TNC 640
Contouring Control for
Milling Machines, Milling-Turning
Machines, and Machining
Centers
Information for
Machine Manufacturers

06/2024

TNC contouring control
General information

TNC 640

Contents• Contouring control for milling machines, milling-turning

machines, and machining centers• Axes: up to 24 control loops, of which up to 4 can be configured
as spindles• For operation with HEIDENHAIN inverter systems and ideallywith HEIDENHAIN motors• Fully digital with HSCI interface and EnDat interface• Version with touchscreen for multi-touch 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)• 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 backup battery and fan.

Standards

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

NoteIntel, Intel Xeon, Core, and Celeron are registered trademarks ofIntel Corporation.

Validity

The features and specifications described here apply to thefollowing control and NC software versions:
TNC 640 with NC software versions
340590-18 (requires an export license in accordance with Annex Iof the EU Dual-Use Regulation)
340591-18 (not covered by Annex I of the EU Dual-Use Regulation)

TNC contouring control

2

Overview tables

4

HSCI control components

17

Accessories

28

Cable overview (examples)

50

Technical description

57

Data transfer and communication

97

Mounting information

101

Key dimensions

102

General information

131

Subject index

134

Please note the page references in the tables with thespecifications.
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 361, TE 361 FS).
Components for which there is also a version with functionalsafety bear the identifier "(FS)" at the end of the productdesignation (e.g., UEC 3xx (FS)).

Use of thisbrochure

This brochure is purely a decision-making aid for selecting
HEIDENHAIN components. Further documents are required
for actual project planning (see "Technical documentation",
Page 131).

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.
Starting with version 34059x-18, the NC software can be installed
only in a storage medium with ≥ 30 GB of nominal capacity.
Smaller storage media can no longer be used. In addition, themain computer (MC) must be equipped with at least 4 GB of main
memory.

23Overview tables
Components

Control systems
Main computer

Storage medium

Accessories

15-inch design

19-inch design

24-inch design

Page

Accessory

For operatingpanel

MC 8522(1024 x 768 pixels)
MC 8512(1024 x 1280 pixels)

MC 8532(1280 x 1024 pixels)

MC 366(Full HD, 1920 x 1080
pixels)17

Electronic handwheels

For electricalcabinet

–MC 306
Workpiece touch probes1)

MC 85x2; MC 306 SSDR solid-state drive

19

NC software license

On SIK component

Monitor–

BF 860(1280 x 1024 pixels)

BF 360(Full HD, 1920 x 1080
pixels)Keyboard

TE 735 and TE 735 FS(for MC 8522)

TE 745 and TE 745 FS

TE 360 and TE 360 FS
TE 361 and TE 361 FS

Machine operating panel

MB 720 and MB 720 FS(for MC 8522)
MB 721 and MB 721 FS(for MC 8512)

Integrated

Integrated

PLC inputs/
outputs1)

With HSCI
interface

19
24

24

PLB 600x (HSCI adapter for OEM machine operating panel)28

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

26

On UEC and UMC
Additional modules1)

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

29

Compact inverters and modular inverters

Connecting cable• HR 510, HR 510 FS portable handwheel• HR 520, HR 520 FS portable handwheel with display• HR 550 FS portable wireless handwheel with display• HR 130 panel-mounted handwheel• Up to three HR 180 panel-mounted handwheels via HRA 180 handwheel adapter• TS 460, TS 760 triggering touch probes with radio or infrared transmission• TS 260, TS 750, TS 150 triggering touch probes with cable connection• TT 160 triggering touch probe with cable connection• TT 460 triggering touch probe with radio or infrared transmission

Page
30

Programming station2)

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

Auxiliary axis control

PNC 61036

Industrial PC

ITC 362/ITC 860 additional operating station with touchscreen and integrated screen
keyboard
ITC 855 additional operating station with touchscreen and ASCII keyboard
IPC 306 industrial PC for Windows
IPC 6490/IPC 8420 industrial PC for PNC 610

34

Vision system

VT 121, VTC vision system for tool inspection

39

Snap-on keys

For controls and handwheels

401) For more information, refer to the Touch Probes brochure2) For more information, refer to the Programming Station for TNC Controls brochure

Modules for fieldbus systems
Inverter systems2)

Tool touch probes1)

TNC 640501) May be necessary depending on the configuration

2) For more information, refer to the Inverter Systems for Gen 3 Drives brochure

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.

Software tools

TNC 640Page

PLCdesign1)

PLC development software

93

KinematicsDesign1)

Software for creation of kinematic models

83

M3D Converter4)

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

83

TNCremo2), TNCremoPlus2)3)

Data transfer software (TNCremoPlus with “live” screen)

98

ConfigDesign1)

Software for configuring the machine parameters

88

CycleDesign1)

Software for creating cycle structures

96

TNCkeygen1)

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

19

TNCscope1)

Software for data recording

89

TNCopt1)

Software for putting digital control loops into service

89

IOconfig1)

Software for configuring PLC I/O and fieldbus components

27

RemoteAccess1)3)

Software for remote diagnostics, monitoring, and operation

90

RemoTools SDK1)

Function library for developing customized applications for communication with
HEIDENHAIN controls

99

virtualTNC1)3)

Control component for virtual machines

99

TNCtest1)

Software for creation and execution of an acceptance test

91

TNCanalyzer1)

Software for the analysis and evaluation of service files

911) 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)

4

5

Specifications

Specifications

TNC 640

Page

Axes

Up to 24 control loops, of which up to 4 can be configured as spindles

63

Rotary axes

Max. 3

Synchronized axes✓

PLC axes✓

Main spindle

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

70

Speed

Max. 60 000 rpm for motors with a single pole pair(with software option 49: max. 120 000 rpm)

70

Operating mode switchover✓70

Position-controlled spindle✓

70

Oriented spindle stop✓70

Gear shifting✓70

NC program memory≈ 17 GiB (with 32 GB SSDR)≈ 189 GiB (with 240 GB SSDR)

17

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 to

TNC 640

Page

Cycle times of main computer

MC

73

Block processing< 0.5 ms

74

Cycle times of controller unit

CC/UEC/UMC

73

Path interpolation

3 ms

73

Fine interpolation

Applies to fPWM = 5 kHz

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
13 333 Hz with software option 49
16 000 Hz with software option 49

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

Position controller
Speed controller

63

Input resolution and display step

Specifications

59• 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

CircleIn 2 axes; in 3 axes with software option 8

Helical✓72

Axis feedback control
With servo lag✓

With feedforward✓

Axis clamping✓

Maximum feed rate

63
60000 rpm
No. of motor pole pairs.

63
Screw pitch [mm]Applies to fPWM = 5000 Hz

67

Interfacing to the machineInterfacing to the machine

TNC 640

Page

Interfacing to the machine

TNC 640

Page

Error compensation✓

85

Setup anddiagnostic aids

Linear axis error✓

85

TNCdiag

Software for the analysis of status and diagnostic information of digital drive systems

88

Nonlinear axis error✓

85

TNCoptSoftware for putting digital control loops into service

89

Backlash✓85

ConfigDesign

Software for creating the machine configuration

88

Reversal spikes during circular
movement✓

85

KinematicsDesign

Software for creating the machine kinematics, initialization of DCM

83

Hysteresis✓

85

Integrated oscilloscope✓

88

Thermal expansion✓

85

Trace function✓

89

Static friction✓

85

API DATA function✓

89

Sliding friction✓

85

Table function✓

89

Dynamic compliance during
acceleration phases✓

79

OLM (online monitor)

✓

89

Log

✓

89

Volumetric compensation with
KinematicsComp✓

87

TNCscope✓

89

Bus diagnostics✓

91

Integrated PLC✓

92

Data interfaces✓

Program format

List of commands

92

Ethernet✓

97

Program input at the control

✓

92

USB

✓

97

Program input by PC✓

92

Protocols

Symbolic PLC-NC interface✓

92

Standard data transmission✓

97

PLC memory≈ 1 GiB (with 32 GB SSDR)≈ 4 GiB (with 240 GB SSDR)

92

Blockwise data transfer✓

97

PLC cycle time

9 ms to 30 ms (adjustable)

92

PLC inputs/outputs

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

57

PLC inputs, DC 24 V

Via PL, UEC, UMC

26

PLC outputs, DC 24 V

Via PL, UEC, UMC

26

Analog inputs ±10 V

Via PL

26

Inputs for PT 100 thermistors

Via PL

26

Analog outputs ±10 V

Via PL26

PLC functions✓

92

Small PLC window✓

93

PLC soft keys✓

93

PLC positioning✓

93

PLC Basic Program✓

95

Integration of applications

94

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

94

User interfaces can be customdesigned

94

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

88

97

9

Short description✓✓
Program entry

Position values

Tool compensation

✓
✓

0-7
77
78

Basic version: 3 axes plus closed-loop spindle
Up to 20 additional NC axes or, for example, 19 additional NC axes plus second spindle

Contour elements

Digital current and speed control

42

HEIDENHAIN Klartext
ISO programming
Direct loading of contours or machining positions from CAD files and saving as Klartext contouring
program or point table✓✓✓

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

9

Option
501)
501)

✓
✓

Straight line
Chamfer
Circular path
Circle center
Circle radius
Tangentially connecting circular arc
Corner rounding
RecessUndercutVia straight line: tangential or perpendicular
Via circular arc

45

AFC adapts the contouring feed rate to the current spindle power

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

Collisionmonitoring

40
40
40
40

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

FK free contour
programming✓

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

Program jumps✓✓✓

Subprograms
Program-section repeat
Any program as a subprogram

Fixed cycles✓✓

Drilling, tapping with a floating tap holder, rigid tapping
Peck drilling, reaming, boring, counterboring, centering
Area clearance cycles, longitudinal and transverse, paraxial and contour-parallel
Recessing cycles, radial/axial
Radial/axial recess turning cycles (combined recessing and roughing motion)
Milling of internal and external threads
Turning of internal and external threads
Cycles for hobbing and skiving
Simultaneous roughing and finishing
Interpolation turning
Clearing level and oblique surfaces
Multi-operation machining of straight and circular slots
Multi-operation machining of rectangular and circular pockets
Cartesian and polar point patterns and point patterns for DataMatrix code
Contour train, contour pocket
Contour slot with trochoidal milling
OEM cycles (special cycles developed by the machine manufacturer) can be integrated
Engraving cycle: engrave text or numbers in a straight line or on an arc✓

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 point
Based on the tool’s cutting edge

Parallel operation✓

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

3D machining

✓

9
9
9
92

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

Rotary tablemachining88Programming of contours on an unrolled cylinder surface
Feed rate in mm/min

Turning

501)
501)
501)
501)
501)
501)
501)
501)
501)
501)

Program-controlled switchover between milling and turning
Constant cutting speed
Tool-tip 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)99Contour approachand departure

✓
✓
✓
✓
✓
✓
✓

TNC 640

Adaptive feed
control

Tool tables

1) Turning v2 (software option 158) includes the functions of software option 50

10FunctionStandard

TNC 640
OptionFunctionStandard

Functions for the user

✓

✓
✓
✓
✓
✓
✓
✓
✓
Coordinatetransformations

✓

501)
501)
501)
501)
157
158
96

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

1) Turning v2 (software option 158) includes the functions of software option 50

11

Q parameters
Programming withvariables

✓
✓
✓
✓
✓
✓

Programming aids

CAD viewer

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

Parallel secondary
axes

✓
✓
✓
✓
✓
✓

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

Display of standardized CAD file formats on the TNC
152

CAD Model
Optimizer

TNC 640
OptionFunctionStandard

TNC 640
OptionStandard

Function✓✓

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 enables execution on different
machine configurations✓
Touch probe cycles

Conversational
languages

✓
✓
✓
✓

✓

48
48
501)

Touch probe calibration
Manual or automatic compensation of workpiece misalignment
Manual or automatic preset setting
Automatic tool and workpiece measurement
Automatic measurement and optimization of machine kinematics
Compensation table for multiple kinematics models
Cycle for measurement of turning tools
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

1) Turning v2 (software option 158) includes the functions of software option 50

Optimize CAD models

Teach-in✓Application of actual positions directly in the NC program

Test graphics
Depictions✓✓✓

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

3D line graphics✓

For verification of programs created offline

Programming
graphics✓

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

Program-run
graphics
Display modes✓✓

Graphic simulation during real-time machining
Plan view / projection in 3 planes / 3D 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 in any block in the program, returning the tool to the calculated nominal
position to continue machining
Program interruption, contour departure and return

Presetmanagement✓

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 programs, and datums)

1) Turning v2 (software option 158) includes the functions of software option 50

1213

Software options

OptionnumberSoftware option

With NC
software34059xand later

ID

Comment

Page

0

Additional Axis 101354540-01

Additional control loop 1

211Additional Axis 201353904-01

Additional control loop 2212Additional Axis 301353905-01

Additional control loop 3

213Additional Axis 401367867-01

Additional control loop 4214Additional Axis 501367868-01

Additional control loop 5215Additional Axis 601370291-01

Additional control loop 6216Additional Axis 701370292-01

Additional control loop 7217Additional Axis 801370293-01

Additional control loop 8218Adv. Function Set 1

01617920-01

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

63

Coordinate transformations• Tilting the working plane, PLANE function

64

Interpolation• Circular in 3 axes with tilted working plane
9Adv. Function Set 2

01617921-01

3D machining64• 3D 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 perpendicular to the contour• Tool radius compensation perpendicular to the tool
direction• Manual traverse in the active tool-axis system
Interpolation• Straight line in more than four axes (requires an export
license in accordance with Annex I of the EU Dual-Use
Regulation)

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM
component

99

40

DCM Collision

01
02526452-01

Dynamic Collision Monitoring (DCM)

82

42

CAD Import

08526450-01

Importing of contours from 2D and 3D 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

76

46

Python OEM Process

01579650-01

Execution of Python applications

94

48

KinematicsOpt

01630916-01

Touch-probe cycles for the automatic measurement ofrotary axes

86

49

Double-Speed Axes

01

632223-01

Short control-loop cycle times for direct drives

73

14

OptionnumberSoftware option

With NC
software34059xand later

ID

Comment

Page

50

Turning

01634608-01

Turning functions (mill-turning)• Turning tool management• Tool radius compensation• Switching between milling and turning mode
• Turning-specific contour elements• Package of turning cycles

66

52

KinematicsComp

05661879-01

Spatial compensation of errors in rotary and linear axes
87
(requires an export license in accordance with Annex I of
the EU Dual-Use Regulation)

56–61

OPC UA NC Server 1
to 6

10

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

100

77

4 Additional Axes

01

634613-01

Four additional control loops

2178

8 Additional Axes

01

634614-01

Eight additional control loops

21

92

3D-ToolComp

07679678-01

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

87

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

99

133

Remote Desk.
Manager

01894423-01

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

99

135

Synchronizing
Functions

041085731-01 Advanced synchronization of axes and spindles

65

141

Cross Talk Comp.

02

800542-01

CTC: compensation of axis couplings

79

142

Pos. Adapt. Control

02800544-01

PAC: position-dependent adaptation of control
parameters

80

143

Load Adapt. Control

02800545-01

LAC: load-dependent adaptation of control parameters

78

144

Motion Adapt. Control

02800546-01

MAC: motion-dependent adaptation of control
parameters

79

145

Active Chatter Control

02800547-01

ACC: active chatter control

77

146

Machine Vibration
Control

11800548-01

Damping of machine oscillations to improve workpiecesurfaces. The following functions are part of Machine
Vibration Control (MVC):• AVD (Active Vibration Damping):
Active damping of vibrations in the control loop
• FSC (Frequency Shaping Control):
Reduction of vibration inducement by means offrequency-based feedforward control

80

15

HSCI control components
Main computers

OptionnumberSoftware option

With NC
software34059xand later

ID

Comment

Page

152

CAD Model Optimizer

171353918-01 Conversion and optimization of CAD models• Fixtures• Workpiece blank• Finished part

83

154

Batch Process
Manager

051219521-01 Planning and executing multiple production jobs

65

155

Component
Monitoring

09

1226833-01 Monitoring for component overloading and wear

84

156

Grinding

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

69

157

Gear Cutting

09

1237235-01 Functions for the machining of gear teeth

67

158

Turning v2171359635-01 Turning functions (mill-turning version 2)• Includes all functions of software option 50 (Turning)plus cycles for simultaneous roughing and finishing

68

160

Integrated FS: Basic

101249928-01 Enables functional safety and four safe control loops

59

161

Integrated FS: Full

101249929-01 Enables functional safety and the maximum number ofsafe control loops

59

162

Add. FS Ctrl. Loop 1

101249930-01 Additional control loop 1

59

163

Add. FS Ctrl. Loop 2

101249931-01 Additional control loop 2

59

164

Add. FS Ctrl. Loop 3

101249932-01 Additional control loop 3

59

165

Add. FS Ctrl. Loop 4

101249933-01 Additional control loop 4

59

166

Add. FS Ctrl. Loop 5

101249934-01 Additional control loop 5

59

167

Optimized Contour
Milling

101289547-01 OCM: optimize roughing processes and fully utilize
milling tools with the integrated cutting data calculator

77

169

Add. FS Full

111319091-01 Enables all FS axis options or control loops. Options 160
and 162 to 166 must already be set.

59

Main computer

The MC main computers feature the following:• Intel high-performance processor• Dual RAM• Gbit HSCI interface to the controller unit and to othercontrol components• HDL2 interface to the BF monitor(with electrical cabinet versions)• Four USB 3.0 ports (e.g., for the TE 361 operating panel)
To be ordered separately and installed in the main computer by theOEM:• SSDR memory card with the NC software• The System Identification Key (SIK) component for enabling
control loops and software options
The following HSCI components are required for operation of the
TNC 640:• MC main computer• Controller unit
• PLB 62xx or PLB 62xx FS PLC I/O unit (system PL; integrated
into UxC)• Keyboard unit with integrated machine operating panel or MB
operating panel

Interfaces

The MC is equipped with USB 3.0 and Ethernet ports.
Connection to PROFIBUS DP or PROFINET IO is optionallypossible via the individual additional modules or a combined
PROFIBUS DP / PROFINET IO module.

ExportlicenseThe main computer is not covered by Annex I of the EU Dual-Use
Regulation. Only the easily replaceable storage medium might
require an export license in accordance with Annex I of the EU
Dual-Use Regulation, depending on the software version.

Gen 3 labels

The different Gen 3 labels identify how control components can be
deployed.
The label indicates that a component is ready for operation in a
Gen 3 (Gbit HSCI) drive system. Whether a component is suitablefor functional safety (integrated FS, external FS, enabling of FS)
must be considered separately.
Gen 3 ready: These components can be used in systems withGen 3 drives (UVR 3xx, UM 3xx, CC 3xx) and also in systems witha 1xx inverter system (UVR 1xx, UE 2xx, UR 2xx, CC 61xx).
Gen 3 exclusive: These components can be used only in systems
with Gen 3 drives (UVR 3xx, UM 3xx, CC 3xx).

16

17

Versions

Various versions of the MC main computer are available:• Installation into the electrical cabinet:
The MC 306 is installed in the electrical cabinet. The operating
panel requires HSCI, USB, and HDL2 cables as control lines• Installation in the operating panel:
The MC 85x2 and MC 366, along with the BF monitor, forma single unit that is 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.

Optional
installation kit
for MC 360 and
BF 360For fastening the MC 366 or BF 360 withmounting braces (set of 6 pieces). Up to six
mounting braces can be fastened to the MC
and BF.

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 14. 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 (SSDR solid state disk), which must beordered separately from the main computer, is removable. It
contains the NC software 34059x-18. The NC software is based on
the HEIDENHAIN HEROS 5 operating system.

MC 306MC 8522 with main computer
installed on the backMC 8532 with main computer
installed on the backMC 366 with main computer installed on the backInstallation Storage
type
mediumProcessor

RAM

Power
Mass
consumption*)ID

MC 85121)

Operatingpanel(19-inch,
portrait)

SSDR(32 GB)Intel Core i7-3,
4 GB
1.7 GHz, dual-core≈ 75 W≈ 8.8 kg

1243919-xx

MC 85221)

Operatingpanel(15-inch)

SSDR(32 GB)Intel Core i7/3,
4 GB
1.7 GHz, dual-core≈ 75 W≈ 6.6 kg

1302998-xx

MC 85321)

Operatingpanel(19-inch)

SSDR(32 GB)Intel Core i7-3,
4 GB
1.7 GHz, dual-core≈ 75 W≈ 9.7 kg

1189190-xx

MC 306

Electricalcabinet

SSDR(240 GB)Intel high-level
CPU

8 GB

≈ 65 W≈ 4.2 kg

1180045-xx

MC 3661)

Operatingpanel(24-inch)

SSDR(var. 01:
32 GB /
var. 02:240 GB)Intel Core i7-3,
8 GB
1.7 GHz, dual-core(var. -01) /Intel high-level
CPU (var. -02)

≈ 75 W≈ 11.4 kg

1246689-01≈ 9.9 kg

1246689-02*) Test conditions: Windows 7 (64-bit) operating system, 100% processor load, interfaces not loaded, no fieldbus

module1) Fulfills IP54 when installed18

ID 1257299-02

Operating panel

Electricalcabinet32 GB

240 GB

240 GB

Free PLC
memoryspace≈ 1 GiB≈ 4 GiB≈ 4 GiB

Free NC
memoryspace≈ 17 GiB≈ 189 GiB

≈ 189 GiB

For maincomputer

MC 85x2 andMC 366
var. -01

MC 366
starting withvar. -02

MC 306

1)

ID 810288-18

ID 1317018-18

ID 1279027-18

2)

ID 810288-68

ID 1317018-68 ID 1279027-68

SSDR for operating panel

SSDR MC 306

1) Requires an export license in accordance with Annex Iof the EU Dual-Use Regulation

2) Not covered by Annex I of the EU Dual-Use Regulation

SIK component

The SIK component contains the NC software license forenabling control loops and software options. It provides the main
computer with 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.

SIK component

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)

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.

19

TNCkeygen(accessory)

TNCkeygen is a collection of PC software tools for generating
enabling keys for HEIDENHAIN controls for a limited period oftime.

Enabling further
control loops

With the 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. This activation is limited to a period of 10 to 90 days.
Each software option can be enabled only once; this is performed
independently 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 308

CC 306 +CC 308CC 310 +CC 302CC 310CC 308CC 306

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

ID 674989-09
ID 674989-59

ID 674989-01
ID 674989-51

ID 674989-28
ID 674989-78

4✓

ID 674989-20
ID 674989-70

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

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. Up to 24 control loops are possible.
Control-loop groups

Software option

4 Additional Control Loops

77

ID 634613-01

8 Additional Control Loops

78

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

For a description of the CC 3xx controller units,
please refer to the Inverter Systems For Gen 3 Drives
brochure (ID 1303180-xx).

Only through subsequent enabling of control loops (additional
axes)

Italicized: Not covered by Annex I of the EU Dual-Use Regulation
Not italicized: Requires an export license in accordance with Annex I of the EU Dual-Use Regulation

20

21

24-inch screen and keyboard units

BF 360 monitor• Supply voltage: DC 24 V/≈ 35 W
• 24-inch; 1920 x 1024 pixels• HDL2 interface to the MC in the electrical cabinet• Integrated USB hub with four USB ports on the rear
• Display for multi-touch operation• Fulfills IP54 when installed
BF 360Mass

TE 361
keyboard unit
with integrated
machineoperating panel

BF 360For fastening the MC 366 or BF 360 withmounting braces (set of 6 pieces). Up to six
mounting braces can be fastened to the MC
and BF.

TE 360
keyboard unit
with an integrated
machineoperating panel

General data:• Fits the BF 360 or MC 366 (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

ID 1257299-02

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 other function keys)• Other operating elements:1) NC start1), NC stop1), emergency stop
button, control voltage on• 4 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

TE 361

Control keyboard (long stroke):• Alphabetic keyboard block• Axis input and value input block• Programming block• Operating modes block• Operating aids block• Navigation block

ID 1275079-xx≈ 8.6 kg

Optional
installation kit
for MC 360 and
BF 360General data:• Fits the BF 360 or MC 366 (24-inch design)• All keycaps are exchangeable• USB interface to the MC main computer• Trackball• USB port with cover cap

Specifications:• Supply voltage: DC 24 V/≈ 4 W• Fulfills IP54 when installed (all keycaps must be in place)• Integrated machine operating panel with 30 exchangeable,
freely assignable keycaps with status LED, freely definable via
PLC (assignment in accordance with PLC basic program: 12 axis
keys, spindle start, spindle stop, 16 further function keys)
NC start key1), NC stop key1), control• Other operating elements:
1)
voltage on/off key , emergency stop button• Override potentiometers for feed rate, rapid traverse, andspindle speed (all override potentiometers are fitted with anadapter so that they can be mounted in any 22.5 mm opening)• 4 openings for operating elements with a mounting diameter of
22.5 mm• Interface for HR handwheel• HSCI interface, (Gbit HSCI)• TE 361: 8 free PLC inputs and 8 free PLC outputs
TE 361 FS: 4 free FS inputs and 8 free PLC outputs; additional
dual-channel FS inputs for emergency stop and handwheel
permissive buttons.

TE 360 with standard potentiometer layout

1)

Illuminated keys, addressable via PLC

TE 361
TE 361 FS
Mass

TE 360 with alternative potentiometer layout

ID 1313011-xx
ID 1326583-xx≈ 3.7 kg

Extraction tool

For replacing keycaps on the TE 361T

ID 1394129-xx

Optional
installation kit for
the TE 361

For fastening the TE 361T with mounting
braces (set of 6 pieces). Up to 4 mounting
braces can be fastened to a TE 361T.

ID 1278826-xx

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

22

23

19-inch screen and keyboard unit

BF 860 screen

15-inch keyboard units and machine operating panels• Supply voltage: DC 24 V/≈ 65 W
• 19-inch; 1280 x 1024 pixels• HDL2 interface to the MC in the electrical cabinet• Integrated USB hub with 4 USB ports on the rear
• Display for multitouch operation

TE 730
keyboard unit

Via touchscreen operation• Soft-key row switchover• Screen layout• Operating mode switchover
BF 860Mass

TE 730Mass

ID 1244875-xx≈ 7.7 kg
BF 860TE 745
keyboard unit
with an integrated
machineoperating panel

General data:• Fits the BF 860 or MC 8532 (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
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)• Other operating elements:1) NC start1), NC stop1), emergency stop
button, control voltage on• 3 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 735
keyboard unit
(with a machine
operating panel)

ID 679817-13
ID 805482-13≈ 4.1 kg

ID 805489-xx≈ 2.4 kg

ID 771898-xx
ID 805493-xx≈ 3.7 kg

TE 735
TE 745

MB 720machineoperating 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: NC1) start1), NC stop1), emergency
stop button, control voltage on , two 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≈ 1.3 kg
MB 721machineoperating panel

Same as the MB 720, except:• Suitable for the MC 8512
• Changed front panel• 3 holes for additional buttons or keylock switches• Spindle-speed and feed-rate override potentiometers• USB port with cover cap
MB 721
ID 1164974-xx
MB 721 FS ID 1164975-xx
Mass≈ 1.5 kg24

TE 730• Suitable for the MC 8522 (15-inch design)• 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

Illuminated keys, addressable via PLC

TE 745
TE 745 FS
Mass• Suitable for the MC 8522 (15-inch version)• 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 potentiometers• USB interface to the MC main computer• Touchpad

MB 72125

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.

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 units can be connected to the control.
I/O modules
PLB 62xx

Basic modules

Mass

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

DC 24 V≈ 48 W at DC 24 V NC
≈ 21 W at DC 24 V PLC≈ 0.65 kg to 1 kg (depending on theversion)

PLD-H 04-08-00 FS

1) PLB 6xxx completely filled, incl. TS, TT

System PL with
EnDat support

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

PLD-H 16-08-00

Basic modules with an HSCI interface exist for 4, 6, 8, and 10
modules. Standard NS 35 rails (DIN 46227 or EN 50022) are used
for fastening.
Supply voltage
Power consumption1)

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.

• Required once for each control system (except with UxC)
• Connections for TS and TT touch probes• TS and TT touch probes with EnDat interface are supported• Without FS: 12 free inputs, 7 free outputs
With FS: 6 free FS inputs, 2 free FS outputs• Functional safety (FS) is enabled via SIK options 160 to 166.

Subsequent enabling of all FS control loops is via SIK option 169.

• Slots are equipped with cover strips

Mass

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

I/O module foraxis enabling

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 1223032-xx
ID 1223033-xx
ID 1223034-xx
ID 1290089-xx

IOconfig(accessory)

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

ID 675572-xx

Axis enabling module for external safety. In combination with the
PLB 620x without FS.
PAE-H 08-00-01

I/O module for enabling 8 axis groups

ID 1203881-xx

PC software for configuring HSCI and PROFIBUS components

Note about the "Gen 3 ready" label:
The label indicates that a component is ready for operation in a
Gen 3 (Gbit HSCI) drive system. Whether a component is suitablefor functional safety (integrated FS, external FS, enabling of FS)
must be considered separately.

26

27

Accessories
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.

Additional modules

Module for analog
axes• HSCI interface• Connection for HR handwheel• Inputs and outputs for keys and key illumination

PLB 6001:
Terminals for 72 PLC inputs / 40 PLC outputs
PLB 6001 FS: Terminals for 36 FS inputs / 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

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 into 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.

PLB 6001

Additional module for analog axes/spindles:• Expansion board for the CC or UEC controller units• 4 analog outputs, ±10 V for axes/spindle• Spring-type plug-in terminals

ID 668792-xx
ID 722083-xx
ID 1137000-xx≈ 1.0 kg

CMA-H 04-04-00
Fieldbus systems

PROFIBUS DP
moduleID 688721-xx

CMA-H 04-04-00

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. The interface is configured with IOconfig (version
3.0 or higher).

• Expansion board for the MC main computer• Connection for 9-pin D-sub connector (female) to X121
MC 85x2, MC 366
MC 306 and MC 366 as of variant -02

ID 828539-xx
ID 1279074-xx

PROFIBUS DP module

PROFINET IO
module• Expansion board for the MC main computer• RJ45 connection at X621 and X622
MC 85x2, MC 366
MC 306 and MC 366 as of variant -02

ID 828541-xx
ID 1279077-xx

PROFINET IO module

Combined
PROFIBUS DP/PROFINET IO
module• Expansion board for the MC main computer• RJ45 connection at X621 (PROFINET IO) and M12 connector at
X121 (PROFIBUS DP)• Additionally connectable terminating resistor for PROFIBUS DP
with front LED

MC 85x2, MC 366
MC 306 and MC 366 as of variant -02

ID 1160940-xx
ID 1233765-xx
Combined module28

29

Electronic handwheels

Overview

The TNC 640 supports the use of electronic handwheels:• HR 550 FS wireless handwheel or• HR 510, HR 510 FS or HR 520, HR 520 FS portable handwheelor• HR 130 panel-mounted handwheel, or• Up to three HR 180 panel-mounted handwheels via the HRA
180 adapter

HR 520

Several handwheels can be operated on a single TNC 640:
• One handwheel via the handwheel input of the main computer(not on main computers in the electrical cabinet)• One handwheel each on HSCI machine operating panels or
PLB 6001 or PLB 600x FS HSCI adapters (for the maximum
number possible, see Page 58)
The mixed operation of handwheels with and without display is
not possible. Handwheels with functional safety (FS) are crosscircuit-proof due to 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

Handwheel

Without
detentWith detent

HR 520ID 670302-xx

ID 670303-xx

HR 520 FS

ID 670304-xx

ID 670305-xx

Holder

ID 591065-xx

Mass ≈ 0.6 kg
HR 550 FS

Electronic handwheel with wireless transmission. Display,
operating elements, and functions like HR 520

All keys are designed as snap-on keys and can be replaced withother symbols (see Overview for the HR 510 in Snap-on keys for
the HR).

In addition:• Functional safety (FS)• Radio transmission range of up to 20 m (depending on
environment)

Handwheel

Keys

Without
detentWith detentHandwheel

Without
detentWith detent

HR 510NC start/stop,
spindle start(for basic PLC
program)

ID 1119971-xx

ID 1120313-xx

HR 550 FS

ID 1200495-xx

ID 1183021-xx

Replacement battery

ID 623166-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

HR 510 FS

Mass ≈ 0.5 kg

30

Portable electronic handwheel with• Display for operating mode, actual position value, programmed
feed rate, spindle speed, and 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

HR 550 FS with HRA 551 FS

Mass: 0.73 kg
HRA 551 FS

Handwheel holder for HR 550 FS• For docking the HR 550 FS on 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
Handwheel holder
HRA 551 FS

ID 1119052-xx

Mass: 0.7 kg
For more information, see the HR 550 FS Product Information
document.

31

Connecting cables

HR 130Panel-mounted handwheel with ergonomic control knob and serial
output signal. Like the other electronic handwheels, it is attachedto the handwheel interface X23 either directly or via an extension
cable.

HR 510HR 510 FS

HR 520HR 520 FS

HR 550 FS
with
HRA 551 FS

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

–

–

✓

✓

–

ID 312879-01

✓

✓

–

–

–

ID1117852-03

Handwheel

Without
detentWith detent

Connecting cablewith metal armor

–

–

✓

✓

–

ID 296687-xx

HR 130ID 540940-03

ID 540940-01

✓

✓

–

–

–

ID 1117855-xx

Mass: ≈ 0.34 kg

Connecting cable–without metal armor
✓

–

✓

✓

✓ (max. 2 m) ID 296467-xx

✓

–

–

–

ID 1117853-xx

HR adapter cableto MC, straightconnector

✓

✓

✓

✓

✓1)

ID 1161072-xx

HR adapter cableto 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 functionalsafety

✓

–

✓

–

–

ID 271958-03

Adapter connector–
for handwheels withfunctional safety

✓

–

✓

✓

ID 271958-05

HR 180Panel-mounted handwheel with ergonomic control knob forconnection to the HRA 180 handwheel adapter.
Handwheel

Without
detentWith detent

HR 180ID 540940-17

ID 540940-16

Mass: ≈ 0.36 kg
HRA 180

The HRA 180 handwheel adapter makes it possible to connect up
to three HR 180 panel-mounted handwheels to the control’s serial
handwheel input at X23.
Handwheel adapter
HRA 180

ID 1395422-xx

Mass: ≈ 0.7 kg

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

32

33

Industrial PCs/ITC

Additional
operating station
with touchscreen

The additional ITC operating stations (Industrial Thin Client)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. All ITCs fulfill IP54 when installed.

ITC 855

Connecting an ITC is very easy: as soon as the TNC 640 identifies
an ITC, it provides it with a current operating system. Afterbooting of the ITC, the complete content of the control's screen
is mirrored 1:1 on the ITC's screen. As a result of this plug&play
principle, no configuration by the machine manufacturer isnecessary. With the standard configuration of the Ethernet
interface at X116, the TNC 640 integrates the ITC into the systemfully self-sufficiently.

ID number
Mass
Installation type
MonitorID 1370459-xx≈ 6.4 kg
Operating panel
15-inch touchscreen(1024 x 768 pixels)
Processor
Low-level
RAM
2 GB
Power consumption ≈ 35 W

ITC 855

The ITC 362 or ITC 860 is an additional operating station forcontrol systems with a main screen.
The ITC 362 or ITC 860 and the separately orderable keyboard unit
together form a complete, second operating station.

IPC 306
for Windows

Along with the touchscreen, the ITC 855 also has an ASCII
keyboard and the most important function keys of the TNC 640.

ITC 362

ITC 362

ITC 860

ID number
Mass
Installation type
MonitorID 1346871-xx≈ 8.6 kg
Operating panel
ITC 755(full HD,1920 x 1080 pixels)
Processor
Intel AtomRAM
2 GBPower consumption ≈ 50 W

With the IPC 306 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. Option 133 isrequired for this.
Since Windows runs on the industrial PC, it does not influence
the NC machining process. The IPC is connected to the NC main
computer via Ethernet. No second screen is necessary, since theWindows applications are displayed on the screen of the TNC 640
via remote accesses.
Along with the industrial PC, a separately orderable hard disk isrequired for operation. Windows 8, 10 or 11 can be installed on theempty data carrier as the operating system.
IPC 306

ID number
Mass
Installation type
Display

ID 1174935-xx≈ 8.2 kg
Operating panel
19-inch touchscreen(1280 x 1024 pixels)
Processor
Intel Atom E3845
1.9 GHzRAM
2 GB
Power consumption ≈ 50 W

SSDR solid-state
memoryID number
Installation type
Mass
RAM
Processor

ID 1179966-xx
Electrical cabinet≈ 3.9 kg
8 GB
Intel high-levelprocessor
Power consumption 65 W
ID number
ID 1282884-51
Memory space

HDMI adapter cable for initial setup

IPC 306≈ 240 GBID 1333118-01

ITC 860

34

35

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(CFast) storage medium, the PNC 610 is a separate HSCl system,
which can be expanded with HEIDENHAIN inverters. In thestandard version the PNC 610 already includes six PLC axis
releases as well as software option 46 (Python OEM Process).
The PLC basic program contains a Python interface for pallet
management that is adaptable by the machine manufacturer.
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

Softwareoptions

PNC 610 with IPC 8420

The IPC auxiliary computer features the following:• Intel mid-level processor• RAM main memory• HSCl interface to the CC controller unit or to the UxC and toother control components• USB 3.0 ports
The following components must be ordered separately by the
OEM and installed in the auxiliary computer:• CFR (CFast) memory card with the NC software• System Identification Key component (SIK) for enabling software
options
The following HSCI components are required for operating thePNC 610:• IPC auxiliary computer• Controller unit
• PLB 62xx PLC I/O unit
(system PL; integrated into UxC)Interfaces

DesignExport license

36

USB 3.0 and Ethernet are available on the MC. Connection to
PROFINET IO or PROFIBUS DP is possible via an additional
module.
IPC 6490

ID number
Installation type
Mass
Power consumption
RAM
Processor

ID 1039541-xx
Electrical cabinet≈ 2.3 kg
48 W
2 GB
Intel Celeron

IPC 8420

ID number
Installation type
Mass
Power consumption
MonitorRAM
Processor

ID 1249510-xx
Operating panel (IP54 when installed)≈ 6.6 kg
48 W
15.6-inch touchscreen (1366 x 768 pixels)
2 GBIntel Celeron

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.
OptionnumberOptionID

Comment

Page

18

HEIDENHAIN DNC

526451-01

Communication with external PC applications
over COM component

99

24

Gantry Axes

634621-01

Gantry axes via master-slave torque control

64

135

Synchronizing
Functions

1085731-01

Advanced synchronization of axes and spindles

65

141

Cross Talk Comp.

800542-01

CTC: compensation of axis couplings

79

142

Pos. Adapt. Control

800544-01

PAC: position-dependent adaptation of control
parameters

80

143

Load Adapt. Control

800545-01

LAC: load-dependent adaptation of control
parameters

78

144

Motion Adapt. Control 800546-01

MAC: motion-dependent adaptation of control
parameters

79

160

Integrated FS: Basic

1249928-01

Enables functional safety and four safe control
loops

59

161

Integrated FS: Full

1249929-01

Enables functional safety and the maximum
number of safe control loops

59

162

Add. FS Ctrl. Loop 1

1249930-01

Additional control loop 1

59

163

Add. FS Ctrl. Loop 2

1249931-01

Additional control loop 2

59

164

Add. FS Ctrl. Loop 3

1249932-01

Additional control loop 3

59

165

Add. FS Ctrl. Loop 41249933-01

Additional control loop 4

59

166

Add. FS Ctrl. Loop 5

1249934-01

Additional control loop 5

59

169

Add. FS Full

1319091-01

Enabling of all FS axis options or control loops.
Options 160 and 162 to 166 must already be set.

59

The NC software of the PNC 610 is not covered by Annex I of the
EU Dual-Use Regulation.

37

Vision system for tool inspection

Storage medium

The storage medium is a CFR (CFast) memory card. It contains
the NC software and must be ordered separately from the main
computer. The NC software is based on the HEIDENHAIN HEROS
5 operating system.
CFR (CFast) 30 GB
Not covered by Annex I of the
EU Dual-Use Regulation
NC software
Free PLC memory space
Free NC memory space

SIK component

ID 1102057-xx
817591-xx
4 GiB
7.7 GiB

The SIK component holds the NC software license for enabling
software options. It provides the main computer with anunambiguous ID code—the SIK number. The SIK component isordered and shipped 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 numberof ten axes must be performed via the UMC compact inverter.
SIK component for PNC 610

ID 617763-53

VT 121 with VTC

The VT 121 vision system, combined with the VTC (visual tool
control) PC software, enables automated and time-saving inprocess tool inspection inside the machine. Using TNC 640 cycles,
for example, you can monitor and document a tool’s condition andlevel of wear even during unattended shifts.
The sealed and highly rugged VT 121 vision system is designed
to be installed inside the machine’s working space. It requires
compressed air only during the cycles for cleaning the workpieceor tool. The vision system can be used regardless of whether
cooling lubricant or dry machining is performed. Compressed air
from the integrated jets cleans the tools and the cameras' coverglass.
In order to integrate VTC on the TNC, you need both an IPC (onwhich the VTC PC software runs) and software option 46 (Python
OEM Process). For more information, please ask your contact
person at HEIDENHAIN. For detailed information on the VT 121
and VTC (specifications, accessories, software options, etc.)
please refer to the "VT 121 VTC" Product Information document(ID 1324220).
VT 121Mass ≈ 1 kg38

VT 121

ID 1249466-01

39

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.

Overview for HR 510 and HR 510 FS
Axis keys

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

OrangeGray
Gray

Machinefunctions

Spindlefunctions

Other keys

Machinefunctions

Black

Black

Green

Red

Black

Gray

Red

Black
Green

Black

Black

Red

Green

Orange

Black
Black
Black

Spindlefunctions

Other keys

Red

Red

Green

Green

Black
Gray

Black

Green

Black

Red

Black

Green

40

Red

Black

Green

41

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.

Overview ofcontrol keys

The snap-on keys with ID 679843-xx are suitable for the following
machine operating panels:• TE 360 or TE 360 FS (integrated machine operating panel)• TE 735 or TE 735 FS (integrated machine operating panel)• TE 745 or TE 745 FS (integrated machine operating panel)• MB 720 or MB 720 FS• MB 721 or MB 721 FS

Special keys

Keycaps can also be made with special key symbols for special
applications. If you need keys for special applications, please
consult your contact person at HEIDENHAIN.

Keys

OrangeGray

Machinefunctions

Black
Green

Black

Red

Black
Black

42

43

Keycaps for keyboard units and machine operating panels

Red

Spindlefunctions

Green
Green

The keycaps make it easy to replace the key symbols, thus
allowing the keyboard to be adapted to different requirements.

Overview ofcontrol keys

The keycaps with IDs 12869xx-xx and 1344337-xx are suitable foruse on the following keyboard units and machine operating panels:• TE 361• TE 361FS

Keycaps foralphabetic
keyboard

Red

Other keys

Keycaps

ID 1286909

-08

-09

-10

-11

-12

-13

-14

-15

-16

ID 1286909

-17

-18

-19

-20

-21

-22

-23

-24

-25

ID 1286909

-26

-27

-28

-29

-30

-31

-32

-33

-34

ID 1286909

-35

-36

–

-38

-39

–

-41

-42

-43

–

–

-01*)

–

–

-02*)

–

–

–

ID 1286909

-44

-45

-46

-47

-48

-49

-50

-51

-52

ID 1286909

-53

-54

-55

-56

-57

-58

-59

-60

ID 1286911-02

ID 1286914-03

ID 1286915-02

ID 1286917

-01

Black

Gray
Black

Red

Orange

Black
Black

Green

44

ID 1344337*)*) With tactile mark

Red

-03

-04

-05

-03

45

Keycaps for
operating aids
ID 1286909

-61

-62

-63

-64

-65

Keycaps for axis
input and value
input

-66

OrangeOrangeOrangeOrangeOrangeOrangeOrangeOrangeOrangeID 1286909

-94

-95

-96

-4K

-4Y

-4L

-5K

-98

-4Z

ID 1286909

-0B

-0C

-0D

-0E

–

-0G

-0H

-2L

-2M

ID 1344337*)

–

–

–

–

-03*)

–

–

–

–

Keycaps for
operating modes
ID 1286909

-67

-68

-69

-70

-71

-72

-73

-74

Keycaps for
programming
ID 1286909

-75

-76

-77

-78

-79

-80

-81

-82

-83

ID 1286909

-84

-85

-86

-87

-88

-89

-90

-91

-93

ID 1286909-92*) With tactile mark

Orange46

ID 1286909

-97

-0N

-3S

-4S

-4T

-3R

-3T

-3U

-3V

ID 1286909

-0K

-0L

-0M

-2N

-0P

-2P

-0R

-0S

-3N

OrangeOrange-99-0A

ID 1286909-3W

ID 1286914

-04

-3P

47

Keycaps fornavigation
ID 1286909

-0T

-0U

-0V

-0W

–

-0Y

-0Z

-1A

ID 1344337*)

–

–

–

–

-04*)

–

–

–

ID 1286909

-3L

-3M

-3X

-3Y

-3Z

-4A

-4B

-4C

-4D

Red

Red

*) With tactile markRed

ID 1286909
ID 1344337*)

-06

-4E

-4F

-4H

-4M

-4N

-4P

-4R

-4U

-06

-5H

-07

*) With tactile markGreen

Keycaps formachine functions
ID 1286909

ID 1286909

-1D

-1P

-1E

-1R

-1F

-1S

-1G

-1T

-1H

-1U

-1K

-1V

-1L

-1W

-4X

-1X

Red

Green

ID 1286909

-07

-5A

-5B

-5C

-5D

-4V

-4W

-5E

ID 1286909

-5F

-5G

2Y

-3K

-4G

-2V

-2W

-2X

Orange

Green

Red

-05

-03

-04

–

–

–

-1N

-1Y

Other keycaps

ID 1286909

ID 1286909

-1Z

-2A

-2B

-2C

-2D

-2E

-2H

-2K

-2R

ID 1286909

–

-2T

-2U

-2Z

-3A

-3E

-3F

-3G

-3H

ID 1344337*)

-05*)

–

–

–

–

–

–

–

–

Special keys

-01

-02

–

Keycaps can also be made with special key symbols for special
applications. If you need keys for special applications, please
consult your contact person at HEIDENHAIN.

*) With tactile mark

48

49

50
TE 361 (FS)TE 360 (FS)MC 3xxTE 361 (FS)TE 360 (FS)BF 360

X502

X501

X500

X502

USB

4)

4)

Mini I/O

25-pin D-sub

3)

3)

3)

3)

X43xx

X40xx

1)

1)

1)

1)

X500A

X502A

X500B

1)

X502B 1)
X500B

X500

X501

1)

X502B 1)

X500A

X502A

CC 3xxUEC 3xx

MC 306

X250

CC 3xxUEC 3xx

X43xx

X40xx

X141...X144

1257765-xx

Mini I/O

25-pin D-sub

1257765-xx

4)1161508-xx max. 20m

2)

2)

PL 62xx (FS)PL 610x (FS)

Cable included with the CC
For the encoder connections, see the brochure

2)
3)

X502

X500

X502

PL 62xx (FS)PL 610x (FS)10.10.2023"Cables and Connectors" (ID 1206103-xx)

CCs with 2nd controller board
1)

HSCI (Gbit) 1257765-xx

HSCI total length 70 m

X502

X500

X502

USB 1.1 (624775-xx)

USB 2.0 (354770-xx)

28.10.2021

For the encoder connections, see the brochure3)"Cables and Connectors" (ID 1206103-xx)

Cable included with the CC

2)

4)

CCs with 2nd controller board

1)

HSCI (Gbit) 1257765-xx

HSCI total length 70 m

Cable overview (examples)
Control systems with CC or UEC (MC in electrical cabinet)
Control system with CC or UEC (MC in operating panel)51

52
UM 3xx

UM 3xx

UM
3xx

UP CMH3xx 3xxUVR 3xx

ID 1265351-xx

UM 3xx

UM 3xxFor power cables to the motor, see“HEIDENHAIN Motors” brochure.

UM
3xx

UP CMH3xx 3xx

Line filter
Epcos
xxA

UVR 3xx

UM 3xxUVR 3xx

ID 1265351-xx

UM 3xx

UM 3xxFor maximum lengths, see“Gen 3 Drives”
Technical Manual.

UM
3xx

CC 3xxFor power cables to the motor, see“HEIDENHAIN Motors” brochure.

RD
BU

ID 1278910-xx

UM 3xxOptional
overvoltage protector

ID 1274603-xx

KDR 3xx

Line filter Epcos
xxA

UM 3xx

UM
3xx

SIEMENS
Sitor gS or gRline fuse

L1 L2 L3

CC 3xx18.12.2019

DC-link and 24 V supply conductor-bar connection (included in delivery)

UM 3xxUP CMH3xx 3xx

CC 3xx

CC 3xxDC-link and 24 V supply conductor-bar connection (included in delivery)

UM 3xxFor maximum lengths, see“Gen 3 Drives” Technical Manual.

UM 3xx

ID 1265351-xx

For power cables to the motor, see“HEIDENHAIN Motors” brochure.

DC-link and 24 V supply conductor-bar connection (included in delivery)

UM 3xxOptional
overvoltage protector

KDR 3xxUVR 3xx

ID 1265351-xx

DC-link and 24 V supply conductor-bar connection (included in delivery)

UM 3xx

L1 L2 L3

UM 3xx

UM 3xxSIEMENS
Sitor gS or gRline fuse

18.12.2019

Optional
overvoltage protector

KDR 3xx

Line filter
Epcos
xxA

SIEMENS
Sitor gS or gRline fuse

L1 L2 L3

Optional
overvoltage protector

KDR 3xx

Line filter
Epcos
xxA

SIEMENS
Sitor gS or gRline fuse

L1 L2 L3

Inverter system
Inverters (multi-row)

53

max. 9m

55m

1 VPP

643450-xx
533631-xx

310128-xx
360645-xx

max. 55m

max. 20m

PW 310735961-xx

max. 5m

729681-xx  4.5mm
1036361-xx  6mm

max. 20m

EIB 5281

1 VPP

509667-xx

1133119-xx  8mm

1133104-xx  6mm

adapter KTYKTY/PT 1000
367770-02

509667-xx

336376-xx

758082-xx  

754232-xx (LS x87, LF x85) max. 9m

Voltage controller 5 V
368210-02

X500B*

X502B*

X500A

X502A

1133119-xx  8mm

1119910-xx  4.5mm
729681-xx  4.5mm
1036361-xx  6mm

643450-xx max. 20m

max. 55m

max. 30m

max. 30m

558727-xx

UEC 3xx

ID 1257765-xx

EIB 5181

X43xx*

X40xx*

UM 3xx

ID 1257765-xx

CMH CC
3xx 302

ID 1265351-xx

1264917-A5 (0.5 m)

1286965-xx
1287073-xx

EnDat
1 VPP

1036372-xx  6mm
745894-xx  8mm

1036521-xx  6mm

max. 20m

729681-xx  4.5mm
1036361-xx  6mm

max. 20m

729681-xx  4.5mm
1036361-xx  6mm

max. 30m

max. 55m

max. 100m

10.06.2022

max. 100m

max. 100m

max. 30m

RCN xx10 / EnDat 221036537-xx  4.5mm
1036547-xx  6mm

max. 5m

1036537-xx  4.5mm
1036547-xx  6mm

max. 100m

max. 30m

max. 100m

LC 211
LC x15 / EnDat 221036537-xx  4.5mm
1036547-xx  6mm

1036537-xx  4.5mm
1036547-xx  6mm
max. 5m
745894-xx  8mm

1119394-xx  4.5mm

1036521-xx  6mm
1130994-xx  8mm

1130994-xx  8mm

1036372-xx  6mm
745894-xx  8mm

1036785-xx  4.5mm
1036814-xx  6mm

1036521-xx  6mm

1245843-xx  4.5mm

1245639-xx  6mm

1245639-xx  6mm

1245592-xx  4.5mm
1245572-xx  6mm

DC-link and 24 V supply
conductor-bar connection

RM
330

only Up = 12 V

CCs with 2nd controller board*

UEC 3xx
CC 3xxFor power cables to the motor, see“HEIDENHAIN Motors” brochure.

1133104-xx  8mm

1083369-xx  6mm

Voltage controller 5 V
368210-02

533631-xx max. 9m

max. 5m

745894-xx  8mm

1036537-xx  4.5mm
1036547-xx  6mm
1036537-xx  4.5mm
1036547-xx  6mm

RCN xx10 / EnDat 22max. 55m

max. 20m

max. 30m

max. 75m

max. 55m

RCN xx80 / EnDat 02

LC 281
LC x85 / EnDat 02

LC 211
LC x15 / EnDat 22

L1 L2 L3

For maximum lengths, see“Gen 3 Drives” Technical Manual.

SIEMENS
Sitor gS or gRline fuse

26.08.2020

Encoder inputs (25-pin D-sub)

54
Encoder inputs (Mini I/O)

UEC 3xx (FS)
Encoders

55

Technical description
Digital control design

Accessories

HR 180540940-16-17max. 20 m
HRA 180
1395422-xx

35m

3 inputs

271958-03-051117855-xx

1117853-xx

1117852-03

296687-xx

296467-xx

683259-xx

1218563-01

1161072-xx

1218563-01

1161072-xx

20m
749368-xx

VL
281429-xx

749369-xx

29.01.2024

VL: Extension cable– for separation points with connecting cable– for extending existing connecting cable"Cables and Connectors" (ID 1206103-xx)"Touch Probes for Machine Tools" (ID 1113984-xx)- For the touch probe connections, see the brochure

50m
312879-01

HRA 551 FS
1119052-xx
296467-xx

max. 2m
50m

In the fully digital control design from HEIDENHAIN, all of thecomponents are connected with each other via purely digitalinterfaces. A high degree of availability for the entire system, fromthe main computer to the encoder, is thereby achieved, with thesystem being diagnosable and immune to noise. The outstanding
characteristics of the fully digital design from HEIDENHAIN
guarantee very high accuracy and surface finish quality, combinedwith high traversing speeds.
Connection of the components:• Control components via HSCI (HEIDENHAIN Serial Controller
Interface), the HEIDENHAIN real-time protocol for Gigabit
Ethernet• Encoders via the EnDat 2.2 bi-directional interface from
HEIDENHAIN• Power modules via digital optical fiber cables

HSCI
HR 130540940-01-03

HR 510 FS
1119974-xx
1120311-xx
1120314-xx
1161281-xx
HR 5101119971-xx
1120313-xx
1099897-xx
1184691-xx- For the touch probe overview, see the brochure

HR 520 FS
670304-xx
670305-xx
HR 520670302-xx
670303-xx

HR 550 FS
1200495-xx
1183021-xx

CC
UEC
UMC

CMA-H 04-04-00
analog axis
688721-xx

Fully digital

HSCI, the HEIDENHAIN Serial Controller Interface, connects themain computer, controller(s), and other control components. The
connection between two HSCI components is referred to as an
HSCI segment. HSCI communication in Gen 3 control systems isbased on Gigabit Ethernet hardware. All HSCI components and
HSCI cables must therefore be Gigabit-capable. A special interface
component developed by HEIDENHAIN makes short cycle times
for data transfer possible.
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 (initial setup, configuration)• Inverters connected via digital optical fiber cables• Long line lengths in the overall system• 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 can be connected to the serial HSCI
bus of the MC main computer. The HR handwheel is connected
directly to the machine operating panel. The combination ofmonitor and main computer is especially advantageous if thecomputer is housed in the operating panel. Besides the power
supply, all that is then required is an HSCI line to the controller unit
in the electrical cabinet.
Maximum cable lengths for HSCI:• For an HSCI segment: 70 m
• For up to 12 HSCI slaves: 290 m (total of all HSCI segments)• For up to 13 HSCI slaves (maximum configuration): 180 m (total of
all HSCI segments)

56

except for MC 30x

X29

MC

MB
TE
PLB 600x

X23

The order of the HSCI slaves can be freely chosen.

57

Control systems with integrated functional safety (FS)HSCI master

HSCI component

Function

MC, IPCHSCI masterMaximum number of HSCI masters
HSCI slave

1xx inverters

Gen 3 drives

1

1

1

1

1xx inverters

Gen 3 drives

HSCI component

Function

CC 61xx
UEC 1xx2), UMC 1xx2)
CC 3xxHSCI slave

4 controller
motherboards1)

6 controller
motherboards1)

UxC 3xx2)

HSCI slave–

Integrated safety
6 controller
motherboards1)

Basic principle

With controls with integrated functional safety (FS) from
HEIDENHAIN, Safety Integrity Level 2 (SIL 2) as per the
standard EN 61508 and Performance Level “d”Category 3 as
per EN ISO 13849-1 can be attained. In these standards, theassessment of safety-related systems is based on, among otherthings, the failure probabilities of integrated components andsubsystems. This modular approach aids the manufacturers ofsafety-related machines in implementing their systems, since
they can then build upon prequalified subsystems. This design istaken into account for in the TNC 640 control, as well as for safetyrelated position encoders. Two redundant, mutually independent
safety channels form the basis of the controls with functionalsafety (FS). All safety-relevant signals are captured, processed, andoutput via two channels. Errors are detected through a reciprocal
data comparison of the two channels’ states. Consequently, theoccurrence of a single error in the control does not cause a loss insafety functionality.

DesignThe safety-related controls from HEIDENHAIN have a dual-channel
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) and CC controller
unit components. The dual-channel configuration through MC and
CC is continued in the PLB 6xxx FS I/O systems and MB machine
operating panel with FS (e.g., MB integrated in TE 361FS). Thismeans that all safety-relevant signals (e.g., permissive buttons,
door contacts, emergency stop buttons) are captured via twochannels, and are evaluated independently of each other by
the MC and CC. The MC and CC use separate channels to also
address the power modules, and to stop the motors in the eventof an error.

Components

In systems with functional safety, certain hardware components
handle safety-relevant tasks. In systems with FS, only safetyrelevant components (including their HEIDENHAIN variant) that areapproved for this are permitted.

External safety
1 (because only one PAE
module permitted)
UVR 3xxHSCI slave–5

PLB 62xx (FS)PLB 61xx (FS)HSCI slave

MB (FS) / TE (FS)PLB 600x (FS)HSCI slave83)
of which up to
4 MB/TE/PLB 600x

103)
of which up to
4 MB/TE/PLB 600x

1221

Maximum number of HSCI slaves
1) Distributed to CC, UEC, UMC as desired2) The UxC compact inverters are logically considered to be two HSCI participants. One participant is theintegrated control-loop board, and the other participant is the integrated PLB.

3) The number of inputs and outputs is limited to 1000 terminals. Dual-channel FS inputs count as one input.

Read-back internal outputs are not counted. Certain inputs and outputs that are used only within the system
are counted.

Control components with functional safety (FS) are recognizeable
by the suffix FS after the type designation (e. g., TE 361 FS).
For a current list of the components approved for functional safety(FS), refer to Functional Safety (FS) – Supplement to the Technical
Manual (ID 1423840).
MB and TE

58

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

59

Control systems with external safety

PLB

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

HR

In systems with functional safety (FS), FS handwheels are
required because they are the only ones equipped with therequired cross-circuit-proof permissive buttons.

Safety functions

Safety functions integrated into 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: Automatic or production mode
– Operating mode 2: Set-up mode
– Operating mode 3: Manual intervention– Operating mode 4: Advanced manual intervention, processmonitoring

Activationof functionalsafety (FS)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.

DesignIn control systems with external safety, a special PL module
for the dual-channel triggering of STO and SBC is absolutely
necessary. This module is the PAE-H 08-00-01, with which up to
eight axis groups can be individually controlled.

The following requirements are absolutely necessary:• At least one PLB 62xx FS must be present in the system• Safety-relevant control components in FS design(e.g., TE 361 FS, HR 550 FS)• Safety-related SPLC program• Configuration of safe machine parameters• Wiring of the machine for systems with functional safety (FS)Functional safety (FS) can be scaled via software options 160
to 166 and 169 (see Page 14). Only the number of safe drive
systems actually needed must be enabled.
For every active drive that is assigned to a safe axis group, a safe
control loop must be enabled. The control will otherwise display
an error message.

Further
information60

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).

61

Operating system

HEROS 5Useradministration

The TNC 640 and PNC 610 work with the real-time-capable
HEROS 5 operating system (HEIDENHAIN Realtime Operating
System). This future-proof operating system contains the following
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
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, XLSX 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 screenshots– Totem: media player for playing audio and video files
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

*)

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

Feed rate in mm/min relative to the workpiece contour, or mm perspindle revolution
Feed rate override: 0% to 150%

Traverse range

The machine manufacturer defines the traverse range. The user
can additionally limit the range of traverse in order to limit theworking 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
Feed rate in degrees per minute [°/min]Traverse range

The machine manufacturer defines the traverse range. The
user can additionally limit the range of traverse in order to limit
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.

Firefox is a registered trademark of the Mozilla Foundation

62

63

Tilting theWorking Plane(software
option 8)

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

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 function
allows complex, simultaneous movements of multiple NC or PLC
axes to be implemented. The interdependencies of the axes aredefined in mathematical formulas.

uZ

Tilting table
Swivel head

5-Axis Machining(software
option 9)

Synchronizedaxes

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.

Batch Process
Manager(software
option 154)

Batch Process Manager provides functions for the planning andexecution of multiple production jobs on the TNC 640. These
functions make it possible to easily edit pallets and to alter thesequence of pending jobs. Batch Process Manager also performs
a duration calculation for all planned jobs or NC programs. It
informs the user as to whether, for example, all NC programs
can be executed without error or whether all required tools areavailable with sufficient tool life. Batch Process Manager thereby
ensures the smooth execution of the planned jobs.

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.

Synchronized axes move synchronously and are programmed withthe 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

65Turning

Performing
Turning
Operations(software
option 50)

The TNC 640 supports machines that can perform a combinationof milling and turning operations in a single setup. It offers the user
a comprehensive package of cycles for both types of operations,which are programmed in HEIDENHAIN’s shopfloor-oriented
Klartext format. Rotationally symmetric contours are produced
during turning operations. The preset must be in the center of thelathe spindle for this.
In turning mode, the rotary table serves as the lathe spindle, while
the milling spindle with the tool does not rotate. Milling-turning
machines are subject to special demands. A basic requirement
is a machine designed with high rigidity so as to ensure a low
oscillation tendency even when the machine table (acting as lathe
spindle) is turning at high speeds.

Toggling between
milling andturning modes

When switching between milling and turning mode, the TNC
switches diameter programming on or off, selects the XZ working
plane for turning, and displays "Milling" or "Turning" mode in thestatus display.

Support for facing
slides (facing
heads)

With complete support for facing slides, the TNC 640 provides
an additional way of performing turning operations on a millingmachine. A longitudinal turning tool, for example, can be mounted
to the facing slide and called with a TOOL CALL block. Even
complex turning operations are programmed with familiar easeusing cycles. Machining operations with the facing slide can be
carried out 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 requirement 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, influencing the accuracyof 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 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.

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 offers 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 assists the user by displaying the mass andposition 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.

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

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.

67Grinding operations

Turning v2(software
option 158)

The software option Turning v2 includes all functions of software
option 50 (Turning).
In addition, software option 158 offers the following advanced
turning functions:• Cycle 882 SIMULTANEOUS ROUGHING FOR TURNING• Cycle 883 TURNING SIMULTANEOUS FINISHING
The advanced turning functions make it possible, for example,
to rough and finish complex contours in one run to avoid opticaltransitions, to produce workpieces with undercuts, and to better
utilize indexable inserts. Furthermore, the TNC 640 makes it
possible to define FreeTurn tools and to use them, for example,
for inclined or simultaneous turning operations. FreeTurn tools
are lathe tools that are equipped with multiple cutting edges.
Depending on the variant, a single FreeTurn tool may be capableof axis-parallel and contour-parallel roughing and finishing. Thanks
to the use of FreeTurn tools, fewer tool changes are required,reducing the machining time.

68

Grinding(software
option 156)

With its Grinding option, the TNC 640 supports jig grinding
technology for the fine machining of 2D 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 reciprocating 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.

69

Spindle

Encoders

Overview

The TNC 640 contouring control operates 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 UxC inverters, a fundamental
PWM frequency can be set for each output. In this case, every
output can have its own fundamental PWM frequency (e.g., with
the CC 306: X551 = 4 kHz, X552 = 5 kHz, etc.).
Possible fundamental frequencies are 3.33 kHz, 4 kHz, or 5 kHz.

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 markAfter the machine has been switched on, the relationship between
the measured value and the machine position must be establishedby traversing the reference marks. For encoders with distancecoded reference marks, the maximum travel until automaticreference mark storage for linear encoders is only 20 mm or
80 mm, depending on the model, 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. Reference-mark traverse is notnecessary. For cyclical closed-loop operation, position informationfrom incremental signals can be used, or from serial absolutesignals (EnDat 2.2) with very short cycles.

EnDat interface

The TNC 640 features the serial EnDat 2.2 interface (includes
EnDat 2.1) for the connection of absolute encoders.

With software option 49 (Double Speed), this frequency
can be increased to up to 16 kHz for fast-turning spindles(e.g., HF spindles).
Maximum spindle
speed

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

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 stages

A specific nominal speed can be defined for each gear stage. The
gear code is output via the PLC.

Multiple main
spindlesUp to 4 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.

Note: The EnDat interface on HEIDENHAIN encoders differs in its
pin layout from the interface on Siemens motors with integrated
absolute ECN/EQN rotary encoders. Special adapter cables areavailable.
Encoder inputs

Incremental and absolute linear, angle, or rotary encoders from
HEIDENHAIN can be connected to the encoder inputs of thecontroller unit (only purely serial encoders with EnDat 2.2 can beconnected to mini-IO connectors).
Channel inputs

Signal 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

71

Digital servo control

Integrated inverter

HEIDENHAIN synchronous or asynchronous motors areconnected to the TNC 640.

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 the time interval in which the actual speed value iscompared to the calculated nominal speed value. The cycle time
for the current controller is defined as the time interval during
which the actual value of the electrical current is compared to thecalculated nominal value of the electrical current.
CC/UEC/UMC
Path interpolation

See values on Page 6

Fine interpolation
Position controller
Speed controller
Current controller

Axis feedback
control

The TNC 640 can be operated with feedforward control or servo
lag.

Operation withfeedforward
controlFeedforward means that a given velocity and acceleration are
adapted to the machine. Together with the values calculated fromthe servo lag, this given velocity and acceleration becomes thenominal value. A much lower servo lag thereby manifests itself.

Operation with
servo lag

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

Compensation of
torque ripples

72

v
kv
sa

= Velocity= Position loop gain
= Servo lag

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 an effecton the workpiece surface. During initial configuration of the axes
with TNCopt, this torque ripple can be compensated for by meansof the Torque Ripple Compensation (TRC) function of the CC or
UEC.

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; i.e., on motors with a speed encoder and position
encoder.

73

Fast contour milling

Short block
processing time

The TNC 640 provides the following important features for fast
contour machining.

Advanced
Dynamic
Prediction (ADP)The block processing time of the MC is less than 0.5 ms. Thismeans that when running even long programs from the hard
drive, the TNC 640 can mill contours approximated in 0.2 mm line
segments at a feed rate of greater than 24 m/min.

Look-ahead

The TNC 640 calculates the geometry ahead of time in order toadjust the feed rate (max. 5000 blocks). In this way, directionalchanges are detected in time to accelerate or decelerate theappropriate 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 permitted
tolerance is programmed by the user via a cycle. Special filters for
HSC machining (HSC filters) can suppress machine-specific natural
frequencies. The desired accuracy along with very high surface
quality is attained.
j74

The Advanced Dynamic Prediction (ADP) function enhances
the look-ahead of the permissible maximum feed rate profile,
thereby enabling optimized motion control for clean surface
finishes and perfect contours. The strengths of ADP are evident,
for example, during bidirectional finish milling through symmetrical
feed behavior on the forward and reverse paths as well as throughparticularly 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 machineparameters, ADP not only improves the surface quality of theworkpiece but also optimizes the machining time.

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

75

Dynamic Efficiency

Overview

With the concept of Dynamic Efficiency, HEIDENHAIN offers
innovative TNC functions that help the user to make heavymachining and roughing more efficient while also enhancing
process reliability. Dynamic Efficiency permits higher removal rates
and therefore increases productivity. At the same time, it prevents
any tool overloading and the concomitant premature cutter wear.

Active Chatter
Control (ACC,
softwareoption 145)

Optimized Contour Milling (OCM, software option 167) led the
Dynamic Efficiency package of functions to the second generation.
Dynamic Efficiency Generation 2 covers 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.
• 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.

During heavy machining (roughing at high cutting speed), 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 induces heavy strain on the machine andcauses ugly marks on the workpiece surface. It also increases
the progress and irregularity of tool wear, even leading to tool
breakage under extreme circumstances. To reduce chattertendencies, HEIDENHAIN offers an effective option with its
Active Chatter Control (ACC) solution. This option is particularly
advantageous during heavy machining. ACC enables substantiallyhigher cutting performance: depending on the machine model,
the metal removal rate can be increased by 25 % or more. Thus,
you can reduce the load on your machine while simultaneously
increasing the life of your tools.

Individually, each of these solutions delivers key improvements tothe machining process. But in combination, these TNC functions
bring out the full potential of the machine and tool while reducing
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.

76

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

Optimized
Contour Milling(OCM, software
option 167)
100%

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 cutting conditions• Higher possible cutting parameters• Higher removal rates• No need for adjustments by the machine manufacturer• Cutting data calculator for the automatic calculation of
cutting values

77

Dynamic Precision

Overview

The 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.

Motion Adaptive
Control (MAC,
softwareoption 144)

The MAC software option was enhanced with the adaptive gearerror compensation of Dynamic Precision Generation 2. Surface
quality problems often do not arise from machine resonances but
rather from transmission errors in mechanical components of thefeed drive systems. Transmission elements in the machine tool’s
power train, such as a rack and pinion, often cause unwanted
shading on the workpiece surface. This results in cost-intensive
rework, particularly in tool and mold making. The active gear-error
compensation minimizes these periodic interferences.

The functions of the Machine Vibration Control (MVC) software
option and the expanded functions of the Motion Adaptive Control(MAC) software option characterize the second generation of
Dynamic Precision.
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 quality anddynamic performance of machine tools. As a result, production
time and cost are reduced.
The software options that make up Dynamic Precision
Generation 2 can be deployed by the machine manufacturer bothalone or in combination:• CTC compensates for acceleration-dependent position errors at

the tool center point, thereby increasing accuracy in acceleration
phases• MVC damps machine oscillations to improve workpiece surface
quality through the following functions:– AVD (Active Vibration Damping)– FSC (Frequency Shaping Control)• 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.

Along with the load-based modification of machine parameters
through the LAC software option, the Motion Adaptive Control(MAC) software option allows machine parameters to bechanged based on their initial values, such as speed, servo lag,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 ask for ever higher
feed rates and acceleration values, while at the same timeneeding 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 axis direction, the dynamic accelerationof an axis due to mechanical axis coupling can also result in
deformation of axes that are perpendicular to the direction ofacceleration. The resulting position error at the TCP in the directionof the accelerated axis and lateral axes is proportional to theamount 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.

In order to optimize changed control behavior at differing loads,
various controller parameters (e.g., loop gains, and feedforward
controls for acceleration, holding torque, static friction, and friction
at high shaft speeds) can be adapted to the currently active load.

78

79

Monitoring functions

Machine Vibration
Control (MVC,
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. With Machine Vibration
Control (MVC, software option 146), two functions that effectively
suppress low-frequency vibrations are available.

Active Vibration
Damping (AVD)The Active Vibration Damping (AVD) controller function increases
dynamic rigidity and damps the especially critical low-frequency
oscillations. At the same time, it optimizes the control behavior of
the affected axis so that high-accuracy workpieces with excellent
surface quality can also be produced at high feed rates.

Frequency Shaping
Control (FSC)

The Frequency Shaping Control (FSC) function suppresses theinducement of low-frequency oscillations through a specificfeedforward control. This can be used to increase dynamic limit
values (e.g. jerk), and therefore make reduced machining times
possible.

Description

The combination of the two functions (AVD and FSC) optimizes
the dynamics, surface quality, and productivity.
Position Adaptive
Control (PAC,
softwareoption 142)

Position Adaptive Control (PAC, software option 142) permits the
dynamic, position-dependent adaption of controller parameters
based on the spatial position of the tool.

With EnDat 2.2 encoders:• 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

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.

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.

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.

*)80

During operation the control monitors the following factors, among
others*):• Amplitude of encoder signals• Edge separation of encoder signals• Absolute position for encoders with distance-coded referencemarks• Current position (servo lag monitoring)• Actual path traversed (movement monitoring)• Position deviation at standstill• Nominal speed value• Checksum of safety-related functions• Supply voltage• Voltage of the buffer battery• Operating temperature of MC and CPU• Run time of PLC program• Motor current / motor temperature• Temperature of power module• DC-link voltage• Difference between position and speed encoder (PosDiff)• Serial connection of all devices in the HSCI chain• Quality of optical connections between CC and UM• Voltages of the main power supply• Utilization of the 24 V supply

No safety functions

81

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.

CAD Model
Optimizer(software
option 152)

The CAD Model Optimizer software option gives the user the
power to simplify and heal 3D models, and thus create valid STL
files for collision monitoring or workpiece blanks for simulation.
The user loads the output model into the CAD viewer. The 3D
mesh function simplifies the model and autonomously corrects
errors such as small holes in the solid model or self-intersecting
lines on a surface. The result is a valid STL file that can be used forvarious functions of the control.

KinematicsDesign(accessory)

KinematicsDesign is a PC program for creating adaptablekinematic configurations. It supports:• Complete kinematic configurations• Transfer of configuration files between control and PC• Description of tool-carrier kinematics

Please note:• The collision of machine parts (for example, the swivel head)with the workpiece cannot be detected• Collision objects are not automatically transformed into
rotationally symmetric objects in turning mode
• DCM is not active in servo-lag operation (no feedforward)

If KinematicsDesign is connected to a control online (operationis also possible with the programming station software), thenmachine movements can be simulated when the axes are moved.
Together with the TNC 640, KinematicsDesign simulates theworking space when DCM is active, and collisions that occur—aswell as machine components that are in danger of collision—aredisplayed in a color that you define.

Collision monitoring also protects fixtures and tool carriers fromcollisions.
The 3D 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 machine’s workspace
Context-sensitive
help

82

A context-sensitive help function is available to the user via the
HELP or ERR key. In the event of an error message, the control
displays the cause of the error and the possibilities for fixing it. The
machine manufacturer can also implement this user support for
PLC error messages.

Visualization options range from a pure depiction of thetransformation chain and a wire model all the way to the complete
machine model.
M3D Converter

The TNC 640 lets you import collision objects from a CAD fileand incorporate them as M3D data into the machine kinematics.
The M3D data format from HEIDENHAIN permits an especiallyfinely detailed depiction of high-resolution collision objects.
The M3D converter, which is capable of performing tasks suchas checking, repairing, simplifying, merging, and optimizing
CAD data for collision objects, is used to generate the M3D
data. As an independent PC tool, the M3D converter is partof the KinematicsDesign installation package (as of version3.1). The M3D converter requires a software release module(ID 1124969-01).

83

Error compensation

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). The MONITORINGHEATMAP function allows you, from the NC program, to color
the real-time machining simulation with the status of a monitoringtask. That way the workpiece shows you where a component was
subject to a strong load.

Overview

The TNC 640 automatically compensates for mechanical errors ofthe machine.

Linear error

Linear error can be compensated for each axis over their entire
travel range.

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.

During their lifecycle, the machine components which are subject
to loads (e.g., guides, ball screws, etc.) become worn and thus
the quality of the axis movements deteriorates. This, in turn,affects production quality. With Component Monitoring (software
option 155) and a cycle, the control is able to measure the current
condition of the machine. As a result, any deviations from themachine’s shipping condition due to wear and aging can bemeasured. The machine manufacturer can read and evaluate thedata, and react using predictive maintenance, thereby avoiding
unplanned machine downtimes.

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.

8485

KinematicsOpt(software
option 48)

Using the KinematicsOpt function, machine manufacturers
or 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.

KinematicsComp(software
option 52)

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 measuring process is thesame, regardless of whether the rotary axis is a rotary table, tilting
table, or a swivel head.
Calibration sphere(accessory)

The KinematicsComp software option allows the machine
manufacturer to save a comprehensive description of themachine errors in the control. KinematicsComp then automaticallycompensates for the position error that results from static errorsof the physical machine axes (volumetric compensation). The
positions of all rotary and linear axes, as well as the current tool
length, are included in the calculation. KinematicsComp can also
be used to define position-dependent temperature compensation.
The required data are supplied by multiple sensors located at
representative positions on the machine.

HEIDENHAIN offers calibration spheres as accessories
for the measurement of rotary axes with KinematicsOpt:
KKH 80KKH 250Height: 80 mm
Height: 250 mm

Increasingly stringent requirements on workpiece tolerances
constantly increase the demands placed on the precisionof a machine tool. However, components of machine tools
inevitably show imperfections that are, for example, caused bymanufacturing or assembly or result from elastic deformation. Thisis the reason why the commanded tool position and orientation
are not always reached exactly everywhere in the working space.
The more axes a machine has, the more sources of error there
are. The use of mechanical means to cope with these problems
requires considerable effort, particularly in the field of 5-axis
machining, or when large machines with parallel axes are involved.

ID 655475-03
ID 655475-01

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.

Fault characteristics according to ISO 230-1: EXA

3D-ToolComp(software
option 92)

86

The 3D-ToolComp software option provides 3D 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 the 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 Advanced Function Set 2
software option must be enabled. During probing with a touchprobe, these compensation values are taken into account only inappropriately prepared new probing cycles (e.g., Cycle 444).

87

Initial setup and diagnostic aids

Overview

The TNC 640 provides extensive internal aids for diagnostics
and initial setup. It also includes highly effective PC software fordiagnostics, optimization, and remote operation.

ConfigDesign(accessory)

PC software for configuring the machine parameters• Stand-alone machine-parameter editor for the control; all support
information, additional data, and input limits are shown for theparameters• 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)

TNCdiag

Oscilloscope

Logic signals

88

TNCopt(accessory)

PC software for initial setup of digital control loops.
Functions (among others):• (Automatic) initial setup of the control loops(current, speed, position)• (Automatic) optimization of various feedforward controls– Reversal peaks– Friction parameters, acceleration feedforward control– Torsion compensation• (Automatic) system identification• Circular form test, contour test
• Working space scan, 3D workspace inspector

Online Monitor(OLM)

The online monitor is a component of the TNC 640 and is calledwith a code number. It supports initial setup 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

TNCdiag comes in a PC version for the analysis of servicing files
and in a control version for the display of real-time data.

TNCscope(accessory)

PC software for transferring the oscilloscope files to a PC.
With TNCscope you can record and save up to 32 channels
simultaneously.
Note: The trace files are saved in the TNCscope data format.

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• Servo lag 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

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.

The HEIDENHAIN TNCdiag application evaluates the status anddiagnostic information of HEIDENHAIN components (with anemphasis on the drive systems) and graphically images the data:• Status and diagnostic information about the HEIDENHAIN
components (drive electronics, encoders, input/output devices,etc.) connected to the control• History of the recorded data

Simultaneous graphic 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)• IpoLogik (X)89

RemoteAccess(accessory)

PC software for remote diagnostics, monitoring and operation.

In Diagnosis mode, the structure of the connected bus systems aswell as the details of the connected components can be shown in
an intuitive manner.

TNCtestAcceptance tests on machine tools with external or integratedfunctional safety (FS) must be conducted reproducibly andverifiably.

RemoteAccess grants quick and easy access to HEIDENHAIN
controls that are installed within the same local network (intranet).
RemoteAccess offers the following functions:• Display of the control's user interface on the PC• Operating the control directly through the live view as well aswith the integrated keyboard• Automatic integration of HEIDENHAIN PC tools• Can be enhanced with OEM-specific applications
Single-station license
Network license (14 stations)
Network license (20 stations)

Secure Remote
Access (SRA)

Bus diagnosis

The TNCtest and TestDesign program package can be used
to plan and perform acceptance tests on machine tools with
HEIDENHAIN controls. The acceptance tests are planned with
TestDesign and run with TNCtest.

ID 1339577-01
ID 1339577-02
ID 1339577-03

The optional Secure Remote Access enhancement makes
it possible to establish an encrypted connection with a
HEIDENHAIN control via the internet. This connection is endto-end encrypted. Once the SRA connection has been set up,
RemoteAccess behaves like a local network connection. Thisconnection can be used by HEIDENHAIN PC tools and by anyother PC application.
Possible applications when using SRA:
• User support• Online training courses• Diagnostics, remote maintenance and online support• Secure internet connection as the basis for other OEM services
Export license
The Secure Remote Access expansion requires an export license
in accordance with Annex I of the EU Dual-Use Regulation. A valid
export license is mandatory for operating this application outsideof the EU or with partners outside of the EU.





Internet

The TNCtest programs are designed to provide support during
acceptance testing, provide required information, and perform
automatic configuration, 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 servicing and log files:• Loading of servicing 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• Graphic display of signals via TNCscope• Interaction with other tools that are intended for the display of
special sections of the service file

License model
The expansion is offered as a software subscription with a twoyear license period. The license term is automatically renewed
for twelve months unless the contract is terminated with at least
three months’ notice. The license requires a HEIDENHAIN Portal
account.
Scope of delivery
A license key is included in order to enable the Secure Remote
Access expansion. During activation in the HEIDENHAIN Portal,
the license key is assigned to the registered user.
Secure Remote Access (SRA)
Software subscription (2-year license term)90

ID 1356741-01

91Integrated PLC

Overview

The PLC program is created by the machine manufacturer either
on 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 I/Os are available via the external PL 6000 and UxC. The PLC
I/Os and the PROFINET IO or PROFIBUS DP-capable I/O system
must be configured with the IOconfig PC software.

PLC programming

FormatStatement list

MemoryAt least 1 GiB (depending on the data carrier used)

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
manufacturer with a tool for preventing third parties from viewing
or changing 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 expertise 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 isthat, in spite of the encryption, the data can backed up from thecontrol to a separate data medium (USB drive or network, e.g.,through TNCremo) and later restored. You need not enter the
password, but the data cannot be made visible until the keyword
is supplied.

92

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 graphs
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 the NC 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. It comes with an extensive selection of sample
PLC programs.
Functions:• User-friendly 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

93

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 employed universally for machinefunctions, complex calculations, and the display of special userinterfaces. 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.

PLC basic
programAxes

SpindlesThe 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 can also be executed without enabling
Python OEM Process (software option 46). 10 MB of dedicatedmemory are reserved for this function. For more information, referto the Python in HEIDENHAIN Controls Technical Manual.

Tool changers

Pallet changers

Safety functions

General functions

94

The PLC basic program serves as a basis for adapting thecontrol to the requirements of the respective machine. It canbe downloaded from the Internet. These essential functions arecovered by the PLC basic program:• Control of analog axes
• Axes with clamping mode, central drive, and the Hirth grid
• Synchronized axes
• 3D head with C-axis mode
• Reference run, reference end position• Axis lubrication• 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)• 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• Translational pallet changer• Rotatory pallet changer• Servicing functions for the pallet changer• Emergency stop test (EN 13849-1)• Brake test (EN 13849-1)• Repeated switch-on test for a wireless handwheel• 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• Diagnosis screen (Python)• Python example applications• Status display in the small PLC window95

Interfacing to the machine

OEM cycles

The machine manufacturer can create and store his own cycles
for recurring 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.

Toolmanagement

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.

Toolmeasurement

With the TT tool touch probes (accessory), tools can be measured
and inspected. 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

Palletmanagement96

All touch-probe data can be configured conveniently throughthe touch-probe table. All HEIDENHAIN touch probes arepreconfigured and can be selected through a drop-down menu.

Data transfer and communication
Data interfaces

Overview

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

Ethernet

Using the Ethernet data interface, you can network the TNC 640
based on the TCP/IP protocol. 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

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

Data transfer speed

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

Protocols

The TNC 640 can transfer data using various protocols.

Standard datatransfer

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.

OPC UA NC Server

Connection of an OPC UA applicationUSB

The TNC 640 features USB ports for connecting standard USB
devices such as a mouse, disk drive, etc. The MCs have fourUSB 3.0 ports. One of them leads to the TE, where a cover cap
protects it from contamination. 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 up to 5 m
Cable length 6 m to 30 m with integrated
amplifier; limited to USB 1.1.

ID 354770-xx
ID 624775-xx

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

97Connected Machining

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 transferring 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.

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 operation 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 job management, from the control.
Remote Desktop Manager

HEIDENHAIN
DNC(software
option 18)

The development environments on Windows operating systems
are particularly well suited as flexible platforms for application
development in order to come to terms with 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 a text message
to the customer's 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 order management software

Additional functions:• Interrogation of control information (NC up time, machine up
time, machine running time, spindle running time, pending
errors, data from the data servers—e.g., symbolic PLC
operands)• Overwriting of specific tool data based on values from a tool
presetter
TNCremoPlus

ID 894423-xx

ID 340447-xx

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 through the
HEIDENHAIN DNC interface.
Single station license
Network license For one workstation
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.

98

99

Mounting information
Clearances and mounting

OPC UA NC
Server(software
option 56-61)

The OPC UA standard (Open Platform Communications Unified
Architecture) has emerged in recent years as a well-establishedinterface for secure and reliable data exchange in industrial
environments. The 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*, forexample, to be connected to the HEIDENHAIN control.

Proper minimum
clearance

When installing the control components and power modules, takenote of the minimum spacing, space needed for servicing, andthe appropriate length and location of the connecting cables asdetailed in the Technical Manual of the TNC 640.

Mounting
and 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

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• Interface for accessing tool data of the TNC 640• 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 (recommended by
the OPC Foundation) – X.509 Certificates• User authentication through X.509 certificates*Apple and macOS are trademarks of Apple Inc.

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

The devices comply with EN 50370-1 and EN 61800-3, and areintended for use in industrially zoned areas.

Likely sources ofinterference

Interference is produced by capacitive and inductive coupling into
electrical conductors or into device connections. This is caused, forexample, by:• Strong magnetic fields from transformers or electric motors• Relays, contactors, and solenoid valves• High-frequency equipment, pulse equipment, and 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• Minimum distance of 10 cm between MC, CC, and signal lines
to cables carrying interfering signals (in metal cable ducts, agrounded separation wall suffices for decoupling)• Shielding by means of closed, grounded metal enclosures(e.g., an electrical cabinet)• Use equipotential bonding lines in accordance with thegrounding diagram (comply with the Technical Manual of yourcontrol).
• Use only genuine HEIDENHAIN cables and connecting
elements

Installation
elevation

100

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

101

Key dimensions
Main computer

277.5±112±0.530170±0.2300±0.315399±1

9.5±0.525.5±121.5

12±0.5

70+5

93±1

23+2

IPC 6490

1+0.5

IPC 84204.89.5±0.5

R5

5.5

19±1

20

30

252±1

20

1

3

Front panel opening
Mounting surface
Space for air circulation

102

103

300

24.75
25

396+2

380

16.95±1

 6.5
 13

410

1–0.5

12±0.2

8

234

9

15

74.5+0.5

87.4+2

MC 851228+2

MC 306, IPC 306

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

104

105

31.4+2

12±1

73.5+523.8±187.4+2

2+0.5

47±1

1–0.5

MC 8532

24.5+2

MC 852212±1

25.5±120.9±1277.5±168.1±115400
10376±0.22015.8±125.5±1332±0.2

350

20

R5

5.5

4x M5

2

Front panel opening
Mounting surface
Space for air circulation

331.5+1

332±0.2376±0.2

385.5+1

106

3

Front panel opening
Mounting surface
Space for air circulation

107

Operating panel, monitor, and keyboard

MC 366

BF 360, ITC 362

Z
3:1

Z
3:1
1.5 - 6




20

Z



157
20

600

365

R



47.5+2

11

81+2

590+1

5.5

R

5

R

5

(4

x)

(4

x)

355+1

355+1

342±0.2590+1
342±0.2

78+2

4xM5
Depth 8mm

11.5

5.5

5.5

11

44

578±0.2

11.5

578±0.2

15

54

10

15

79

365

10
R



4xM5
Depth 8mm

Z

79

58

600

267

15

185

15

138

1.5 - 6

7

13

7

13



5.5

5.5

= Front panel opening= Mounting surface= Space for air circulation
1 = Holding clamp (6x), each with two M4 setscrews with hexagon socket and cone point
2 = O-ring cord, EPDM

108

5.5

= Front panel opening= Mounting surface= Space for air circulation
1 = Mounting brace (6x), each with two M4 setscrews with hexagon socket and centering cone (Md = 0.4 – 0.5 Nm)
2 = O-ring cord, EPDM109

BF 860, ITC 860

ITC 855

71.5+2

27±1

28

47±1

72+5

2

1.4

12

90°

476±0.2

24.5+2500

25.25±161.5±1

244±2

476
176.2

470

15

454±0.2

10

3
1–0.5

12
190.5

20

R5

104.5

7.8±1

12

20

12

8

384±0.2400400
376±0.2

 5.5

2–0.5
1.4
376±0.2454±0.2

459+1

232

376

4.75

15x45°= Front panel opening= Mounting surface= Space for air circulation

2.5

385.5+1= Front panel opening= Mounting surface= Space for air circulation

110

111

TE 745, TE 745 FS

TE 360, TE 360 FS
Z
3:1



Y (4x)
2:1

X
2:1



3.2

3

1.5 - 6

41.6


40

.2
23

R

1.8

600

10

Z
38

X
350

140

251.75

Y

53.5

535 563580±0.2

2.5

580±0.2

2.5

10

485

310

10

335+1

330±0.2

330±0.225x45°585+1

 5.5±0.2

Front panel opening
Mounting surface= Front panel opening= Mounting surface= Space for air circulation
1 = Mounting brace (6x), each with two M4 setscrews with hexagon socket and centering cone (Md = 0.4 – 0.5 Nm)
2 = Seal
3 = Weld stud M5 (4x)

112

113

TE 361, TE 361 FS

R

TE 730

52+5

600

10

X

0

Y

23+2

30

225

84
139.5

85

133

533 574

46

X (10x)
2:1

10

10



580±0.222.5±0.1

205±0.2

100

2.3

±0

.1

Y
3:1
1.5 - 6580±0.2

3.5

3.5





587+1


212+1

205±0.215x45°

 5.5±0.2= Front panel cutout= Mounting surface
1 = Nut M5
2 = Optional mounting braces (6x), each with two M5 setscrews with hexagon socket and centering cone (Md = 0.4 – 0.5 Nm)
3 = Seal
4 = Weld stud with external thread M5 (4x)114

Front panel opening
Mounting surface115

TE 735, TE 735 FS

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

Front panel opening
Mounting surface

116

117

MB 721, MB 721 FS

PLB 6001, PLB 600x 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

118

119

PLC inputs and outputs

Electronic handwheels

PL 6000 (PLB 62xx, PLB 61xx)

HR 510, HR 510 FS

3

46

76.5

Clearance for air circulation

278
296

HR 520, HR 520 FS

120

121

Holder for HR 520, HR 520 FS

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

73.5
72

69.3

70.3

HR 550 FS

122

123

HR 130, HR 180

HRA 180
HR 180

X223

124

125

Adapter cable for handwheels (straight)

Adapter cable for handwheels (angled)

X1

X2




X2



Mounting opening

36





 

X1



 



 







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

126

127

Interface accessories

Line-drop compensator for encoders with EnDat interface

KTY adapter connector

Leave space for connecting cable!

Connect i on t o KTY

USB extension cable with hubs

Ordering length

128

129

General information
Documentation

Vision system

VT 121

Technical
documentation

68

19±0.219±0.648

6.7±0.1

19.1
37.1



(13)

User
documentation

28

47.7

84

56.5

71

92

(13)

24.2

35

10±0.2

 8±0.228105
19±0.2 
19±0.6 

59.5

137
32
17

1 = Focal plane
2 = Focus range
3 = Field of view

13

Other
documentation


28

8±0.2

49

10±0.2



23.5
98

Programming
stationView with fixing clamps, cables, and compressed air tubes
 
 
212

 

199
5
R3

130

User's Manuals
TNC 640:• Klartext Programming• Setup, Testing, and Running NC Programs• Programming of Machining Cycles• Programming of Measuring Cycles for Workpieces and Tools• ISO Programming

ID 892903-xx
ID 1261174-xx
ID 1303406-xx
ID 1303409-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
• Touch Probes• Inverter Systems for Gen 3 Drives• Motors• RemoTools SDK virtualTNC• Options and Accessories for TNC Controls

ID 892916-xx
ID 1113984-xx
ID 1303180-xx
ID 208893-xx
ID 628968-xx
ID 827222-xx

Booklets• HR 550 FS• OPC UA NC Server

ID 636227-xx
ID 1355797-xx

To find the programming station software, drivers for the software
security module (USB dongle) and the related documentation, visit
the Downloads area of the HEIDENHAIN website.
Without the software security module (USB dongle), theprogramming station software runs as a demo version (withlimitations).
For more information, please ask your contact person at
HEIDENHAIN.

ID 825930-xx



5
R3


175

ID 892899
ID 1191125
ID 1252650
ID 749363
ID 1423840
ID 757807
ID 1309365
ID 1296230
ID 1418899

Brochure• Programming Station for TNC Controls



15.5

162

Technical Manuals(PDF format on HESIS-Web including Filebase)• TNC 640
• PNC 610
• Inverter Systems for Gen 3 Drives• Functional Safety (FS)• Functional Safety (FS) Supplement to the Technical Manual• Python in HEIDENHAIN Controls• OPC UA NC Server• Motors• Control Components 


131

Service and training

Safetyparameters

The safety parameters must be calculated for every machine(e.g., as per EN ISO 13849-1), with the assemblies being usedtaken into account. HEIDENHAIN provides relevant documents
containing the failure rates.
Registered customers will find the safety parameters for the
Gen 3 drives with external and built-in functional safety (FS) in the
HESIS including Filebase.
Non-registered customers will recieve the documents uponrequest from their HEIDENHAIN contact persons. Documents forolder inverter systems are available only upon request.

Technical support

HEIDENHAIN offers technical support to the machine
manufacturer in order to optimize the interfacing of the control tothe 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)

The following documents can be downloaded via the Filebase:

Basic circuit
diagramDocument

ID

System Description and Failure Rates –Supplement to the Technical Manuel – Gen 3
Drives – PFH values for controls

1312624+49 8669 31-3101
E-mail: service.ncsupport@heidenhain.de

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

System Description and Failure Rates –815683
Supplement to the Technical Manual – MTTF values
for emergency stop buttons and permissive buttons

NC/Cycle programmingand kinematics+49 8669 31-3103
E-mail: service.ncpgm@heidenhain.de

System Description and Failure Rates –Supplement to the Technical Manual – Failure rates
of HEIDENHAIN motors

Encoders and machine
calibration+49 8669 31-3104
E-mail: service.mssupport@heidenhain.de

1029960

Application programming +49 8669 31-3106
E-mail: service.app@heidenhain.deMore information on basic circuit diagrams can be requested fromyour HEIDENHAIN contact person.

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
training
courses

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

132

Technical training courses inGermany+49 8669 31-3049

Technical training courses
outside of Germany

www.heidenhain.com
EN ► Service & Support ►Technical training

E-mail: mtt@heidenhain.de133

Subject index

3

Dynamic Precision............................... 78

3D-ToolComp...................................... 87

E

5

EA module for axis enabling................ 27
Electromagnetic compatibility............ 101
Electronic handwheels........................ 30
Encoder inputs.................................... 71
EnDat 2.2............................................ 57
Error compensation............................. 85
Ethernet.............................................. 97
Expansion PL...................................... 27
Exportlicense....................................... 17

5-Axis Machining................................. 64

A
Absolute encoders.............................. 71
ACC.................................................... 77
Accessories........................................... 5
Adaptive Feed Control (AFC)................ 76
Additional modules.............................. 29
Advanced Dynamic Prediction (ADP).... 75
API DATA............................................ 89
Axes................................................... 63
Axis clamping...................................... 73
Axis feedback control.......................... 72

B
Backlash.............................................. 85
Basic modules..................................... 26
Batch Process Manager (BPM)............ 65
BF 360................................................ 22
BF 360, ITC 362................................ 109
BF 860................................................ 24
BF 860,............................................. 110
Bus diagnosis...................................... 91

C
Cable overview................................... 50
CAD Model Optimizer......................... 83
Calibration sphere................................ 86
CMA-H 04-04-00................................. 29
Combined PROFIBUS DP/PROFINET IO
module................................................ 29
Compensation of torque ripples........... 72
Component Monitoring....................... 84
Components......................................... 4
ConfigDesign...................................... 88
Connected Machining.......................... 99
Connecting cables............................... 32
Context-sensitive help......................... 82
Control loop cycle times...................... 73
Control systems with external safety... 61
Control systems with integratedfunctional safety (FS)........................... 59
Crossover Position Filter (CPF)............. 73
Cross Talk Compensation (CTC)........... 79
Cylinder Surface Interpolation.............. 63

D
Data interfaces.................................... 97
Degrees of protection........................ 101
Digital control design........................... 57
Digital servo control............................ 72
Display step.......................................... 6
DNC applications................................. 99
Double-Speed Control Loops............... 73
Dynamic Collision Monitoring.............. 82
Dynamic Efficiency.............................. 76

134

F
Facing heads....................................... 67
Facing slides....................................... 67
Fast contour milling............................. 74
Feedforward control............................ 72
Fieldbus systems................................ 29

G
Gantry axes......................................... 64
Gear Cutting........................................ 67
Gear stages........................................ 70
Global Program Settings...................... 65
Grinding.............................................. 69

H
HEROS 5............................................ 62
HR 130............................................... 33
HR 130, HR 180................................ 124
HR 180............................................... 33
HR 510............................................... 30
HR 510, HR 510 FS........................... 121
HR 510 FS........................................... 30
HR 520............................................... 31
HR 520, HR 520 FS........................... 121
HR 520 FS.......................................... 31
HR 550 FS.................................. 31, 122
HRA 180..................................... 33, 125
HRA 551 FS................................ 31, 123
HSCI................................................... 57
HSCI adapter....................................... 28
HSCI control components.................... 17
Hysteresis........................................... 85

I
I/O modules........................................ 27
Incremental encoders.......................... 71
Industrial PCs/ITC................................ 34
Initial setup and diagnostic aids............ 88
Input resolution..................................... 6
Installation elevation.......................... 101
Integrated inverter............................... 72
Integrated PLC.................................... 92
Interfacing to the machine..................... 8
Inverter system................................... 52
IOconfig.............................................. 27
IPC 306....................................... 35, 104
IPC 6490........................................... 103
IPC 8420........................................... 102

ITC 362............................................... 34
ITC 855....................................... 35, 111
ITC 860....................................... 34, 110

J
Jerk..................................................... 74
Jerk limiting........................................ 74

K
Keyboard............................................. 25
Keycaps.............................................. 45
KinematicsComp................................. 87
KinematicsDesign................................ 83

LLinear axes.......................................... 63
Linear error......................................... 85
Load Adaptive Control (LAC)................ 78
Log..................................................... 89
Look-ahead.......................................... 74

M
M3D Converter................................... 83
Machine operating panel..................... 25
Machine Vibration Control (MVC).......... 80
Main computer................................... 17
Master keyword.................................. 19
Maximum spindle speed..................... 70
MB 720.............................................. 25
MB 720, MB 720 FS......................... 117
MB 720 FS......................................... 25
MB 721.............................................. 25
MB 721, MB 721 FS......................... 118
MB 721 FS......................................... 25
MC 306...................................... 18, 104
MC 366...................................... 18, 108
MC 8512............................................. 18
MC 8522..................................... 18, 106
MC 8532..................................... 18, 107
Module for analog axes....................... 29
Monitoring functions........................... 81
Motion Adaptive Control (MAC)........... 79
Mounting and electrical installation..... 101
Multiple main spindles......................... 70N
NC software license............................ 20
Nonlinear error.................................... 85

O
Online Monitor.................................... 89
Operating system................................ 62
Optimized Contour Milling (OCM)........ 77
Oscilloscope........................................ 88

P
PAE-H 08-00-01................................... 27
PL 6000...................................... 26, 120
PLA-H 08-04-04................................... 27

PLB 6001, PLB 600x FS.................... 119
PLB 600x............................................ 28
PLB 6104............................................ 27
PLB 6104 FS....................................... 27
PLB 6106............................................ 27
PLB 6106 FS....................................... 27
PLB 6108............................................ 27
PLB 6108 FS....................................... 27
PLB 6204 EnDat................................. 26
PLB 6204 FS EnDat............................ 26
PLB 6206 EnDat................................. 26
PLB 6206 FS EnDat............................ 26
PLB 6208 EnDat................................. 26
PLB 6208 FS EnDat............................ 26
PLB 6210 EnDat.................................. 26
PLB 6210 FS EnDat............................. 26
PLC axes...................................... 65, 93
PLC basic program.............................. 95
PLCdesign........................................... 93
PLC encryption................................... 92
PLC inputs/outputs.............................. 92
PLC positioning................................... 93
PLC programming............................... 92
PLC soft keys...................................... 93
PLC window....................................... 93
PLD-H 04-04-00 FS.............................. 27
PLD-H 04-08-00 FS.............................. 27
PLD-H 08-04-00 FS.............................. 27
PLD-H 08-16-00................................... 27
PLD-H 16-08-00................................... 27
PNC 610............................................. 36
Position Adaptive Control (PAC)............ 80
Position-controlled spindle................... 70
PROFIBUS DP module........................ 29
PROFINET IO module......................... 29
Proper minimum clearance................ 101
Python OEM Process.......................... 94

R
Real-Time Coupling Function................ 65
RemoteAccess.................................... 90
Remote Desktop Manager.................. 99
RemoTools SDK.................................. 99
Reversal spikes................................... 85
Rotary axes......................................... 63

System PL with EnDat support............ 26

T
Table function...................................... 89
Tapping............................................... 70
TE 360.......................................... 22, 22
TE 360, TE 360 FS............................ 113
TE 360 FS..................................... 22, 22
TE 361................................................ 23
TE 361, TE 361 FS............................ 114
TE 361 FS........................................... 23
TE 730................................................ 25
TE 735................................................ 25
TE 735, TE 735 FS............................ 116
TE 735 FS........................................... 25
TE 745................................................ 24
TE 745, TE 745 FS............................. 112
TE 745 FS........................................... 24
Thermal expansion.............................. 85
Tilting the Working Plane..................... 64
TNCanalyzer........................................ 91
TNCdiag.............................................. 88
TNCkeygen......................................... 20
TNCopt............................................... 89
TNCremo............................................ 98
TNCremoPlus...................................... 98
TNCscope........................................... 89
TNCtest.............................................. 91
Torque Control..................................... 64
Trace function...................................... 89
Turning v2........................................... 68

U
USB.................................................... 97
User administration............................. 62VvirtualTNC........................................... 99
Vision system.................................... 130
VT 121.............................................. 130
VT 121 with VTC................................. 39

S
Screen................................................ 25
Servo lag............................................. 72
SIK component................................... 19
Sliding friction..................................... 85
Smoothed jerk.................................... 74
Snap-on keys................................. 40, 42
Software options................................. 14
Software tools....................................... 5
Specifications........................................ 6
Spindle................................................ 70
Spindle orientation............................... 70
Spindle override.................................. 70
Static friction....................................... 85
Storage medium................................. 19
Synchronized axes............................... 64

135

Mastering nanometer accuracy

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1303179-23 · 06/2024 · H · Printed in Germany

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