MANUALplus 620
The Contouring Control for CNC
and Cycle Lathes
Information for the
Machine Tool Builder

01/2024

Contouring control
General information

MANUALplus 620

Contents• Compact contouring control for CNC and cycle lathes• Suitable for horizontal and vertical lathes as well as verticalContouring control

2• Axes: max. 10 control loops, of which up to 6 can be configured

Overview tables

4• Up to 3 principal axes (X, Z, and Y), B axis, closed-loop spindle

HSCI control components

16

Accessories

24

Cable overview

33

Technical description

39

Data transfer and communication

65

Mounting information

68

Key dimensions

69

General information

80

Other HEIDENHAIN controls

83

Subject index

85

boring and turning mills
as spindles

and counter spindle, C1/C2 axis, and driven tools• Up to 3 programmable auxiliary axes (U, V, W) for control ofsteady rest, tailstock, and counter spindle• The position of a parallel secondary axis can be showncombined with its principal axis
• Compact design: screen and main computer in one unit
• For operation with HEIDENHAIN inverter systems and ideallywith HEIDENHAIN motors• Fully digital with HSCI interface and EnDat interface• 15.6-inch multi-touch display with 1366 × 768 pixels• Integration of the keyboard on the right side of the display• Storage medium: CFR CompactFlash memory card (CFast)• Programming of turning, drilling, and milling operations withsmart.Turn, according to DIN, or via cycles• TURN PLUS: automated smart.Turn program generation• ICP free contour programming for turning and milling contours• For simple tool holders (multifix), turrets, or magazines
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:
MANUALplus 620 with NC software versions
548431-18 (no export license required)

Please note the page references in the tables with thespecifications.
Functional safety(FS)

If standard components and FS components (FS = Functional
Safety) are not explicitly differentiated, then the information applies
to both versions (e.g., MB 720T, MB 720T 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)).

Using thisbrochure

This brochure is purely a decision-making aid for selecting
HEIDENHAIN components. Further documentation is needed
for actual project planning (see "Technical documentation",
Page 80).

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 548431-18, 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

Accessories

Control system

MANUALplus 620

Page

Accessory

Main computer

MC 8420T

16

Electronic handwheels

Storage medium

CFR memory card18

NC software license

On SIK component

18

Multi-touch display

15.6-inch

Operating panel

Integrated in the right-hand side of the display

Machine operating panel

MB 720T, MB 720T FS

21

PLB 6001, PLB 600x FS (HSCI adapter for OEM machine operating panel)24

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

22

PLC inputs/
outputs1)

With HSCI
interface

Workpiece touch probes1)

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

With cuboid probe contact as accessory• TT 160 triggering touch probe• TT 460 triggering touch probe with radio or infrared transmission

Programming station2)

DataPilot MP 620
Control software for PCs for programming, archiving, and training• Full version with single user license or network license• Demo version (free of charge)

Snap-on keys

For controls and handwheels

25

Modules for fieldbus systems
Inverter systems2)

Compact inverters and modular inverters

Connecting cables✓• HR 180 panel-mounted handwheels for connection to position inputs, plus
• 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• TS 460, TS 760 triggering touch probes with radio or infrared transmission• TS 260, TS 750, TS 150 triggering touch probes with cable connection

Tool touch probes1)

On UEC2) and UMC3)
Additional modules1)

MANUALplus 620

Page
26

29

1) For more information, refer to the Touch Probes brochure331) May be necessary depending on the configuration

2) For more information, refer to the Inverter Systems for Gen 3 Drives brochure3) For more information, refer to the Inverter Systems UV 1xx, UVR 1xx, UM 1xx, UEC 1xx, UE 2xx, UR 2xx brochure

Please note: The MC main computer has no PLC inputs/outputs. Therefore, one PL 6000, one UEC, or one UMC is necessary for eachcontrol. They feature safety-relevant inputs/outputs, as well as ports for touch probes.

2) For more information, refer to the Programming Station for Turning Controls brochure

Software tools

MANUALplus 620

Page

PLCdesign1)

PLC development software

62

TNCremo2), TNCremoPlus2)3)

Data transfer software (TNCremoPlus with “live” screen)

66

ConfigDesign1)

Software for configuring the machine parameters

57

TNCkeygen1)

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

TNCscope1)

Software for data recording

58

TNCopt1)

Software for putting digital control loops into service

58

IOconfig1)

Software for configuring PLC I/O and fieldbus components

23

RemoteAccess1)3)

Software for remote diagnostics, monitoring, and operation

59

RemoTools SDK1)

Function library for developing customized applications for communication with
HEIDENHAIN controls

67

TNCtest1)

Software for creation and execution of an acceptance test

60

TNCanalyzer1)

Software for the analysis and evaluation of service files

601) 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 required

45

Specifications

Specification

MANUALplus 620

Page

Axes

Max. 10 control loops , of which up to 6 can be configured as spindles

45

Axes

Up to 6 closed-loop linear axes
X, Z, U, V, W: Standard
Y: Option

Specification

MANUALplus 620

Block processing

3 ms

Cycle times of controller unit

CC/UEC/UMC

51

Path interpolation

3 ms

51

Fine interpolation

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

B axis

OptionPosition controller

C1/C2 axis

OptionSpeed controller

Synchronized axes✓

Current controller

PLC axes✓

SpindlesUp to 6 controlled spindles:
Main spindle
Counter spindle
Driven tool

fPWM
3.333 kHz
4 kHz
5 kHz
6.666 kHz (software option 49)
8 kHz (software option 49)
10 kHz (software option 49)
13.333 kHz (software option 49)
16 kHz (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 to 60 °C

47
48

Speed

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

47

Operating mode switchover✓

47

Position-controlled spindle✓

47

Oriented spindle stop✓47

Gear shifting✓47

NC program memory≈ 7.7 GiB

16

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

45

Input resolution and display step
Linear axes

X axis: 0.5 µm (diameter 1 µm)
U,V, W, Y, Z axes: 1 µm

Rotary axes

B, C1/C2 axis: 0.001°

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

For applications with up to

Page

41

• SIL 2 according to EN 61 508• Category 3, PL d as per EN ISO 13 849-1:2008

Interpolation
Straight line

In 2 axes (maximum: ±100 m); in 3 main axes with software option 70

Circular

In 2 axes (max. radius: 999 m); additional linear interpolation of the third axis
with software option 55 or 70

C1/C2 axis

Interpolation of the linear axes X and Z with the C1/C2 axis (software option 55)

B axisInterpolation for X, Z, Y, B and C axis (software option 54)
50

Axis feedback control
With following error✓

With feedforward✓

With jerk limiting✓

Maximum feed rate

45
60000 rpm
No. of motor pole pairs.

45
Screw pitch [mm]At fPWM = 5000 Hz
Constant surface speed

✓

Input

mm/min or mm/revolution

Cycle times of main computer

MC

6

51

7

Interfacing to the machineInterfacing to the machine

MANUALplus 620

Page

Interfacing to the machine

MANUALplus 620

Page

Error compensation✓

56

Setup anddiagnostic aids

Linear axis error✓

56

TNCdiag

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

57

Nonlinear axis error✓

56

TNCoptSoftware for putting digital control loops into service

58

Backlash✓

56

ConfigDesign

Software for creating the machine configuration

57

Reversal spikes during circular
movement✓

56

Integrated oscilloscope✓

57

Hysteresis✓

56

Trace function✓

58

Thermal expansion✓

56

API DATA function✓

58

Static friction✓

56

Table function✓

58

Sliding friction✓

56

OLM (online monitor)✓

58

Integrated PLC

✓

61

Log

✓

58

Program format

List of commands

61

TNCscope✓

58

Program input at the control

By screen keyboard

61

Bus diagnostics✓

60

Program input by PC✓

61

Data interfaces✓

Symbolic PLC-NC interface✓

61

Ethernet✓

65

PLC memory≈ 4 GiB

61

USB

✓

65

PLC cycle time

9 ms to 30 ms (adjustable)

61

PLC inputs/outputs

For the maximum configuration of the PLC system, see Page 40

22

PLC inputs, DC 24 V

Via PL, UEC, UMC

22

PLC outputs, DC 24 V

Via PL, UEC, UMC

22

Analog inputs ±10 V

Via PL

22

Inputs for PT 100 thermistors

Via PL

22

Analog outputs ±10 V

Via PL22

PLC functions✓

61

PLC soft keys✓

62

PLC positioning✓

62

PLC Basic Program✓

63

Integration of applications

62

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

62

User interfaces can be customdesigned

62

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.

57

65

Protocols
Standard data transmission✓

65

Blockwise data transfer

✓

65

9

Configuration✓✓

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

Interactive Contour
Programming (ICP)

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

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

smart.Turn
programming

9

Operating modes
Manual operation

✓
✓
11
8

Teach-in mode
Program run

Setup functions

✓

✓
✓
✓
✓
✓
✓

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

98

All are possible in single-block and full-sequence modes
DIN PLUS programs
smart.Turn programs
Cycle programs

17
17
17

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

9
9
9
9
9
9
9
9+55/70
9+55
9+55/70

Programming
Cycle programming

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

10

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

MANUALplus 620
OptionFunctionStandard

MANUALplus 620
OptionFunctionStandard

Functions for the user✓
TURN PLUS

9
9
9
9
9
9
63

The basis is the "unit," which is the complete description of a machining block (geometry,technology and cycle data)
Dialog boxes divided into overview and detail forms
Fast navigation between the forms and the input groups via the "smart" keys
Context-sensitive help graphics
Start unit with global settings
Transfer of global values from the start unit
Transfer of cutting values from the technology database
Units for all turning and recessing operations for simple contours and ICP contours
Units for boring, drilling, and milling operations with the C or Y axis for holes, milling contours,
and drilling and milling patterns that are simple or that have been programmed with ICP
Activating/deactivating special units for the C axis; subprograms and section repeats
Verification graphics for the workpiece blank and finished part, also for C- and Y-axis contours
Turret assignment and other setup information in the smart.Turn program
Parallel programming
Parallel simulation
Trochoidal milling
Hobbing
Multiple plunging
Batch Mode (automatic execution of multiple different main programs)
Automatic smart.Turn program generation with– Automatic tool selection– Automatic turret assignment– Automatic calculation of cutting data
– Automatic generation of machining sequence in all working planes, also for C-axis machining(with option 55) and Y-axis machining (with option 70)– Automatic cutting limitation through chucking equipment– Automatic generation of work blocks for rechucking for turning with counter spindles– Automatic generation of work blocks for rear-face machining (with option 132)11

DIN PLUS
programming

✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓

Simulation✓✓

Graphical simulation of the cycle process, or of the cycle, smart.Turn or DIN PLUS program
Depiction of the tool paths as pencil-trace or cutting-path graphics; special identification of therapid traverse paths
Machining simulation (2D material-removal graphics)
Side or face view or 2D view of cylindrical surface for verification of C-axis machining
Display of programmed contours
View of the tilted plane (B-axis machining)
View of front face and YZ plane for verification of Y-axis machining
Three-dimensional rendering of the workpiece blank and finished part
Simulation of mirrored contours for rear-face machining
Shifting and magnifying functions
Block scan in the simulation✓

Graphical depiction of the current machining operation✓✓✓

B-axis machining✓

Monitoring
functions

12

55
54
132

54
54
9+54
135
135

Eccentric machining

Machining time
analysis

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

Program-run
graphics✓✓✓

Tool database

✓
✓
✓
✓
✓
✓
✓

MANUALplus 620
OptionFunctionStandard

MANUALplus 620
OptionStandard

Function

10

10

✓
✓
8/9

Technology
database

8/9
8/9
8/9
10

For 250 tools
For 999 tools
Tool description can be entered for every tool
Automatic inspection of the tool-tip position relative to the machining contour
Compensation of the tool-tip position in the X/Y/Z plane
Fine compensation of tool via handwheel with application of compensation values in the tool
table
Automatic tool-tip and cutter radius compensation
Tool monitoring for lifetime of the insert (tool tip) or the number of workpieces produced
Tool monitoring with automatic tool change after end of tool life
Management of multipoint tools (multiple inserts or multiple reference points)
Support of quick-change tool systems
Access to cutting data upon definition of workpiece material, cutting material, and themachining mode. The MANUALplus 620 distinguishes between 16 machining modes. Eachcombination of workpiece material and tool material includes the cutting speed, the main feed
rate, the secondary feed rate, and the infeed for the 16 machining modes.
Automatic determination of the machining modes based on the cycle or the machining unit
The cutting data are entered in the cycle or in the unit as suggested values
9 combinations of workpiece material and tool material (144 entries)
62 combinations of workpiece material and tool material (992 entries)

User management✓

Configurable tying of permissions to user roles– Login at the control with a user account– User-specific HOME folder for simplified data management– Role-based access to the control and the network data

Conversational
languages✓

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

Machining with the B axis
Tilting the working plane
Rotating the machining position of the tool
Simultaneous turning
Cycles for eccentric turning and for the manufacture of oval and polygonal contours
Superimpositioning of traversing movements of the X and Y axes synchronously to therotational motion of the spindle
Calculation of machining times and idle times
Consideration of the switching commands triggered by the CNC
Representation of time per individual cycle or per tool change

151
155

Load Monitoring: detect tool wear and tool breakage during machining
Component Monitoring: monitor for the overloading and wear of machine components

13Software options

OptionnumberOptionStartingwith NCSoftware
548431-ID

Comment

94

Parallel Axes

01

679676-01

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

101–130

OEM option

01

579651-01 to
579651-30

Options of the machine manufacturer

131

SpindleSynchronism

01

806270-01

Synchronization (of two or more spindles)

48

132

Counter Spindle

01806275-01

Counter spindle (spindle synchronization, rear-facemachining)

47

133

Remote Desktop
Manager

07894423-01

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

67

135

Synchronizing
Functions

03

1085731-01

Expanded synchronization of axes and spindles

46

143

Load Adapt. Control 01

800545-01

LAC: load-dependent adaptation of control parameters

56

151

Load Monitoring

03

1111843-01

Monitoring of the tool load

55

155

Component
Monitoring

07

1226833-01

Monitoring for component overloading and wear

55

160

Integrated FS: Basic 07

1249928-01

Enables functional safety and four safe control loops

41

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

161

Integrated FS: Full

07

1249929-01

Enables functional safety and the maximum number ofsafe control loops

41

162

Add. FS Ctrl. Loop 1 07

1249930-01

Additional control loop 1

41

163

Add. FS Ctrl. Loop 2 07

1249931-01

Additional control loop 2

41

Threads• Thread recutting• Handwheel superimposition during thread cutting

164

Add. FS Ctrl. Loop 3 07

1249932-01

Additional control loop 3

41

165

Add. FS Ctrl. Loop 4 07

1249933-01

Additional control loop 4

41

166

Add. FS Ctrl. Loop 5 07

1249934-01

Additional control loop 5

41

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.

41

OptionnumberOptionStartingwith NCSoftware
548431-ID

Comment

page

0

Additional Axis 101354540-01

Additional control loop 1

191Additional Axis 201353904-01

Additional control loop 2

192

Additional Axis 301353905-01

Additional control loop 3

193

Additional Axis 401367867-01

Additional control loop 4

194Additional Axis 501367868-01

Additional control loop 5195Additional Axis 601370291-01

Additional control loop 6196Additional Axis 701370292-01

Additional control loop 7

19

8

Teach-In

01632226-01

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

9

10

11

smart.Turn

Tools andTechnology

Thread Recutting

01

01

01

632227-01

632228-01

632229-01

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

17

Touch Probe
Functions

01

632230-01

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

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM
component

67

24

Gantry Axes

01

634621-01

Gantry axes via master-slave torque control

46

42

DXF Import

01

632231-01

DXF import: importing of DXF contours

46

Python OEM
Process

01

579650-01

Python application on the control

62

49

Double-Speed Axes 01

632223-01

Short control-loop cycle times for direct drives

51

54

B-Axis Machining

01825742-01

B axis: tilting the working plane, rotating the machining
position of the tool46

55

C-Axis Machining

01633944-01

C-axis machining

47

63

TURN PLUS

01825743-01

TURN PLUS: automatic generation of smart.Turn
programs

70

Y-Axis Machining

01

661881-01

Y-axis machining

77

4 Additional Axes

03

634613-01

4 additional control loops

14

08

page

19

15

HSCI control components
Main computer

Main computer

The MC 8420T main computer consists of:• 15.6-inch multi-touch display with 1366 x 768 pixels• CPU: Intel Celeron 1047, 1.4 GHz, dual-core• RAM: 4 GB
• IP54 protection rating (when installed)• Compatible successor of the MC 7410 T• MANUALplus control panel• HSCI interface to the controller unit and to other control
components

Versions

The MC 8420 T main computer is designed for direct installation
into the operating panel. It contains a 15.6-inch multi-touch display
with integrated operating panel. It is thus an extremely compact
unit. The MC 8420 T main computer is supported starting withNC software 548431-05.

To be ordered separately, and installed in the main computer by
the OEM:• CFR memory card with the NC software• The System Identification Key (SIK) component for enabling
control loops and software options.
The following HSCI components are necessary for operation of
the MANUALplus 620:
• MC main computer• Controller unit
• PLB 62xx PLC I/O unit (system PL; integrated into UxC))• MB 720 T or MB 720 T FS machine operating panel or PLB 6001
or PLB 600x FS HSCI adapter for connecting an OEM machine
operating panel
Interfaces

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

Gen 3 labels

The different Gen 3 labels identify how control components can be
deployed.

MC 8420 T

Installation Storage
type
mediumMC 8420T1)

Processor

RAM

Operating
CFR (30 GB) Intel Celeron 1047 4 GB
panel (15.61.4 GHz, dual-core
inch)

Power
Mass
consumption*)ID≈ 43 W

1213689-xx≈ 6.7 kg*) Test conditions: Windows 7 (64-bit) operating system, 100% processor load, interfaces not loaded, no fieldbus

module1) Fulfills IP54 when installed

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

Software options

Software options allow the performance of the MANUALplus 620
to be adapted 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 is a CFR (= CompactFlash Removable)compact flash memory card. It contains the NC software andis used to store NC and PLC programs. The storage medium
is removable and must be ordered separately from the main
computer.

NC software
license andenabling ofcontrol loops
based on the CC

SIK with software license and enabling for

SIK component≈ 4 GiB≈ 7.7 GiB
ID 1075055-68

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.
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)

TNCkeygen(accessory)

For putting the MANUALplus 620 into service, there is a master
keyword that enables all software options once for 90 days. After
this period, the software options can be activated only with thecorrect keywords. The general key is activated via a soft key.

SIK

Control Included options
loops
3This CFR uses the fast SATA protocol (CFast).
CFR CompactFlash, 30 GB
Free PLC memory space
Free NC memory space
Export license not required(NC-SW 548431-18)

Three control loops are always enabled in the basic version. The
controller unit must be designed for the corresponding numberof activated control loops. Maximum possible: UEC 3x4: 4 control
loops; UEC 3x5: 5 control loops; CC 302: 2 control loops; CC 308:
8 control loops; CC 310: 10 control loops. You can find the usual
SIK combinations in the following table. Other versions areavailable upon request.

CFR CompactFlash3
4

Enabling further
control loops
SIK component• Teach-In (option 8)• smart.Turn (option 9)• Thread Recutting (option 11)• C-Axis Machining (option 55)• Teach-In (option 8)• Additional Axis 1 (option 0)• Teach-In (option 8)• C-Axis Machining (option 55)

ID 733604-53

ID 733604-55
ID 733604-56

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 10 control loops are possible.
Control-loop groups

Software option

4 Additional Control Loops

77

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

ID 634613-01

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

18

19

Machine operating panel

SIK for purely
analog drive
systems

A special SIK is available for systems with purely analog drives on
the basis of the HSCI platform.
Please note: The SIK can be used only with NC software
548431-04 or later.
The following HSCI components are required:• MC main computer• CC controller unit
• SPI module CMA-H 04-04-00• PLB 6xxx
• MB 720T machine operating panel or PLB 6001 (HSCI adapter
for OEM machine operating panel)

SIK with software license and enabling for

SIK

4 control loops, including options:• Teach-In (option 8)• smart.Turn (option 9)• Thread Recutting (option 11)• C-Axis Machining (option 55)

1158453-51

MB 720T
MB 720T FS• Voltage supply: DC 24 V/≈ 4 W• 36 exchangeable snap-on keys with status LEDs, freely
definable via PLC• Operating elements: Keys preassigned through the PLC basic

program: Control voltage on1); NC start; NC stop; emergency
stop; 4 axis keys; rapid traverse key; electronic handwheel,
permissive key, tool change key, switch gear stage, spindle
right and left; spindle stop; jog spindle to right and left; spindle
positioning; clamp spindle; spindle switchover; chip removal;
chip removal backwards; tool change right and left; unlock door;
coolant keys
• Spindle-speed and feed-rate override potentiometers• Two holes for additional keys or keylock switches• MB 720T: 8 free PLC inputs and 8 free PLC outputs
MB 720T FS: 4 free FS inputs and 8 free PLC outputs; additional
dual-channel FS inputs for emergency stop and permissive keysof the HR handwheel• Connection for HR handwheel• HSCI interface
1)

Illuminated keys, addressable via PLC

MB 720T
MB 720T FS
Mass

20

MB 720T

ID 1043707-xx
ID 1280932-xx≈ 1.0 kg21

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

There are I/O modules with digital and analog inputs and outputs.

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

Total current
Power output
Mass

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

PLD-H 16-08-00
PLB 62xx

Basic modules

PLD-H 08-16-00

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

PLD-H 08-04-00 FS
PLD-H 04-08-00 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)1) PLB 6xxx completely filled, incl. TS, TT

System PL with
EnDat support• 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

PLA-H 08-04-04

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
PLB 6204
PLB 6206
PLB 6208
PLB 6210

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

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

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

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

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

Mass
I/O module foraxis release

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

ID 675572-xx≈ 0.2 kg

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

IOconfig(accessory)

Analog module for PL 6xxx with

• 8 analog inputs, ±10 V• 4 analog outputs, ±10 V• 4 analog inputs for PT 100 thermistors

ID 594243-xx

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 expresses the fact that a component is ready for
operation in a Gen 3 (Gbit HSCI) drive system. Whether acomponent is suitable for functional safety (integrated FS,
external FS, enabling of FS) must be considered separately.

22

23

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 MANUALplus 620.

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 MANUALplus
620 with a 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 a master possible. With version 3.0 or later, theinterface is configured with IOconfig.

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

ID 828539-xx

PROFIBUS DP module

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

ID 828541-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

PROFIBUS-DP and PROFINET-IO

ID 1160940-xx
Combined module

24

25

Electronic handwheels

Overview
Connection
possibilities
Quantity

The standard MANUALplus 620 supports the use of electronic
handwheels. The MANUALplus 620 offers various possibilities.

HR 520• Connection to position encoder inputs• Connection to serial handwheel inputs
It is possible to operate multiple handwheels at the serial
handwheel inputs of the MANUALplus 620 (one handwheel via
the handwheel input of the main computer and one handwheel
each on HSCI machine operating panels or PLB 6001 or PLB 600x
FS HSCI adapters; for the maximum possible number, see
Page 40).

• HR 550 FS wireless handwheel or• HR 510, HR 510 FS, HR 520, HR 520 FS portable handwheel or• HR 130 panel-mounted handwheel
Examples andlimitations

HR 510On cycle lathes, for example, two HR 180 and one HR 510 are
in use. On CNC lathes, usually only one HR 130 or one HR 510
is used. The mixed operation of handwheels with and without
display is not possible. Only one serial handwheel can be active.
Handwheels with functional safety (FS) are cross-circuit-proof due
to special permissive-button logic.

With detent

HR 520ID 670302-xx

ID 670303-xx

HR 520 FS

ID 670304-xx

ID 670305-xx

Holder for HR 520

For attaching to a machine

HR 550 FS

Electronic handwheel with wireless transmission. Display,
operating elements, and functions are like those of the HR 520

HR 520ID 591065-xx

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

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).

HR 510 FS

Without
detentMass ≈ 0.6 kg

Portable 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

HR 510Portable 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

Without detentWith detent

ID 1200495-xx
ID 1183021-xx

Replacement
battery

For HR 550 FS

ID 623166-xx

Keys

Without
detentWith detent

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

ID 1119971-xx

ID 1120313-xx

FCT A, FCT B,
FCT C

ID 1099897-xx –Spindle right/left/
stop

ID 1184691-xx–

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

ID 1120311-xx

ID 1161281-xx

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

FCT A, FCT B,
FCT C

–

ID 1120314-xx

HRA 551 FS
Mass

Spindle start,
FCT B, NC start–

ID 1119974-xx

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

HR 510
HR 550 FS with HRA 551 FS

HRA 551 FS

ID 1119052-xx≈ 0.7 kg

Mass ≈ 0.5 kg

26

27

Snap-on keys for handwheels

Connecting cables

Snap-on keys

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

Connecting cablewith metal armor

–

–

✓

✓

–

ID 296687-xx

✓

✓

–

–

–

ID 1117855-xx

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

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

OrangeGray

Machinefunctions

Adapter connector–
for handwheels withfunctional safety

✓

–

✓

✓

Black

ID 271958-05

Black1) For maximum cable lengths up to 20 m between the MB and HRA 551 FS

Black2) For maximum cable lengths up to 50 m between the MB and HRA 551 FS

Black

See also Cable overview Page 38.
HR 180Panel-mounted handwheel with ergonomic control knob forconnection to a position encoder input.
HR 180
Mass

With detent≈ 0.7 kg

ID 540940-08
Spindlefunctions

HR 180

HR 130The snap-on keys make it easy to replace the key symbols. In thisway, the HR handwheel can be adapted to different requirements.

Panel-mounted handwheel with ergonomic control knob.
It is attached to the MB 720T either directly or via an extension
cable.
HR 130
Mass

Without detentWith detent≈ 0.3 kg

ID 540940-03
ID 540940-01

Other keys

Red

Red

Green

Green

Black

Red

Gray

Black

Green

Black

Red

Black

Green

Black

Green

HR 1302829Snap-on keys for the control

Snap-on keys

Overview for HR 510 and HR 510 FS
Axis keys

OrangeThe snap-on keys make it easy to replace the key symbols, thus
allowing the keyboard to be adapted to different requirements.
Keys

OrangeGray
Gray

Machinefunctions

Spindlefunctions

Other keys

Black

Black

Black

Green

Red

Black

Gray

Red

Black
Green
Red

Green

OrangeMachinefunctions

Black
Green

Black

Red

Black
Black

30

31

32
1)

1)

CC 3xxUEC 3xx

X500B

1)

X502B 1)

X500A

X502A

2)

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.
Red

X43xx

X40xx

Green

X502

X500

PL 620x (FS)PL 610x (FS)

Black

3)

3)

OrangeMini I/O

25-pin D-sub

Black

X502

Gray

For the encoder connections, see the brochure3)

07.05.2021

Cable included with the CC
2)"Cables and Connectors" (ID 1206103-xx)

CCs with 2nd controller board
1)

Green

X500

Special keys
Black

HSCI (Gbit) 1257765-xx

Red

MB 720 T(FS)

Other keys

MC 8420T

Green

X502

X500

Spindlefunctions

HSCI total length 70 m

Cable overview
Control system with CC or UEC

Red

Red
Black

33

34
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)

35

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)

36
Encoder inputs (Mini I/O)

UEC 3xx (FS)
Encoders

37

Technical description
Digital control design

Accessories

HR 510 FS
1119974-xx
1120311-xx
1120314-xx
1161281-xx
HR 5101119971-xx
1120313-xx
1099897-xx
1184691-xx

27.10.2022

HSCI

50m

271958-03-05"Cables and Connectors" (ID 1206103-xx)- For the touch probe connections, see the brochure"Touch Probes for Machine Tools" (ID 1113984-xx)

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)
The order of the HSCI slaves can be freely chosen.

except for MC 30x

X29

MC

MB
TE
PLB 600x

X23

VL
281429-xx- For the touch probe overview, see the brochure1218563-01

1161072-xx

1218563-01

1161072-xx

749368-xx
749369-xx

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 (commissioning, configuration)• Inverter connection 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

20m

1117855-xx

1117853-xx

1117852-03

296687-xx

296467-xx

312879-01

HRA 551 FS
1119052-xx
296467-xx

max. 2m
50m

38

In the uniformly digital control design from HEIDENHAIN, all of
the components 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 uniformly 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

HR 130540940-01-03

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

HR 550 FS
1200495-xx
1183021-xx

CC
UEC
UMC

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

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

Uniformly digital

39

Control systems with integrated functional safety (FS)The maximum permissible number of individual HSCI participants is listed below:
Gbit HSCI component
MC, IPC

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
is taken into account for the MANUALplus 620 control, as well
as for safety-related position encoders. Two redundant, mutuallyindependent safety channels form the basis of the controls withfunctional safety (FS). All safety-relevant signals are captured,
processed, and output via two channels. Errors are detected
through a reciprocal data comparison of the two channels’ states.
Consequently, the occurrence of a single error in the control does
not cause a loss in safety 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. This means that all safety-relevant signals(e.g., permissive buttons, door contacts, emergency stop buttons)
are captured via two channels, and are evaluated independentlyof 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 event of an error.

Components

In systems with functional safety, certain hardware components
handle safety-relevant tasks. In systems with FS, only safetyrelevant components are permitted to be used that, including theirvariant from HEIDENHAIN, are approved for this.

Maximum number in thecontrol system1)
HSCI master

1

CC, UEC (drive-control motherboards) HSCI slave

6

UVR

HSCI slave

5MB, PLB 600x

HSCI slave2

PLB 6xxx(integrated in UEC 3xx (FS))

HSCI slave

7

PLB 6xxx FS(integrated in UEC 3xx FS)

HSCI slave

2

HR
PLD-H xx-xx-xx FS

Basic principle

5
In PLB 6xxx FS

102)

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

In PLB 6xxx (FS)252)

PAE-H xx-xx-xx

In PLB 62xx

13)

UEC 3xx for external safety

HSCI slave (PAE module integrated)

13)1) For more information on the NCK software, see the Technical Manual of the respective control.

2) Total maximum of 1000 inputs/outputs and maximum of 10 PL units (PL, PLB, MB, TE)
3) Only in systems without integrated functional safety (FS)Control components with functional safety (FS) are identifiable by
the addition of “FS” after the type designation (e.g., MB 720T FS.
For a current list of the components approved for functional safety(FS), refer to Functional safety (FS) supplement to the Technical
Manual (ID 1177599).
An MB machine operating panel with functional safety is
indispensable for systems with FS. Only on this MB do all the keys
have a dual-channel design. Axes can be moved without additional
permissive keys.

40

41

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

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.

Please note: Full functionality is not yet available for all machinetypes with functional safety (FS). Before planning a machine withfunctional safety (FS), please determine whether the current rangeof features is sufficient for your machine design.
Activationof functionalsafety (FS)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., MB 720T 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.

For more
information42

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).

43

Operating system

HEROS 5Useradministration

The MANUALplus 620 works 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– Printer: management of printers– Shares: management of network shares– VNC: virtual network computing server
Safety– Portscan (OEM): port scanner– Firewall: protection against undesired network access– SELinux: protection against unauthorized changes to system
files– Sandbox: running applications in separated environments
System– Backup/Restore: function for backing-up and restoring thesoftware on the control– HELogging: evaluation and creation of log files– Perf2: system monitor– User administration: define users with different roles andaccess permissions
Tools– Web browser: Firefox®*)– Document Viewer: display PDF, TXT, 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

Overview

The MANUALplus 620 is a contouring control for lathes with one
spindle and a slide (X, Z, and Y) for tool movement. For rear-facemachining of the workpiece, an optional counter spindle can be
operated in addition to the main spindle.
The control can offset the display of movements in the Z axis withthose of its secondary axis W. Additional axes are available forpositioning steady rests and the tailstock.
The MANUALplus 620 is suitable for various machine
configurations, and supports horizontal as well as vertical lathes.
Some examples of machine configurations:

Display andprogramming

Feed rate in• mm/min• mm/revolution• Feed rate override: 0 % to 150 %• Maximum feed rate at fPWM = 5000 Hz:
60000 rpm
No. of motor pole pairs.

Screw pitch [mm]Traverse range–99 999.9999 to +99 999.9999 [mm]The machine manufacturer defines the traverse range. The user
can set additional limits to the traverse range if he wishes toreduce the working space (software limit switch). A protection
zone for the spindle (Z–) can also be specified.

Tool carriers

The MANUALplus 620 supports quick change tool posts (multifix),
tool turrets, and tool magazines. The tool carriers can be located in
front of or behind the workpiece.

Firefox is a registered trademark of the Mozilla Foundation

44

45

Main spindle and counter spindle

Synchronizedaxes

Synchronized axes move synchronously and are programmed withthe same axis designation.

Overview

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.

For machines featuring a higher level of automation, you canposition the spindle or counter spindle, or switch to C-axis
operation.

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.
B Axis(software
option 54)

Torque Control(software
option 24)

Controller unit

With a B axis it is possible to drill, bore, and mill in oblique planes.
Programming can be done in the main plane as usual.

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

Moreover, by tilting the B axis and rotating the tool you can bringit into positions that enable you, for example, to use a single tool
to machine in the longitudinal and transverse directions on themain and counter spindles. The number of required tools and toolchanges can thus be reduced.
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).

Display andprogramming

Spindle speed:• Constant shaft speed: 1 to 99 999 rpm• Constant surface speed: 1 to 9 999 m/min

Spindlepositioning

Input resolution and display step: 0.001°

Speed limiting

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.

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.

• The MANUALplus 620 monitors the actual speed.
• Speed limiting can be adjusted via parameter and in thetool/spindle/feed-rate menu (TSF menu).

Spindle override

50% to 150%

Maximum spindle
speed

The maximum spindle speed is calculated as follows:
nmax =
fPWM =NPP =u

f PWM . 60000 rpm
NPP . 5000 Hz

PWM frequency in Hz
Number of pole pairs

Gear ranges

A specific parameter set can be defined for each gear range.
The gears are switched via the PLC. Up to 10 gear ranges aresupported.

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.

C-Axis Machining(software
option 55)

For milling, drilling, and boring cycles, either the spindle or counterspindle is switched to C-axis operation, or a separate C-axis drive isactivated.

Z

PLC axes

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.

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.
Real-Time
Coupling Function(software
option 135)

The MANUALplus 620 contouring control operates in conjunction
with the HEIDENHAIN inverter systems with field-oriented control.
As an alternative, an analog nominal speed value can be output.

Input resolution and display step: 0.001°
Counter Spindle(software
option 132)

46

The Counter Spindle option is necessary in order to work with acounter spindle. The Spindle Synchronism option is included in theCounter Spindle option.

47

Driven tools

Overview

Display andprogramming
Speed limiting

Encoders

The driven tool is used for drilling and tapping holes as well as formilling in M19 or C-axis operation. Programs for the driven tool canbe input in manual operation, via cycles with smart.Turn, or in the
DIN editor.

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 MANUALplus 620 features the serial EnDat 2.2 interface(includes EnDat 2.1) for the connection of absolute encoders.

Speed of the driven tool:• Constant shaft speed: 1 to 99 999 rpm• Constant surface speed: 1 to 9 999 m/min• The MANUALplus 620 monitors the actual speed.
• Speed limiting can be adjusted via parameter and in thetool/spindle/feed-rate menu (TSF menu).

SpindleSynchronism(software
option 131)

The Spindle Synchronism option is necessary for special
operations with a driven tool (e.g. polygonal turning.) This option is
included in the Counter Spindle option.

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

48

49

Digital servo control

Integrated inverter

HEIDENHAIN synchronous or asynchronous motors areconnected to the MANUALplus 620.

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 at Page 6

Fine interpolation
Position controller
Speed controller
Current controller

Axis feedback
control

The MANUALplus 620 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

50

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 bymeans of 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.

51

Fast machining

Look-ahead

The MANUALplus 620 calculates the geometry ahead of time inorder to adjust the feed rate. In this way, directional changes aredetected in time to accelerate or decelerate the appropriate NC
axes.

Jerk

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

Jerk limiting

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

Smoothed jerk

The jerk is smoothed by nominal position value filters. The
MANUALplus 620 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 machinespecific natural frequencies. The desired accuracy along with very
high surface quality is attained.

Advanced
Dynamic
Prediction (ADP)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.

j

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

52

53

Monitoring functions

Description

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
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
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
MANUALplus 620 in the machine’s EMERGENCY STOP loop ischecked when the control system is switched on. In the event ofan error, the control displays a message in plain language.

*)

Context-sensitive
help

A context-sensitive help function is available to the user via the
Info or ERR soft keys. In the event of an error message, thecontrol 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.

Load Monitoring(software
option 151)

This option monitors the load that occurs during machining
processes in order to detect the wear or breakage of tools. By
performing a reference operation for each machining step, thenominal load on the motors is determined. The actual motor load
is then continuously compared to the nominal load. Up to four
motors can be monitored per machining step. In the event oftool wear or breakage, two definable limit values trigger error
reactions.

Tool wear

If the load and/or load integral exceed the limit values for tool wear,
the MANUALplus 620 designates the current tool as worn. With
active tool life monitoring, the tool will automatically be replaced
by a defined replacement tool the next time it is called.

Tool breakage

If the load exceeds the limit value for tool breakage, the
MANUALplus 620 immediately stops machining (cycle stop).
Meaningful error messages are issued if the limit values are
exceeded. Furthermore, the MANUALplus 620 can display theload values numerically and graphically in a separate window.

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

No safety functions

54

55

Error compensation

Overview

The MANUALplus 620 automatically compensates for mechanicalerrors of the machine.

Linear error

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

Nonlinear error

The MANUALplus 620 can compensate for ball-screw pitch errors
and sag errors simultaneously. The compensation values are
stored in a table. Nonlinear axis-error compensation also makes it
possible to compensate 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 MANUALplus 620
can compensate 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 MANUALplus 620 can compensate forthis problematic behavior.

Sliding friction

Sliding friction is compensated for by the speed controller of the
MANUALplus 620.

Thermalexpansion

To compensate for thermal expansion, the machine’s expansion
behavior must be known.
The temperature is measured via thermistors connected to theanalog inputs of the MANUALplus 620. The PLC evaluates thetemperature information and passes a compensation value to theNC.

Load Adaptive
Control (LAC,
softwareoption 143)

56

Initial setup and diagnostic aids

Overview

The MANUALplus 620 provides extensive internal aids fordiagnostics and initial setup. It also includes highly effective
PC software for diagnostics, 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

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

Oscilloscope

The MANUALplus 620 features an integrated oscilloscope. BothX/t and X/Y graphs are possible. The following characteristic curves
can be recorded 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• Content of PLC operands• Encoder signal (0° – A) and (90° – B)
• Difference between position and speed encoder• Nominal velocity value• Integral-action component of the nominal current value• Torque-determining nominal current value

Logic signals

Simultaneous 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)With LAC (software option 143), you can dynamically adjust
controller parameters based on the load or friction.
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.

57

TNCopt(accessory)

Online Monitor(OLM)

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
The online monitor is a component of the MANUALplus 620 andis called with a code number. It supports initial setup and diagnosisof control components through the following:• Display of control-internal variables for axes and channels• Display of controller-internal variables (if a CC is present)• Display of hardware signal states• Various trace functions• Activation of spindle commands• Enabling of control-internal debug outputs

TNCscope(accessory)

PC software for transferring the oscilloscope files to a PC.
With TNCscope you can record and save up to 32 channels
simultaneously.

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.

RemoteAccess(accessory)

PC software for remote diagnostics, monitoring and operation.
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 integraton 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)

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.



 



Internet






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 required
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.
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)

58

ID 1356741-01

59Integrated PLC

Bus diagnosis

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.
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.

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

Memory

4 GiB

Cycle time

9 ms to 30 ms (adjustable)

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

Commandset

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

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 know-how and special customer-specificsolutions cannot be copied or changed.
The machine manufacturer can also determine the size of theencrypted partition. This is not determined until the machine
manufacturer creates the PLCE partition. Another advantage
is that, in spite of the encryption, the data can backed up fromthe control to a separate data medium (USB drive or network,e.g., through TNCremo) and later restored. You need not enter
the password, but the data cannot be read until the keyword is
supplied.

60

61

PLC window

The MANUALplus 620 can display PLC error messages in the
dialog line during operation.

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)

General information

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 widget)

SystemAxes

SpindlesTool changers

Simple Python scripts can also be executed without enabling
Python OEM Process (software option 46). Reserved for thisfunction are 10 MB of dedicated memory. For more information,refer to the Python in HEIDENHAIN Controls Technical Manual.

• Tailstock (coupled Z axis) with quill• Milling/turning with B axis
• Control of analog and digital axes
• Axes with clamping mode, central drive, and the Hirth grid
• Synchronized axes
• Reference run, reference end position• Feed rate control• Axis lubrication• Temperature compensation• Control of analog and digital spindles (S1 to S5)• Spindle synchronism for main and counter spindles (S1/S4)• Torque reduction for workpiece transfer (SI/S4)• Oriented spindle stop
• Spindles with clamping mode
• Gear switching via M functions• C-axis operation of spindles (S1/S4)• C-axis operation via separate motor• Manual tool changer• Tool change with multifix• Positioning of the tool turret with three-phase AC motor• Tool changer with revolver system (five types)• Tool changer with B axis, tool gripper, tool shuttle, and n tool
magazines

Safetyfunctions62• Vertical PLC soft-key row• Display and management of PLC error messages• Hydraulic control• Work envelope protection• Chuck protection• Chuck (inner and outer chucking for compression and tension
fixtures)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.
The applications you create can be included via the PLC in thefamiliar PLC windows, or they can be displayed in separate freewindows that can be expanded to the control’s full screen size.

The PLC basic program serves as the basis for the adaptation of
the control to the requirements of the respective machine model.
It can be downloaded from the Internet. These essential functions
are covered by the PLC basic program:• Control of the coolant system (internal, external, air)
• Handling of M functions• Chip conveyor• PLC support for handwheels• PLC log
• Diagnostic screen (Python)• Python example applications• Status display is modifiable by the user in the dashboard area

PC software for PLC program development.
The PC program PLCdesign can be used for easy creation of
PLC programs. Extensive examples of PLC programs are included.
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

Python OEM
Process(software
option 46)

PLC basic
program• Service functions for the tool changer• Functional safety (FS)• Emergency stop test (EN 13849-1)• Brake test (EN 13849-1)• Repeated switch-on test

63

Interfacing to the machine

OEM cycles

Machine manufacturers can create their own units for
programming in smart.Turn (menus, texts, dialogs andevaluations). These units can be called by a menu item in the unit
menu.

Data transfer and communication
Data interfaces

Overview

The MANUALplus 620 is connected to PCs, networks, and otherdata storage devices via data interfaces.

Ethernet

Using the Ethernet data interface, you can network the
MANUALplus 620 based on the TCP/IP protocol. For connection to
the data network, the control features a 1000BASE-T (twisted pair
Ethernet) connection.

With the MANUALplus 620 you can create your own manufacturer
cycles (OEM G functions). The range G500 to G590 is intended forthese G functions. They can be called via the G-function menu andintegrated directly into the NC program.
In addition to the OEM G functions, PLC G functions (G602 toG699) can also be defined. The PLC G functions are processed
directly in the PLC.
Tool
management

With the built-in PLC, the tool changer is moved either
via proximity switch or as a controlled axis. Complete tool
management with tool life monitoring and replacement tool
monitoring is carried out by the MANUALplus 620.

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

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.

Magazine
management

The magazine management provides several functions for various
magazine types:• Loading and unloading of tools in chain-type magazines• Loading and unloading between magazine and spindle• Support for manual tools in manual magazines• Support for block search in tool magazines

64

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 MANUALplus 620 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.

USB

The MANUALplus 620 features USB ports for connecting standard
USB devices such as a mouse, disk drive, etc. The MCs have fourUSB 3.0 ports. 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

65Connected Machining

Software for datatransfer

We recommend using HEIDENHAIN software to transfer files
between the MANUALplus 620 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 the customer
a text message to his cell phone reporting problems on thecurrently running machining process• Standard or customer-specific PC software that decidedly
increases process reliability and equipment availability• Software solutions controlling the processes of manufacturingsystems• Information exchange with 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.

66

67

Degrees ofprotection

The following components fulfill the requirements for IP54 (dust
protection and splash-proof protection):• Display unit (when properly installed)• Machine operating panel (when properly installed)• Handwheel

93±1

277.5±112±0.512±0.525.5±1399±1All 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.

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

Installation
elevation

5.5• Ensure that the MC, CC, and signal lines are at least 20 cm

3

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

1

Protective
measures20

Likely sources ofinterference

9.5±0.5

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

252±1

Intended place of
operation

19±1

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

20

R5Electromagnetic
compatibility

15

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

9.5±0.5

Mounting
and electricalinstallation

MC 8420T

70+5

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 MANUALplus 620.

23+2

Proper minimum
clearance

Key dimensions
Main computer

1+0.5

Mounting information
Clearances and mounting

Front panel opening
Mounting surface
Space for air circulation

68

69

Machine operating panel

PLC inputs and outputs

MB 720T, MB 720T FS

PL 6000 (PLB 62xx, PLB 61xx)

Clearance for air circulation

Front panel opening
Mounting surface

PLB 6001, PLB 600x FS

7071

Electronic handwheels

Holder for HR 520, HR 520 FS

3

46

76.5

HR 510, HR 510 FS

278
296

HR 520, HR 520 FS

73.5
72

69.3

70.3

HR 550 FS

72

73

HRA 551 FS

HR 130, HR 180
122
68.6

12
180

48.6
4

83±0.2320

6192±0.2

210

204

120

32
116

5.5
4x

74

75

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)

76

77Interface accessories

Line-drop compensator for encoders with EnDat interface

USB extension cable with hubs

Connection to KTY

Ordering length

KTY adapter connector

Leave space for connecting cable!

78

79

General information
Documentation

Technical
documentation

User
documentation

Other
documentation

Programming
station for lathe
controls

Technical Manuals(PDF format on HESIS-Web including Filebase)• MANUALplus 620• Inverter Systems for Gen 3 Drives• Functional Safety (FS)• Functional Safety (FS) Supplement to the Technical Manual• Python in HEIDENHAIN Controls• Motors

Safetyparameters
ID 747323
ID 1252650
ID 749363
ID 1177599
ID 757807
ID 1296230

User's Manuals• MANUALplus 620• smart.Turn and DIN (ISO) Programming

ID 1079948-xx
ID 1118606-xx

General:• TNCremo• TNCremoPlus• IOconfig• PLCdesign

Integrated help
Integrated help
Integrated help
Integrated help

Brochures• MANUALplus 620• Touch Probes• Inverter Systems for Gen 3 Drives• Motors• RemoTools SDK virtualTNC• Programming Station for Lathe Controls

ID 1082181-xx
ID 1113984-xx
ID 1303180-xx
ID 208893-xx
ID 628968-xx
ID 826688-xx

Booklets• HR 550 FS

ID 636227-xx

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.
The following documents can be downloaded via the Filebase:
Document

ID

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

1312624

System Description and Failure Rates –815683
Supplement to the Technical Manual – MTTF values
for emergency stop buttons and permissive buttons
System Description and Failure Rates –Supplement to the Technical Manual – Failure rates
of HEIDENHAIN motors
Basic circuit
diagram

1029960

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

The DataPilot CP 640, MP 620 is the programming station for the
CNC PILOT 640 and MANUALplus 620 lathe controls:• Full version, single-station license (ID 1230536-02)• Full version, network license for 14 training stations (ID1230537-02)• Full version, network license for 20 training stations (ID1230538-02)Note:

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.

80

81

Other HEIDENHAIN controls
ExamplesService and training

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)+49 8669 31-3101
E-mail: service.nc-support@heidenhain.de

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

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

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

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

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

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

Technical
training
courses

HEIDENHAIN provides technical customer training in the following
subjects:• NC programming• PLC programming• TNC optimization• TNC servicing• Encoder servicing• Customized training

TNC 620

Information:
TNC 620 brochure• Compact contouring control for milling, drilling, and boringmachines• Axes: 8 control loops, of which up to 2 can be configured as
spindles• For operation with HEIDENHAIN inverter systems and ideally
HEIDENHAIN motors• Uniformly digital with HSCI interface and EnDat interface• Compact size
• CompactFlash memory card
• Programming in HEIDENHAIN Klartext format or G-code (ISO)• Standard milling, drilling, and boring cycles• Touch probe cycles• Short block processing time (1.5 ms)
19-inch screen (portrait) design• Monitor, keyboard, and main computer in one unit (MC 8410)• Integration of the keyboard in the lower screen area
• Multi-touch operation
15-inch screen (landscape) design• Monitor and main computer in one unit (MC 8420)• Separate keyboard unit
• Multi-touch operation

TNC 640

Information:
TNC 640 brochure• 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• Uniformly 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)

For more information on dates or registration:

82

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.de83Subject index

TNC7• Contouring control for milling machines, milling-turning

machines, and machining centers• Axes: up to 24 control loops (22 control loops with functionalsafety (FS)), of which up to 4 can be configured as spindles• For operation with HEIDENHAIN inverter systems and ideallywith HEIDENHAIN motors• Uniformly digital with HSCI interface and EnDat interface• Intuitive multi-touch operational design• Leading-edge functions combined with the familiarity of
HEIDENHAIN Klartext: graphical programing allows beginners
and experts alike to rapidly program complex workpieces• Graphically supported alignment of workholding equipment• Integrated process monitoring• New, intuitive machine setup with smart probing functions• Easy operating solutions for everyday production tasks,
including complete integration of program testing with highresolution simulation of the machining process in the Editor
operating mode
• Graphical programming• Short block processing time (< 0.5 ms)
CNC PILOT 640

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

A

G

O

Absolute encoders.............................. 49
Accessories........................................... 5
Additional modules.............................. 25
Advanced Dynamic Prediction (ADP).... 53
API DATA............................................ 58
Axes................................................... 45
Axis clamping...................................... 51
Axis feedback control.......................... 50

Gantry axes......................................... 46
Gear ranges........................................ 47

Online Monitor.................................... 58
Operating system................................ 44
Oscilloscope........................................ 57

B
Backlash.............................................. 56
Basic modules..................................... 22
B Axis................................................. 46
Bus diagnosis...................................... 60

C
Cable overview................................... 33
C-Axis Machining (software option 55).. 47
CMA-H 04-04-00................................. 25
Combined PROFIBUS DP/PROFINET IO
module................................................ 25
Compensation of torque ripples........... 50
Component Monitoring....................... 55
Components......................................... 4
ConfigDesign...................................... 57
Connected Machining.......................... 67
Connecting cables............................... 28
Context-sensitive help......................... 55
Control loop cycle times...................... 51
Control systems with external safety... 43
Control systems with integratedfunctional safety (FS)........................... 41
Counter Spindle (software option 132).. 47
Crossover Position Filter (CPF)............. 51

D
CNC PILOT 640 with
24-inch multitouch screen

HEROS 5............................................ 44
HR 130............................................... 28
HR 130, HR 180.................................. 75
HR 180............................................... 28
HR 510............................................... 26
HR 510, HR 510 FS............................. 72
HR 510 FS........................................... 26
HR 520............................................... 27
HR 520, HR 520 FS............................ 72
HR 520 FS.......................................... 27
HR 550 FS.................................... 27, 73
HRA 551 FS.................................. 27, 74
HSCI................................................... 39
HSCI adapter....................................... 24
HSCI control components.................... 16
Hysteresis........................................... 56

I
I/O modules........................................ 23
Incremental encoders.......................... 49
Initial setup and diagnostic aids............ 57
Input resolution..................................... 6
Installation elevation............................ 68
Integrated inverter............................... 50
Integrated PLC.................................... 61
Interfacing to the machine..................... 8
Inverter system................................... 34
IOconfig.............................................. 23

J
Jerk..................................................... 52
Jerk limiting........................................ 52

Data interfaces.................................... 65
Degrees of protection......................... 68
Digital control design........................... 39
Digital servo control............................ 50
Display step.......................................... 6
DNC applications................................. 67
Double-Speed Control Loops............... 51
Driven tools......................................... 48

Linear error......................................... 56
Load Adaptive Control (LAC)................ 56
Load Monitoring.................................. 55
Log..................................................... 58
Look-ahead.......................................... 52

E

M

EA module for axis release.................. 23
Electromagnetic compatibility.............. 68
Electronic handwheels........................ 26
Encoder inputs.................................... 49
EnDat 2.2............................................ 39
Error compensation............................. 56
Ethernet.............................................. 65
Expansion PL...................................... 23

Main computer................................... 16
Main spindle and counter spindle......... 47
Master keyword.................................. 18
Maximum spindle speed..................... 47
MB 720 T, MB 720 T FS................ 21, 70
MC 8420 T................................... 16, 17
Module for analog axes....................... 25
Monitoring functions........................... 54
Mounting and electrical installation....... 68

F
Feedforward control............................ 50
Fieldbus systems................................ 25
Functions for the user......................... 10

84

H

L

N
Nonlinear error.................................... 56

P
PAE-H 08-00-01................................... 23
PL 6000........................................ 22, 71
PLA-H 08-04-04................................... 23
PLB 6001, PLB 600x FS...................... 70
PLB 600x............................................ 24
PLB 6104............................................ 23
PLB 6104 FS....................................... 23
PLB 6106............................................ 23
PLB 6106 FS....................................... 23
PLB 6108............................................ 23
PLB 6108 FS....................................... 23
PLB 6204 EnDat................................. 22
PLB 6204 FS EnDat............................ 22
PLB 6206 EnDat................................. 22
PLB 6206 FS EnDat............................ 22
PLB 6208 EnDat................................. 22
PLB 6208 FS EnDat............................ 22
PLB 6210 EnDat.................................. 22
PLB 6210 FS EnDat............................. 22
PLC axes...................................... 46, 62
PLC basic program.............................. 63
PLCdesign........................................... 62
PLC encryption................................... 61
PLC inputs/outputs.............................. 61
PLC positioning................................... 62
PLC programming............................... 61
PLC soft keys...................................... 62
PLC window....................................... 62
PLD-H 04-04-00 FS.............................. 23
PLD-H 04-08-00 FS.............................. 23
PLD-H 08-04-00 FS.............................. 23
PLD-H 08-16-00................................... 23
PLD-H 16-08-00................................... 23
Position-controlled spindle................... 47
PROFIBUS DP module........................ 25
PROFINET IO module......................... 25
Proper minimum clearance.................. 68
Python OEM Process.......................... 62

R
Real-Time Coupling Function................ 46
RemoteAccess.................................... 59
Remote Desktop Manager.................. 67
RemoTools SDK.................................. 67
Reversal spikes................................... 56

S
Servo lag............................................. 50
SIK component................................... 18
SIK for purely analog drive systems...... 20
Sliding friction..................................... 56
Smoothed jerk.................................... 52
Snap-on keys................................. 29, 31
Software options................................. 14
Software tools....................................... 585

Specifications........................................ 6
Spindle override.................................. 47
Spindle Synchronism........................... 48
Static friction....................................... 56
Storage medium................................. 18
Synchronized axes............................... 46
System PL with EnDat support............ 22

T
Table function...................................... 58
Thermal expansion.............................. 56
TNCanalyzer........................................ 60
TNCdiag.............................................. 57
TNCkeygen......................................... 18
TNCopt............................................... 58
TNCremo............................................ 66
TNCremoPlus...................................... 66
TNCscope........................................... 58
TNCtest.............................................. 60
Tool carriers......................................... 45
Torque Control..................................... 46
Trace function...................................... 58
Traverse range..................................... 45

U
USB.................................................... 65
User administration............................. 44
User management.............................. 1386

Mastering nanometer accuracy

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743682-28 · 01/2024 · H · Printed in Germany

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