

CC 6110

CC 6108

CC 6106

Recommended combinations
Activecontrol loops

NC software
license andenabling ofcontrol loops
depending on
the CC

Without
optionIncl. option 8 Incl. options
8+9

Incl. options
8 + 9 + 50

SIK

SIK

SIK

SIK

4

✓

ID 674989-20
ID 674989-70

ID 674989-09
ID 674989-59

ID 674989-01
ID 674989-51

ID 674989-28
ID 674989-78

5✓

ID 674989-24
ID 674989-74

ID 674989-17
ID 674989-67

ID 674989-02
ID 674989-52

ID 674989-29
ID 674989-79

6✓

ID 674989-25
ID 674989-75

ID 674989-18
ID 674989-68

ID 674989-03
ID 674989-53

ID 674989-30
ID 674989-80

7✓

ID 674989-26
ID 674989-76

ID 674989-19
ID 674989-69

ID 674989-04
ID 674989-54

ID 674989-31
ID 674989-81

8✓

ID 674989-27
ID 674989-77

ID 674989-23
ID 674989-73

ID 674989-05
ID 674989-55

ID 674989-32
ID 674989-82

9✓

ID 674989-06
ID 674989-56

ID 674989-33
ID 674989-83

10✓

ID 674989-07
ID 674989-57

ID 674989-34
ID 674989-84

ID 674989-10
ID 674989-60

ID 674989-35
ID 674989-85

ID 674989-11
ID 674989-61

ID 674989-36
ID 674989-86

ID 674989-12
ID 674989-62

ID 674989-37
ID 674989-87

ID 674989-13
ID 674989-63

ID 674989-38
ID 674989-88

11

✓

12

✓

13

✓

14

✓

Only through subsequent
enabling of control loops(additional axes)

15✓

ID 674989-14
ID 674989-64

ID 674989-39
ID 674989-89

16✓

ID 674989-15
ID 674989-65

ID 674989-40
ID 674989-90

17 –
24

Only through subsequent enabling of control loops (additional
axes)(Italics: export version)

19

Enabling further
control loops

20

Further control loops can be enabled either as groups orindividually. The combination of control-loop groups and individual
control loops makes it possible to enable any number of control
loops. No more than 24 control loops are possible.
Control-loop groups

Software option

4 additional control loops77

ID 634613-01

8 additional control loops78

ID 634614-01

Individual control loops

Software option

1st additional control loop

0

ID 354540-01

2nd additional control loop

1

ID 353904-01

3rd additional control loop2

ID 353905-01

4th additional control loop3

ID 367867-01

5th additional control loop

4

ID 367868-01

6th additional control loop5

ID 370291-01

7th additional control loop

6

ID 370292-01

8th additional control loop

7

ID 370293-01

Controller unit

Controller unit

Due to the very short cycle times of the position, speed, andcurrent controllers, the controller units from HEIDENHAIN are
equally suited for conventional motors, for direct drive motors(linear motors, torque motors), and for HSC spindles. They permit
a high loop gain and short reaction times to changing machining
forces, and so make the high contour accuracy and surface qualityof the workpiece possible.

Single-speed
Double-speed

For linear and torque motors, as well as for conventional axes,
single-speed control loops are usually sufficient. For HSC
spindles and difficult-to-control axes, double-speed control loops
are the preferred choice (software option 49). By default, all axes
are set to single-speed. Every axis that is switched from singlespeed to double-speed can reduce the number of available control
loops by one. At a PWM frequency greater than 5 kHz, doublespeed is always required. Software option 49 must be enabled for
this.

Cycle times

At fPWM

Current controller

Speed controller

Position controller

Single-speed

Double-speed1)3333 Hz150 µs300 µs150 µs4000 Hz125 µs250 µs125 µs5000 Hz100 µs200 µs100 µs6666 Hz1)75 µs

150 µs150 µs8000 Hz1)60 µs

125 µs125 µs

10 000 Hz1)50 µs

100 µs100 µsSame as speed
controller

1) Possible only with software option 49

Number of control
loops
Versions

The number of enabled control loops depends on the SIK (seeMain computers), or on additionally enabled control loops, which
can also be ordered as needed later.

• Modular CC 61xx controller units with PWM interface to theinverters• Compact UEC/UMC inverters with integrated controller unit
Controller units, main computers, and inverters operate in any
desired combination.

21

CC 61xx

The CC 61xx controller units feature:• Position controller, speed controller, current controller• HSCI interfaces• PWM interfaces to the UM, UR, UE power modules• Interfaces to the speed and position encoders• Interfaces for power supply (via inverter or PSL 135)• SPI interfaces for expansion modules (e. g. CMA-H)

CC 6110

CC 6106

CC 6108

CC 6110

Digital control loops

Max. 6 (single speed)

Max. 8 (single speed)

Max. 10 (single speed)

Speed inputs

6 x 1 VPP or EnDat 2.2

8 x 1 VPP or EnDat 2.2

10 x 1 VPP or EnDat 2.2

Position inputs

6 x 1 VPP or EnDat 2.2

8 x 1 VPP or EnDat 2.2

10 x 1 VPP or EnDat 2.2

PWM outputs

6

8

10

SPI expansion slots

2

4

4

Power consumption(without encoders)

25 W

35 W

40 W

Mass

4.1 kg

4.7 kg

4.8 kg

ID 662636-xx

ID 662637-xx

ID 662638-xx

For more than 10 control loops, an HSCI line is used to combine
the controller units. For example:
CC 6106 + CC 6106 for up to 12 control loops
CC 6106 + CC 6108 for up to 14 control loops
CC 6110 + CC 6108 for up to 18 control loops
Constraints:• Up to 24 control loops (22 control loops with functional safety(FS)) can be activated, of which up to 4 can be configured as
spindles• Maximum of 4 controller motherboards are permissible
in the HSCI system (CC 6106 contains one motherboard,CC 6108/CC 6110 each have two)22

Ribbon cables for
supply voltage

Additional ribbon cables are necessary if multiple CC 6xxx units
are combined.
Combination

LengthDimensionc

2 x CC 6108, or
2 x CC 6110, or
CC 6108 andCC 6110160 mm1)

26.5 mm

ID 325816-22

2 x CC 6106

110 mm31.5 mm

ID 325816-24

1) In order to reduce the voltage drop, the long ribbon cable isrouted doubled.

With a combination of CC 6108 and/or CC 6110, the shortribbon cables included in delivery are not needed. They are only
necessary for connecting sockets X69 A and X69 B if the CC units
are used separately.
For more information about connecting a CC 6xxx to a supply unit
via ribbon cables, see the Inverter Systems brochure.

UEC 11x

The UEC 11x compact inverters not only include the inverter, butalso a controller with PLC inputs and outputs and an integrated
braking resistor. They form a complete solution for machines witha limited number of axes and low power demands.
Controllers• Position controller, speed controller, current controller• HSCI interface• Interfaces to the speed and position encoders• SPI interface
Inverters• Power electronics• Connections for axis motors and spindle motor• Braking resistor• Connections for motor holding brakes• Additional DC-link connection on the front for connection of a
PSL 130
System PL (without EnDat support)• Interfaces for one workpiece touch probe and one tool touchprobe• Integrated PLC (expandable with PL 61xx)
UEC 11x: 38 free inputs, 23 free outputs (7 of which can beswitched off)
• Configuration with IOconfig PC software

UEC 113

23

UEC 111/UEC 112/UEC 113
Controllers

4/5/6 digital control loops

Speed inputs

4/5/6 x 1 VPP or EnDat 2.2

Position inputs

4/5/6 x 1 VPP or EnDat 2.2

Inverters

2/3/4 axes

1 axisSpindle3333 Hz

6.0/12.0 A

9.0/18.0 A

24.0/36.0 A

4000 Hz

5.5/11.0 A

8.3/16.5 A

22.0/33.0 A

5000 Hz

5.0/10.0 A

7.5/15.0 A

20.0/30.0 A

6666 Hz

4.2/8.4 A

6.3/12.6 A

16.8/25.2 A

8000 Hz

3.6/7.3 A

5.5/11.0 A

14.6/21.9 A

10 000 Hz

3.0/6.0 A

4.6/9.2 A

12.2/18.3 A

Rated current IN/
Maximum current Imax1)
at a PWM frequency ofSupply voltage

3AC 400 V (± 10 %); 50 Hz or 3AC 480 V (+6 %/–10 %); 60 Hz

Rated power of DC link

14 kW

Peak power2) of DC link

18 kW / 25 kWPower loss at IN≈ 450 W

DC-link voltage

DC 565 V

Integral braking resistance3)

2.1 kW / 27 kW

Power supply unit for HSCI components

DC 24 V / 3.5 A

Module width

150 mmMass≈ 14 kg

Functional safety (FS)-✓UEC 111
UEC 112
UEC 113

ID 1081002-xx
ID 1081003-xx
ID 828471-xx

ID 1075825-xx
ID 1075826-xx
ID 1038694-xx

1) Axis: 0.2 s cyclic duration factor for cycle duration of 10 s with 70 % rated current preload

Spindle: 10 s cyclic duration factor for cycle duration of 60 s with 70 % rated current preload2) 1st value: 40 % cyclic duration factor for cycle duration of 10 min (S6-40 % )2nd value: 4 s cyclic duration factor for cycle duration of 20 s3) 1st value: continuous power

2nd value: peak power (1.5 % cyclic duration factor for cycle duration of 120 s)

24UMC 11x FS

The UMC 111 FS is a compact inverter with an integrated
controller unit and PLC inputs/outputs. In contrast to the UEC, it
is used exclusively for controlling axis motors and is powered by
an external DC link. The UMC automatically enables the control
loops needed for auxiliary axes. Additional software options are
not necessary.
Please note: The UMC does not expand the number of possible
axes. Interpolation with NC axes is not possible.
Controllers• Position controller, speed controller, current controller• HSCI interface• Interfaces to the speed encoders• SPI interface
Inverters• Power electronics• Connections for axis motors• Connections for motor holding brakes
System PL (without EnDat support)• Integrated PLC, expandable with PL 61xx
UMC 111 FS: 38 free inputs, 28 free outputs (7 of which can beswitched off)
8 FS inputs, 8 FS outputs• Configuration with IOconfig PC software

UMC 111 FS

UMC 111 FS
Controllers

4 digital control loops

Speed inputs

4 x 1 VPP or EnDat 2.2

Inverters

4 axesRated current IN/
Maximum current
Imax1) at a PWM
frequency of3333 Hz

9.0/18.0 A

4000 Hz

8.3/16.5 A

5000 Hz

7.5/15.0 A

6666 Hz

6.3/12.6 A

8000 Hz

5.5/11.0 A

10 000 Hz

4.6/9.2 A

Power loss at IN≈ 300 W

DC-link voltage

DC 565 V or DC 650 V

24 V PLC current consumption

DC 24 V / 2 A

Module width

150 mmMass≈ 11 kg

UMC 111 FS

ID 664231-xx

1) Axis: 0.2 s cyclic duration factor for cycle duration of 10 s with 70 % rated current preload

Spindle: 10 s cyclic duration factor for cycle duration of 60 s with 70 % rated current preload

25

Adapterconnector for
temperature
sensorFor applications with purely serial EnDat 2.2 encoders, the adapter
connector offers the option of interposing an external KTY or
PT 1000 temperature sensor (e.g., of linear and torque motors)
and route it to the speed encoder input of the controller unit.
The adapter connector can also be used in conjunction withencoders with EnDat02 or 1 VPP interface. The adapter connector
is plugged directly onto the speed encoder input (X15 to X20) of
the controller unit.
KTY adapter connector ID 367770-xx
Mass≈ 0.1 kg
Additional cables are required for the use of multiple adapter
connectors on one controller unit because the connector for an
external KTY or PT 1000 temperature sensor does not permit themounting of multiple adapter connectors in a row on the CC 61xx.

26

Encoders with EnDat interface(EnDat2.1, EnDat2.2)

Encoders with 1 VPP interface

1 m cable

ID 336377-01

ID 312533-01

3 m cable

ID 336377-03

ID 312533-03

15-inch screen and keyboard

BF 750 monitor• Supply voltage: DC 24 V/≈ 50 W
• 15-inch; 1024 x 768 pixels• HDL interface to the MC 6xxx
• 8 horizontal soft keys, 6 vertical soft keys for PLC• Soft-key row switchover• Selectable screen layout• Operating mode switchover• USB port with cover cap on front• Integrated USB hub with four USB interfaces on the rear
BF 750Mass

ID 785080-xx≈ 4 kg
BF 750TE 730 keyboard• For BF 750 or MC 7522
• Axis keys
• The keys for axes IV and V are exchangeable snap-on keys.
• Contouring keys
• Operating mode keys
• ASCII keyboard• Spindle-speed and feed-rate override potentiometer• USB interface to the MC• Touchpad
TE 730Mass

TE 735 keyboard
with an integrated
machine operatingpanel

ID 805489-xx≈ 2.4 kg

TE 730• For BF 750 or MC 7522
• NC keyboard same as TE 730• USB interface to the MC main computer• Machine operating panel (same as MB 720)
• HSCI interface
TE 735
TE 735 FS
Mass

ID 771898-xx
ID 805493-xx≈ 3.4 kg

TE 73527

MB 720 machine
operating panel• Supply voltage: DC 24 V/≈ 4 W• 36 exchangeable snap-on keys with status LED, freely definable

via PLC (assignment as per PLC basic program: 12 axis keys,
spindle start, spindle stop, 22 further function keys)• Further operating elements:1)NC start1), NC stop1), emergencystop key, control voltage On , two bore holes for additional keys
or keylock switches• HSCI interface• MB 720: 8 free PLC inputs and 8 free PLC outputs
MB 720 FS: 4 free FS inputs and 8 free PLC outputs; additional
dual-channel FS inputs for emergency stop and permissive
buttons of the handwheel.
1)

MB 720Illuminated keys, addressable via PLC

MB 720
ID 784803-xx
MB 720 FS ID 805474-xx
Mass≈ 1 kg
MB 721 machine
operating panel

Same as the MB 720, except:• Suitable for the MC 8512
• Changed front panel• Three holes for additional push buttons or keylock switches
MB 721
ID 1164974-xx
MB 721 FS ID 1164975-xx
Mass≈ 1.6 kg

28

MB 721

19-inch screen and keyboard

BF 860 monitor• Supply voltage: DC 24 V/≈ 65 W
• 19-inch; 1280 x 1024 pixels• Integrated USB hub with 4 USB ports on the rear
• Display for multitouch operation
Via touchscreen operation• Soft-key row switchover• Screen layout• Operating mode switchover
BF 860Mass

ID 1244875-xx≈ 7.1 kg
BF 860TE 745 keyboard
with an integrated
machine operating
panel

General data:• Suitable for BF 860 (19-inch design)• Axis keys
• The keys for axes IV and V are exchangeable snap-on keys
• Contouring keys
• Operating mode keys
• ASCII keyboard• Spindle, feed-rate, and rapid-traverse override potentiometers• USB interface to the MC main computer• Touchpad• USB port with cover cap on front
Specifications:• Supply voltage: DC 24 V/≈ 4 W• 36 exchangeable snap-on keys with status LED, freely definable
via PLC (assignment in accordance with PLC basic program:
12 axis keys, spindle start, spindel stop, 22 other function keys)• Further operating elements:1)NC start1), NC stop1), emergencystop key, control voltage on , two holes for additional keys or
keylock switches• Connection for HR handwheel• HSCI interface• TE 745: 8 free PLC inputs and 8 free PLC outputs
TE 745 FS: 4 free FS inputs and 8 free PLC outputs; additional
dual-channel FS inputs for emergency stop and permissive
buttons of the handwheel.
1)

TE 745

Illuminated keys, addressable via PLC

TE 745
TE 745 FS
Mass

ID 679817-xx
ID 805482-xx≈ 4.3 kg29

24-inch keyboard

TE 360 keyboard
with an integrated
machine operating
panel

General data:• Suitable for BF 360 (24-inch design)• Axis keys
• The keys for axes IV and V are exchangeable snap-on keys
• Contouring keys
• Operating mode keys
• ASCII keyboard• Spindle, feed-rate, and rapid-traverse override potentiometers• USB interface to the MC main computer• Trackball• USB port with cover cap on front
Specifications:• Supply voltage: DC 24 V/≈ 4 W• 36 exchangeable snap-on keys with status LED, freely definable
via PLC (assignment in accordance with PLC basic program:
12 axis keys, spindle start, spindle stop, 22 further function keys)• Further operating elements:1)NC start1), NC stop1), emergencystop key, control voltage on , holes for additional keys or keylock
switches• Connection for HR handwheel• HSCI interface• TE 360: 8 free PLC inputs and 8 free PLC outputs
TE 360 FS: 4 free FS inputs and 8 free PLC outputs; additional
dual-channel FS inputs for emergency stop and permissive
buttons of the handwheel.
1)

Illuminated keys, addressable via PLC

Standard potentiometer layout:
TE 360
ID 1280184-xx
TE 360 FS ID 1275710-xx
Mass≈ 5.8 kg
Alternative potentiometer layout:
TE 360
ID 1284265-xx
TE 360 FS ID 1284263-xx
Mass≈ 5.8 kg30

TE 360 with standard potentiometer layout

TE 360 with alternative potentiometer layout

PL 6000 PLC input/output systems with HSCI

PL 6000

The PLC inputs and outputs are available via external modular
PL 6000 PLC input/output systems. They consist of a basic
module and one or more input/output modules. A total maximumof 1000 inputs/outputs is supported. The PL 6000 units areconnected to the MC main computer via the HSCI interface. The
PL 6000 units are configured with the IOconfig PC software.

PLB 62xx

Basic modules

Basic modules with an HSCI interface exist for 4, 6, 8, and10 modules. Fastening is performed on standard NS 35 rails(DIN 46227 or EN 50022).
Supply voltage
Power consumption1)
Mass

DC 24 V≈ 48 W at DC 24 V NC
≈ 21 W at DC 24 V PLC≈ 0.36 kg (bare)1) PLB 6xxx completely filled, incl. TS, TT. For more details withregard to sizing the power supply for DC 24 V NC, see Powersupply for HSCI components.

System PL with
EnDat support• Required once for each control system (except with UEC)
• Connections for TS and TT touch probes• TS and TT touch probes with EnDat interface are supported• Safety-relevant inputs/outputs• Without FS: 12 free inputs, 7 free outputs
With FS: 6 free FS inputs, 2 free FS outputs• The slots are fitted with cover strips, so no empty housings areneeded• Software support as of NC software 34059x-08• Enabling of functional safety with the PLB 62xx FS
PLB 6204
PLB 6206
PLB 6208
PLB 6210

For 4 I/O modules
For 6 I/O modules
For 8 I/O modules
For 10 I/O modules

ID 1129809-xx
ID 1129812-xx
ID 1129813-xx
ID 1278136-xx

PLB 6204 FS
PLB 6206 FS
PLB 6208 FS
PLB 6210 FS

For 4 I/O modules
For 6 I/O modules
For 8 I/O modules
For 10 I/O modules

ID 1129808-xx
ID 1129811-xx
ID 1129810-xx
ID 1278134-xx

31

Expansion PL

For connection to the system PL to increase the number of PLC
inputs/outputs
PLB 6104
PLB 6106
PLB 6108

For 4 I/O modules
For 6 I/O modules
For 8 I/O modules

ID 1129799-xx
ID 1129803-xx
ID 1129804-xx

PLB 6104 FS
PLB 6106 FS
PLB 6108 FS

For 4 I/O modules
For 6 I/O modules
For 8 I/O modules

ID 1129796-xx
ID 1129806-xx
ID 1129807-xx

Up to seven PLB 6xxx can be connected to the control.
I/O modules

There are I/O modules with digital and analog inputs and outputs.
For partially occupied basic modules, the unused slots must be
occupied by an empty housing.

PLD-H 04-04-00
HSLS FSI/O module with 16 digital inputs and8 digital outputs
I/O module with 8 digital inputs and
16 digital outputs
I/O module with 8 digital FS inputs and4 digital FS outputs
I/O module with 4 digital FS inputs and8 digital FS outputs
I/O module with 4 digital FS inputs and4 high-side/low-side FS outputs

Total current
Power output
Mass

Outputs 0 to 7: ≤ 2 A per output (≤ 8 A simultaneously)
Max. 200 W≈ 0.2 kg

PLA-H 08-04-04

Analog module for PL 6xxx with
• 8 analog inputs, ±10 V• 4 analog outputs, ±10 V• 4 analog inputs for PT 100 thermistors≈ 0.2 kg

PLD-H 16-08-00
PLD-H 08-16-00
PLD-H 08-04-00 FS
PLD-H 04-08-00 FS

Mass
IOconfig(accessory)

32

PC software for configuring HSCI and PROFIBUS components

ID 594243-xx
ID 650891-xx
ID 598905-xx
ID 727219-xx
ID 746706-xx

ID 675572-xx

Accessories
Power supply for HSCI components

PSL 13x

HEIDENHAIN offers the PSL 13x power supply unit in orderto power the HSCI components. Either line voltage and DClink voltage or only line voltage is provided to the PSL 13x. The
PSL 13x provides the safely separated DC 24 V PELV NC power
supply required for the HSCI components by EN 61800-5-1. The
NC supply voltage and the PLC supply voltage are separated fromeach other by basic insulation.
Supplyvoltage
Outputs• PSL 13x (L1, L2): AC 400 V (360 V to 480 V),
50/60 Hz

• PSL 13x (DC-link voltage): DC 400 V to 750 V• Power consumption ≤1000 W

NC:

PLC:
Total:DC 24 V/≤ 20 A
(double insulation from line power)
DC 5 V/≤ 16 A (only for PSL 135)
galvanically connected with DC 24 V NC
DC 24 V/≤ 20 A (basic insulation from line
power)≤ 32 A/750 W

PSL 130

The PSL 130 serves as a DC 24 V power supply unit for supplying
the HSCI components. It is not necessary in connection with
the UEC if the total current consumption of the connected HSCI
components does not exceed 3.5 A.
HSCI components

Current consumption DC 24 V NC

Main computer

MC 6541, MC 6542
MC 6641, MC 7532
MC 7522

2.0 A
3.2 A
2.5 A

Machine operating panel

PLB 600x
MB 7x00.2 A (without handwheel)
0.2 A (without handwheel)

Keyboard

TE 7x5 (MB integrated)

0.2 A (without handwheel)

PLC inputs/outputs

PLB 62xx
PLB 61xx
PLD
PLA

0.3 A (without touch probe)
0.2 A
0.05 A
0.1 A

Monitor

BF 750
BF 860

2.1 A
1.9 A

Handwheels

HR 520
HRA 551 FS + HR 550 FS
HR 510
HR 1300.05 A
0.5 A (during charging)
0.05 A
0.05 A

Touch probes

See specifications of the touch probes

The PSL 135 has an additional DC 5 V output and is therefore
suited for supplying the CC controller unit and the MC main
computer. It might be necessary with multi-row configuration.
Module width

Degree ofprotection

Mass

PSL 130

50 mm

IP20

≈ 2.1 kg

ID 575047-xx

PSL 135

50 mm

IP20

≈ 2.5 kg

ID 627032-xx

The UV(R) supply units currently available also feature an
integrated power supply that provides DC 24 V to HSCI
components.

33

HSCI adapter for OEM machine operating panel

PLB 600x

The PLB 600x HSCI adapter is required in order to connect anOEM-specific machine operating panel to the TNC 640. The
spindle-speed and feed-rate override potentiometers of the TE 7xx
and the HR handwheel are also connected to these adapters.

• HSCI interface• Connection for HR handwheel• Inputs/outputs for keys/key illumination

PLB 6001: terminals for 72 PLC inputs and 40 PLC outputs
PLB 6001 FS: terminals for 36 FS inputs and 40 PLC outputs
PLB 6002 FS: terminals for 4 FS inputs, 64 PLC inputs and 40
PLC outputs• Screw fastening or top-hat-rail mounting• Configuration of the PLC inputs/outputs with the IOconfig
computer software
PLB 6001
PLB 6001 FS
PLB 6002 FS
Mass

34

ID 668792-xx
ID 722083-xx
ID 1137000-xx≈ 1.2 kg

PLB 6001

Additional modules

Overview

The additional modules are directly connected to the HSCI control
system through a slot on the MC main computer, on the CC
controller unit, or on the UEC or UMC inverter.

Module for analog
axes

Digital drive designs sometimes also require analog axes orspindles. The additional module CMA-H 04-04-00 (Controller
Module Analog—HSCI) makes it possible to integrate analog drive
systems in an HSCI system.
The CMA-H is integrated into the HSCI control system via a sloton the underside of the CC or UEC. Every controller unit has slots
for two boards. The CMA-H does not increase the total numberof available axes: every analog axis used reduces the number ofavailable digital control loops by one. Analog control loops alsoneed to be enabled on the SIK. The analog control-loop outputs
can be accessed only via the NC, not via the PLC.
Additional module for analog axes/spindles:• Expansion board for CC 61xx or UEC controller units• 4 analog outputs, ±10 V for axes/spindle• Spring-type plug-in terminals
CMA-H 04-04-00

ID 688721-xx

Fieldbus systems

An expansion board can be used to provide the TNC 640 witha PROFIBUS or PROFINET interface at any time. The modules
are integrated into the control system through a slot on the MC.
This makes the connection to an appropriate fieldbus system as amaster possible. As of version 3.0, the interface is configured with
IOconfig.

PROFIBUS DP
moduleAdditional module for PROFIBUS DP:• Expansion board for the MC main computer• Connection for 9-pin D-sub connector (female) to X121
PROFIBUS DP additional module

CMA-H 04-04-00

ID 828539-xx

PROFIBUS DP module

PROFINET IO
moduleAdditional module for PROFINET IO:• Expansion board for the MC main computer• RJ45 connection at X621 and X622
PROFINET IO additional module

ID 828541-xx

PROFINET IO module

Combined
PROFIBUS DP/PROFINET IO
moduleAdditional module for PROFIBUS DP and PROFINET IO:• Expansion board for the MC main computer• Connection for RJ45 connector to X621 (PROFINET IO) andM12 connector to X121 (PROFIBUS DP)• Additionally connectable terminating resistor for PROFIBUS DP
with front LED
Additional PROFIBUS DP and
PROFINET IO

ID 1160940-xx
Combined module

35

Touch probes

Overview

Touch probes for tool and workpiece measurement are connected
via the system PL 62xx or the UEC/UMC. These touch probes
generate a trigger signal that saves the current position value
to the NC. The EnDat interface makes touch probes intelligent
and allows for greater convenience when connecting them to
HEIDENHAIN controls. For more information on touch probes,
please refer to the Touch Probes for Machine Tools brochure(ID 1113984).

Workpiece
measurement

The TS touch trigger probes feature a stylus for probing
workpieces. HEIDENHAIN controls feature standard routines foraligning and measuring workpieces, and for setting presets. The
touch probes are available with various clamping shanks. Assorted
styli are available as accessories.
Touch probes with cable-bound signal transmission:

TS 260Touch probe for milling, turning, drilling, boring, and grinding
machines with manual tool changing capability

TS 248

Like the TS 260, but with reduced deflection forces

TS 260Touch probes with cableless signal transmission for machining
centers and milling, drilling, and boring machines with automatedtool changing capability (for the appropriate transceiver, see Page37):
TS 460Touch probe with radio and infrared transmission:• Hybrid technology: signal transmission via radio and infrared
signals• Large transmission range and long operating time
• Mechanical collision protection and thermal decoupling• With EnDat functionality

TS 460Touch probes with infrared transmission:
TS 642

Activation via switch in taper shank

TS 740High probing accuracy and reproducibility, low probing force

36

Tool
measurement

The touch probes for tool measurement from HEIDENHAIN
are suited for probing stationary or rotating tools directly on
the machine. The TNC 640 features standard cycles for themeasurement of tool length and diameter, as well as of individual
teeth. The TNC 640 automatically saves the measured tool
dimensions in a tool table. It is also possible to measure tool wear
between two machining steps. For the next machining operation,
the TNC 640 automatically compensates for the tool dimensions
or inserts a replacement tool (as when a tool breaks).
With the TT touch trigger probes, the disk-shaped probe contact
is deflected from its resting position by contact with the stationary
or rotating tool, and a trigger signal is transmitted to the TNC 640.

TT 160Touch probe with signal transmission to the control via aconnected cableTT 160TT 460Touch probe with hybrid technology: radio or infrared-beamtransmission (for the appropriate transceiver, see below).
Optionally available with EnDat functionality.

TransceiverRadio and infrared communication is established between the TS
or TT touch probe and the SE transceiver.
SE 660 for radio and infrared transmission (hybrid technology);
SE unit for both the TS 460 and TT 460;
SE 661 for radio and infrared transmission (hybrid technology);
SE for both the TS 460 and TT 460; EnDat functionality
for the transmission of the switching status, as well as fordiagnostic information and additional data.
SE 540 for infrared transmission; for installation in the spindle
head
SE 642 for infrared transmission; SE for both the TS and TT

SE 661

The following combinations are possible:
SE 660*UTI 660

SE 661*

SE 540SE 642

InfraredInfraredInfraredInfrared

TS 460Radio/infrared

TS 642

Infrared

TS 740–InfraredInfrared

TT 460Radio/infrared

InfraredInfrared–With EnDat interface

The UTI 660 interface unit is required for connecting multiple
TS 460 and TT 460 touch probes to a HEIDENHAIN control that
does not support EnDat. With the UTI 660, up to four touchprobes (TS 460 / TT 460 / combined) can be operated with an
SE 660 on the control.
ID 1169537-01

37Electronic handwheels

Overview

Support for electronic handwheels is standard on the TNC 640:
• HR 550 FS wireless handwheel, or• HR 510 or HR 520 portable handwheel, or• HR 130 panel-mounted handwheel
It is possible to operate up to five handwheels or handwheel
adapters on a single TNC 640:
• One handwheel via the handwheel input of the main computer• One handwheel each on up to four HSCI machine operating
panels or the PLB 600x HSCI adapter
A mixed operation of handwheels with and without display is notpossible. Handwheels with functional safety are cross-circuit-proof
due to their special permissive-button logic.

HR 510Portable electronic handwheel with:• Keys for actual-position capture and the selection of five axes
• Keys for traverse direction and three preset feed rates• Three keys for machine functions (see below)• Emergency stop button and two permissive buttons (24 V)• Magnetic holding pads
All keys are designed as snap-on keys and can be replaced by keys
with other symbols (see overview for HR 510 in Snap-on keys for
handwheels).

HR 510HR 510 FS

Keys

Without
detentWith detent

NC start/stop,
spindle start(for basic PLC
program)

ID 1119971-xx

ID 1120313-xx

FCT A, FCT B,
FCT C

ID 1099897-xx –Spindle right/left/
stop

ID 1184691-xx–

NC start/stop,
spindle start(for basic PLC
program)

ID 1120311-xx

ID 1161281-xx

FCT A, FCT B,
FCT C

–

ID 1120314-xx

Spindle start,
FCT B, NC start–

ID 1119974-xx

Mass ≈ 0.6 kg

38

HR 510HR 520

Portable electronic handwheel with:• Display for operating mode, actual position value, programmed
feed rate and spindle speed, error messages• Override potentiometers for feed rate and spindle speed• Selection of axes via keys or soft keys
• Actual position capture• NC start/stop• Spindle on/off• Keys for continuous traverse of the axes
• Soft keys for machine functions of the machine manufacturer• Emergency stop button
Without detent With detent
HR 520ID 670302-xx

ID 670303-xx

HR 520 FS

ID 670304-xx

ID 670305-xx

Mass ≈ 1 kg

HR 520Holder for HR 520

For attaching to a machine

ID 591065-xx

HR 550 FS

Electronic handwheel with wireless transmission. Display,
operating elements, and functions are like those of the HR 520
In addition:• Functional safety (FS)• Radio transmission range of up to 20 m (depending on
environment)
HR 550 FS

Without detentWith detent

ID 1200495-xx
ID 1183021-xx

Replacement
battery

For HR 550 FS

ID 623166-xx

HR 550 FS with HRA 551 FS

HRA 551 FS

Handwheel holder for HR 550 FS• For docking the HR 550 FS onto the machine• Integrated battery charger for HR 550 FS• Connections to the control and the machine• Integrated transceiver• HR 550 FS magnetically held to front of HRA 551 FS
HRA 551 FS
Mass

ID 1119052-xx≈ 1.0 kg

For more information, see the HR 550 FS Product Information
document.

39

Connecting cables

HR 510HR 510 FS

HR 520HR 520 FS

HR 550 FS
with
HRA 551 FS

–

–

✓

✓

–

ID 312879-01

✓

✓

–

–

–

ID1117852-03

Connecting cable with –metal armor
✓

–

✓

✓

–

ID 296687-xx

✓

–

–

–

ID 1117855-xx

Connecting cablewithout metal armor

–

–

✓

✓

✓ (max. 2 m)

ID 296467-xx

✓

✓

–

–

–

ID 1117853-xx

Adapter cable for
HR/HRA to MC,straight connector

✓

✓

✓

✓

✓1)

ID 1161072-xx

Adapter cable for
HR/HRA to MC,
angled connector
(1 m)

✓

✓

✓

✓

✓1)

ID 1218563-01

Extension cable toadapter cable

✓

✓

✓

✓

✓1)

ID 281429-xx

Adapter cable for HRA –
to MC

–

–

–

✓2)

ID 749368-xx

Extension cable toadapter cable

–

–

–

–

✓2)

ID 749369-xx

Adapter connector for ✓handwheels without
functional safety

–

✓

–

–

ID 271958-03

Adapter connector
for handwheels withfunctional safety

✓

–

✓

✓

ID 271958-05

Connecting cable(spiral cable) to HR
(3 m)

–

1) For maximum cable lengths up to 20 m between the MB and HRA 551 FS
2) For maximum cable lengths up to 50 m between the MB and HRA 551 FS

See also Cable overview on Page 51.
HR 130Panel-mounted handwheel with ergonomic control knob.
It is attached to the MB 7x0 or the TE 7x5 either directly or via an
extension cable.
HR 130
Mass

Without detentWith detent≈ 0.7 kg

ID 540940-03
ID 540940-01

HR 13040

Industrial PC

Additional
operating station

The additional ITC operating stations (Industrial Thin Clients)from HEIDENHAIN are convenient solutions for the additional,
decentralized operation of the machine or of machine units suchas tool-changing stations. The remote operation strategy, which
is tailored to the TNC 640, makes it very easy to connect the ITC
over a standard Ethernet connection with a cable length of up to
100 m.
Connecting an ITC is very easy: as soon as the TNC 640 identifies
an ITC, it provides it with a current operating system. Afterthe ITC has been started, the complete content of the main
screen is mirrored to the ITC's screen. As a result of this plugand-play principle, no configuration by the machine tool builder
is necessary. With the standard configuration of the Ethernet
interface at X116, the TNC 640 integrates the ITC into the systemfully self-sufficiently.

ITC 755

With touchscreen

The ITC 755 is a compact additional operating station for control
systems with a 15-inch or 19-inch main screen. Along with the
ASCII keyboard and touchscreen it also has the most importantfunction keys of the TNC 640. The ITC 755 adjusts its resolution
automatically to fit the size of the main screen. The soft keys arepressed on the touchscreen.
The ITC 860 (19-inch screen) and the keyboard unit (to be orderedseparately) together comprise a complete second operating
station. Along with the touchscreen, it also has the most importantfunction keys of the control. The soft keys are pressed on thetouchscreen.

With
operating keys

ITC 860

ID 1039527-xx
ID 1174935-xx

ITC 755
ITC 8601)
1)

The ITC 750 (15-inch screen) and the keyboard unit (to be orderedseparately) form a complete second operating station.
ITC 7501)

With 15-inch screen ID 1039544-xx
for TE 73x1) No NRTL approval

41

IPC 6641
for Windows

With the IPC 6641 industrial PC, you can start and remotely
operate Windows-based applications via the user interface of the
TNC 640. The user interface is displayed on the control screen.
Software option 133 is required for this.
Since Windows runs on the industrial PC, Windows has no effecton the NC machining process. The IPC is connected to the NC
main computer via Ethernet. No second screen is necessary, since
the Windows applications are displayed on the TNC 640’s screen
via remote accesses.
Along with the IPC 6641 industrial PC, a hard disk (to be orderedseparately) is required for operation. The Windows 8 or 10
operating system can be installed on the empty data carrier.
IPC 6641

With 8 GB of RAM
With 16 GB of RAM
Installation type
Processor
Mass

HDR hard disk42

ID 1039543-01
ID 1039543-02
Electrical cabinet
Intel Core i7-3
2.1 GHz, quad-core≈ 4.0 kg

ID 1074770-51
Empty data carrier for Windows OS
Free capacity≈ 160 GB

IPC 6641

Control of auxiliary axes

PNC 610The PNC 610 auxiliary axis control is designed for controlling
PLC axes independently of the TNC 640. The PNC 610 does
not have an NC channel and thus cannot perform interpolating
NC movements. With the IPC auxiliary computer, SIK, and CFR
storage medium, the PNC 610 is a separate HSCl system, which
can be expanded with HEIDENHAIN inverters. The standard
PNC 610 features activation for six PLC axes.
The system’s design is identical to that of the TNC 640. All
relevant HEIDENHAIN tools and a basic program can be used.
The position information can be transmitted over PROFIBUS DP(optional), PROFINET IO (optional), or TCP/IP (integrated, system is
not capable of real-time), regardless of the platform.

Auxiliary computer

The IPC auxiliary computer features the following:• Processor• RAM memory• HSCl interface to the CC controller unit or to the UEC and toother control components• USB 3.0 interface
The following components must be ordered separately by the
OEM and installed in the auxiliary computer:• CFR CompactFlash memory card with the NC software• System ldentification Key component (SIK) for enabling software
options
The following HSCI components are required for operation of the
TNC 640:• IPC auxiliary computer• Controller unit
• PLB 62xx PLC input/output unit (system PL; integrated in UEC/
UMC)

Interfaces

For the end user, USB 3.0, V.24/RS-232-C, and Ethernet interfaces
are available on the MC. The connection to PROFINET IO or
PROFIBUS DP is possible via an additional module.

Power supply

The DC 24 V power supply of the auxiliary computer and other
HSCI components is provided through the PSL 13x supply unit
with a supply voltage of 24 V-NC, or through the power supply
of a UEC compact inverter. For the entire HSCI system, thisDC 24 V-NC supply voltage is required to be safely separated
voltage (PELV). It must not be connected to the DC 24 V supply
voltage for PLC components (e.g., holding brakes).

43

Design

IPC 6490

ID number
Mounting location
Mass
Power consumption
RAM
Processor

ID 1039541-xx
Electrical cabinet≈ 2.3 kg
48 W
2 GB
Intel Celeron Dual Core,
1.4 GHzIPC 8420

ID number
Mounting location
Mass
Power consumption
Screen

ID 1249510-xx
Operating panel≈ 6.7 kg
48 W
15.6-inch, with touchscreen
operation
2 GBIntel Celeron Dual Core,
1.4 GHzRAM
Processor
Export version

Because the complete NC software is saved on the CFR
CompactFlash storage medium, no export version is required forthe main computer itself. The NC software of the PNC 610 needs
no export license.

Softwareoptions

The performance of the PNC 610 can also be adapted to the actual
requirements at a later time through software options. Software
options are enabled and saved in the SIK component through theentry of keywords based on the SIK number. Please provide the
SIK number when ordering new options.

44

OptionnumberOptionID

RemarkPage

18

HEIDENHAIN DNC

526451-01

Communication with external PC applications
over COM component

94

24

Gantry Axes

634621-01

Gantry axes in master-slave torque control

46

Python OEM
Process

579650-01

Execute Python applications

89

135

Synchronizing
Functions

1085731-01

Expanded synchronization of axes and spindles

65

141

Cross Talk Comp.

800542-01

CTC: compensation of axis couplings

77

142

Pos. Adapt. Control

800544-01

PAC: position-dependent adaptation of control
parameters

77

143

Load Adapt. Control

800545-01

LAC: load-dependent adaptation of control
parameters

76

144

Motion Adaptive
Control

800546-01

MAC: motion-dependent adaptation of control
parameters

76

Storage medium

The storage medium is a CFR (= CompactFlash Removable)compact flash memory card. It carries the NC software 817591-08.
The storage medium is removable and must be ordered separatelyfrom the main computer. The NC software is based on the
HEIDENHAIN HEROS 5 operating system.
CFR CompactFlash, 30 GB
No export license required
Free capacity for PLC programs

SIK component

4 GB

The SIK component holds the NC software license for enabling
software options. It gives the main computer an unambiguous
ID code—the SIK number. The SIK component is ordered andshipped separately. It must be inserted into a special slot in the
IPC auxiliary computer. The SIK component of the PNC can enable
six axes. The enabling of up to the maximum number of ten axes
must be performed via the UMC compact inverter.
SIK component for PNC 610

TNCkeygen(accessory)

ID 1102057-58

ID 617763-53

TNCkeygen is a collection of PC software tools for generating
enabling keys for HEIDENHAIN controls for a limited period oftime see "TNCkeygen (accessory)", Page 19.

45

Camera system

VS 101The VS 101 camera system, in conjunction with Visual Setup
Control (software option 136), enables you to monitor the working
space of the machine. The sealed and extremely sturdy VS 101
camera system is designed for integration into the machine’s
working space. The protective housing features a closing coverand connections for sealing air to prevent the camera optics frombeing damaged. The VS 101 camera system can be connected
directly to the control’s main computer over a Gbit Ethernet
interface.
The camera system can be adapted using various lenses to therespective machine size. The proper lens selection depends
on various factors. For more information, please contact
HEIDENHAIN.
VS 101Mass ≈ 2.3 kg

46

ID 1137063-xx

VS 101Snap-on keys for handwheels

Snap-on keys

The snap-on keys make it easy to replace the key symbols. In thisway, the HR handwheel can be adapted to different requirements.
The snap-on keys are available in packs of five keys.

Overview for HR 520, HR 520 FS, and HR 550 FS
Axis keys

OrangeGray

Machinefunctions
Black
Black
Black
Black

Spindlefunctions

Other keys

Red

Red

Green

Green

Black

Red

Gray

Black

Green

Black

Red

Black

Green

Black

Green

47

Overview for HR 510 and HR 510 FS
Axis keys

OrangeGray

Machinefunctions

Spindlefunctions

Other keys

Black

Black

Green

Red

Black

Gray

Red

Black
Green
Red

48

Black

Green

OrangeSnap-on keys for the control

Snap-on keys

The snap-on keys make it easy to replace the key symbols, thus
allowing the keyboard to be adapted to different requirements. The
snap-on keys are available in packs of five keys.

Overview of control keys

Keys

OrangeGray

Machinefunctions

Black
Green

Black

Red

Black
Black

49

Red

Spindlefunctions

Green
Green

Red

Other keys

Black

Gray
Black

Red

Orange

Black
Black

Green

Special keys

50

Snap-on keys can also be made with special key symbols for
special applications. The laser labeling differs in appearance fromthe labeling of the standard keys. If you need keys for special
applications, please consult your contact person at HEIDENHAIN.

Red

HSCI
618893-xx

X502

X500

HSCI

X502

X500

X502

PLB 600x

X10

Axes: 60m

EnDat 2.1 interface
VL (max. 6m)
340302-xx

Axes + spindle: 60m

1 VPP

PL 610x

9)

8)

X502B
X500B

40 inputs
24 outputs

X500

X502

VL
340302-xx

KTY

336376-xx

289440-xx

PLC I/0

X15...X18

1)

8)

CC 6xxx

X51B...X56B

X249

5),6)

5),6)

5),6)

X15A ... X18A
X15B ... X20B 8)

X201A ... X204A
X201B ... X206B8)

MC 6xxx

UMC 11x

X51A...X54A

8)

X500A

X502A

X500

X141
X142

USB

289440-xx

336376-xx

4)

6)1036785-xx
1036814-xx

KTY

4)

3)

309783-xx

310199-xx

1m

30m

LC x85max. 9m

1036537-xx
1036547-xx

LC x85LB/LS

60m

LC x85

RCN 729
RCN 226
RCN 22855m

55m

23.05.2019

RCN 729
RCN 226
RCN 228

55m

1 VPP

1 VPP

1 VPP

533631-xx max. 6m

1m

max. 16m
max. 16m

1 VPP

4)

533631-xx max. 9m

max. 20m
max. 20m

3)360974-xx (LS x87) max. 20m
298429-xx (LB)
max. 12m

9) Cable included with the CC

8) CCs with 2nd controller board7) Included with the MB (0.5m)

6) Optional for looping in KTY

5) Adapter connector 367770-02

4) Purely serial EnDat 2.23) EnDat with incremental signals2) Only for connection of the KTY/ PT 1000

1) Adapter connector 544703-01 for spindle (if necessary)

HSCI 618893-xx

HSCI total length 70 m

VL: Extension cable– for separation points with connecting cable– for extending existing connecting cable558714-xx max. 30m

VL323897-xx
KTY
Voltage controller 5 V
383951-01

Voltage controller 5 V
368210-02
2)509667-xx

368330-xx

4)1036521-xx

332115-xx

VL
3)323897-xx

3)

BF 860

Position inputs

max. 5m
max. 20m

625901-xx
max. 20m

USB 2.0 354770-xx
USB 1.1 624775-xx

USB 2.0 354770-xx max. 5m
USB 1.1 624775-xx max. 20m

688144-xx

Voltage controller 5 V

HSCI

M12

X502

Electrical cabinet

370226-01
VL
336847-xx

HSCI

HSCI
618893-xx

722414-xx

PL 620x250479-60 Ribbon cable for pots7)

X60

2x USBTE 745

Speed inputs

TE 740

Cable overview
Control systems with CC

51

52

X502

X502

X500

PLB 600x

X10

Axes: 60m

EnDat 2.1 interface
VL (max. 6m)
340302-xx

Axes + spindle: 60m

1 VPP

PL 610x

HSCI 722414-xx

250479-60 Ribbon cable for pots 7)

X60

2x USB

VL
336847-xx

M12

VL
340302-xx

KTY

Voltage controller 5 V
370226-01

24 outputs

40 inputs

336376-xx

1)

X80 ... X85

5),6)

5),6)

5),6)

X15 ... X18 (UEC 111)
X15 ... X19 (UEC 112)
X15 ... X20 (UEC 113)

UEC 11x289440-xx

X249

X201 ... X204 (UEC 111)
X201 ... X205 (UEC 112)
X201 ... X206 (UEC 113)

MC 6xxx

PLC I/O

X500

X502

X500

X141
X142

USB

289440-xx

336376-xx

KTY

Voltage controller 5 V
368210-02
2)509667-xx

4)1036521-xx

332115-xx

3)

BF 860

Position inputs

max. 5m
max. 20m

625901-xx
max. 20m

USB 2.0 354770-xx
USB 1.1 624775-xx

USB 2.0 354770-xx max. 5m
USB 1.1 624775-xx max. 20m

HSCI 688144-xx

Electrical cabinet

X502

TE 745

Speed inputs

TE 740

6)

4)

KTY

3)

1m

max. 9m

1036537-xx
1036547-xx

1 VPP

60m
LB/LS

12m

LC x85

LC x85

RCN 729
RCN 226
RCN 22855m

30m

LC x8555m

23.05.2019

RCN 729
RCN 226
RCN 228

55m

1 VPP

1 VPP

533631-xx max. 6m

1m

max. 16m
max. 16m

1 VPP

4)

533631-xx max. 9m

max. 20m
max. 20m

Voltage controller 5 V
383951-01

VL
323897-xx

368330-xx

VL
3)323897-xx

1036785-xx
1036814-xx

4)

3)558714-xx max. 30m

309783-xx

310199-xx

360974-xx (LS x87) max. 20m
298429-xx (LB)
max. 12m

7) Included with the MB (0.5m)

6) Optional for looping in KTY

5) Adapter connector 367770-02

4) Purely serial EnDat 2.23) EnDat with incremental signals2) Only for connection of the KTY/ PT 1000

1) Adapter connector 544703-01 for spindle (if necessary)

HSCI 618893-xx

HSCI total length 70 m

VL: Extension cable– for separation points with connecting cable– for extending existing connecting cable

Control systems with UEC

Inverter system53

max. 55m

max. 25m

Axes: 60m

1)

1)735961-xx

643450-xx max. 20m

VL340302-xx

1)1119910-xx

1036361-xx max. 6m
729681-xx max. 6m

533631-xx max. 9m

558727-xx

1083369-xx

1036537-xx max. 6m
1036547-xx max. 6m

1 VPP

max. 9m

336377-xx

1133104-xx
1133119-xx

336377-xx

1133104-xx
1133119-xx

336376-xx

3)2)332115-xx

1036521-xx

332115-xx

1036521-xx

309783-xx

310199-xx

LC 211
LC x15 / EnDat22

max. 55m

max. 30m

max. 55m

max. 55m

max. 25m

643450-xx max. 20m

max. 55m

max. 20m

RCN xx80 / EnDat02

1036361-xx max. 6m
729681-xx max. 6m

727658-xx

1119394-xx

max. 9m

55m

max. 25m

RCN xx10 / EnDat22

533631-xx max. 9m

LC 281
LC x85 / EnDat02

1036537-xx max. 6m
1036547-xx max. 6m

558714-xx

1036785-xx
1036814-xx

1 VPP

1 VPP

310128-xx (LB 382)
360645-xx (LS x87, LF x85)

1 VPP

3) Adapter connector 544703-01
for spindle (if necessary)2) Adapter KTY/PT 1000 367770-02

1) Voltage controller 5 V 368210-02

360974-xx (LS x87, LF x85) max. 20m
max. 12m
298429-xx (LB 382)

X201A ... X204A
X201B ... X206B*)*) CCs with 2nd controller board
X15A ... X18A
X15B ... X20B*)

758082-xx

289440-xx

754232-xx (LS x87, LF x85)

360645-xx (LS x87, LF x85)
310128-xx (LB 382)

VL
336847-xx

max. 55m

max. 20m

RCN xx80 / EnDat02

EnDat 2.1 interface
VL (max. 6m)
340302-xx

Axes + spindle: 60m

1 VPP

max. 55m

max. 20m

max. 20m

max. 55m

RCN xx10 / EnDat22

LC 281
LC x85 / EnDat02

LC 211
LC x15 / EnDat22

max. 55m

max. 9m

55m

X500B*)

X502B*)UEC 1xx
UMC 1xx
CC 6xxx

Speed inputs

X502A

Position inputs

54
X500A

11.03.2019

Encoders

PL 620x
UEC 11x
UMC 11x

MC 8xxx

X113

X112

X29

MB 3xx/7xx
TE 3xx/7xx X23
PLB 600x

368330-xx

1070794-xx

20m

660042-xx

1070794-xx

1070795-xx

1070795-xx

1073372-xx 2)

663631-xx 1)

368330-xx

823924-xx

633608-xx

633611-xx

1218563-01

1161072-xx

1218563-01

1161072-xx

749368-xx

1070794-xx

VL
281429-xx

749369-xx

50m

368330-xx

1117855-xx

1117853-xx

1117852-03

296687-xx

296467-xx

312879-01

TT 160271958-03-05296467-xx

max. 2m

TS 260

HRA 551 FS
1119052-xx

50m

663631-xx

2)TS3) Only TNC 640, TNC 620

SE 642TT

TS

With SE 660:
TT 460 and TS 460

With SE 661:
TT 460 and TS 460 with EnDat

SE 661 3) (Connection possible only to PL 620x)

26.02.20192) If the total length is >20m: Select the cable
ID1073372-xx longer than ID663631-xx.

1) Up to 20m

With SE 642:
TT 460 or TT 449 and TS 460,
TS 740, TS 64x or TS 44x
SE 660CMA-H 04-04-00
analog axes
688721-xx

CC 3xx/6xxx
UEC 11x
UMC 11x

VL: Extension cable– for separation points with connecting cable– for extending existing connecting cableWith SE 540:
TS 460, TS 740, TS 64x
or TS 44x

HR 510 FS
1119974-xx
1120311-xx
1120314-xx
1161281-xx

HR 520 FS
670304-xx
670305-xx

626001-xx

823924-xx

HR 130540940-01-03

HR 5101119971-xx
1120313-xx
1099897-xx
1184691-xx

HR 520670302-xx
670303-xx

HR 550 FS
1200495-xx
1183021-xx

Accessories

55

56

1 VPP

PL 610x

Axes: 60m

EnDat 2.1 interface
VL (max. 6m)
340302-xx

Axes + spindle: 60m

X500

X502

HSCI 722414-xx

VL
336847-xx

M12

VL
340302-xx

KTY

Voltage controller 5 V
370226-01

23 outputs

38 inputs

X502

X501

336376-xx

1)

5),6)

5),6)

5),6)

X15 ... X18 (UEC 111)
X15 ... X19 (UEC 112)
X15 ... X20 (UEC 113)

X201 ... X204 (UEC 111)
X201 ... X205 (UEC 112)
X201 ... X206 (UEC 113)

X80 ... X85289440-xx

PLC I/O

X500

X502

UEC 11x

HSCI 688144-xx

Electrical cabinet

X500

Speed inputs

289440-xx

336376-xx

4)

4)

KTY

Voltage controller 5 V
368210-02
2)509667-xx

6)

KTY

1m

30m

LC x83

1 VPP

LB/LS

60m

RCN 729
RCN 226
RCN 22855m

55m

LC x83

RCN 729
RCN 226
RCN 228

55m

1 VPP

1 VPP

533631-xx max. 6m

1m

533661-xx max. 16m

4)533631-xx max. 9m

max. 9m

Voltage controller 5 V
383951-01

4)673459-xx max. 20m

3)309783-xx

310199-xx

3)

Optional for looping in KTY

6)

LC x83

Adapter connector 367770-02

5)

1 VPP

Purely serial EnDat 2.2

4)

12m

EnDat with incremental signals

3)298429-xx
298430-xx

Only for connection of the KTY/ PT 10002)

12.12.2018

Adapter connector 544703-01 for spindle (if necessary)1)558714-xx max. 30m

VL323897-xx

368330-xx

VL
3)323897-xx

3)533627-xx

332115-xx

Position inputs

PLB 600x

IPC 8420

HSCI total length 70 m
HSCI 618893-xx

VL: Extension cable– for separation points with connecting cable– for extending existing connecting cable

PNC 610 with UEC

Technical description
Digital control design

Uniformly digital

In the uniformly digital control design from HEIDENHAIN, allof the components are connected to each other via purely
digital interfaces. The control components are connected via the
HEIDENHAIN Serial Controller Interface (HSCI), the HEIDENHAIN
real-time protocol for fast Ethernet. The encoders are connected
over EnDat 2.2, the bidirectional interface from HEIDENHAIN.
A high degree of availability for the entire system, from themain computer to the encoder, is thereby achieved, with thesystem being diagnosable and immune to noise. The outstanding
characteristics of the uniformly digital design from HEIDENHAIN
guarantee very high accuracy and surface finish quality, combinedwith high traversing speeds. For more information, refer to the
Uniformly Digital Technical Information document.

HSCI

HSCI, the HEIDENHAIN Serial Controller Interface, connects themain computer, controller(s), and other control components. The
connection between two HSCI components is also referred to as
an HSCI segment. HSCI is based on 100BaseT Ethernet hardware.
A special interface component developed by HEIDENHAIN
enables short cycle times for data transfer.
Main advantages of the control design with HSCI:• Hardware platform for a flexible and scalable control system (e.g.,
decentralized axis systems)• High noise immunity due to digital communication between
components• Hardware basis for implementing “functional safety”• Simple wiring (commissioning, configuration)• Inverter connection via proven PWM interface• Large cable lengths in the entire system (HSCI segment up to
max. 70 m)• High number of possible control loops• High number of PLC inputs/outputs• Decentralized arrangement of the controller units
CC or UEC controller units, up to nine PL 6000 PLC I/O modules,
and machine operating panels (e.g., MB 72x from HEIDENHAIN)
can be connected to the serial HSCI bus of the MC main
computer. The HR handwheel is connected directly to themachine operating panel. The combination of monitor and main
computer is especially advantageous if the computer is housedin the operating panel. Besides the power supply, all that is thenrequired is an HSCI line to the controller unit in the electricalcabinet.
Maximum cable lengths for HSCI:• For one HSCI segment: 70 m
• For up to 11 HSCI slaves: 290 m (total of all HSCI segments)• For up to 12 HSCI slaves (maximum configuration): 180 m (total of
all HSCI segments)

57

The maximum permissible number of individual HSCI participants
is listed below.
HSCI components

58

Maximum number

MC/IPCHSCI master1 in the system

CC, UEC, UMC

HSCI slave

4 controller motherboards (distributed to CC, UEC, UMC as
desired)MB, PLB 600x

HSCI slave

2 in the system

PLB 61xx, PLB 62xx

HSCI slave

6 in the system

HR

On MB and/or
PLB 600x

5 in the system

PLD-H-xx-xx-xx FS

In PLB 6xxx FS

10 in the system

PLD-H-xx-xx-xx,
PLA-H-xx-xx-xx

In PLB 6xxx

25 in the system

Total maximum of1000 inputs/outputs

Control systems with integrated functional safety (FS)Basic principle

With controls featuring integrated functional safety (FS) from
HEIDENHAIN, it is possible to attain Safety Integrity Level 2(SIL 2) in accordance with EN 61508, and Performance
Level “d,”Category 3, as per EN ISO 13849-1 (successor standard
to EN 954-1). In these standards, the assessment of safetyrelated systems is based on, among other things, the failure
probabilities of integrated components and subsystems. This
modular approach aids the manufacturers of safety-related
machines in implementing their systems, since they can thenbuild upon prequalified subsystems. This design is taken into
account for the TNC 640 control, as well as for safety-related
position encoders. Two redundant, mutually independent safety
channels form the basis of the controls with functional safety (FS).
All safety-relevant signals are captured, processed, and output via
two channels. Errors are detected through the mutual comparisonof the states and data of both channels. Therefore, the occurrenceof a single error in the control does not result in a loss of the safetyfunction.

Structure

The safety-related controls from HEIDENHAIN have a dualchannel design with mutual monitoring. The SPLC (safety-related
PLC program) and SKERN (safety kernel software) software
processes are the basis of the two redundant systems. The two
software processes run on the MC main computer (CPU) andCC controller unit components. The dual-channel structure throughMC and CC is continued in the PLB 6xxx FS input/output systems
and the MB 720 FS. This means that all safety-relevant signals(e.g., permissive buttons and keys, door contacts, emergency
stop button) are captured via two channels and are evaluatedindependently of each other by the MC and CC. The MC and CC
use separate channels to also address the power modules and tostop the motors in case of an error.

Components

In systems with functional safety, certain hardware components
assume safety-relevant tasks. Systems with FS must consist of
only those safety-relevant components, including their variants,that HEIDENHAIN has approved for use!
Control components with functional safety are indicated by thesuffix “FS” following the model designation (e.g., MB 72x FS).

MB and TE

An MB machine operating panel with functional safety (FS) is
indispensable for systems with FS. Only on such a machine
operating panel do all keys have a dual-channel design. Axes canbe moved without additional permissive keys.

PLB

In systems with functional safety (FS), a combination of hardware(FS and standard) is possible, but a PLB 62xx FS is mandatory.

HR

FS handwheels are required in systems with functional safety
because only they have the required cross-circuit-proof permissive
buttons.
For a current list of components approved for FS, see theFunctional Safety FS Technical Manual.

59

Safety functions

The following safety functions are integrated into the hardware
and software:• Safe stop reactions (SS0, SS1, and SS2)
• Safe torque off (STO)• Safe operating stop (SOS)• Safely limited speed (SLS)• Safely limited position (SLP)• Safe brake control (SBC)• Safe operating modes– Operating mode 1: Automated or production mode
– Operating mode 2: Set-up mode
– Operating mode 3: Manual intervention– Operating mode 4: Advanced manual intervention, processmonitoring
Please note:
Full functionality is not yet available for all machine types withfunctional safety (FS). Before planning a machine with functionalsafety, please inform yourself of whether the current scope offeatures suffices for your machine design.

Activationof functionalsafety (FS)If the control identifies a PLB 62xx FS in the system during
booting, functional safety (FS) is activated.
In this case, it is essential that the following prerequisites befulfilled:• FS version of safety-relevant control components(e.g. TE 745 FS, HR 550 FS)• Safety-related SPLC program• Configuration of safe machine parameters• Wiring of the machine for systems with functional safety
Functional safety (FS) cannot be activated or deactivated byparameter.

For more
information

For more information on the topic of functional safety (FS),refer to the Technical Information documents Safety-Related
Control Technology for Machine Tools and Safety-Related Position
Encoders.
For details, see the Functional Safety FS Technical Manual. Your
contact person at HEIDENHAIN will be glad to answer any
questions concerning controls with functional safety (FS).

60

Control systems with external safety

Basic principle

In control systems without integrated functional safety (FS), no
integrated safety functions, such as safe operating modes, safe
speed monitoring, or safe operating stop, are available. Suchfunctions must be implemented entirely with the help of externalsafety components.
Control systems without integrated functional safety (FS) solely
support the realization of the safety functions STO (safe torqueoff: dual-channel interruption of the motor power supply) and SBC(safe brake control: dual-channel triggering of the motor holding
brakes). The dual-channel redundancy of the functions must be
realized by the OEM through appropriate wiring.

61

Operating system

HEROS 5The TNC 640 and PNC 610 work with the real-time capable
HEROS 5 operating system (HEIDENHAIN Realtime Operating
System). This future-oriented operating system contains thefollowing powerful functions as part of its standard repertoire:
Network– Network: management of network settings– Remote Desktop Manager: management of remoteapplications– Printer: management of printers– Shares: management of network shares– VNC: virtual network computing server
Safety– Portscan (OEM): port scanner– Firewall: protection against undesired network access– SELinux: protection against unauthorized changes to system
files– Sandbox: running applications in separated environments
System– Backup/Restore: function for backing-up and restoring thesoftware on the control– HELogging: evaluation and creation of log files– Perf2: system monitor– User administration: define users with different roles andaccess permissions
Tools– Web browser: Firefox®*– Document Viewer: display PDF, TXT, XLS, and JPEG files– File Manager: file explorer for managing files and memory
media– Gnumeric: spreadsheet calculations– Leafpad: text editor for creating notes– Ristretto: display of image files– Orage Calendar: simple calendar function– Screenshot: creation of screendumps– Totem: media player for playing audio and video files

Useradministration

The improper operation of a control often leads to unplannedmachine downtime and costly scrap. The user administration
feature can significantly improve process reliability throughthe systematic avoidance of improper operation. Through theconfigurable linkage of rights with user roles, access can be
tailored to the activities of the respective user.

• 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*

Firefox is a registered trademark of the Mozilla Foundation

62

Axes

Linear axes

Depending on its configuration, the TNC 640 can control linear
axes with any axis designation (X, Y, Z, U, V, W, ...).

Display andprogramming–99 999.99999 to +99 999.99999 [mm]Feed rate in mm/min relative to the workpiece contour, or mm perspindle revolution
Feed rate override: 0 % to 150 %Traverse range–99 999.99999 to +99 999.99999 [mm]The machine tool builder defines the traverse range. The user can
set additional limits to the traverse range if he wishes to reduce
the working space. Three different traverse ranges can be defined(selection via PLC).

Rotary axes

The TNC 640 can control rotary axes with any axis designation(A, B, C, U, ...). Special parameters and PLC functions are available
for rotary axes with Hirth coupling.

Display andprogramming

0° to 360° or–99 999.99999 to +99 999.99999 [°]Feed rate in degrees per minute [°/min]Traverse range–99 999.99999 to +99 999.99999 [°]The machine tool builder defines the traverse range. The user can
set additional limits to the traverse range if he wishes to reduce
the working space. Various traverse ranges can be defined via
parameter sets for each axis (selection via PLC).

Free rotation

For milling-turning operations, the rotary axis can be started via
the PLC with a defined feed rate. For functions specific to millingturning machines, see Turning operations.

Cylinder Surface
Interpolation(software
option 8)

A contour defined in the working plane is machined on a cylindricalsurface.

63

Tilting theWorking Plane(software
option 8)

The TNC 640 has special coordinate transformation cycles forcontrolling swivel heads and tilting tables. The tool lengths andoffset of the tilting axes are compensated for by the TNC.
The TNC can manage more than one machine configuration (e.g.,different swivel heads).

Tilting table
Swivel head

5-Axis Machining(software
option 9)

Tool Center Point Management (TCPM)
The offset of the tilting axes is compensated for in a mannersuch that the position of the tool tip relative to the contour ismaintained. Even during machining, handwheel positioning
commands can be superimposed such that the tool tip remains on
the programmed contour.

Synchronized
Axes

Synchronized axes move in synchronism and are programmedwith the same axis designation.
With HEIDENHAIN controls, parallel axis systems (gantry axes),
such as on portal-type machines or tilting tables, can be moved
synchronously to each other through high-accuracy and dynamic
position control.
In the case of gantry axes, multiple gantry slave axes can be
assigned to a single master axis. They may also be distributed tomultiple controller units.

Torque Control

Torque control is used on machines with mechanically coupledmotors, for which• a defined distribution of drive torque is desired,or• parts of the controlled system show a backlash effect that canbe eliminated by “tensioning” the motors (e.g. toothed racks).
For torque control, the master and slave must be on the same
controller motherboard. Depending on the controller unit being
used, up to five slave axes can thereby be configured for eachmaster.

64

Real-Time
Coupling Function(software
option 135)

The real-time coupling function (synchronizing functions) allows
the cyclic calculation of a position offset for an axis from the actualand nominal values of any other axes in the system. This enables
you to realize complex simultaneous movements of several NC
or PLC axes. The mutual dependence of the axes is defined inmathematical formulas.

uZ

Batch Process
Manager(software
option 154)

Batch Process Manager provides functions for the planning andexecution of multiple production jobs on the TNC. It makes it
possible to easily edit pallets and to alter the sequence of pending
jobs. Batch Process Manager also performs a duration calculation
for all planned jobs or NC programs. It informs the user as towhether, for example, all NC programs can be executed without
error or whether all required tools are available with sufficient
tool life. Batch Process Manager thereby ensures the smooth
execution of the planned jobs. Batch Process Manager also
requires software option 22 (Pallet Management) to be enabled.

Global PGM
Settings(software
option 44)

The functions provided by global program settings allow adaptationof the machining process without changing the original NC
program. This makes it easy to mirror axes or activate additional
offsets, for example. The TNC 640 also provides the ability to use
handwheel superimpositioning in various coordinate systems
and utilize virtual tool axes. This function is typically employed intoolmaking and mold manufacturing.

PLC axes

Axes can be defined as PLC axes. Programming is performed
through M functions or OEM cycles. The PLC axes are positioned
independently of the NC axes and are therefore designated asasynchronous axes.

65Turning

Performing
Turning
Operations(software
option 50)

The TNC 640 supports machines that can perform a
combination of milling and turning operations in a single
setup. It offers the operator a comprehensive package ofcycles for both types of operations, which are programmed in
HEIDENHAIN’s shopfloor-oriented Klartext format. Rotationallysymmetric contours are produced during turning operations. The
preset must be in the center of the lathe spindle for this.
In turning mode, the rotary table serves as the lathe spindle, while
the milling spindle with the tool remains stationary. Milling-turning
machines are subject to special demands. A basic prerequisite
is a machine designed with high rigidity so as to ensure a low
oscillation tendency even when the machine table (acting as alathe spindle) is turning at high speeds.

Toggling between
milling andturning modes

During the transition between milling and turning mode, the TNC
switches diameter programming on or off, selects the XZ working
plane for turning, and displays "Milling" and "Turning" mode in thestatus display.
The user switches between turning and milling mode with the
NC command FUNCTION MODE TURN or FUNCTION MODE
MILL. The machine-specific procedures necessary for this are
realized via OEM macros. In these macros, the OEM defines, forexample, which kinematic model is active for the turning or milling
operation, and which axis and spindle parameters take effect inmilling or turning mode. Because the FUNCTION MODE TURN
and FUNCTION MODE MILL commands are independent of
the machine model, NC programs can be exchanged between
different types of machines.
FUNCTION MODE TURN
Machine in milling mode

Machine in turning mode+Z+Z

FUNCTION MODE MILL

+A

+A
S

+C
S

+Y

+X

66

+Y

+X

Support for facing
slides (facing
heads)

With complete support for facing slides, the TNC 640 provides afurther way of performing turning operations on a milling machine.
A longitudinal turning tool, for example, can be mounted to thefacing slide and called with a TOOL CALL block. Even complex
turning operations are programmed with familiar ease using
cycles. Machining operations with the facing slide can be carriedout with the TNC 640 in any inclination (PLANE functions). In
addition, numerous useful turning functions, such as constantcutting speed, are available. The use of facing slides requires
the enabling of software option 50 for turning operations on the
TNC 640.

Measuring
unbalance andbalancing

An important and basic prerequisite for turning operations isthat the radial runout of the workpiece has been balanced. Boththe machine (rotary table) and the workpiece must be balanced
before machining. If the clamped workpiece has an unbalance,
undesirable centrifugal forces can result, thereby influencing theaccuracy of the runout.
An unbalance on the rotary table can endanger the safety of theuser and has a negative effect on the quality of the workpiece andthe service life of the machine.
The TNC 640 can detect an unbalance in the rotary table based on
the effects of the centrifugal forces on neighboring linear axes. To
this end, the rotary table should ideally be positioned via a linear
axis. For other machine designs, unbalance detection by means ofexternal sensors lends itself as a solution.
The TNC 640 features the following functions:• Unbalance calibration
A calibration cycle determines the unbalance behavior of therotary table. This unbalance calibration is generally performedby the OEM before the machine is shipped. During execution of
the calibration cycle, the TNC generates a table describing theunbalance behavior of the rotary table.
• Balancing
After the blank to be turned has been set up, the user canascertain the unbalance using a measuring cycle. Duringbalancing, the TNC supports the user by displaying the massand position of the balancing weights.
• Unbalance monitoring
During the machining operation, the TNC continually monitors
the unbalance. An NC stop is triggered if a specified limit value
is exceeded.

Gear Cutting(software
option 157)

The Gear Cutting software option provides user-friendly cycles
for the economical production of external and internal gear teeth.
The hobbing and skiving cycles enable the complete machining of
high-quality gear teeth in a single setup, including static shifting for
prolonged tool life and synchronous shifting for the production ofhelical gear teeth.

Advanced
Function Set
Turning (software
option 158)

The Advanced Function Set Turning option expands the packageof turning cycles to include Cycle 883 (TURNING SIMULTANEOUS
FINISHING). This cycle enables the finishing of complex contours
in a single run so as to avoid visible transitions.

67

Grinding operations

Grinding(software
option 156)

With its Grinding option, the TNC 640 supports jig grinding
technology for the fine finishing of 2-D contours.
Grinding operations are programmed with the familiar
HEIDENHAIN Klartext dialog guidance. Convenient cycles areavailable to the user. Instead of a milling cutter, jig grinding
employs a grinding tool (e.g., grinding pin) for material removal.
Since machining is performed in milling mode, a separate
operating mode is not needed.
A stroke movement or oscillating movement in the tool axis canbe activated by means of a cycle. There is also the capability ofdressing or truing-up grinding tools inside the machine.

68

Spindle

Overview

The TNC 640 contouring control is used in conjunction with the
HEIDENHAIN inverter systems with field-oriented control. As analternative, an analog nominal speed value can be output.

Controller unit

With the CC controller units and the UEC/UMC inverters, afundamental PWM frequency can be set for each controller
assembly (e.g., 4 kHz). Possible fundamental frequencies are
3.33 kHz, 4 kHz, or 5 kHz. With software option 49 (DoubleSpeed), this frequency can be increased to up to 16 kHz for highspeed spindles (e.g., for HF spindles). See the Technical Manual.

Controller groups

For example with CC 6106
1: X51 + X52
2: X53 + X54
3: X55 + X56

Maximum spindle
speed

The maximum spindle speed is calculated as follows:f PWM . 60000 rpm
NPP . 5000 Hz

nmax =
fPWM =NPP =PWM frequency in Hz
Number of pole pairs

Operating modeswitchover

For controlling the spindle, different parameter sets can be saved
for closed-loop control (e.g., for wye or delta connections). You canswitch between the parameter sets in the PLC.

Positioncontrolled spindle

The position of the spindle is monitored by the control.

Encoder

HEIDENHAIN rotary encoder with sinusoidal voltage signals (1 VPP)
or EnDat interface.

Tapping

There are special cycles for tapping with or without a floating tap
holder. For tapping without a floating tap holder, the spindle must
be operated under position control.

Spindleorientation

With a position-controlled spindle, the spindle can be positioned
exactly to 0.1°.

Spindle override

0 % to 150 %Gear ranges

A separate nominal speed is defined for each gear range. The gearcode is output via the PLC.

Multiple main
spindlesUp to four spindles can be controlled alternately. The spindles are
switched by the PLC. One control loop is required for each active
spindle.

SpindleSynchronism(software option
131)

The Spindle Synchronism software option allows the speed of two
or more spindles to be synchronized. Spindle synchronization is
also possible with a transmission ratio or a defined offset.

69

Encoders

Overview

For speed and position control of the axes and spindle,
HEIDENHAIN offers both incremental and absolute encoders.

Incremental
encoders

Incremental encoders have as their measuring standard a grating
consisting of alternating lines and spaces. Relative movement
between the scanning head and the scale causes the output ofsinusoidal scanning signals. The measured value is calculated bycounting the signals.

Reference markWhen the machine is switched on, the machine axes needto traverse a reference mark for an accurate reference to beestablished between the measured value and the machine
position. For encoders with distance-coded reference marks,
the maximum travel until automatic reference mark evaluation
for linear encoders is only 20 mm or 80 mm, depending on themodel, or 10° or 20° for angle encoders.

Evaluation ofreference marks

The routine for traversing the reference marks can also be started
for specific axes via the PLC during operation (reactivation ofparked axes).

Output signals

Incremental encoders with sinusoidal output signals with ~ 1 VPP
levels are suitable for connection to HEIDENHAIN numericalcontrols.

Absolute
encoders

With absolute encoders, the position information is contained
in several coded tracks. Thus, an absolute reference is available
immediately after switch-on. A reference-mark traverse is notnecessary. Additional incremental signals are output for highly
dynamic control loops.

EnDat interface

The TNC 640 features the serial EnDat 2.2 interface (includes
EnDat 2.1) for the connection of absolute encoders.
Note: The EnDat interface on HEIDENHAIN encoders differs in
its pin assignment from the interface on Siemens motors withintegrated absolute ECN/EQN rotary encoders. Special adapter
cables are available.

Encoder inputs

Incremental and absolute linear, angle, or rotary encoders from
HEIDENHAIN can be connected to all position encoder inputs ofthe controller unit.
Incremental and absolute rotary encoders from HEIDENHAIN canbe connected to all speed encoder inputs of the controller unit.
InputsSignal level/
Interface1)

Input frequency1)
Position

Speed

Incremental signals~1 VPP
EnDat 2.1

33 kHz/350 kHz

350 kHz

Absolute position values

EnDat 2.1
EnDat 2.2––

1) Switchable

70Digital servo control

Integrated inverter

Position controllers, speed controllers, current controllers,and inverters are integrated into the TNC 640. HEIDENHAIN
synchronous or asynchronous motors are connected to the
TNC 640.

Axis feedback
control

The TNC 640 can be operated with following error or feedforward
control. During roughing operations at high speeds, for example,
you can switch to velocity semi-feedforward control via an OEM
cycle in order to machine faster at reduced accuracy.

Operation withfollowing error

The term “following error” denotes the distance between the
momentary nominal position and the actual position of the axis.
The velocity is calculated as follows:v = kv · sa

v
kv
sa

= Velocity= Position loop gain
= Following error

Operation withfeedforward
controlFeedforward means that a given velocity and acceleration are
adapted to the machine. Together with the values calculated fromthe following error, this given velocity and acceleration becomesthe nominal value. A much lower following error thereby manifests
itself (in the range of only a few microns).

Compensation of
torque ripples

The torque of synchronous, torque, and linear motors is subject
to periodic oscillations, one cause of which can be permanent
magnets. The amplitude of this torque ripple depends on the
motor design, and under certain circumstances can have aneffect on the workpiece surface. After the axes have beencommissioned with the TNCopt software, the Torque Ripple
Compensation (TRC) of the CC 61xx or UEC 11x can be used tocompensate for it.

71

Control loop cycle
times

The cycle time for path interpolation is defined as the timeinterval during which interpolation points on the path arecalculated. The cycle time for fine interpolation is defined as thetime interval during which interpolation points are calculated thatlie within the interpolation points calculated for path interpolation.
The cycle time for the position controller is defined as the timeinterval during which the actual position value is compared to thecalculated nominal position value. The cycle time for the speed
controller is defined as the time interval in which the actual speed
value is compared to the calculated nominal speed value. The
cycle time for the current controller is defined as the timeinterval during which the actual value of the electrical current iscompared to the calculated nominal value of the electrical current.
CC/UEC/UMC
Path interpolation

3 ms

Fine interpolation

0.2 ms/0.1 ms1) at fPWM = 5000 Hz

Position controller

0.2 ms/0.1 ms at fPWM = 5000 Hz

Speed controller

0.2 ms/0.1 ms1) at fPWM = 5000 Hz

Current controller

0.1 ms at fPWM = 5000 Hz

1) Double speed (with software option 49)

Axis clamping

The control loop can be opened through the PLC in order to clamp
specific axes.

Double Speed
Control Loops(software
option 49)

Double-speed control loops permit higher PWM frequencies andshorter cycle times for the speed controller. This enables improved
current control for spindles and higher controller performance forlinear and torque motors.

Crossover Position
Filter (CPF)

To increase the stability of the position control loop in systems
with resonances, the position signal from the position encoder,which is filtered through a low-pass filter, is combined with theposition signal from the motor speed encoder, which is filteredthrough a high-pass filter. This signal combination is made available
to the position controller as the actual position value. The possible
position controller gain (kV factor) is increased significantly by this.
The filter separation frequency is set specifically for each axis via
machine parameters. The CPF can be used only in dual-encoder
systems on motors with speed and position encoders.

72Fast contour milling

Short block
processing time

The TNC 640 provides the following important features for fast
contour machining.
The block processing time of the MC is 0.5 ms. This means that,during the execution of long programs from the hard drive, theTNC 640 can even mill contours approximated in 0.2 mm line
segments at a feed rate of up to 24 m/min.

Look-ahead

For feed rate adaptation, the TNC 640 performs a precalculation of
the geometry (max. 5000 blocks). In this way, directional changes
are detected in time to accelerate or decelerate the appropriate
NC axes.

Jerk

The derivative of acceleration is referred to as jerk. A linear changein acceleration causes a jerk step. Such motion sequences may
cause the machine to oscillate.

Jerk limiting

To prevent machine oscillations, the jerk is limited in order to attain
optimum path control.

Smoothed jerk

The jerk is smoothed by nominal position value filters. The
TNC 640 therefore mills smooth surfaces at the highest possible
feed rate and yet keeps the contour accurate. The operator
programs the permissible tolerance in a cycle. Special filters for
HSC machining (HSC filters) can specifically suppress the natural
frequencies of an individual machine. The desired accuracy and avery high surface quality are attained.

Advanced
Dynamic
Prediction (ADP)The Advanced Dynamic Prediction (ADP) function enhances
the conventional look-ahead of the permissible maximum feed
rate profile, thereby enabling optimized motion control for cleansurface finishes and perfect contours. The strengths of ADP are
evident, for example, during bidirectional finish milling throughsymmetrical feed behavior on the forward and reverse paths, aswell as through particularly smooth feed rate curves on parallel
milling paths. NC programs that are generated on CAM systems
have a negative effect on the machining process due to various
factors such as short, step-like contours; coarse chord tolerances;and heavily rounded end-point coordinates. Through an improved
response to such factors and the exact adherence to dynamic
machine parameters, ADP not only improves the surface quality of
the workpiece but also optimizes the machining time.

73

Dynamic Efficiency

Overview

With the concept of Dynamic Efficiency, HEIDENHAIN offers
innovative TNC functions that help the user make heavy machining
and roughing more efficient while also enhancing its processreliability. Dynamic Efficiency permits higher removal rates andtherefore increases productivity. At the same time, it prevents any
tool overloading and the concomitant premature cutter wear.
Dynamic Efficiency comprises three software functions:• ACC (Active Chatter Control): this software option reduceschatter susceptibility, thus enabling higher feed rates andinfeeds.
• AFC (Adaptive Feed Control): this software option controls thefeed rate based on the machining situation.
• Trochoidal milling: a function for the roughing of slots thateases the load on the tool
• OCM (Optimized Contour Milling): the OCM software option
allows pockets and islands of any shape to be machinedwith low tool wear using the highly efficient trochoidal milling
method.
Each solution in itself offers decisive advantages in the machining
process. But the combination of these TNC features, in particular,
exploits the potential of the machine and tool and at the sametime reduces the mechanical load.

Adaptive
Feed Control(AFC), software
option 45

With Adaptive Feed Control (AFC), the contouring feed rate iscontrolled based on the respective percentage of spindle power.
Benefits of adaptive feed control:• Optimization and reduction of machining time
• Prevention of subsequent damage through tool monitoring• Automatic insertion of a replacement tool when the tool is worn
(machine-dependent function)• Protection of the machine mechanics• Documentation by capturing and saving the learning andprocess data
• Integrated NC function, and therefore an alternative to external
software solutions
Restrictions:
AFC cannot be used for analog spindles or in volts-per-hertz control
mode.

74

100%

Active Chatter
Control (ACC),
softwareoption 145

During heavy machining (roughing at a high removal rate), strong
milling forces arise. Depending on the tool spindle speed, theresonances in the machine tool, and the chip volume (metalremoval rate during milling), the phenomenon known as “chatter”
may occur. Chatter puts the machine under heavy strain andcauses blemishes on the workpiece surface. Tool wear is also
accelerated and less evenly distributed. In extreme cases, the tool
may even break. To reduce chatter susceptibility, HEIDENHAIN
now offers an effective remedy through its Active Chatter Control(ACC) option. This option is particularly beneficial during heavymachining. ACC enables substantially higher cutting performance:
depending on the machine model, the metal removal rate can beincreased by 25 % or more. Thus, you can reduce the load on yourmachine while simultaneously increasing the life of your tools.

Top figure: part milled with ACC
Bottom figure: part milled without ACC

Optimized
Contour Milling(OCM), software
option 167

With Optimized Contour Milling (OCM), you can machine pockets
and islands of any shape while reducing tool wear thanks to highly
efficient trochoidal milling. You simply program the contour as
usual directly in Klartext or make use of the convenient CAD
Import function. The control then automatically calculates thecomplex movements required for trochoidal milling.
Advantages of OCM over conventional machining:• Reduced thermal load on the tool
• Superior chip removal• Uniform tool-workpiece contact• Higher possible cutting parameters• Higher removal rates• No need for adjustments by the machine tool builder

75

Dynamic Precision

Overview

The umbrella term Dynamic Precision encompasses a number
of HEIDENHAIN milling solutions that significantly improve thedynamic accuracy of a machine tool. The dynamic accuracy ofmachine tools can be seen in the errors at the tool center point(TCP). The size of these errors depends on the magnitudes of the
motion (e.g., speed and acceleration, as well as jerk) and result
from the vibrations of the machine components, among otherthings. Taken together, all of these errors are partially to blame fordimensional errors and faults on the surfaces of workpieces. They
therefore have a decisive impact on quality and, in the event ofquality-related scrap, on productivity as well.
Because the stiffness of machine tools is limited for reasons ofdesign and economy, problems such as compliance and vibration
within the machine design are very difficult to avoid. Dynamic
Precision counteracts these problems with intelligent control
technology to enable designers to further improve the qualityand dynamic performance of machine tools. This saves time andmoney in production.
The software options that make up Dynamic Precision canbe deployed by the machine manufacturer both alone or in
combination:• CTC: compensates for acceleration-dependent position errors
at the tool center point, thereby increasing accuracy during
acceleration phases• AVD: active vibration damping improves surfaces• PAC: position-dependent adaptation of control parameters• LAC: load-dependent adaptation of control parameters
enhances accuracy regardless of load and aging• MAC: motion-dependent adaptation of control parameters
Load Adaptive
Control (LAC),
softwareoption 143

With LAC (software option 143), you can dynamically adjust
controller parameters based on the load or friction.
The dynamic behavior of machines with rotary tables can varydepending on the mass moment of inertia of the fixed workpiece.
The Load Adaptive Control (LAC) software option allows thecontrol to automatically determine the current mass moment ofinertia of the workpiece and the current frictional forces.
In order to optimize changed control behavior at differing loads,
adaptive feedforward controls can exploit data on acceleration,
holding torque, static friction, and friction at high shaft speeds.

Motion Adaptive
Control (MAC),
softwareoption 144

76

Along with the position-based modification of machine parameters
through the PAC software option, the Motion Adaptive Control(MAC) software option allows machine parameters to be changed
based on their initial values, such as speed, following error, or
acceleration. Through this motion-dependent adaptation of thecontrol parameters, a speed-dependent adaptation of the kV factor
can be implemented for drive systems whose stability changes
due to the different traversing speeds.

Cross Talk
Compensation(CTC), software
option 141

CTC (software option 141) enables the compensation of dynamic
position errors potentially arising from acceleration forces.
To increase productivity, machine tool users are asking for everhigher feed rates and accelerations, while at the same timethey need to maintain the highest possible surface quality andaccuracy, placing very special requirements on path control.
Highly dynamic acceleration processes introduce forces to thestructure of a machine tool. They can deform parts of the machine
and thereby lead to deviations at the tool center point (TCP).
Besides deformation in the direction of the axis, the dynamic
acceleration of an axis due to mechanical axis coupling can also
result in the deformation of axes that are perpendicular to thedirection of acceleration. The resulting position error at the TCP in
the direction of the accelerated axis and lateral axes is proportional
to the amount of acceleration.
If the dynamic position errors relative to the axis acceleration
are known, then these acceleration-dependent errors can becompensated for by the Cross Talk Compensation (CTC) software
option in order to avoid negative effects on the surface quality andaccuracy of the workpiece. Often, the resulting error at the TCP
depends not only on the acceleration but also on the position of
the axes in the working space. This can also be compensated forby CTC.

Active Vibration
Damping (AVD),
softwareoption 146

The high dynamics of modern machine tools lead to deformationsin the machine base, frame, and drive train during acceleration anddeceleration of the feed motors. This results in vibrations, such asmachine setup vibrations, that may reduce the attainable accuracy
and surface quality of the workpieces. The Active Vibration
Damping (AVD) controller function dampens the especially criticallow-frequency oscillations and optimizes the control behaviorof the affected axis at the same time so that high-accuracy
workpieces with increased surface quality can also be produced
at high feed rates. The improved rigidity attained can be used toincrease the dynamic limit values (e.g., jerk), and therefore makes
reduced machining times possible.

Position Adaptive
Control (PAC),
softwareoption 142

PAC (software option 142) permits the dynamic, positiondependent adaption of controller parameters based on the spatial
position of the tool.
The specifics of a machine’s kinematics cause a unique positionof the axes’ center of gravity in the working space. This results ina variable dynamic behavior of the machine, which can negatively
influence the control’s stability depending on the axis positions.
To take full advantage of the machine’s dynamic performance,
the Position Adaptive Control (PAC) software option enables
changes to machine parameters based on position, thus
permitting assignment of the respective optimal loop gain to
defined interpolation points. Additional position-dependent filter
parameters can be defined in order to further increase control loop
stability.

77

Monitoring functions

Description

During operation, the control monitors the following details*:• Amplitude of the encoder signals• Edge separation of the encoder signals• Absolute position from encoders with distance-coded referencemarks• Current position (following error monitoring)• Actual distance traversed (movement monitoring)• Position deviation at standstill• Nominal speed value• Checksum of safety-related functions• Supply voltage• Voltage of the backup battery• Operating temperature of the MC and CPU• Run time of the PLC program• Motor current / motor temperature• Temperature of the power module• DC-link voltage
With EnDat 2.2 encoders:• The CRC checksum of the position value• EnDat alarm Error1→ EnDat status alarm register (0xEE)• EnDat alarm Error2• Edge speed of 5 µs
• Transmission of the absolute position value on the time grid
In the event of hazardous errors, an emergency stop message
is sent to the external electronics via the control-is-ready output,
and the axes are brought to a stop. The correct connection of
the TNC 640 in the machine’s emergency stop loop is checked
when the control system is switched on. In the event of an error,
the control displays a message in plain language.

*

No safety functions

78

Dynamic Collision
Monitoring(DCM), software
option 40

With the Dynamic Collision Monitoring (DCM) software option,
the TNC cyclically monitors the working space of the machine forpossible collisions between machine components. To this end,
the OEM must define three-dimensional collision objects in theworking space that are to be monitored by the TNC during all
machine movements, including those of the swivel head and tilting
table. If two objects monitored for collision come within a defined
distance of each other, the TNC outputs an error message. At thesame time, the affected machine components are shown in red
in the machine image. Collision monitoring is active in the manual
operating modes and in the machine operating modes, and isindicated by a symbol in the operating mode line.
Please note:• Collision objects (including fixtures) are defined exclusively by
the OEM• The collision of machine parts (e.g., the swivel head) with theworkpiece cannot be detected• Collision objects are not automatically transformed into
rotationally symmetric objects in turning mode
• In servo-lag operation (no feedforward), DCM is inactive• It is not possible to check for collisions in Test Run mode
Collision monitoring also protects fixtures and tool carriers fromcollisions.
The 3-D collision objects are configured with the commissioning
software KinematicsDesign.
With the TNC 640, collision objects can also be transferred in M3D
format from standard CAD models (e.g., STL) to the control.
Advantages of the M3D format:• Simple data transfer from already available CAD models• Fully detailed illustration of machine components• Greater exploitation of the working space

Context-sensitive
help

Context-sensitive help is available to the user through the HELPor ERR buttons. As a result, when there is an error message,
the control displays the cause of the error, as well as possible
solutions. The machine manufacturer can also implement this user
support for PLC error messages.

79

KinematicsDesign(accessory)

KinematicsDesign is a PC program for creating adaptablekinematic configurations. It supports the following:• Complete kinematic configurations• Transfer of configuration files between control and PC• Description of tool-carrier kinematics
Kinematic descriptions created for the iTNC 530 can
also be transferred into kinematic descriptions for the
TNC 640/620/320/128.
If KinematicsDesign is connected to a control online (operationis also possible with the programming station software), thenmachine movements can be simulated, and the axes are moved.
Together with the TNC 640, KinematicsDesign simulates theworking space when DCM is active, and collisions that occur, or
machine components in danger of collision, are displayed in a colorthat you define.
Visualization options range from a pure depiction of thetransformation chain and a wire model all the way to the complete
machine model.

M3D Converter

With the TNC 640, you can transfer collision objects out of a CAD
file and integrate them into the machine kinematics using the
M3D format. The M3D data format from HEIDENHAIN permits
an especially finely detailed depiction of high-resolution collisionobjects. The M3D converter, which is capable of performing
tasks such as checking, repairing, simplifying, merging, andoptimizing the CAD data of collision objects, is used to generate
the M3D data. As an independent PC tool, the M3D converter
is part of the KinematicsDesign installation package (as ofversion 3.1). The M3D converter requires a software releasemodule (ID 1124969-01).

Visual Setup
Control (VSC),
software option
136

With the Visual Setup Control (VSC) option, the TNC can
automatically monitor the current clamping or machining situation
while the program is running. To make this possible, the VS 101
camera system takes reference photos of the first parts in aseries and compares them with photos of subsequent parts.
User-friendly cycles let you specify multiple locations within the
NC program at which you want the control to perform a visualcomparison between the nominal and actual conditions. If an error
is detected, the TNC executes a reaction selected by the user.

Component
Monitoring(software
option 155)

The overloading of machine components is often the cause of
expensive machine damage and unplanned production downtime.
Component monitoring keeps the user informed about the current
load on the spindle bearings and reacts upon exceedance of thespecified limit values (e.g., with an NC stop).

80

Error compensation

Overview

The TNC 640 automatically compensates for mechanical errors ofthe machine.

Linear error

Linear error can be compensated over the entire travel range foreach axis.

Nonlinear error

The TNC 640 can compensate for ball-screw pitch errors and sag
errors simultaneously. The compensation values are stored in atable. Nonlinear axis-error compensation also makes it possible tocompensate for position-dependent backlash.

Backlash

The play between table movement and rotary encoder movement
during direction changes can be compensated for in length
measurements by the spindle and rotary encoder. This backlash isoutside the controlled system.

Hysteresis

The hysteresis between the table movement and motor
movement is also compensated for in direct length
measurements. In this case, the hysteresis is within the controlled
system.

Reversal spikes

In circular movements, reversal spikes can occur at quadranttransitions due to mechanical influences. The TNC 640 cancompensate for these reversal spikes.

Static friction

At very low feed rates, high static friction can cause the slide tostop and start repeatedly for short periods. This is commonly
known as stick-slip. The TNC 640 can compensate for thisproblematic behavior.

Sliding friction

Sliding friction is compensated for by the speed controller of the
TNC 640.

Thermalexpansion

To compensate for thermal expansion, the machine’s expansion
behavior must be known.
The temperature is measured via thermistors connected to theanalog inputs of the TNC 640. The PLC evaluates the temperature
information and passes a compensation value to the NC.

81KinematicsOpt(software
option 48)

Using the KinematicsOpt function, machine tool builders or
end users can check the accuracy of rotary or swivel axes andcompensate for possible displacements of the center of rotationof these axes. The deviations are automatically transferred to
the kinematics description and can be taken into account in the
kinematics calculation.
In order to measure the rotary axes, you must attach a calibration
sphere (e.g., KKH 100 or KKH 250 from HEIDENHAIN) at any
position on the machine table. A HEIDENHAIN touch probe uses
a special cycle to probe this calibration sphere and measures therotary axes of the machine fully automatically. But first you define
the resolution of the measurement and define for each rotary axis
the range that you want to measure. The measurement results are
the same regardless of whether the axis is a rotary table, a tilting
table, or a swivel head.

Calibration
sphere(accessory)

82

HEIDENHAIN offers calibration spheres as accessories
for the measurement of rotary axes with KinematicsOpt:
KKH 100
KKH 250Height: 100 mm
Height: 250 mm

ID 655475-02
ID 655475-01

KinematicsComp(software
option 52)

Increasingly stringent requirements on workpiece tolerances
constantly increase the demands placed on the precision ofa machine tool. However, components of the machine tool
inevitably show imperfections that are, for example, caused bymanufacturing or installation or result from elastic deformation.
This is the reason why the commanded tool position andorientation are not always reached with exactness everywherein the working space. The more axes a machine has, the more
sources of error there are. The use of mechanical means to copewith these problems requires considerable effort, particularly inthe field of 5-axis machining, or if large machines with parallel axes
are involved.
The KinematicsComp software option allows the OEM to store acomprehensive description of the machine errors in the control.
KinematicsComp then automatically compensates for the position
error that results from static errors of the physical machineaxes (volumetric compensation). The positions of all rotary andlinear axes, as well as the current tool length, are included in thecalculation. KinematicsComp can continue to be used to define
position-dependent temperature compensation. The required
data are supplied by multiple sensors located at representative
positions on the machine.

Fault characteristics according to ISO 230-1: EBA

For example, the spatial errors of the tool tip can bemeasured with a laser tracer or laser interferometer. However,multidimensional tables for component errors make it possible
to use measured data directly for compensation withoutbuilding a model. PLC variables as initial values for formulasand multidimensional tables make it easy to enter parameters
for powerful compensation, for example, for various thermal
conditions or load situations.
The KinematicsComp software option cannot be enabled in theexport versions.
3D-ToolComp(software
option 92)

Fault characteristics according to ISO 230-1: EXA

The 3D-ToolComp software option provides 3-D tool radiuscompensation irrespective of the tool’s angle of contact,
thus allowing for the compensation of tool form errors. A
compensation-value table is used to define angle-dependent delta
values. These delta values define the deviation of a tool from its
ideal circular form or any deviation in a touch probe’s switching
behavior. For use with a tool, this function requires surface
normal vectors in the NC program, for which the software option
Advanced Function Set 2 must be enabled. These compensation
values will only be taken into account during probing with a touchprobe if new probing cycles (e.g. Cycle 444) are used, which havebeen prepared for this purpose.

83Commissioning and diagnostic aids

Overview

The TNC 640 provides comprehensive internal commissioning anddiagnostic aids. It also includes highly effective PC software fordiagnostics, optimization, and remote control.

ConfigDesign(accessory)

PC software for configuring the machine parameters• Stand-alone machine-parameter editor for the control; allsupporting information, additional data, and input limits areshown for the parameters• Configuration of machine parameters• Comparison of parameters from different controls• Importing of service files: easy testing of machine parameters in
the field• Rule-based creation and management of machine configurations
for multiple controls (together with PLCdesign)

DriveDiag

DriveDiag permits quick and easy troubleshooting of the drive
systems. The following diagnostic functions are available:• Reading and displaying the electronic ID labels of QSY motors
with EQN 13xx or ECN 13xx as well as the inverter modules
UVR 1xxD and UM 1xxD
• Displaying and evaluating the internal control conditions and thestatus signals of the inverter components• Displaying the analog values available to the drive controller• Automatic test for the proper functioning of motors andinverters, as well as of position and speed encoders
DriveDiag can be called immediately at the control through thediagnostics soft key. End users have read-access, whereas
the code number for the machine tool builder gives access tocomprehensive testing possibilities with DriveDiag.

Oscilloscope

The TNC 640 features an integrated oscilloscope. Both X/t and X/Ygraphs are possible. The following characteristic curves can berecorded and stored in six channels:• Actual value and nominal value of the axis feed rate
• Contouring feed rate
• Nominal and actual position• Following error of the position controller• Nominal and actual values for speed, acceleration, and jerk
• Content of PLC operands• Encoder signal (0°–A) and (90°–B)• Difference between position and speed encoder• Nominal velocity value• Integral-action component of the nominal current value• Torque-determining nominal current value

Logic signals

Simultaneous graphical representation of the logic states of up to
16 operands (markers, words, inputs, outputs, counters, timers)• Marker (M)(I)• Input• Output (O)• Timer (T)• Counter (C)• IpoLogic (X)84

TNCopt(accessory)

PC software for commissioning digital control loops.
Functions (among others):• Commissioning the current controller• (Automatic) commissioning the velocity controller• (Automatic) optimization of sliding-friction compensation• (Automatic) optimization of compensation for reversal spikes• (Automatic) optimization of the kV factor• Circular interpolation test, contour test

Online Monitor(OLM)

The online monitor is a component of the TNC 640 and is calledwith a code number. It supports commissioning and diagnosis ofcontrol components through the following:• Display of control-internal variables for axes and channels• Display of controller-internal variables (if a CC is present)• Display of hardware signal states• Various trace functions• Activation of spindle commands• Enabling of control-internal debug outputs

TNCscope(accessory)

PC software for transferring the oscilloscope files to a PC.
With TNCscope you can record and save up to 16 channels
simultaneously.
Note: The trace files are saved in the TNCscope data format.

API DATAWith the API DATA function, the control displays the states orcontents of the symbolic API markers and API double words.

Table function

The current conditions of the markers, words, inputs, outputs,
counters, and timers are displayed in tables. The conditions can bechanged through the keyboard.

Trace function

The current content of the operands and the accumulators isshown in the statement list in each line in hexadecimal or decimalcode. The active lines of the statement list are marked.

Log

For the purpose of error diagnostics, all error messages andkeystrokes are recorded in a log. The entries can be read using the
PLCdesign or TNCremo software for PCs.

85

TeleService(accessory)

PC software for remote diagnostics, remote monitoring, andremote operation of the control. For more information, please ask
for the Remote Diagnosis with TeleService Technical Information
sheet.
Single station license
Network license For 14 workstations
For 20 workstations

ID 340449-xx
ID 340454-xx
ID 340455-xx

Bus diagnosis

In Diagnosis mode, the structure of the connected bus systems aswell as the details of the connected components can be displayed
in a clearly laid out screen.

State Reporting(software
option 137)

With the State Reporting Interface (SRI) software option,
HEIDENHAIN offers an interface for the simple provision ofmachine operating states for a higher-level machine data or
production data acquisition system (MDA/PDA).

TNCtestAcceptance tests on machine tools with external or integratedfunctional safety (FS) must be conducted reproducibly andverifiably.
The TNCtest and TestDesign program package can be used
to plan and perform acceptance tests for machine tools with
HEIDENHAIN controls. The acceptance tests are planned with
TestDesign and run with TNCtest.
The TNCtest programs are designed to provide support during
acceptance testing, provide required information, and perform
automatic configurations, as well as record data and evaluate thedata semiautomatically. A tester must evaluate manually whether
a test case passed or failed.

TNCanalyzer

The TNCanalyzer application from HEIDENHAIN provides for
simple and intuitive evaluation of service files and log files.
Function:• Loading of service and log files• Analysis of temporal sequences and static states• Filters and search functions• Data export (HELogger, CSV, and JSON formats)• Definition of application-specific analysis profiles• Preconfigured analysis profiles• Graphical display of signals via TNCscope• Interaction with other tools that are intended for the display of
special sections of the service file86

Integrated PLC

Overview

The PLC program is created by the machine manufacturer either
at the control or with the PLC development software PLCdesign(accessory). Machine-specific functions are activated andmonitored via the PLC inputs/outputs. The number of PLC inputs/
outputs required depends on the complexity of the machine.

PLC inputs/
outputs

PLC inputs and outputs are available via the external PL 6000 PLC
input/output systems or the UEC 11x. The PLC inputs/outputs andthe PROFINET IO or PROFIBUS DP-capable I/O system must be
configured with the IOconfig PC software.

PLC programming

FormatStatement list

MemoryMin. 1 GB

Cycle time

9 ms to 30 ms (adjustable)

Commandset

Encryption of
PLC data• Bit, byte, and word commands• Logical operations• Arithmetic commands• Comparisons• Bracketed terms• Jump commands• Subprograms• Stack operations• Submit programs• Timers• Counters• Comments• PLC modules• Strings

The encrypted PLC partition (PLCE:) provides the machine toolbuilder with a tool for preventing third parties from viewing orchanging files. The files on the PLCE partition can be read onlyby the control itself or by using the correct OEM keyword. This
ensures that proprietary know-how and special customer-specificsolutions cannot be copied or changed.
The machine manufacturer can also determine the size of theencrypted partition. This is not determined until the machine
manufacturer creates the PLCE partition. Another advantage
is that, in spite of the encryption, the data can backed up fromthe control to a separate data medium (USB drive, network,e. g., through TNCremo) and later restored. You need not enter
the password, but the data cannot be read until the keyword is
supplied.

87PLC window

The TNC 640 can display PLC error messages in the dialog line
during operation.

Small PLC window

The TNC 640 can show additional PLC messages and bar
diagrams in the small PLC window.

PLC soft keys

The machine manufacturer can display his own PLC soft keys inthe vertical soft-key row on the screen.

PLC positioning

All closed-loop axes can also be positioned
via the PLC. PLC positioning of theNC axes cannot be superimposed on
NC positioning.

PLC axes

Axes can be defined as PLC axes. They are programmedby means of M functions or OEM cycles. The PLC axes are
positioned independently of the NC axes.

PLCdesign(accessory)

PC software for PLC program development. The PC program
PLCdesign can be used for easy creation of PLC programs.
Extensive examples of PLC programs are included with the
product.
Functions:• Easy-to-use text editor• Menu-guided operation• Programming of symbolic operands• Modular programming techniques• “Compiling” and “linking” of PLC source files• Operand commenting, creation of the documentation file• Comprehensive help system• Data transfer between the PC and control• Creation of PLC soft keys

88

Python OEM
Process(software
option 46)

The Python OEM Process software option gives the machine
manufacturer a powerful tool for using a high-level, object-oriented
programming language in the control (PLC). Python is an easy-tolearn script language supporting all necessary high-level language
elements.
Python OEM Process can be used universally for machinefunctions and complex calculations, as well as to display special
user interfaces. User-specific or machine-specific solutions can be
efficiently implemented. Numerous libraries on the basis of Python
and GTK are available, regardless of whether you want to create
special algorithms for special functions, or separate solutions suchas an interface for machine maintenance software.
The applications you create can be included via the PLC in thefamiliar PLC windows, or they can be displayed in separate freewindows that can be expanded to the control’s full screen size.
Simple Python scripts (e.g., for display masks) can also be
executed without enabling the Python OEM Process software
option (software option 46). Ten megabytes of dedicated memory
are reserved for this function. For more information, refer to the
Python in HEIDENHAIN Controls Technical Manual.

89

PLC basic
program

The PLC basic program serves as a basis for adapting thecontrol to the requirements of the respective machine. It can be
downloaded from the Internet.
These essential functions are covered by the PLC basic program:
Axes– Control of analog and digital axes
– Axes with clamping mode
– Axes with central drive– Axes with Hirth grid
– Synchronized axes
– 3-D head with C-axis mode
– Reference run, reference end position– Axis lubrication
Spindles– Control and orientation of the spindles– Spindle clamping– Alternative double-spindle operation– Parallel spindle operation– Conventional 2-stage gear system– Wye/delta connection switchover (static, dynamic)
Tool changers– Manual tool changer– Tool changer with pick-up system– Tool changer with dual gripper– Tool changer with positively driven gripper– Rotating tool magazine with closed-loop axis
– Rotating tool magazine with controlled axis
– Servicing functions for the tool changer– Python tool management
Pallet changers– Translational pallet changer– Rotatory pallet changer– Servicing functions for the pallet changer
Safety functions– Emergency stop test (EN 13849-1)– Brake test (EN 13849-1)– Repeated switch-on test for a wireless handwheel
General functions– Feed rate control– Control of the coolant system (internal, external, air)– Toggling between milling and turning modes– Temperature compensation– Activate tool-specific torque monitoring– Hydraulic control– Chip conveyor– Indexing fixture– Touch probes– PLC support for handwheels– Control of doors– Handling of M functions– PLC log
– Display and management of PLC error messages– Diagnostics screen (Python)– Python example applications– Status display in the small PLC window90Interfacing to the machine

OEM cycles

The machine tool builder can create and store his own cycles forrecurring machining tasks. These OEM cycles are used in thesame way as standard HEIDENHAIN cycles.

CycleDesign(accessory)

The soft-key structure for the cycles is managed using the
CycleDesign PC program. In addition, CycleDesign can be used
to store help graphics and soft keys in BMP format in the TNC.
Graphic files can be compressed to ZIP format to reduce theamount of memory used.

Tool
Management

With integral PLC, the tool changer is moved either via proximity
switch or as a controlled axis. Complete tool management withtool life monitoring and replacement tool monitoring is carried out
by the TNC 640.

Tool Calibration

Tool touch probes can be measured and checked with the TT tool
touch probe system (accessory). Standard cycles for automatic
tool measurement are available in the control. The control
calculates the probing feed rate and the optimal spindle speed.
The measured data are stored in a tool table.

Touch-Probe
Configuration

All touch-probe data can be configured conveniently through atable. All HEIDENHAIN touch probe systems are preconfigured
and can be selected through a drop-down menu.

PalletManagement

Pallet feeding can be controlled via
PLC axes. The user defines the pallet
sequence, pallet presets, and workpiecepresets in the pallet tables. The pallet
tables are freely configurable; any
information can be stored in the tables andcalled via the PLC. Pallet table execution
can be workpiece- or tool-oriented.

91

Data transfer and communication
Data interfaces

Overview

The TNC 640 is connected to PCs, networks, and other data
storage devices via data interfaces.

Ethernet

The TNC 640 can be interconnected via the Ethernet interface.
For connection to the data network, the control features a
1000BASE-T (twisted pair Ethernet) connection.
Maximum transmission distance:
Unshielded: 100 m
Shielded: 400 m

ProtocolThe TNC 640 communicates using the TCP/IP protocol.

Network
connection• NFS file server• Windows networks (SMB)

Data transmission
speed

Approx. 400 to 800 Mbit/s (depending on the file type andnetwork utilization)

V.24/RS-232-C for
the MC 8xxx andMC 6xxx

Data interface according to DIN 66020 or EIA standard RS-232-C.
Maximum transmission distance: 20 m

Data transmission
speed

115 200; 57 600; 38 400; 19 200; 9600; 4800; 2400; 1200; 600;
300; 150; 110 bps

Protocols

The TNC 640 can transfer data using various protocols.

Standard datatransmission

The data is transferred character by character. The number of data
bits, stop bits, the handshake, and character parity must be set by
the user.

Blockwise datatransfer

The data is transferred blockwise. A block check character (BCC) is
used for data backup. This method improves data security.

LSV2

Bidirectional transfer of commands and data as per DIN 66019.
The data is divided into telegrams (blocks) and transmitted.

USB

The TNC 640 features USB interfaces for the connection ofstandard USB devices such as a mouse, hard drive, etc. On theback of the MC 8xxx and MC 6xxx are four USB 3.0 ports. Oneof them leads to the TE, where a cover cap protects it fromcontamination. More USB 2.0 ports are in the integrated USB hub
on the rear of the BF. The USB ports are rated for a maximum of
0.5 A.

USB cables

Cable length of up to 5 m
Cable length of 6 m to 30 m with integrated
amplifier; limited to USB 1.1.

92

ID 354770-xx
ID 624775-xx

Software for datatransfer

We recommend using HEIDENHAIN software to transfer files
between the TNC 640 and a PC.

TNCremo(accessory)

This PC software package supports the user in transmitting datafrom the PC to the control. This software implements blockwise
data transfer with block check characters (BCC).
Functions:• Data transfer (including blockwise)• Remote control (only serial)• File management and data backup of the control• Reading out the log• Print-out of screen contents• Text editor• Managing more than one machine

TNCremoPlus(accessory)

In addition to the features already familiar from TNCremo,
TNCremoPlus can also transfer the current content of the control’s
screen to the PC (live screen). This makes it very simple tomonitor the machine.
Additional functions:• Interrogation of control information (NC uptime, machine
uptime, machine running time, spindle running time, pending
errors, data from the data servers—e.g., symbolic PLC
operands)• Targeted overwriting of tool data using the values of a tool
presetter
TNCremoPlus

ID 340447-xx

93Connected Machining

Overview

Connected Machining makes uniformly digital job management
possible in networked manufacturing. You also profit from:• Easy data usage• Time-saving procedures• Transparent processes

Remote Desktop
Manager(software
option 133)

Remote control and display of external computers over an
Ethernet connection (e.g., Windows PC). The information isdisplayed on the control’s screen. Remote Desktop Manager
allows you to access important applications, such as CAD/CAM
applications or order management, from the control.
Remote Desktop Manager

HEIDENHAIN
DNC(software
option 18)

ID 894423-xx

The development environments on Windows operating systems
are particularly well suited as flexible platforms for application
development in order to handle the increasingly complex
requirements of the machine’s environment.
The flexibility of the PC software and the large selection ofready-to-use software components and standard tools in thedevelopment environment enable you to develop PC applicationsof great use to your customers in a very short time, for example:• Error reporting systems that, for example, send the customer
a text message to his cell phone reporting problems on thecurrently running machining process• Standard or customer-specific PC software that decidedly
increases process reliability and equipment availability• Software solutions controlling the processes of manufacturingsystems• Information exchange with job management software
The HEIDENHAIN DNC software interface is an attractive
communication platform for this purpose. It provides all the dataand configuration capabilities needed for these processes so thatan external PC application can evaluate data from the control and,if required, influence the manufacturing process.

RemoTools SDK(accessory)

To enable you to use HEIDENHAIN DNC effectively, HEIDENHAIN
offers the RemoTools SDK development package. It contains the
COM component and the ActiveX control for integration of the
DNC functions in development environments.
RemoTools SDK

ID 340442-xx

For more information, refer to the HEIDENHAIN DNC brochure.
virtualTNC(accessory)

The virtualTNC control software is a control component for
virtual machines for machine simulations, and is available via the
HEIDENHAIN DNC interface.
Single station license
Network license For one work station
For 14 workstations
For 20 workstations

ID 1113933-02
ID 1122145-02
ID 1113935-02
ID 1113936-02

For more information, refer to the HEIDENHAIN DNC brochure.

94

OPC UA NC
Server(software
option 56-61)

The Open Platform Communications Unified Architecture (OPC
UA) standard has emerged in recent years as a well-establishedinterface for secure and reliable data exchange in industrial
environments. The new HEIDENHAIN OPC UA NC Server
software option makes this forward-looking interface available on
the TNC 640. OPC UA features cross-operating system capability:
along with the widespread Windows systems, OPC UA also
allows Linux-based systems or Apple Computers with macOS*,for example, to be connected to the HEIDENHAIN control.
Numerous developer toolkits are available for OPC UA. RemoTools
SDK is not needed. Thanks to the standardized protocol, thefreedom to choose the toolkit, and the application-oriented
HEIDENHAIN information model, highly individualized applications
and standard software can be developed with significantly reduced
time to market.
The HEIDENHAIN OPC UA NC Server supports the following
OPC UA services:• Reading and writing variables• Subscribing to value changes• Executing methods• Subscribing to events
With Sign&Encrypt, HEIDENHAIN ensures that even the standard
solution provides state-of-the-art IT security:• SecurityMode: Sign&Encrypt• Cryptographic algorithm: Basic256Sha256 (recommendation of
OPC Foundation) – X.509 Certificates• User authentication through X.509 certificates*Apple and macOS are trademarks of Apple Inc.

95

Mounting information
Clearances and mounting

Proper minimum
clearance

When mounting the control components, please observe proper minimum clearances and space requirements,
as well as the length and position of the connecting cables.
Installation in an electrical cabinet

Installation in an operating panel

20

15

Air out

Air inLeave space for air circulation and servicing

Leave space for air circulation and servicing

96

Mountingand electricalinstallation

Observe the following points during mounting and electricalconnection:• National regulations for low-voltage installations at the operatingsite of the machine or components• National regulations regarding interference and noise immunity
at the operating site of the machine or components• National regulations regarding electrical safety and operating
conditions at the operating site of the machine or components• Specifications for the installation position• Specifications of the Technical Manual

Degrees ofprotection

The following components fulfill the requirements for IP54 (dust
protection and splash-proof protection):• Display unit (when properly installed)• Keyboard unit (when properly installed)• Machine operating panel (when properly installed)• Handwheel
All electric and electronic control components must be installed
in an environment (e.g., electrical cabinet, housing) with an
IP54 rating (dust and splash-proof protection) in order to fulfill
the requirements of pollution degree 2. All components of the
OEM operating panel must also have an IP54 rating, just like theHEIDENHAIN operating panel components.

Electromagnetic
compatibility

Protect your equipment from interference by observing the rules
and recommendations specified in the Technical Manual.

Intended place of
operation

This unit fulfills the requirements of EN 50370-1 and is intended
for operation in industrially zoned areas.

Likely sources ofinterference

Interference is produced by capacitive and inductive coupling into
electrical conductors or into device connections, caused by, e. g.:• Strong magnetic fields from transformers or electric motors• Relays, contactors, and solenoid valves• High-frequency equipment, pulse equipment, and straymagnetic fields from switch-mode power supplies• Power lines and leads to the above equipment

Protective
measures• Ensure that the MC, CC, and signal lines are at least 20 cm
away from interfering devices• Ensure that the MC, CC, and signal lines are at least 10 cm

away from cables carrying interfering signals. For cables inmetallic ducting, adequate decoupling can be achieved by usinga grounded separation shield.
• Shielding according to EN 50178• Use equipotential bonding lines according to the grounding plan.
Please refer to the Technical Manual of your control.
• Use only genuine HEIDENHAIN cables and connecting
elements
Installation
elevation

The maximum altitude for installation of HEIDENHAIN control
components (MC, CC, PLB, MB, TE, BF, IPC, etc.) is 3000 m
above sea level.

97

Overall dimensions
Main computer

MC 6541, MC 6641, IPC 6641

98

30

170±0.230300±0.3

21.5

MC 6542, IPC 6490

4

.8

99

MC 7522= Front panel opening= Mounting surface= Space for air circulation10087.4+2

1–0.5

12±0.2

16.95±1

28+2

MC 85123= Front panel opening= Mounting surface= Space for air circulation

101

12±1

25.5±120.9±187.4+212±131.4+2

1–0.5

MC 8532

3

Front panel opening
Mounting surface
Space for air circulation

102

Controller unit

CC 6106103

CC 6108, CC 6110

7

CC 6108: 8 control loops
CC 6110: 10 control loops

104

UEC 111, UEC 112, UEC 113

105

UMC 111 FS

106

Operating panel, screen, and keyboard

ITC 755

8.5

29.6

72.1



9.5
188

176

36

376

454

470

23

8

11

12

15

400

15

18

20

376

459+1

4.75

454

Front panel opening
Mounting surface
Space for air circulation



385.5+1

107

BF 860, ITC 860

71.5+2
500

28
1.4

12

10

384±0.240090°476±0.2

3
1–0.5

476

232

376

104.5

12

176.2

= Front panel opening= Mounting surface= Space for air circulation

108

12
190.5

TE 745, TE 745 FS

Front panel opening
Mounting surface

109

156

ITC 750= Front panel opening= Mounting surface= Space for air circulation

110

TE 730

Front panel opening
Mounting surface111

TE 735, TE 735 FS

Front panel opening
Mounting surface112

MB 720, MB 720 FS= Front panel opening= Mounting surface113

MB 721, MB 721 FS
25+5

90

200

130

270

310

360

8+1

40

8

0

124

29.5
63.5

140

90°

0

112.5
12

376
400

124+1124X (3x)

384+1= Front panel opening= Mounting surface

114

PLB 600x

115PLC inputs and outputs

PL 6000 (PLB 62xx, PLB 61xx)

Clearance for air circulation

116

Power supply units

PSL 130

PSL 135

117

Electronic handwheels

3

46

76.5

HR 510, HR 510 FS

278
296

HR 520, HR 520 FS

118

Holder for HR 520, HR 520 FS

73.5
72

69.3

70.3

HR 550 FS

119

HRA 551 FS
122
68.6

12
180

48.6
4

83±0.2320

6192±0.2

210

204

120

32

116

5.5
4x

120

HR 130121

Adapter cable for handwheels (straight)

X1

X2







 

Mounting opening up to wall thickness S = 4
Mounting opening for wall thickness S = 4 or more

HR/HRA adapter cable to MC (straight connector)

122





 





 

Adapter cable for handwheels (angled)

X2

Mounting opening

36

X1









 

Adapter cable for HR/HRA to MC (angled connector)

123Interface accessories

Line-drop compensator for encoders with EnDat interface

Connection to KTY

USB extension cable with hubs

Ordering length124

KTY adapter connector

Leave space for connecting cable!

29

31

UTI 660

80
75
71
69.5

135

132.5

36.8

56
65.5
81.5

125

Camera system

VS 101

37
15.5

125

M5

67.25

184.5

50±0.1

7.6

49.5

37

65.5

92.9

74.4

56.5

21.2
52.8

126

46.2

28.2

9.2

37.2

53

17.5

96.04

General information
Documentation

Technical
documentation

User
documentation

Other
documentation

Technical Manuals(PDF format on HESIS-Web including Filebase)• TNC 640
• PNC 610
• Inverter Systems and Motors• Functional Safety (FS)ID 892899-xx
ID 1191125-xx
ID 208962-xx
ID 749363-xx

Mounting Instructions• TS 260• TS 460• TS 740• TT 160• TT 460

ID 808652-9x
ID 808653-9x
ID 632761-9x
ID 808654-xx
ID 808655-xx

User's Manuals
TNC 640• Klartext Conversational Programming• Setup, Testing, and Running NC Programs• Cycle Programming• ISO Programming

ID 892903-xx
ID 1261174-xx
ID 892905-xx
ID 892909-xx

General• TNCremo• TNCremoPlus• PLCdesign• CycleDesign• IOconfig• KinematicsDesign• M3D converter

Integrated help
Integrated help
Integrated help
Integrated help
Integrated help
Integrated help
Integrated help

Brochures• TNC 640
• Functions of the TNC 640• Touch Probes• 1xx Inverter Systems• Motors• RemoTools SDK virtualTNC

ID 892916-xx
ID 1110731-xx
ID 1113984-xx
ID 622420-xx
ID 208893-xx
ID 628968-xx

Product Information documents• HR 550FS

PDF

Product Overviews• Remote Diagnosis with TeleService

ID 348236-xx

DVDs• Touch Probes• Programming Station: TNC 640 (Demo Version)

ID 344353-xx
ID 1114029-xx

Technical Information documents• Safety-Related Control Technology• Safety-Related Position Encoders• Uniformly Digital

PDF
PDF
PDF

Safetyparameters

For HEIDENHAIN products (such as control components,
encoders, or motors), the safety characteristics (such as failure
rates or statements on fault exclusion) are available on productspecific request from your HEIDENHAIN contact person.

Basic circuit
diagramMore information on basic circuit diagrams can be requested fromyour HEIDENHAIN contact person.

127Service and training

Technical support

HEIDENHAIN offers the machine manufacturer technical support
to optimize the adaptation of the control to the machine, including
on-site support.

Exchange control

In the event of a malfunction, HEIDENHAIN guarantees thetimely shipment of an exchange control (usually within 24 hours in
Europe).

Helpline

Our customer service technicians are available for questions
regarding adaption or in the event of malfunctions:
NC support(initial configuration/optimization,
field service/troubleshooting)+49 8669 31-3101
E-mail: service.nc-support@heidenhain.de

PLC/Python programming
Functional safety (FS)+49 8669 31-3102
E-mail: service.plc@heidenhain.de

NC/Cycle programming and kinematics+49 8669 31-3103
E-mail: service.nc-pgm@heidenhain.de

Encoders / machine calibration+49 8669 31-3104
E-mail: service.ms-support@heidenhain.de

Application programming+49 8669 31-3106
E-mail: service.app@heidenhain.de

If you have questions about repairs, spare parts, or exchange units,
please contact our Service department:
Customer service, Germany+49 8669 31-3121
E-mail: service.order@heidenhain.deCustomer service,international+49 8669 31-3123
E-mail: service.order@heidenhain.deMachinecalibration

On request, HEIDENHAIN engineers will calibrate your machine’s
geometry (e.g., with a KGM grid encoder).

Technical courses

HEIDENHAIN provides technical customer training in the following
subjects:• NC programming• PLC programming• TNC optimization• TNC servicing• Encoder servicing• Special training for specific customers
For more information on dates or registration:

128

Technical training courses inGermany+49 8669 31-3049

Technical training courses
outside of Germany

www.heidenhain.deEN ► Company ► Contact ►HEIDENHAIN worldwide

E-Mail: mtt@heidenhain.deOther HEIDENHAIN controls
ExamplesTNC 620

Information:
TNC 620 brochure• Compact contouring control for milling, drilling, and boringmachines• Axes: 8 control loops, up to two of which are configurable asspindles• For operation with HEIDENHAIN inverter systems and ideally
HEIDENHAIN motors• Uniformly digital with HSCI interface and EnDat interface• Compact size
• CompactFlash memory card
• Programming in HEIDENHAIN Klartext format or G-code (ISO)• Standard milling, drilling, and boring cycles• Touch probe cycles• Short block processing time (1.5 ms)
Version with touchscreen:• 19-inch screen (portrait), keyboard, and main computer in one
unit (MC 8410)• Integration of the keyboard in the lower screen area
• Multi-touch operation
Version with operating keys:• Screen and main computer in one unit (MC 7420) and separate
keyboard with integrated ASCII keys

CNC PILOT 640

Information:
CNC PILOT 640 brochure• Contouring control for lathes and turning-milling machines• Suitable for horizontal and vertical lathes as well as verticalboring and turning mills• Axes: max. 24 control loops (22 control loops with functionalsafety (FS), max. 8 NC axes per channel, max. 6 spindles in theoverall system• Multi-channel capability: up to 3 channels for asynchronous
multi-slide machining• Up to 3 principal axes (X, Z, and Y), B axis, closed-loop spindle
and counter spindle, C1/C2 axis and driven tools• 5-axis simultaneous machining (X, Z, Y, B, and C axes)• Up to 3 programmable auxiliary axes (U, V, W) for control ofsteady rest, tailstock and counter spindle• The position of a parallel secondary axis can be showncombined with its principal axis
• For operation with HEIDENHAIN inverter systems andpreferably with HEIDENHAIN motors• Uniformly digital with HSCI interface and EnDat interface• 19-inch or 15.6-inch multi-touch display• CFR CompactFlash memory card (CFast) with 8 GB
• Programming of turning, drilling, and milling operations withsmart.Turn, according to DIN, or via cycles• TURN PLUS for automated smart.Turn program generation• ICP free contour programming for turning and milling contours• For simple tool holders (multifix), turrets, or magazines

CNC PILOT 640
with 15.6-inch multi-touch display

129

Subject index

33D-ToolComp...................................... 83

55-Axis Machining................................. 64

A
Absolute encoders.............................. 70
Accessories........................................... 5
Active Chatter Control (ACC)................ 75
Active Vibration Damping (AVD)........... 77
Adapter connector for temperature
sensor................................................. 26
Adaptive Feed Control (AFC)................ 74
Additional modules.............................. 35
Advanced Dynamic Prediction (ADP).... 73
Advanced Function Set Turning............ 67
API DATA............................................ 85
Axes................................................... 63
Axis clamping...................................... 72
Axis feedback control.......................... 71

B
Backlash.............................................. 81
Basic modules..................................... 31
Batch Process Manager (BPM)............ 65
BF 750................................................ 27
BF 860........................................ 29, 108
Bus diagnosis...................................... 86

C
Cable overview................................... 51
Calibration sphere................................ 82
Camera system................................. 126
CC 6106...................................... 22, 103
CC 6108.............................................. 22
CC 6108, CC 6110............................. 104
CC 6110.............................................. 22
CC 61xx.............................................. 22
CMA-H 04-04-00................................. 35
Combined PROFIBUS DP/PROFINET IO
module................................................ 35
Commissioning and diagnostic aids...... 84
Compensation of torque ripples........... 71
Component Monitoring....................... 80
Components......................................... 4
ConfigDesign...................................... 84
Connected Machining.......................... 94
Connecting cables............................... 40
Context-sensitive help......................... 79
Controller unit..................................... 21
Control loop cycle times...................... 72
Control systems with external safety... 61
Control systems with integratedfunctional safety (FS)........................... 59
Crossover Position Filter (CPF)............. 72
Cross Talk Compensation (CTC)........... 77

130

Cycle times......................................... 21
Cylinder Surface Interpolation.............. 63

HSCI control components.................... 16
Hysteresis........................................... 81

DI

Data interfaces.................................... 92
Degrees of protection......................... 97
Digital control design........................... 57
Digital servo control............................ 71
Display step.......................................... 6
DNC applications................................. 94
Double-speed...................................... 21
Double Speed Control Loops............... 72
DriveDiag............................................ 84
Dynamic Collision Monitoring (DCM).... 79
Dynamic Efficiency.............................. 74
Dynamic Precision............................... 76

I/O modules........................................ 32
Incremental encoders.......................... 70
Industrial PC........................................ 41
Input resolution..................................... 6
Installation elevation............................ 97
Integrated inverter............................... 71
Integrated PLC.................................... 87
Interfacing to the machine..................... 8
Inverter system................................... 53
IOconfig.............................................. 32
IPC 6641....................................... 42, 98
ITC 750....................................... 41, 110
ITC 755....................................... 41, 107
ITC 860....................................... 41, 108

EElectromagnetic compatibility.............. 97
Electronic handwheels........................ 38
Encoder inputs.................................... 70
EnDat 2.2............................................ 57
Error compensation............................. 81
Ethernet.............................................. 92
Expansion PL...................................... 32
Export version..................................... 16

F
Facing heads....................................... 67
Facing slides....................................... 67
Fast contour milling............................. 73
Feedforward control............................ 71
Fieldbus systems................................ 35
Following error.................................... 71

G
Gantry axes......................................... 64
Gear Cutting........................................ 67
Gear ranges........................................ 69
Global Program Settings...................... 65
Grinding.............................................. 68

H
HEROS 5............................................ 62
HR 130....................................... 40, 121
HR 510............................................... 38
HR 510, HR 510 FS........................... 118
HR 510 FS........................................... 38
HR 520............................................... 39
HR 520, HR 520 FS........................... 118
HR 520 FS.......................................... 39
HR 550 FS.................................. 39, 119
HRA 551 FS................................ 39, 120
HSCI................................................... 57
HSCI adapter....................................... 34

J
Jerk..................................................... 73
Jerk limiting........................................ 73

K
Keyboard............................................. 27
KinematicsComp................................. 83
KinematicsDesign................................ 80

LLinear axes.......................................... 63
Linear error......................................... 81
Load Adaptive Control (LAC)................ 76
Log..................................................... 85
Look-ahead.......................................... 73

M
M3D Converter................................... 80
Machine operating panel..................... 27
Main computer................................... 16
Master keyword.................................. 18
Maximum spindle speed..................... 69
MB 720.............................................. 28
MB 720, MB 720 FS......................... 113
MB 720 FS......................................... 28
MB 721.............................................. 28
MB 721, MB 721 FS......................... 114
MB 721 FS......................................... 28
MC 366.............................................. 17
MC 6541...................................... 17, 98
MC 6542............................................ 17
MC 6542, IPC 6490............................ 99
MC 6641...................................... 17, 98
MC 7522..................................... 17, 100
MC 8512............................................. 17
MC 8532..................................... 17, 102
Module for analog axes....................... 35
Monitor............................................... 27

Monitoring functions........................... 78
Motion Adaptive Control (MAC)........... 76
Mounting and electrical installation....... 97
Multiple main spindles......................... 69N
NC software license............................ 19
Nonlinear error.................................... 81

O
Online Monitor.................................... 85
Operating system................................ 62
Optimized Contour Milling (OCM)........ 75
Oscilloscope........................................ 84

P
PL 6000...................................... 31, 116
PLA-H 08-04-04................................... 32
PLB 600x.................................... 34, 115
PLB 6104............................................ 32
PLB 6104 FS....................................... 32
PLB 6106............................................ 32
PLB 6106 FS....................................... 32
PLB 6108............................................ 32
PLB 6108 FS....................................... 32
PLB 6204 EnDat................................. 31
PLB 6204 FS EnDat............................ 31
PLB 6206 EnDat................................. 31
PLB 6206 FS EnDat............................ 31
PLB 6208 EnDat................................. 31
PLB 6208 FS EnDat............................ 31
PLB 6210 EnDat.................................. 31
PLB 6210 FS EnDat............................. 31
PLC axes...................................... 65, 88
PLC basic program.............................. 90
PLCdesign........................................... 88
PLC encryption................................... 87
PLC inputs/outputs.............................. 87
PLC positioning................................... 88
PLC programming............................... 87
PLC soft keys...................................... 88
PLC window....................................... 88
PLD-H 04-04-00 FS.............................. 32
PLD-H 04-08-00 FS.............................. 32
PLD-H 08-04-00 FS.............................. 32
PLD-H 08-16-00................................... 32
PLD-H 16-08-00................................... 32
PNC 610............................................. 43
Position Adaptive Control (PAC)............ 77
Position-controlled spindle................... 69
Power supply................................ 16, 33
PROFIBUS DP module........................ 35
PROFINET IO module.......................... 35
Proper minimum clearance.................. 96
PSL 130...................................... 33, 117
PSL 135...................................... 33, 117
Python OEM Process.......................... 89R

U

Real-Time Coupling Function................ 65
Remote Desktop Manager.................. 94
RemoTools SDK.................................. 94
Reversal spikes................................... 81
Ribbon cables..................................... 23
Rotary axes......................................... 63

UEC 111...................................... 24, 105
UEC 112...................................... 24, 105
UEC 113...................................... 24, 105
UEC 11x.............................................. 23
UMC 111 FS................................ 25, 106
UMC 11x FS....................................... 25
USB.................................................... 92
User administration............................. 62
UTI 660............................................... 37

S
Screen................................................ 27
SE 540................................................ 37
SE 642................................................ 37
SE 660................................................ 37
SE 661................................................ 37
SIK component................................... 18
Single-speed....................................... 21
Sliding friction..................................... 81
Smoothed jerk.................................... 73
Snap-on keys................................. 47, 49
Software............................................... 5
Software options................................. 13
Specifications........................................ 6
Spindle................................................ 69
Spindle orientation............................... 69
Spindle override.................................. 69
State Reporting................................... 86
Static friction....................................... 81
Storage medium................................. 18
Synchronized Axes.............................. 64
System PL with EnDat support............ 31

V
V.24/RS-232-C protocols...................... 92
virtualTNC........................................... 94
Visual Setup Control (VSC)................... 80
VS 101........................................ 46, 126

W
Workpiece measurement.................... 36

T
Table function...................................... 85
Tapping............................................... 69
TE 360.......................................... 30, 30
TE 360 FS..................................... 30, 30
TE 730................................................ 27
TE 735................................................ 27
TE 735, TE 735 FS............................ 112
TE 735 FS........................................... 27
TE 745................................................ 29
TE 745, TE 745 FS............................. 109
TE 745 FS........................................... 29
TeleService.......................................... 86
Thermal expansion.............................. 81
Tilting the Working Plane..................... 64
TNCanalyzer........................................ 86
TNCkeygen......................................... 19
TNCopt............................................... 85
TNCremo............................................ 93
TNCremoPlus...................................... 93
TNCscope........................................... 85
TNCtest.............................................. 86
Tool measurement.............................. 37
Torque Control............................... 64, 64
Touch probes....................................... 36
Trace function...................................... 85
Transceiver.......................................... 37131

Mastering nanometer accuracy

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896020-2A · 2/2020 · H · Printed in Germany

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