heidenhain iTNC 530 Programming Manual

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User’s Manual HEIDENHAIN Conversational Programming

iTNC 530

NC software 606 420-02 606 421-02 606 424-02

English (en) 12/2011

Controls of the TNC

100

F %

100

S %

Keys on visual display unit

Key Function

Split screen layout

Toggle the display between machining and programming modes

Soft keys for selecting functions on screen

Shifts between soft-key rows

Alphanumeric keyboard

Key Function

File names, comments

DIN/ISO programming

Machine operating modes

Key Function

Manual Operation

Electronic Handwheel

Program/file management, TNC functions

Key Function

Select or delete programs and files, external data transfer

Define program call, select datum and point tables

Select MOD functions

Display help text for NC error messages, call TNCguide

Display all current error messages

Show calculator

Navigation keys

Key Function

Move highlight

Go directly to blocks, cycles and parameter functions

Potentiometer for feed rate and spindle speed

Feed rate Spindle speed

Programming modes

Key Function

smarT.NC

Positioning with Manual Data Input

Program Run, Single Block

Program Run, Full Sequence

Programming and Editing

Test Run

Cycles, subprograms and program section repeats

Key Function

Define touch probe cycles

Define and call cycles

Enter and call labels for subprogramming and program section repeats

Program stop in a program

Tool functions

Key Function

Define tool data in the program

Coordinate axes and numbers: Entering and editing

Key Function

Select coordinate axes or enter them into the program

Call tool data

Programming path movements

Key Function

Approach/depart contour

FK free contour programming

Straight line

Circle center/pole for polar coordinates

Circle with center

Circle with radius

Circular arc with tangential connection

Chamfering/corner rounding

Numbers

Decimal point / Reverse algebraic sign

Polar coordinate input / Incremental values

Q-parameter programming / Q-parameter status

Save actual position or values from calculator

Skip dialog questions, delete words

Confirm entry and resume dialog

Conclude block and exit entry

Clear numerical entry or TNC error message

Abort dialog, delete program section

Special functions / smarT.NC

Key Function

Show special functions

smarT.NC: Select next tab on form

smarT.NC: Select first input field in previous/next frame

About this Manual

The symbols used in this manual are described below.

This symbol indicates that important information about the function described must be considered.

This symbol indicates that there is one or more of the following risks when using the described function:

 Danger to workpiece  Danger to fixtures  Danger to tool  Danger to machine  Danger to operator

This symbol indicates that the described function must be adapted by the machine tool builder. The function described may therefore vary depending on the machine.

This symbol indicates that you can find detailed information about a function in another manual.

About this Manual

Would you like any changes, or have you found any errors?

We are continuously striving to improve documentation for you. Please help us by sending your requests to the following e-mail address: tnc-userdoc@heidenhain.de.

HEIDENHAIN iTNC 530 5

TNC Model, Software and Features

This manual describes functions and features provided by TNCs as of the following NC software numbers.

TNC model NC software number

iTNC 530, HSCI and HeROS 5 606 420-02

iTNC 530, HSCI and HeROS 5 606 421-02

iTNC 530 Programming Workstation, HeROS 5

The suffix E indicates the export version of the TNC. The export versions of the TNC have the following limitations:

 Simultaneous linear movement in up to 4 axes

HSCI (HEIDENHAIN Serial Controller Interface) identifies the new hardware platform of the TNC controls.

HeROS 5 identifies the operating system of HSCI-based TNC controls. The machine tool builder adapts the usable features of the TNC to his

machine by setting machine parameters. Some of the functions described in this manual may therefore not be among the features provided by the TNC on your machine tool.

TNC Model, Software and Features

TNC functions that may not be available on your machine include:

 Tool measurement with the TT

Please contact your machine tool builder to become familiar with the features of your machine.

606 421-02

Many machine manufacturers, as well as HEIDENHAIN, offer programming courses for the TNCs. We recommend these courses as an effective way of improving your programming skill and sharing information and ideas with other TNC users.

User’s Manual for Cycle Programming:

All of the cycle functions (touch probe cycles and fixed cycles) are described in a separate manual. Please contact HEIDENHAIN if you require a copy of this User’s Manual. ID: 670 388-xx

smarT.NC user documentation:

The smarT.NC operating mode is described in a separate Pilot. Please contact HEIDENHAIN if you require a copy of this Pilot. ID: 533 191-xx.

TNC Model, Software and Features

HEIDENHAIN iTNC 530 7

Software options

The iTNC 530 features various software options that can be enabled by you or your machine tool builder. Each option is to be enabled separately and contains the following respective functions:

Software option 1

Cylinder surface interpolation (Cycles 27, 28, 29 and 39)

Feed rate in mm/min for rotary axes: M116

Tilting the machining plane (Cycle 19, PLANE function and 3-D ROT soft key in the Manual operating mode)

Circle in 3 axes with tilted working plane

Software option 2

5-axis interpolation

Spline interpolation

3-D machining:

 M114: Automatic compensation of machine geometry when

working with swivel axes

TNC Model, Software and Features

 M128: Maintaining the position of the tool tip when positioning

with tilted axes (TCPM)

 FUNCTION TCPM: Maintaining the position of the tool tip when

positioning with tilted axes (TCPM) in selectable modes

 M144: Compensating the machine’s kinematic configuration for

ACTUAL/NOMINAL positions at end of block

 Additional parameters for finishing/roughing and tolerance

for rotary axes in Cycle 32 (G62)

 LN blocks (3-D compensation)

DCM Collision software option Description

Function that monitors areas defined by the machine manufacturer to prevent collisions.

DXF Converter software option Description

Extract contours and machining positions from DXF files (R12 format).

Additional dialog language software option

Function for enabling the conversational languages Slovenian, Slovak, Norwegian, Latvian, Estonian, Korean, Turkish, Romanian, Lithuanian.

Page 396

Page 268

Description

Page 680

Global Program Settings software option Description

Function for superimposing coordinate transformations in the Program Run modes, handwheel superimposed traverse in virtual axis direction.

AFC software option Description

Function for adaptive feed-rate control for optimizing the machining conditions during series production.

KinematicsOpt software option Description

Touch-probe cycles for inspecting and optimizing the machine accuracy.

3D-ToolComp software option Description

3-D radius compensation depending on the tool’s contact angle for LN blocks.

Page 416

Page 427

User’s Manual for Cycles

Page 427

Extended Tool Management software option

Tool management that can be changed by the machine manufacturer using Python scripts.

Interpolation Turning software option Description

Interpolation turning of a shoulder with cycle

290.

CAD Viewer software option Description

Opening of 3-D models on the NC control. Page 285

Remote Desktop Manager software option

Remote operation of external computer units (e.g. a Windows PC) via the user interface of the TNC

Description

Page 200

User’s Manual for Cycles

Description

Page 712

TNC Model, Software and Features

HEIDENHAIN iTNC 530 9

Cross Talk Compensation software option (CTC)

Compensation of axis couplings Machine Manual

Description

Position Adaptive Control (PAC) software option

Changing control parameters Machine Manual

Load Adaptive Control (LAC) software option

Dynamic changing of control parameters Machine Manual

Description

TNC Model, Software and Features

Feature content level (upgrade functions)

Along with software options, significant further improvements of the TNC software are managed via the Feature Content Level (FCL) upgrade functions. Functions subject to the FCL are not available simply by updating the software on your TNC.

All upgrade functions are available to you without surcharge when you receive a new machine.

Upgrade functions are identified in the manual with FCL n, where n indicates the sequential number of the feature content level.

You can purchase a code number in order to permanently enable the FCL functions. For more information, contact your machine tool builder or HEIDENHAIN.

FCL 4 functions Description

Graphical depiction of the protected space when DCM collision monitoring is active

Page 400

Handwheel superimposition in stopped condition when DCM collision monitoring is active

3-D basic rotation (set-up compensation)

FCL 3 functions Description

Touch probe cycle for 3-D probing User’s Manual for

Touch probe cycles for automatic datum setting using the center of a slot/ridge

Feed-rate reduction for the machining of contour pockets with the tool being in full contact with the workpiece

PLANE function: Entry of axis angle Page 484

User documentation as a context-sensitive help system

smarT.NC: Programming of smarT.NC and machining can be carried out simultaneously

Page 399

Machine Manual

Cycles

User’s Manual for Cycles

Page 164

Page 124

TNC Model, Software and Features

HEIDENHAIN iTNC 530 11

FCL 3 functions Description

smarT.NC: Contour pocket on point pattern

smarT.NC Pilot

smarT.NC: Preview of contour programs in the file manager

smarT.NC: Positioning strategy for machining point patterns

FCL 2 functions Description

3-D line graphics Page 156

Virtual tool axis Page 601

USB support of block devices (memory sticks, hard disks, CD-ROM drives)

Filtering of externally created contours Page 441

Possibility of assigning different depths to each subcontour in the contour formula

Touch-probe cycle for global setting of

TNC Model, Software and Features

touch-probe parameters

smarT.NC: Graphic support of block scan

smarT.NC: Coordinate transformation smarT.NC Pilot

smarT.NC: PLANE function smarT.NC Pilot

smarT.NC Pilot

Page 134

User’s Manual for Cycles

User’s Manual for Touch Probe Cycles

smarT.NC Pilot

Intended place of operation

The TNC complies with the limits for a Class A device in accordance with the specifications in EN 55022, and is intended for use primarily in industrially-zoned areas.

Legal information

This product uses open source software. Further information is available on the control under

U Programming and Editing operating mode U MOD function U LEGAL INFORMATION soft key

New functions 606 42x-01 since the predecessor versions 340 49x-05

 Opening and Editing of externally created files is new (see

“Additional tools for management of external file types” on page

139)

 New functions in the task bar added (see “Soft-key row” on page

92)

 Enhanced functions for configuration of the Ethernet interface (see

“Configuring the TNC” on page 651)

 Improvements regarding Functional Safety FS (option):

 General information on Functional Safety FS (see “General

Information” on page 560)

 Explanation of terms (see “Explanation of terms” on page 561)  Checking the axis positions (see “Check axis positions” on page

562)

 Activating feed-rate limitation (see “Activating feed-rate

limitation” on page 564)

 Improvements regarding the general status view of a TNC with

functional safety (see “Additional Status displays” on page 564)

 The new HR 520 and HR 550 FS handwheels are supported (see

“Traversing with electronic handwheels” on page 548)

 New software option 3-D ToolComp: 3-D tool radius compensation

depending on the tool’s contact angle on blocks with surface normal vectors (LN blocks, see "3-D tool radius compensation depending on the tool’s contact angle (3D-ToolComp software option)", page 515)

 3-D line graphics is now also possible in full-screen mode (see “3-D

Line Graphics (FCL2 Function)” on page 156)

 A file selection dialog for selecting files in different NC functions and

in the table view of the pallet table is available now (see “Calling any program as a subprogram” on page 291)

 DCM: Saving and restoring of fixture situations  DCM: The form for test program generation now also contains icons

and tooltips (see “Check the position of the measured fixture” on page 408)

 DCM, FixtureWizard: Touch points and probing sequence are shown

more clearly now

 DCM, FixtureWizard: Designations, touch points and measuring

points can be shown or hidden as desired.(see “Operating FixtureWizard” on page 405)

 DCM, FixtureWizard: Chucking equipment and insertion points can

now also be selected by mouse click

 DCM: A library with standard chucking equipment is available now

(see “Fixture templates” on page 404)

 DCM: Tool carrier management (see “Tool Holder Management

(DCM Software Option)” on page 413)

 In the Test Run mode, the working plane can now by defined

manually (see “Setting a tilted working plane for the test run” on page 626)

New functions 606 42x-01 since the predecessor versions 340 49x-05

HEIDENHAIN iTNC 530 13

 In Manual mode the RW-3D mode for position display is now also

available (see “Position Display Types” on page 663)

 Entries in the tool table TOOL.T (see “Tool table: Standard tool data”

on page 176)

 New DR2TABLE column for definition of a compensation table for

tool radius compensation depending on the tool’s contact angle

 New LAST_USE column, into which the TNC enters the date and

time of the last tool call

 Q parameter programming: QS string parameters can now also be

used for jump addresses of conditional jumps, subprograms or program section repeats (see "Calling a subprogram", page 289, see "Calling a program section repeat", page 290 and see "Programming If-Then decisions", page 315)

 The generation of tool usage lists in the Program Run modes can be

configured in a form (see “Settings for the tool usage test” on page

197)

 The behavior during deletion of tools from the tool table can now be

influenced via machine parameter 7263 see "Editing tool tables", page 183

 In the positioning mode TURN of the PLANE function you can now

define a clearance height to which the tool is to be retracted before tilting to tool axis direction (see “Automatic positioning: MOVE/TURN/STAY (entry is mandatory)” on page 486)

 The following additional functions are now available in the expanded

tool management (see “Tool management (software option)” on page 200):

 Columns with special functions are also editable now  The form view of the tool data can now be exited with or without

saving changed values

 The table view now offers a search function  Indexed tools are now shown correctly in the form view  The tool sequence list includes more detailed information now  The loading and unloading list of the tool magazine can now be

loaded and unloaded by drag and drop

 Columns in the table view can be moved simply by drag and drop

 Several special functions (SPEC FCT) are now available in the MDI

operating mode (see “Programming and Executing Simple Machining Operations” on page 604)

 There is a new manual probing cycle that can be used to

compensate workpiece misalignments by rotating the rotary table (see “Workpiece alignment using 2 points” on page 586)

 New touch probe cycle for calibrating a touch probe by means of a

calibration sphere (see User's Manual for Cycle Programming)

New functions 606 42x-01 since the predecessor versions 340 49x-05

 KinematicsOpt: Better support for positioning of Hirth-coupled axes

(see User's Manual for Cycle Programming)

 KinematicsOpt: An additional parameter for determination of the

backlash in a rotary axis was introduced (see User's Manual for Cycle Programming)

 New Cycle 275 for Trochoidal Slot Milling (see User’s Manual for

Cycle Programming)

 In Cycle 241 "Single-Fluted Deep-Hole Drilling" it is now possible to

define a dwell depth (see User's Manual for Cycle Programming)

 The approach and departure behavior of Cycle 39 "Cylinder Surface

Contour" can now be adjusted (see User's Manual for Cycle Programming)

HEIDENHAIN iTNC 530 15

New functions 606 42x-01 since the predecessor versions 340 49x-05

New Functions with 606 42x-02

 New function for opening 3-D data (software option) directly on the

TNC (see "Open 3-D CAD data (software option)" page 285)

 Improvement of Dynamic Collision Monitoring (DCM):

 Chucking equipment archives can now be activated (see “Loading

fixtures under program control” on page 412) and deactivated (see “Deactivating fixtures under program control” on page 412) under program control

 The display of stepped tools has been improved  When you select tool carrier kinematics, the TNC now displays a

graphical preview of the carrier kinematics (see “Assigning the tool-carrier kinematics” on page 186)

 Extension of the functions for multiple axis machining:

 In manual mode, you can now also travel the axes again when

TCPM and Tilt Machining Plane are active at the same time

 You can now also change tools when M128/FUNCTION TCPM is active

 File management: archiving of files in ZIP archives (see "Archive

files" page 137)

 The nesting depth for program calls has been increased from 6 to 10

New Functions with 606 42x-02

(see “Nesting depth” on page 293)

 smarT.NC-UNITs can now be inserted anywhere in plain-language

programs (see “smartWizard” on page 447)

 There is now a search function based on tool names available in the

tool selection pop-up window (see “Search for tool names in the selection window” on page 193)

 Improvements in pallet machining:

 The new column FIXTURE has been added to the pallet table to be

able to activate fixtures automatically (see "Pallet Operation with Tool-Oriented Machining" page 528)

 The new workpiece status SKIP has been added to the pallet table

(see "Setting up the pallet level" page 534)

 If a tool sequence list is created for a pallet table, the TNC now

also checks that all the NC programs of the pallet table are available (see “Calling tool management” on page 200)

 The new host computer operation was introduced (see “Host

computer operation” on page 675)

 The SELinux security software is available (see “SELinux security

software” on page 93)

 Improvements to the DXF converter:

 Contours can now also be extracted from .H files (see “Data

transfer from plain-language programs” on page 284)

 Preselected contours can now also be selected in the tree

structure (see “Selecting and saving a contour” on page 274)

 A snap function facilitates contour selection  Extended status display (see “Basic settings” on page 270)  Adjustable background color (see “Basic settings” on page 270)  Display can be changed between 2-D and 3-D (see “Basic

settings” on page 270)

 Improvements to the global program settings (GS):

 All the form data can now be set and reset under program control

(see “Technical prerequisites” on page 418)

 Handwheel superimposition value VT can be reset when tool is

changed (see “Virtual axis VT” on page 426)

 If the Swapping Axes function is active, it is now permitted to

position to machine-based positions on the axes that have not been swapped

 Using the new SEL PGM function you can assign variable program

names via QS string parameters call them with CALL SELECTED (see “Define program call” on page 446)

 Improvements to the tool table TOOL.T

 Using the FIND ACTIVE TOOL NAMES soft key you can check

whether identical tool names are defined in the tool table (see "Editing tool tables" page 183)

 The input range of the delta values DL, DR and DR2 have been

increased to 999.9999 mm (see "Tool table: Standard tool data" page 176)

 The following additional functions are now available in the expanded

tool management (see “Tool management (software option)” on page 200):

 Importing of tool data in CSV format (see “Import tool data” on

page 205)

 Exporting of tool data in CSV format (see “Export the tool data”

on page 206)

 Marking and deleting of selectable tool data (see “Delete marked

tool data” on page 207)

 Inserting of tool indices (see “Operating the tool management”

on page 202)

New Functions with 606 42x-02

HEIDENHAIN iTNC 530 17

 New cycle 225 Engraving (see User’s Manual for Cycle

Programming)

 New cycle 276 Contour Train (see User’s Manual for Cycle

Programming)

 New cycle 290 Interpolation Turning (software option, see User’s

Manual for Cycle Programming)

 In the thread milling cycles 26x a separate feed rate is now available

for tangential approach to the thread (see User’s Manual for Cycle Programming)

 The following improvements were made to the KinematicsOpt

cycles (see User’s Manual for Conversational Programming):

 Newer, faster optimization algorithm  It is no longer necessary to run a separate measurement series for

position optimization after angle optimization

 Return of the offset errors (change of machine datum) to the

parameters Q147-149

 More plane measuring points for ball measurement  Rotary axes that are not configured are ignored by TNC when

executing the cycle

New Functions with 606 42x-02

Changed functions 606 42x-01 since the predecessor versions 340 49x-06

 Q-parameter programming: In the FN20 function WAIT FOR you can

now enter 128 characters (see “FN 20: WAIT FOR: NC and PLC synchronization” on page 335)

 In the calibration menus for touch probe length and radius, the

number and name of the active tool are also displayed now (if the calibration data from the tool table are to be used, MP7411 = 1, see "Managing more than one block of calibrating data", page 580)

 During tilting in the Distance-To-Go mode, the PLANE function now

shows the angle actually left to be traversed until the target position (see “Position display” on page 471)

 The approach behavior during side finishing with Cycle 24 (DIN/ISO:

G124) was changed (see User's Manual for Cycle Programming).

HEIDENHAIN iTNC 530 19

Changed functions 606 42x-01 since the predecessor versions 340 49x-06

Changed functions with 606 42x-02

 Tool names can now be defined with 32 characters (see “Tool

numbers and tool names” on page 174)

 Improved and simplified operation by mouse and touchpad in all

graphics windows (see “Functions of the 3-D line graphics” on page

156)

 Various pop-up windows have been redesigned  If you do a Test Run without calculating the machining time, the TNC

generates a tool usage file nevertheless (see “Tool usage test” on page 197)

 The size of the Service ZIP files has been increased to 40 MB (see

“Generating service files” on page 163)

 M124 can now be deactivated by entering M124 without T (see “Do

not include points when executing non-compensated line blocks: M124” on page 374)

 The PRESET TABLE soft key has been renamed to DATUM

MANAGEMENT

 The SAVE PRESET soft key has been renamed to SAVE ACTIVE

PRESET

Changed functions with 606 42x-02

Table of Contents

First Steps with the iTNC 530

Introduction

Programming: Fundamentals, File Management

Programming: Programming Aids

Programming: Tools

Programming: Programming Contours

Programming: Data Transfer from DXF Files or Plain-language Contours

Programming: Subprograms and Program Section Repeats

Programming: Q-Parameters

Programming: Miscellaneous Functions

Programming: Special Functions

Programming: Multiple Axis Machining

Programming: Pallet Editor

Manual Operation and Setup

Positioning with Manual Data Input

Test Run and Program Run

MOD Functions

Tables and Overviews

Industrial PC 6341 with Windows 7 (Option)

HEIDENHAIN iTNC 530 21

1 First Steps with the iTNC 530 ..... 51

1.1 Overview ..... 52

1.2 Machine Switch-On ..... 53

Acknowledge the power interruption and move to the reference points ..... 53

1.3 Programming the First Part ..... 54

Select the correct operating mode ..... 54

The most important TNC keys ..... 54

Create a new program/file management ..... 55

Define a workpiece blank ..... 56

Program layout ..... 57

Program a simple contour ..... 58

Create a cycle program ..... 61

1.4 Graphically Testing the First Program ..... 64

Selecting the correct operating mode ..... 64

Select the tool table for the test run ..... 64

Choose the program you want to test ..... 65

Select the screen layout and the view ..... 65

Start the program test ..... 65

1.5 Tool Setup ..... 66

Selecting the correct operating mode ..... 66

Prepare and measure tools ..... 66

The tool table TOOL.T ..... 66

The pocket table TOOL_P.TCH ..... 67

1.6 Workpiece Setup ..... 68

Selecting the correct operating mode ..... 68

Clamp the workpiece ..... 68

Align the workpiece with a 3-D touch probe system ..... 69

Set the datum with a 3-D touch probe ..... 70

1.7 Running the First Program ..... 71

Selecting the correct operating mode ..... 71

Choose the program you want to run ..... 71

Start the program ..... 71

HEIDENHAIN iTNC 530 23

2 Introduction ..... 73

2.1 The iTNC 530 ..... 74

Programming: HEIDENHAIN conversational, smarT.NC and ISO formats ..... 74

Compatibility ..... 74

2.2 Visual Display Unit and Keyboard ..... 75

Visual display unit ..... 75

Sets the screen layout ..... 76

Operating panel ..... 77

2.3 Operating Modes ..... 78

Manual Operation and Electronic Handwheel ..... 78

Positioning with Manual Data Input ..... 78

Programming and Editing ..... 79

Test Run ..... 79

Program Run, Full Sequence and Program Run, Single Block ..... 80

2.4 Status Displays ..... 81

“General” status display ..... 81

Additional status displays ..... 83

2.5 Window Manager ..... 91

Soft-key row ..... 92

2.6 SELinux security software ..... 93

2.7 Accessories: HEIDENHAIN 3-D Touch Probes and Electronic Handwheels ..... 94

3-D touch probes ..... 94

HR electronic handwheels ..... 95

3 Programming: Fundamentals, File Management ..... 97

3.1 Fundamentals ..... 98

Position encoders and reference marks ..... 98

Reference system ..... 98

Reference system on milling machines ..... 99

Polar coordinates ..... 100

Absolute and incremental workpiece positions ..... 101

Setting the datum ..... 102

3.2 Creating and Writing Programs ..... 103

Organization of an NC program in HEIDENHAIN Conversational ..... 103

Define the blank: BLK FORM ..... 103

Creating a new part program ..... 104

Programming tool movements in conversational format ..... 106

Actual position capture ..... 108

Editing a program ..... 109

The TNC search function ..... 113

3.3 File Management: Fundamentals ..... 115

Files ..... 115

Show externally created files on the TNC ..... 117

Data backup ..... 117

HEIDENHAIN iTNC 530 25

3.4 Working with the File Manager ..... 118

Directories ..... 118

Paths ..... 118

Overview: Functions of the file manager ..... 119

Calling the file manager ..... 121

Selecting drives, directories and files ..... 122

Creating a new directory (only possible on the drive TNC:\) ..... 125

Creating a new file (only possible on the drive TNC:\) ..... 125

Copying a single file ..... 126

Copying files into another directory ..... 127

Copying a table ..... 128

Copying a directory ..... 129

Choosing one of the last files selected ..... 129

Deleting a file ..... 130

Deleting a directory ..... 130

Marking files ..... 131

Renaming a file ..... 133

Additional functions ..... 134

Working with shortcuts ..... 136

Archive files ..... 137

Extract files from archive ..... 138

Additional tools for management of external file types ..... 139

Data transfer to or from an external data medium ..... 144

The TNC in a network ..... 146

USB devices on the TNC (FCL 2 function) ..... 147

4 Programming: Programming Aids ..... 149

4.1 Adding Comments ..... 150

Function ..... 150

Entering comments during programming ..... 150

Inserting comments after program entry ..... 150

Entering a comment in a separate block ..... 150

Functions for editing of the comment ..... 151

4.2 Structuring Programs ..... 152

Definition and applications ..... 152

Displaying the program structure window / Changing the active window ..... 152

Inserting a structuring block in the (left) program window ..... 152

Selecting blocks in the program structure window ..... 152

4.3 Integrated Pocket Calculator ..... 153

Operation ..... 153

4.4 Programming Graphics ..... 154

Generating / not generating graphics during programming ..... 154

Generating a graphic for an existing program ..... 154

Block number display ON/OFF ..... 155

Erasing the graphic ..... 155

Magnifying or reducing a detail ..... 155

4.5 3-D Line Graphics (FCL2 Function) ..... 156

Function ..... 156

Functions of the 3-D line graphics ..... 156

Highlighting NC blocks in the graphics ..... 158

Block number display ON/OFF ..... 158

Erasing the graphic ..... 158

4.6 Immediate Help for NC Error Messages ..... 159

Displaying error messages ..... 159

Display HELP ..... 159

4.7 List of All Current Error Messages ..... 160

Function ..... 160

Show error list ..... 160

Window contents ..... 161

Calling the TNCguide help system ..... 162

Generating service files ..... 163

4.8 The Context-Sensitive Help System TNCguide (FCL3 Function) ..... 164

Function ..... 164

Working with the TNCguide ..... 165

Downloading current help files ..... 169

HEIDENHAIN iTNC 530 27

5 Programming: Tools ..... 171

5.1 Entering Tool-Related Data ..... 172

Feed rate F ..... 172

Spindle speed S ..... 173

5.2 Tool Data ..... 174

Requirements for tool compensation ..... 174

Tool numbers and tool names ..... 174

Tool length L ..... 174

Tool radius R ..... 174

Delta values for lengths and radii ..... 175

Entering tool data into the program ..... 175

Entering tool data in the table ..... 176

Tool-carrier kinematics ..... 186

Using an external PC to overwrite individual tool data ..... 187

Pocket table for tool changer ..... 188

Calling tool data ..... 191

Tool change ..... 194

Tool usage test ..... 197

Tool management (software option) ..... 200

5.3 Tool Compensation ..... 208

Introduction ..... 208

Tool length compensation ..... 208

Tool radius compensation ..... 209

6 Programming: Programming Contours ..... 213

6.1 Tool Movements ..... 214

Path functions ..... 214

FK free contour programming ..... 214

Miscellaneous functions M ..... 214

Subprograms and program section repeats ..... 214

Programming with Q parameters ..... 214

6.2 Fundamentals of Path Functions ..... 215

Programming tool movements for workpiece machining ..... 215

6.3 Contour Approach and Departure ..... 219

Overview: Types of paths for contour approach and departure ..... 219

Important positions for approach and departure ..... 220

Approaching on a straight line with tangential connection: APPR LT ..... 222

Approaching on a straight line perpendicular to the first contour point: APPR LN ..... 222

Approaching on a circular path with tangential connection: APPR CT ..... 223

Approaching on a circular arc with tangential connection from a straight line to the contour: APPR LCT ..... 224

Departing on a straight line with tangential connection: DEP LT ..... 225

Departing on a straight line perpendicular to the last contour point: DEP LN ..... 225

Departure on a circular path with tangential connection: DEP CT ..... 226

Departing on a circular arc tangentially connecting the contour and a straight line: DEP LCT ..... 226

6.4 Path Contours—Cartesian Coordinates ..... 227

Overview of path functions ..... 227

Straight line L ..... 228

Inserting a chamfer between two straight lines ..... 229

Corner rounding RND ..... 230

Circle center CCI ..... 231

Circular path C around circle center CC ..... 232

Circular path CR with defined radius ..... 233

Circular path CT with tangential connection ..... 235

6.5 Path Contours—Polar Coordinates ..... 240

Overview ..... 240

Zero point for polar coordinates: pole CC ..... 241

Straight line LP ..... 241

Circular path CP around pole CC ..... 242

Circular path CTP with tangential connection ..... 243

Helical interpolation ..... 244

HEIDENHAIN iTNC 530 29

6.6 Path Contours—FK Free Contour Programming ..... 248

Fundamentals ..... 248

Graphics during FK programming ..... 250

Converting FK programs into HEIDENHAIN conversational format ..... 251

Initiating the FK dialog ..... 251

Pole for FK programming ..... 253

Free programming of straight lines ..... 253

Free programming of circular arcs ..... 254

Input possibilities ..... 254

Auxiliary points ..... 258

Relative data ..... 259

7 Programming: Data Transfer from DXF Files or Plain-language Contours ..... 267

7.1 Processing DXF Files (Software Option) ..... 268

Function ..... 268

Opening a DXF file ..... 269

Basic settings ..... 270

Layer settings ..... 271

Specifying the reference point ..... 272

Selecting and saving a contour ..... 274

Selecting and storing machining positions ..... 277

Zoom function ..... 283

7.2 Data transfer from plain-language programs ..... 284

Application ..... 284

Open plain-language file ..... 284

Define a reference point; select and save contours ..... 284

7.3 Open 3-D CAD data (software option) ..... 285

Application ..... 285

Operate CAD viewer ..... 286

HEIDENHAIN iTNC 530 31

8 Programming: Subprograms and Program Section Repeats ..... 287

8.1 Labeling Subprograms and Program Section Repeats ..... 288

Labels ..... 288

8.2 Subprograms ..... 289

Operating sequence ..... 289

Programming notes ..... 289

Programming a subprogram ..... 289

Calling a subprogram ..... 289

8.3 Program Section Repeats ..... 290

Label LBL ..... 290

Operating sequence ..... 290

Programming notes ..... 290

Programming a program section repeat ..... 290

Calling a program section repeat ..... 290

8.4 Separate Program as Subprogram ..... 291

Operating sequence ..... 291

Programming notes ..... 291

Calling any program as a subprogram ..... 291

8.5 Nesting ..... 293

Types of nesting ..... 293

Nesting depth ..... 293

Subprogram within a subprogram ..... 294

Repeating program section repeats ..... 295

Repeating a subprogram ..... 296

8.6 Programming Examples ..... 297

9 Programming: Q-Parameters ..... 303

9.1 Principle and Overview ..... 304

Programming notes ..... 306

Calling Q-parameter functions ..... 307

9.2 Part Families—Q Parameters in Place of Numerical Values ..... 308

Function ..... 308

9.3 Describing Contours through Mathematical Operations ..... 309

Function ..... 309

Overview ..... 309

Programming fundamental operations ..... 310

9.4 Trigonometric Functions ..... 311

Definitions ..... 311

Programming trigonometric functions ..... 312

9.5 Circle Calculations ..... 313

Function ..... 313

9.6 If-Then Decisions with Q Parameters ..... 314

Function ..... 314

Unconditional jumps ..... 314

Programming If-Then decisions ..... 315

Abbreviations used: ..... 315

9.7 Checking and Changing Q Parameters ..... 316

Procedure ..... 316

9.8 Additional Functions ..... 317

Overview ..... 317

FN 14: ERROR: Displaying error messages ..... 318

FN 15: PRINT: Output of texts or Q parameter values ..... 322

FN 16: F-PRINT: Formatted output of text and Q-parameter values ..... 323

FN 18: SYS-DATUM READ: Read system data ..... 327

FN 19: PLC: Transfer values to the PLC ..... 334

FN 20: WAIT FOR: NC and PLC synchronization ..... 335

FN 25: PRESET: Setting a new datum ..... 337

9.9 Entering Formulas Directly ..... 338

Entering formulas ..... 338

Rules for formulas ..... 340

Programming example ..... 341

HEIDENHAIN iTNC 530 33

9.10 String Parameters ..... 342

String processing functions ..... 342

Assigning string parameters ..... 343

Chain-linking string parameters ..... 344

Converting a numerical value to a string parameter ..... 345

Copying a substring from a string parameter ..... 346

Copying system data to a string parameter ..... 347

Converting a string parameter to a numerical value ..... 349

Checking a string parameter ..... 350

Finding the length of a string parameter ..... 351

Comparing alphabetic priority ..... 352

9.11 Preassigned Q Parameters ..... 353

Values from the PLC: Q100 to Q107 ..... 353

WMAT block: QS100 ..... 353

Active tool radius: Q108 ..... 353

Tool axis: Q109 ..... 354

Spindle status: Q110 ..... 354

Coolant on/off: Q111 ..... 354

Overlap factor: Q112 ..... 354

Unit of measurement for dimensions in the program: Q113 ..... 355

Tool length: Q114 ..... 355

Coordinates after probing during program run ..... 355

Deviation between actual value and nominal value during automatic tool measurement with the TT 130 ..... 356

Tilting the working plane with mathematical angles: rotary axis coordinates calculated by the TNC ..... 356

Measurement results from touch probe cycles (see also User’s Manual for Touch Probe Cycles) ..... 357

9.12 Programming Examples ..... 359

10 Programming: Miscellaneous Functions ..... 367

10.1 Entering Miscellaneous Functions M and STOP ..... 368

Fundamentals ..... 368

10.2 Miscellaneous Functions for Program Run Control, Spindle and Coolant ..... 369

Overview ..... 369

10.3 Miscellaneous Functions for Coordinate Data ..... 370

Programming machine-referenced coordinates: M91/M92 ..... 370

Activating the most recently entered datum: M104 ..... 372

Moving to positions in a non-tilted coordinate system with a tilted working plane: M130 ..... 372

10.4 Miscellaneous Functions for Contouring Behavior ..... 373

Smoothing corners: M90 ..... 373

Insert rounding arc between straight lines: M112 ..... 373

Do not include points when executing non-compensated line blocks: M124 ..... 374

Machining small contour steps: M97 ..... 375

Machining open contours corners: M98 ..... 377

Feed rate factor for plunging movements: M103 ..... 378

Feed rate in millimeters per spindle revolution: M136 ..... 379

Feed rate for circular arcs: M109/M110/M111 ..... 380

Calculating the radius-compensated path in advance (LOOK AHEAD): M120 ..... 381

Superimposing handwheel positioning during program run: M118 ..... 383

Retraction from the contour in the tool-axis direction: M140 ..... 384

Suppressing touch probe monitoring: M141 ..... 385

Delete modal program information: M142 ..... 386

Delete basic rotation: M143 ..... 386

Automatically retract tool from the contour at an NC stop: M148 ..... 387

Suppress limit switch message: M150 ..... 388

10.5 Miscellaneous Functions for Laser Cutting Machines ..... 389

Principle ..... 389

Output the programmed voltage directly: M200 ..... 389

Output voltage as a function of distance: M201 ..... 389

Output voltage as a function of speed: M202 ..... 390

Output voltage as a function of time (time-dependent ramp): M203 ..... 390

Output voltage as a function of time (time-dependent pulse): M204 ..... 390

HEIDENHAIN iTNC 530 35

11 Programming: Special Functions ..... 391

11.1 Overview of Special Functions ..... 392

Main menu for SPEC FCT special functions ..... 392

Program defaults menu ..... 393

Functions for contour and point machining menu ..... 393

Functions for contour and point machining menu ..... 394

Menu of various conversational functions ..... 394

Menu of programming aids ..... 395

11.2 Dynamic Collision Monitoring (Software Option) ..... 396

Function ..... 396

Collision monitoring in the manual operating modes ..... 398

Collision monitoring in Automatic operation ..... 399

Graphic depiction of the protected space (FCL4 function) ..... 400

Collision monitoring in the Test Run mode of operation ..... 401

11.3 Fixture Monitoring (DCM Software Option) ..... 403

Fundamentals ..... 403

Fixture templates ..... 404

Setting parameter values for the fixture: FixtureWizard ..... 404

Placing the fixture on the machine ..... 406

Editing fixtures ..... 407

Removing fixtures ..... 407

Check the position of the measured fixture ..... 408

Manage fixtures ..... 410

11.4 Tool Holder Management (DCM Software Option) ..... 413

Fundamentals ..... 413

Tool-holder templates ..... 413

Set the tool holder parameters: ToolHolderWizard ..... 414

Removing a tool holder ..... 415

11.5 Global Program Settings (Software Option) ..... 416

Application ..... 416

Technical prerequisites ..... 418

Activating/deactivating a function ..... 419

Basic rotation ..... 421

Swapping axes ..... 422

Superimposed mirroring ..... 423

Additional, additive datum shift ..... 423

Axis locking ..... 424

Superimposed rotation ..... 424

Feed rate override ..... 424

Handwheel superimposition ..... 425

11.6 Adaptive Feed Control Software Option (AFC) ..... 427

Application ..... 427

Defining the AFC basic settings ..... 429

Recording a teach-in cut ..... 431

Activating/deactivating AFC ..... 434

Log file ..... 435

Tool breakage/tool wear monitoring ..... 437

Spindle load monitoring ..... 437

11.7 Generate a Backward Program ..... 438

Function ..... 438

Prerequisites for the program to be converted ..... 439

Application example ..... 440

11.8 Filtering Contours (FCL 2 Function) ..... 441

Function ..... 441

11.9 File Functions ..... 442

Application ..... 442

Defining file functions ..... 442

11.10 Defining Coordinate Transformations ..... 443

Overview ..... 443

TRANS DATUM AXIS ..... 443

TRANS DATUM TABLE ..... 444

TRANS DATUM RESET ..... 445

Define program call ..... 446

11.11 smartWizard ..... 447

Application ..... 447

Insert UNIT ..... 448

Edit UNIT ..... 449

HEIDENHAIN iTNC 530 37

11.12 Creating Text Files ..... 450

Application ..... 450

Opening and exiting text files ..... 450

Editing texts ..... 451

Deleting and re-inserting characters, words and lines ..... 452

Editing text blocks ..... 453

Finding text sections ..... 454

11.13 Working with Cutting Data Tables ..... 455

Note ..... 455

Applications ..... 455

Table for workpiece materials ..... 456

Table for tool cutting materials ..... 457

Table for cutting data ..... 457

Data required for the tool table ..... 458

Working with automatic speed / feed rate calculation ..... 459

Data transfer from cutting data tables ..... 460

Configuration file TNC.SYS ..... 460

11.14 Freely Definable Tables ..... 461

Fundamentals ..... 461

Creating a freely definable table ..... 461

Editing the table format ..... 462

Switching between table and form view ..... 463

FN26: TABOPEN: Opening a freely definable table ..... 464

FN 27: TABWRITE: Writing to a freely definable table ..... 465

FN28: TABREAD: Reading a freely definable table ..... 466

12 Programming: Multiple Axis Machining ..... 467

12.1 Functions for Multiple Axis Machining ..... 468

12.2 The PLANE Function: Tilting the Working Plane (Software Option 1) ..... 469

Introduction ..... 469

Define the PLANE function ..... 471

Position display ..... 471

Reset the PLANE function ..... 472

Defining the machining plane with space angles: PLANE SPATIAL ..... 473

Defining the machining plane with projection angles: PROJECTED PLANE ..... 475

Defining the machining plane with Euler angles: EULER PLANE ..... 477

Defining the working plane with two vectors: VECTOR PLANE ..... 479

Defining the machining plane via three points: PLANE POINTS ..... 481

Defining the machining plane with a single, incremental spatial angle: PLANE RELATIVE ..... 483

Tilting the working plane through axis angle: PLANE AXIAL (FCL 3 function) ..... 484

Specifying the positioning behavior of the PLANE function ..... 486

12.3 Inclined-Tool Machining in the Tilted Plane ..... 491

Function ..... 491

Inclined-tool machining via incremental traverse of a rotary axis ..... 491

Inclined-tool machining via normal vectors ..... 492

12.4 TCPM FUNCTION (Software Option 2) ..... 493

Function ..... 493

Define TCPM FUNCTION ..... 494

Mode of action of the programmed feed rate ..... 494

Interpretation of the programmed rotary axis coordinates ..... 495

Type of interpolation between the starting and end position ..... 496

Reset TCPM FUNCTION ..... 497

12.5 Miscellaneous Functions for Rotary Axes ..... 498

Feed rate in mm/min on rotary axes A, B, C: M116 (software option 1) ..... 498

Shorter-path traverse of rotary axes: M126 ..... 499

Reducing display of a rotary axis to a value less than 360°: M94 ..... 500

Automatic compensation of machine geometry when working with tilted axes: M114 (software option 2) ..... 501

Maintaining the position of the tool tip when positioning with tilted axes (TCPM): M128 (software

option 2) ..... 503

Exact stop at corners with nontangential transitions: M134 ..... 506

Selecting tilting axes: M138 ..... 506

Compensating the machine’s kinematics configuration for ACTUAL/NOMINAL positions at end of block: M144

(software option 2) ..... 507

HEIDENHAIN iTNC 530 39

12.6 Three-Dimensional Tool Compensation (Software Option 2) ..... 508

Introduction ..... 508

Definition of a normalized vector ..... 509

Permissible tool forms ..... 510

Using other tools: Delta values ..... 510

3-D compensation without tool orientation ..... 511

Face milling: 3-D compensation with and without tool orientation ..... 511

Peripheral milling: 3-D radius compensation with workpiece orientation ..... 513

3-D tool radius compensation depending on the tool’s contact angle (3D-ToolComp software option) ..... 515

12.7 Contour Movements – Spline Interpolation (Software Option 2) ..... 519

Application ..... 519

13 Programming: Pallet Editor ..... 521

13.1 Pallet Editor ..... 522

Application ..... 522

Selecting a pallet table ..... 524

Leaving the pallet file ..... 524

Pallet datum management with the pallet preset table ..... 525

Executing the pallet file ..... 527

13.2 Pallet Operation with Tool-Oriented Machining ..... 528

Application ..... 528

Selecting a pallet file ..... 533

Setting up the pallet file with the entry form ..... 533

Sequence of tool-oriented machining ..... 538

Leaving the pallet file ..... 539

Executing the pallet file ..... 539

HEIDENHAIN iTNC 530 41

14 Manual Operation and Setup ..... 541

14.1 Switch-On, Switch-Off ..... 542

Switch-on ..... 542

Switch-off ..... 545

14.2 Moving the Machine Axes ..... 546

Note ..... 546

Moving the axis using the machine axis direction buttons ..... 546

Incremental jog positioning ..... 547

Traversing with electronic handwheels ..... 548

14.3 Spindle Speed S, Feed Rate F and Miscellaneous Functions M ..... 558

Function ..... 558

Entering values ..... 558

Changing the spindle speed and feed rate ..... 559

14.4 Functional Safety FS (Option) ..... 560

General Information ..... 560

Explanation of terms ..... 561

Check axis positions ..... 562

Overview of permitted feed rates and speeds ..... 563

Activating feed-rate limitation ..... 564

Additional Status displays ..... 564

14.5 Datum Setting without a 3-D Touch Probe ..... 565

Note ..... 565

Preparation ..... 565

Workpiece presetting with axis keys ..... 566

Datum management with the preset table ..... 567

14.6 Using the 3-D Touch Probe ..... 573

Overview ..... 573

Selecting probe cycles ..... 574

Recording measured values from the touch-probe cycles ..... 574

Writing the measured values from touch probe cycles in datum tables ..... 575

Writing the measured values from touch probe cycles in the preset table ..... 576

Storing measured values in the pallet preset table ..... 577

14.7 Calibrating a 3-D Touch Probe ..... 578

Introduction ..... 578

Calibrating the effective length ..... 578

Calibrating the effective radius and compensating center misalignment ..... 579

Displaying calibration values ..... 580

Managing more than one block of calibrating data ..... 580

14.8 Compensating Workpiece Misalignment with a 3-D Touch Probe ..... 581

Introduction ..... 581

Basic rotation using 2 points: ..... 583

Determining basic rotation using 2 holes/studs: ..... 585

Workpiece alignment using 2 points ..... 586

14.9 Datum Setting with a 3-D Touch Probe ..... 587

Overview ..... 587

Datum setting in any axis ..... 587

Corner as datum – using points that were already probed for a basic rotation ..... 588

Corner as datum—without using points that were already probed for a basic rotation. ..... 588

Circle center as datum ..... 589

Center line as datum ..... 590

Setting datum points using holes/cylindrical studs ..... 591

Measuring workpieces with a 3-D touch probe ..... 592

Using touch probe functions with mechanical probes or dial gauges ..... 595

14.10 Tilting the Working Plane (Software Option 1) ..... 596

Application, function ..... 596

Traversing the reference points in tilted axes ..... 598

Setting the datum in a tilted coordinate system ..... 598

Datum setting on machines with rotary tables ..... 599

Datum setting on machines with spindle-head changing systems ..... 599

Position display in a tilted system ..... 599

Limitations on working with the tilting function ..... 599

Activating manual tilting ..... 600

Setting the current tool-axis direction as the active machining direction (FCL 2 function) ..... 601

HEIDENHAIN iTNC 530 43

15 Positioning with Manual Data Input ..... 603

15.1 Programming and Executing Simple Machining Operations ..... 604

Positioning with Manual Data Input (MDI) ..... 604

Protecting and erasing programs in $MDI ..... 607

16 Test Run and Program Run ..... 609

16.1 Graphics ..... 610

Application ..... 610

Overview of display modes ..... 612

Plan view ..... 612

Projection in 3 planes ..... 613

3-D view ..... 614

Magnifying details ..... 617

Repeating graphic simulation ..... 618

Displaying the tool ..... 618

Measuring the machining time ..... 619

16.2 Functions for Program Display ..... 620

Overview ..... 620

16.3 Test Run ..... 621

Application ..... 621

16.4 Program Run ..... 627

Application ..... 627

Running a part program ..... 628

Interrupting machining ..... 629

Moving the machine axes during an interruption ..... 631

Resuming program run after an interruption ..... 632

Mid-program startup (block scan) ..... 633

Returning to the contour ..... 636

16.5 Automatic Program Start ..... 637

Application ..... 637

16.6 Optional Block Skip ..... 638

Application ..... 638

Erasing the “/” character ..... 638

16.7 Optional Program-Run Interruption ..... 639

Application ..... 639

HEIDENHAIN iTNC 530 45

17 MOD Functions ..... 641

17.1 Selecting MOD Functions ..... 642

Selecting the MOD functions ..... 642

Changing the settings ..... 642

Exiting the MOD functions ..... 642

Overview of MOD functions ..... 643

17.2 Software Numbers ..... 644

Application ..... 644

17.3 Entering Code Numbers ..... 645

Application ..... 645

17.4 Loading Service Packs ..... 646

Application ..... 646

17.5 Setting the Data Interfaces ..... 647

Application ..... 647

Setting the RS-232 interface ..... 647

Setting the RS-422 interface ..... 647

Setting the OPERATING MODE of the external device ..... 647

Setting the baud rate ..... 647

Assignment ..... 648

Software for data transfer ..... 649

17.6 Ethernet Interface ..... 651

Introduction ..... 651

Connection possibilities ..... 651

Configuring the TNC ..... 651

17.7 Configuring PGM MGT ..... 657

Application ..... 657

Changing the PGM MGT setting ..... 657

Dependent files ..... 658

17.8 Machine-Specific User Parameters ..... 659

Application ..... 659

17.9 Showing the Workpiece in the Working Space ..... 660

Application ..... 660

Rotate the entire image ..... 662

17.10 Position Display Types ..... 663

Application ..... 663

17.11 Unit of Measurement ..... 664

Application ..... 664

17.12 Selecting the Programming Language for $MDI ..... 665

Application ..... 665

17.13 Selecting the Axes for Generating L Blocks ..... 666

Application ..... 666

17.14 Entering the Axis Traverse Limits, Datum Display ..... 667

Application ..... 667

Working without additional traverse limits ..... 667

Find and enter the maximum traverse ..... 667

Datum display ..... 668

17.15 Displaying HELP Files ..... 669

Application ..... 669

Selecting HELP files ..... 669

17.16 Displaying Operating Times ..... 670

Application ..... 670

17.17 Checking the Data Carrier ..... 671

Application ..... 671

Performing the data carrier check ..... 671

17.18 Setting the System Time ..... 672

Application ..... 672

Selecting appropriate settings ..... 672

17.19 TeleService ..... 673

Application ..... 673

Calling/exiting TeleService ..... 673

17.20 External Access ..... 674

Application ..... 674

17.21 Host computer operation ..... 675

Application ..... 675

17.22 Configuring the HR 550 FS Wireless Handwheel ..... 676

Application ..... 676

Assigning the handwheel to a specific handwheel holder ..... 676

Setting the transmission channel ..... 677

Selecting the transmitter power ..... 678

Statistics ..... 678

HEIDENHAIN iTNC 530 47

18 Tables and Overviews ..... 679

18.1 General User Parameters ..... 680

Input possibilities for machine parameters ..... 680

Selecting general user parameters ..... 680

List of general user parameters ..... 681

18.2 Pin Layouts and Connecting Cables for the Data Interfaces ..... 696

RS-232-C/V.24 interface for HEIDENHAIN devices ..... 696

Non-HEIDENHAIN devices ..... 697

RS-422/V.11 interface ..... 698

Ethernet interface RJ45 socket ..... 699

18.3 Technical Information ..... 700

18.4 Exchanging the Buffer Battery ..... 710

19 Industrial PC 6341 with Windows 7 (Option) ..... 711

19.1 Introduction ..... 712

Functionality ..... 712

Specifications of the IPC 6341 ..... 712

End User License Agreement (EULA) for Windows 7 ..... 713

Switch to Windows interface ..... 713

Exiting Windows ..... 713

HEIDENHAIN iTNC 530 49

First Steps with the iTNC 530

1.1 Overview

This chapter is intended to help TNC beginners quickly learn to handle the most important procedures. For more information on a respective topic, see the section referred to in the text.

The following topics are included in this chapter

 Machine Switch-On

1.1 Overview

 Programming the First Part  Graphically Testing the Program  Tool Setup  Workpiece Setup  Running the First Program

52 First Steps with the iTNC 530

1.2 Machine Switch-On

Acknowledge the power interruption and move to the reference points

Switch-on and crossing the reference points can vary depending on the machine tool. Your machine manual provides more detailed information.

U Switch on the power supply for control and machine. The TNC starts

the operating system. This process may take several minutes. Then the TNC will display the message “Power interruption.”

U Press the CE key: The TNC converts the PLC

program

U Switch on the control voltage: The TNC checks

operation of the emergency stop circuit and goes into the reference run mode

U Cross the reference points manually in the displayed

sequence: For each axis press the machine START button. If you have absolute linear and angle encoders on your machine there is no need for a reference run

The TNC is now ready for operation in the Manual Operation mode.

Further information on this topic

 Traversing the reference marks: See “Switch-on” on page 542  Operating modes: See “Programming and Editing” on page 79

1.2 Machine Switch-On

HEIDENHAIN iTNC 530 53

1.3 Programming the First Part

Select the correct operating mode

You can write programs only in the Programming and Editing mode:

U Press the operating modes key: The TNC goes into

the Programming and Editing mode

Further information on this topic

 Operating modes: See “Programming and Editing” on page 79

The most important TNC keys

Functions for conversational guidance Key

Confirm entry and activate the next dialog prompt

Ignore the dialog question.

1.3 Programming the First Part

End the dialog immediately.

Abort dialog, discard entries.

Soft keys on the screen with which you select functions appropriate to the active state

Further information on this topic

 Writing and editing programs: See “Editing a program” on page 109  Overview of keys: See “Controls of the TNC” on page 2

54 First Steps with the iTNC 530

Create a new program/file management

U Press the PGM MGT key: the TNC displays the file

management. The file management of the TNC is arranged much like the file management on a PC with the Windows Explorer. The file management enables you to manipulate data on the TNC hard disk

U Use the arrow keys to select the folder in which you

want to open the new file

U Enter a file name with the extension .H: The TNC then

automatically opens a program and asks for the unit of measure for the new program. Please note the restrictions regarding special characters in the file name (see “File names” on page 116)

U To select the unit of measure, press the MM or INCH

soft key: The TNC automatically starts the workpiece blank definition (see “Define a workpiece blank” on page 56)

The TNC automatically generates the first and last blocks of the program. Afterwards you can no longer change these blocks.

Further information on this topic

 File management: See “Working with the File Manager” on page

118

 Creating a new program: See “Creating and Writing Programs” on

page 103

1.3 Programming the First Part

HEIDENHAIN iTNC 530 55

Define a workpiece blank

MAX

MIN

-40

100

Immediately after you have created a new program, the TNC starts the dialog for entering the workpiece blank definition. Always define the workpiece blank as a cuboid by entering the MIN and MAX points, each with reference to the selected reference point.

After you have created a new program, the TNC automatically initiates the workpiece blank definition and asks for the required data:

U Spindle axis Z?: Enter the active spindle axis. Z is saved as default

setting. Accept with the ENT key

U Def BLK FORM: Min-corner?: Smallest X coordinate of the workpiece

blank with respect to the reference point, e.g. 0. Confirm with the ENT key

U Def BLK FORM: Min-corner?: Smallest Y coordinate of the workpiece

blank with respect to the reference point, e.g. 0. Confirm with the ENT key

U Def BLK FORM: Min-corner?: Smallest Z coordinate of the workpiece

blank with respect to the reference point, e.g. -40. Confirm with the ENT key

U Def BLK FORM: Max-corner?: Largest X coordinate of the workpiece

1.3 Programming the First Part

blank with respect to the reference point, e.g. 100. Confirm with the ENT key

U Def BLK FORM: Max-corner?: Largest Y coordinate of the workpiece

blank with respect to the reference point, e.g. 100. Confirm with the ENT key

U Def BLK FORM: Max-corner?: Largest Z coordinate of the workpiece

blank with respect to the reference point, e.g. 0. Confirm with the ENT key

Example NC blocks

0 BEGIN PGM NEW MM 1 BLK FORM 0.1 Z X+0 Y+0 Z-40 2 BLK FORM 0.2 X+100 Y+100 Z+0 3 END PGM NEW MM

Further information on this topic

 Defining the workpiece blank: (see page 104)

56 First Steps with the iTNC 530

Program layout

NC programs should be arranged consistently in a similar manner. This makes it easier to find your place and reduces errors.

Recommended program layout for simple, conventional contour machining

1 Call tool, define tool axis 2 Retract the tool 3 Pre-position the tool in the working plane near the contour starting

point

4 In the tool axis, position the tool above the workpiece, or pre-

position immediately to workpiece depth. If required, switch on the spindle/coolant

5 Move to the contour 6 Machine the contour 7 Leave the contour 8 Retract the tool, end the program

Further information on this topic:

 Contour programming: See “Tool Movements” on page 214

Recommended program layout for simple cycle programs 1 Call tool, define tool axis 2 Retract the tool 3 Define the machining positions 4 Define the fixed cycle 5 Call the cycle, switch on the spindle/coolant 6 Retract the tool, end the program

Further information on this topic:

 Cycle programming: See User’s Manual for Cycles

Example: Layout of contour machining programs

0 BEGIN PGM BSPCONT MM 1 BLK FORM 0.1 Z X... Y... Z... 2 BLK FORM 0.2 X... Y... Z... 3 TOOL CALL 5 Z S5000 4 L Z+250 R0 FMAX 5 L X... Y... R0 FMAX 6 L Z+10 R0 F3000 M13 7 APPR ... RL F500 ... 16 DEP ... X... Y... F3000 M9 17 L Z+250 R0 FMAX M2 18 END PGM BSPCONT MM

Example: Cycle program layout

0 BEGIN PGM BSBCYC MM 1 BLK FORM 0.1 Z X... Y... Z... 2 BLK FORM 0.2 X... Y... Z... 3 TOOL CALL 5 Z S5000 4 L Z+250 R0 FMAX 5 PATTERN DEF POS1( X... Y... Z... ) ... 6 CYCL DEF... 7 CYCL CALL PAT FMAX M13 8 L Z+250 R0 FMAX M2 9 END PGM BSBCYC MM

1.3 Programming the First Part

HEIDENHAIN iTNC 530 57

Program a simple contour

The contour shown to the right is to be milled once to a depth of 5 mm. You have already defined the workpiece blank. After you have initiated a dialog through a function key, enter all the data requested by the TNC in the screen header.

U Call the tool: Enter the tool data. Confirm each of your

entries with the ENT key. Do not forget the tool axis

U Retract the tool: Press the orange axis key Z in order

to get clear in the tool axis, and enter the value for the position to be approached, e.g. 250. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Confirm the Miscellaneous function M? with the

END key: The TNC saves the entered positioning block

1.3 Programming the First Part

U Preposition the tool in the working plane: Press the

orange X axis key and enter the value for the position to be approached, e.g. -20

U Press the orange Y axis key and enter the value for the

position to be approached, e.g. -20. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Confirm the Miscellaneous function M? with the

END key: The TNC saves the entered positioning block

U Move the tool to workpiece depth: Press the orange Y

axis key and enter the value for the position to be approached, e.g. -5. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

U Feed rate F=? Enter the positioning feed rate, e.g.

3000 mm/min and confirm with the ENT key

U Miscellaneous function M? Switch on the spindle and

coolant, e.g. M13. Confirm with the END key: The TNC saves the entered positioning block

58 First Steps with the iTNC 530

U Move to the contour: Press the APPR/DEP key: The

TNC shows a soft-key row with approach and departure functions

U Select the approach function APPR CT: Enter the

coordinates of the contour starting point 1 in X and Y, e.g. 5/5. Confirm with the ENT key

U Center angle? Enter the approach angle, e.g.90°, and

confirm with the ENT key

U Circle radius? Enter the approach radius, e.g. 8 mm,

and confirm with the ENT key

U Confirm the Radius comp.: RL/RR/no comp? with the

RL soft key: Activate the radius compensation to the left of the programmed contour

U Feed rate F=? Enter the machining feed rate, e.g.

700 mm/min, and confirm your entry with the END key

U Machine the contour and move to contour point 2: You

only need to enter the information that changes. In other words, enter only the Y coordinate 95 and save your entry with the END key

U Move to contour point 3: Enter the X coordinate 95

and save your entry with the END key

U Define the chamfer at contour point 3: Enter the

chamfer width 10 mm and save with the END key

U Move to contour point 4: Enter the Y coordinate 5 and

save your entry with the END key

U Define the chamfer at contour point 4: Enter the

chamfer width 20 mm and save with the END key

U Move to contour point 1: Enter the X coordinate 5 and

save your entry with the END key

1.3 Programming the First Part

HEIDENHAIN iTNC 530 59

U Contour departure

U Select the departure function DEP CT U Center angle? Enter the departure angle, e.g. 90°, and

confirm with the ENT key

U Circle radius? Enter the departure radius, e.g. 8 mm,

and confirm with the ENT key

U Feed rate F=? Enter the positioning feed rate, e.g.

3000 mm/min and confirm with the ENT key

U Miscellaneous function M? Switch off the coolant,

e.g. M9, with the END key: The TNC saves the entered positioning block

U Retract the tool: Press the orange axis key Z in order

to get clear in the tool axis, and enter the value for the position to be approached, e.g. 250. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

1.3 Programming the First Part

U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Miscellaneous function M? Enter M2 to end the

program and confirm with the END key: The TNC saves the entered positioning block

Further information on this topic

 Complete example with NC blocks: See “Example: Linear

movements and chamfers with Cartesian coordinates” on page 236

 Creating a new program: See “Creating and Writing Programs” on

page 103

 Approaching/departing contours: See “Contour Approach and

Departure” on page 219

 Programming contours: See “Overview of path functions” on page

227

 Programmable feed rates: See “Possible feed rate input” on page

107

 Tool radius compensation: See “Tool radius compensation” on page

209

 Miscellaneous functions (M): See “Miscellaneous Functions for

Program Run Control, Spindle and Coolant” on page 369

60 First Steps with the iTNC 530

Create a cycle program

100

9080

The holes (depth of 20 mm) shown in the figure at right are to be drilled with a standard drilling cycle. You have already defined the workpiece blank.

U Call the tool: Enter the tool data. Confirm each of your

entries with the ENT key. Do not forget the tool axis

U Retract the tool: Press the orange axis key Z in order

to get clear in the tool axis, and enter the value for the position to be approached, e.g. 250. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Confirm the Miscellaneous function M? with the

END key: The TNC saves the entered positioning block

U Call the cycle menu

U Display the drilling cycles

U Select the standard drilling cycle 200: The TNC starts

the dialog for cycle definition. Enter all parameters requested by the TNC step by step and conclude each entry with the ENT key. In the screen to the right, the TNC also displays a graphic showing the respective cycle parameter

1.3 Programming the First Part

HEIDENHAIN iTNC 530 61

U Call the menu for special functions

U Display the functions for point machining

U Select the pattern definition

U Select point entry: Enter the coordinates of the

4 points and confirm each with the ENT key. After entering the fourth point, save the block with the END key

U Display the menu for defining the cycle call

U Run the drilling cycle on the define pattern: U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Miscellaneous function M? Switch on the spindle and

coolant, e.g. M13. Confirm with the END key: The TNC saves the entered positioning block

U Retract the tool: Press the orange axis key Z in order

1.3 Programming the First Part

to get clear in the tool axis, and enter the value for the position to be approached, e.g. 250. Confirm with the ENT key

U Confirm Radius comp.: RL/RR/no comp? by pressing

the ENT key: Do not activate the radius compensation

U Confirm Feed rate F=? with the ENT key: Move at

rapid traverse (FMAX)

U Miscellaneous function M? Enter M2 to end the

program and confirm with the END key: The TNC saves the entered positioning block

62 First Steps with the iTNC 530

Example NC blocks

0 BEGIN PGM C200 MM 1 BLK FORM 0.1 Z X+0 Y+0 Z-40 2 BLK FORM 0.2 X+100 Y+100 Z+0 3 TOOL CALL 5 Z S4500 4 L Z+250 R0 FMAX 5 PATTERN DEF

POS1 (X+10 Y+10 Z+0) POS2 (X+10 Y+90 Z+0) POS3 (X+90 Y+90 Z+0) POS4 (X+90 Y+10 Z+0)

6 CYCL DEF 200 DRILLING

Q200=2 ;SETUP CLEARANCE Q201=-20 ;DEPTH Q206=250 ;FEED RATE FOR PLNGN Q202=5 ;PLUNGING DEPTH Q210=0 ;DWELL TIME AT TOP Q203=-10 ;SURFACE COORDINATE Q204=20 ;2ND SETUP CLEARANCE

Q211=0.2 ;DWELL TIME AT DEPTH 7 CYCL CALL PAT FMAX M13 8 L Z+250 R0 FMAX M2 9 END PGM C200 MM

Definition of workpiece blank

Tool call Retract the tool Define the machining positions.

Define the cycle

1.3 Programming the First Part

Spindle and coolant on, call cycle Retract in the tool axis, end program

Further information on this topic

 Creating a new program: See “Creating and Writing Programs” on

page 103

 Cycle programming: See User’s Manual for Cycles

HEIDENHAIN iTNC 530 63

1.4 Graphically Testing the First Program

Selecting the correct operating mode

You can test programs only in the Test Run mode:

U Press the operating modes key: The TNC goes into

the Test Run mode

Further information on this topic

 Operating modes of the TNC: See “Operating Modes” on page 78  Testing programs: See “Test Run” on page 621

Select the tool table for the test run

You only need to execute this step if you have not activated a tool table in the Test Run mode.

U Press the PGM MGT key: the TNC displays the file

management

U Press the SELECT TYPE soft key: The TNC shows a

soft-key menu for selection of the file type to be displayed

U Press the SHOW ALL soft key: The TNC shows all

saved files in the right window

1.4 Graphically Testing the First Program

U Move the highlight to the left onto the directories

U Move the highlight to the TNC:\ directory

U Move the highlight to the right onto the files

U Move the highlight to the file TOOL.T (active tool

table) and load with the ENT key: TOOL.T receives that status S and is therefore active for the Test Run

U Press the END key: Leave the file manager

Further information on this topic

 Tool management: See “Entering tool data in the table” on page 176  Testing programs: See “Test Run” on page 621

64 First Steps with the iTNC 530

Choose the program you want to test

U Press the PGM MGT key: The TNC displays the file

manager

U Press the LAST FILES soft key: The TNC opens a

pop-up window with the most recently selected files

U Use the arrow keys to select the program that you

want to test. Load with the ENT key

Further information on this topic

 Selecting a program: See “Working with the File Manager” on page

118

Select the screen layout and the view

U Press the key for selecting the screen layout. The TNC

shows all available alternatives in the soft-key row

U Press the PROGRAM + GRAPHICS soft key: In the

left half of the screen the TNC shows the program; in the right half it shows the workpiece blank

U Select the desired view via soft key U Plan view

U Projection in three planes

U 3-D view

Further information on this topic

 Graphic functions: See “Graphics” on page 610  Running a test run: See “Test Run” on page 621

Start the program test

U Press the RESET + START soft key: The TNC

simulates the active program up to a programmed break or to the program end

U While the simulation is running you can use the soft

keys to change views.

U Press the STOP soft key: The TNC interrupts the test

run

U Press the START soft key: The TNC resumes the test

run after a break

Further information on this topic

 Running a test run: See “Test Run” on page 621  Graphic functions: See “Graphics” on page 610  Adjusting the test speed:See “Setting the speed of the test run” on

page 611

1.4 Graphically Testing the First Program

HEIDENHAIN iTNC 530 65

1.5 Tool Setup

Selecting the correct operating mode

Tools are set up in the Manual Operation mode:

U Press the operating modes key: The TNC goes into

the Manual Operation mode

Further information on this topic

1.5 Tool Setup

 Operating modes of the TNC: See “Operating Modes” on page 78

Prepare and measure tools

U Clamp the required tools in their chucks U When measuring with an external tool presetter: Measure the tools,

note down the length and radius, or transfer them directly to the machine through a transfer program

U When measuring on the machine: Place the tools into the tool

changer (see page 67)

The tool table TOOL.T

In the tool table TOOL.T (permanently saved under TNC:\), save the tool data such as length and radius, but also further tool-specific information that the TNC needs to conduct its functions.

To enter tool data in the tool table TOOL.T, proceed as follows:

U Display the tool table U Edit the tool table: Set the EDITING soft key to ON U With the upward or downward arrow keys you can

select the tool number that you want to edit

U With the rightward or leftward arrow keys you can

select the tool data that you want to edit

U To leave the tool table, press the END key

Further information on this topic

 Operating modes of the TNC: See “Operating Modes” on page 78  Working with the tool table: See “Entering tool data in the table” on

page 176

66 First Steps with the iTNC 530

The pocket table TOOL_P.TCH

The function of the pocket table depends on the machine. Your machine manual provides more detailed information.

In the pocket table TOOL_P.TCH (permanently saved under TNC:\) you specify which tools your tool magazine contains.

To enter data in the pocket table TOOL_P.TCH, proceed as follows:

U Display the tool table U Display the pocket table U Edit the pocket table: Set the EDITING soft key to ON U With the upward or downward arrow keys you can

select the pocket number that you want to edit

U With the rightward or leftward arrow keys you can

select the data that you want to edit

U To leave the pocket table, press the END key

Further information on this topic

 Operating modes of the TNC: See “Operating Modes” on page 78  Working with the pocket table: See “Pocket table for tool changer”

on page 188

1.5 Tool Setup

HEIDENHAIN iTNC 530 67

1.6 Workpiece Setup

Selecting the correct operating mode

Workpieces are set up in the Manual Operation or Electronic Handwheel mode

U Press the Manual Operation operating mode key: the

TNC switches to that mode.

Further information on this topic

 Manual Operation mode: See “Moving the Machine Axes” on page

546

1.6 Workpiece Setup

Clamp the workpiece

Mount the workpiece with a fixture on the machine table. If you have a 3-D touch probe on your machine, then you do not need to clamp the workpiece parallel to the axes.

If you do not have a 3-D touch probe available, you have to align the workpiece so that it is fixed with its edges parallel to the machine axes.

68 First Steps with the iTNC 530

Align the workpiece with a 3-D touch probe system

U Insert the 3-D touch probe: In the Manual Data Input (MDI) operating

mode, run a TOOL CALL block containing the tool axis, and then return to the Manual Operation mode (in MDI mode you can run an individual NC block independently of the others)

U Select the probing functions: The TNC displays the

available functions in the soft-key row

U Measure the basic rotation: The TNC displays the

basic rotation menu. To identify the basic rotation, probe two points on a straight surface of the workpiece

U Use the axis-direction keys to pre-position the touch

probe to a position near the first contact point

U Select the probing direction via soft key U Press NC start: The touch probe moves in the defined

direction until it contacts the workpiece and then automatically returns to its starting point.

U Use the axis-direction keys to pre-position the touch

probe to a position near the second contact point

U Press NC start: The touch probe moves in the defined

direction until it contacts the workpiece and then automatically returns to its starting point

U Then the TNC shows the measured basic rotation U Press the END key to close the menu and then

answer the question of whether the basic rotation should be transferred to the preset table by pressing the NO ENT key (no transfer)

1.6 Workpiece Setup

Further information on this topic

 MDI operating mode: See “Programming and Executing Simple

Machining Operations” on page 604

 Workpiece alignment: See “Compensating Workpiece

Misalignment with a 3-D Touch Probe” on page 581

HEIDENHAIN iTNC 530 69

Set the datum with a 3-D touch probe

U Insert the 3-D touch probe: In the MDI mode, run a TOOL CALL block

containing the tool axis and then return to the Manual Operation mode

U Select the probing functions: The TNC displays the

available functions in the soft-key row

U Set the reference point at a workpiece corner, for

example: The TNC asks whether the prove points from the previously measured basic rotation should be loaded. Press the ENT key to load points

U Position the touch probe at a position near the first

touch point of the side that was not probed for basic

1.6 Workpiece Setup

rotation

U Select the probing direction via soft key U Press NC start: The touch probe moves in the defined

direction until it contacts the workpiece and then automatically returns to its starting point

U Use the axis-direction keys to pre-position the touch

probe to a position near the second contact point

U Press NC start: The touch probe moves in the defined

direction until it contacts the workpiece and then automatically returns to its starting point

U Then the TNC shows the coordinates of the measured

corner point

U Set to 0: Press the SET DATUM soft key U Press the END to close the menu

Further information on this topic

 Datum setting: See “Datum Setting with a 3-D Touch Probe” on

page 587

70 First Steps with the iTNC 530

1.7 Running the First Program

Selecting the correct operating mode

You can run programs either in the Single Block or the Full Sequence mode:

U Press the operating mode key: The TNC goes into the

Program Run, Single Block mode and the TNC executes the program block by block. You have to confirm each block with the NC key

U Press the operating mode key: The TNC goes into the

Program Run, Full Sequence mode and the TNC executes the program after NC start up to a program break or to the end of the program

Further information on this topic

 Operating modes of the TNC: See “Operating Modes” on page 78  Running programs: See “Program Run” on page 627

Choose the program you want to run

U Press the PGM MGT key: The TNC displays the file

manager

U Press the LAST FILES soft key: The TNC opens a pop-

up window with the most recently selected files

U If desired, use the arrow keys to select the program

that you want to run. Load with the ENT key

Further information on this topic

 File management: See “Working with the File Manager” on page

118

Start the program

U Press the NC start button: The TNC executes the

active program

Further information on this topic

 Running programs: See “Program Run” on page 627

1.7 Running the First Program

HEIDENHAIN iTNC 530 71

1.7 Running the First Program

72 First Steps with the iTNC 530

Introduction

2.1 The iTNC 530

HEIDENHAIN TNC controls are workshop-oriented contouring controls that enable you to program conventional machining operations right at the machine in an easy-to-use conversational programming language. They are designed for milling, drilling and boring machines, as well as for machining centers. The iTNC 530 can control up to 18 axes. You can also change the angular position of up to 2 spindles under program control.

An integrated hard disk provides storage for as many programs as you like, even if they were created off-line. For quick calculations you can

2.1 The iTNC 530

call up the on-screen pocket calculator at any time. Keyboard and screen layout are clearly arranged in such a way that the

functions are fast and easy to use.

Programming: HEIDENHAIN conversational, smarT.NC and ISO formats

The HEIDENHAIN conversational programming format is an especially easy method of writing programs. Interactive graphics illustrate the individual machining steps for programming the contour. If a production drawing is not dimensioned for NC, the FK free contour programming performs the necessary calculations automatically. Workpiece machining can be graphically simulated either during or before actual machining.

The smarT.NC operating mode offers TNC beginners an especially simple possibility to quickly and without much training create structured conversational dialog programs. Separate user documentation is available for smarT.NC.

It is also possible to program the TNCs in ISO format or DNC mode. You can also enter and test one program while the control is running

another.

Compatibility

The TNC can run all part programs that were written on HEIDENHAIN controls TNC 150 B and later. In as much as old TNC programs contain OEM cycles, the iTNC 530 must be adapted to them with the PC software CycleDesign. For more information, contact your machine tool builder or HEIDENHAIN.

74 Introduction

2.2 Visual Display Unit and

131

678

191

Keyboard

Visual display unit

The TNC is shipped with a 15-inch color flat-panel screen. A 19-inch color flat-panel screen is also available as an alternative.

1 Header

When the TNC is on, the selected operating modes are shown in the screen header: the machining mode at the left and the programming mode at right. The currently active mode is displayed in the larger box, where the dialog prompts and TNC messages also appear (unless the TNC is showing only graphics).

2 Soft keys

In the footer the TNC indicates additional functions in a soft-key row. You can select these functions by pressing the keys immediately below them. The lines immediately above the softkey row indicate the number of soft-key rows that can be called with the black arrow keys to the right and left. The active soft-key row is indicated by brightened bar.

The15-inch screen has 8 soft keys, the 19-inch screen has 10 soft keys.

3 Soft-key selection keys 4 Shifts between soft-key rows 5 Setting the screen layout 6 Shift key for switchover between machining and programming

modes

7 Soft-key selection keys for machine tool builder soft keys

The15-inch screen has 6 soft keys, the 19-inch screen has 18 soft keys.

8 Switches soft-key rows for machine tool builders

2.2 Visual Display Unit and Keyboard

HEIDENHAIN iTNC 530 75

Sets the screen layout

You select the screen layout yourself: In the PROGRAMMING AND EDITING mode of operation, for example, you can have the TNC show program blocks in the left window while the right window displays programming graphics. You could also display the program structure in the right window instead, or display only program blocks in one large window. The available screen windows depend on the selected operating mode.

To change the screen layout:

Press the SPLIT SCREEN key: The soft-key row shows the available layout options (see "Operating Modes", page 78)

Select the desired screen layout.

2.2 Visual Display Unit and Keyboard

76 Introduction

Operating panel

1798

The TNC is delivered with different keyboards. The figures show the controls and displays of the TE 730 (15") and TE 740 (19") keyboard units.

1 Alphabetic keyboard for entering texts and file names, and for ISO

programming. Dual-processor version: Additional keys for Windows operation

2  File management

 Calculator  MOD function  HELP function

3 Programming modes 4 Machine operating modes 5 Initiation of programming dialog 6 Navigation keys and GOTO jump command 7 Numerical input and axis selection 8 Touchpad 9 smarT.NC navigation keys 10 USB connection

The functions of the individual keys are described on the inside front cover.

Some machine manufacturers do not use the standard operating panel from HEIDENHAIN. Please refer to your machine manual in these cases.

Machine panel buttons, e.g. NC START or NC STOP, are also described in the manual for your machine tool.

2.2 Visual Display Unit and Keyboard

HEIDENHAIN iTNC 530 77

2.3 Operating Modes

Manual Operation and Electronic Handwheel

The Manual Operation mode is required for setting up the machine tool. In this mode of operation, you can position the machine axes manually or by increments, set the datums, and tilt the working plane.

The Electronic Handwheel mode of operation allows you to move the machine axes manually with the HR electronic handwheel.

Soft keys for selecting the screen layout (select as described previously)

Window Soft key

2.3 Operating Modes

Positions

Left: positions, right: status display

Left: positions, right: active collision objects (FCL4 function).

Positioning with Manual Data Input

This mode of operation is used for programming simple traversing movements, such as for face milling or pre-positioning.

Soft keys for selecting the screen layout

Window Soft key

Program

Left: program blocks, right: status display

Left: program blocks, right: active collision objects (FCL4 function). If this view is selected, then the TNC indicates a collision with a red frame around the graphics window.

78 Introduction

Programming and Editing

In this mode of operation you can write your part programs. The FK free programming feature, the various cycles and the Q parameter functions help you with programming and add necessary information. If desired, the programming graphics or the 3-D line graphics (FCL 2 function) display the programmed traverse paths.

Soft keys for selecting the screen layout

Window Soft key

Program

Left: program, right: program structure

Left: program blocks, right: graphics

Left: program blocks, right: 3-D line graphics

3-D line graphics

Test Run

In the Test Run mode of operation, the TNC checks programs and program sections for errors, such as geometrical incompatibilities, missing or incorrect data within the program or violations of the work space. This simulation is supported graphically in different display modes.

With the dynamic collision monitoring (DCM) software option you can test the program for potential collisions. As during program run, the TNC takes into account all permanent machine components defined by the machine manufacturer as well as all measured fixtures.

Soft keys for selecting the screen layout: see "Program Run, Full Sequence and Program Run, Single Block", page 80.

2.3 Operating Modes

HEIDENHAIN iTNC 530 79

Program Run, Full Sequence and Program Run, Single Block

In the Program Run, Full Sequence mode of operation the TNC executes a part program continuously to its end or to a manual or programmed stop. You can resume program run after an interruption.

In the Program Run, Single Block mode of operation you execute each block separately by pressing the machine START button.

Soft keys for selecting the screen layout

Window Soft key

Program

2.3 Operating Modes

Left: program, right: program structure

Left: program, right: status

Left: program, right: graphics

Graphics

Left: program blocks, right: active collision objects (FCL4 function). If this view is selected, then the TNC indicates a collision with a red frame around the graphics window.

Active collision objects (FCL4 function). If this view is selected, then the TNC indicates a collision with a red frame around the graphics window.

Soft keys for selecting the screen layout for pallet tables

Window Soft key

Pallet table

Left: program blocks, right: pallet table

Left: pallet table, right: status

Left: pallet table, right: graphics

80 Introduction

2.4 Status Displays

ACTL.

X Y Z

F S M

“General” status display

The status display in the lower part of the screen informs you of the current state of the machine tool. It is displayed automatically in the following modes of operation:

 Program Run, Single Block and Program Run, Full Sequence, except

if the screen layout is set to display graphics only, and

 Positioning with Manual Data Input (MDI).

In the Manual mode and Electronic Handwheel mode the status display appears in the large window.

Information in the status display

Symbol Meaning

Actual or nominal coordinates of the current position

Machine axes; the TNC displays auxiliary axes in lower-case letters. The sequence and quantity of displayed axes is determined by the machine tool builder. Refer to your machine manual for more information.

The displayed feed rate in inches corresponds to one tenth of the effective value. Spindle speed S, feed rate F and active M functions.

2.4 Status Displays

Program run started.

Axis is locked.

Axis can be moved with the handwheel.

Axes are moving under a basic rotation.

Axes are moving in a tilted working plane.

The M128 function or TCPM FUNCTION is active.

HEIDENHAIN iTNC 530 81

Symbol Meaning

2.4 Status Displays

The Dynamic Collision Monitoring function (DCM) is active.

The Adaptive Feed Function (AFC) is active (software option).

One or more global program settings are active (software option)

Number of the active presets from the preset table. If the datum was set manually, the TNC displays the text MAN behind the symbol.

82 Introduction

Additional status displays

The additional status displays contain detailed information on the program run. They can be called in all operating modes except for the Programming and Editing mode of operation.

To switch on the additional status display:

Call the soft-key row for screen layout.

Screen layout with additional status display: In the right half of the screen, the TNC shows the Overview status form.

To select an additional status display:

Shift the soft-key rows until the STATUS soft keys appear.

Either select the additional status display, e.g. positions and coordinates, or

2.4 Status Displays

use the soft keys to select the desired view.

With the soft keys or switch-over soft keys, you can choose directly between the available status displays.

Please note that some of the status information described below is not available unless the associated software option is enabled on your TNC.

HEIDENHAIN iTNC 530 83

Overview

After switch-on, the TNC displays the Overview status form, provided that you have selected the PROGRAM+STATUS screen layout (or POSITION + STATUS). The overview form contains a summary of the most important status information, which you can also find on the various detail forms.

Soft key Meaning

Position display in up to 5 axes

Tool information

2.4 Status Displays

General program information (PGM tab)

Soft key Meaning

No direct selection possible

Active M functions

Active coordinate transformations

Active subprogram

Active program section repeat

Program called with PGM CALL

Current machining time

Name of the active main program

Circle center CC (pole)

Dwell time counter

Machining time when the program was completely simulated in the Test Run operating mode

Current machining time in percent

Current time

Current feed rate

Active programs

84 Introduction

General pallet information (PAL tab)

Soft key Meaning

No direct selection possible

Program section repeat/Subprograms (LBL tab)

Soft key Meaning

No direct selection possible

Information on standard cycles (CYC tab)

Soft key Meaning

No direct selection possible

Number of the active pallet preset

Active program section repeats with block number, label number, and number of programmed repeats/repeats yet to be run

Active subprogram numbers with block number in which the subprogram was called and the label number that was called

Active machining cycle

Active values of Cycle 32 Tolerance

2.4 Status Displays

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Active miscellaneous functions M (M tab)

Soft key Meaning

No direct selection possible

List of the active M functions with fixed meaning

List of the active M functions that are adapted by your machine manufacturer

2.4 Status Displays

86 Introduction

Positions and coordinates (POS tab)

Soft key Meaning

Type of position display, e.g. actual position

Value traversed in virtual axis direction VT (only with “global program settings” software option)

Tilt angle of the working plane

Angle of a basic rotation

Information on tools (TOOL tab)

Soft key Meaning

 T: Tool number and name  RT: Number and name of a replacement tool

Tool axis

Tool lengths and radii

Oversizes (delta values) from the tool table (TAB) and the TOOL CALL (PGM)

Tool life, maximum tool life (TIME 1) and maximum tool life for TOOL CALL (TIME 2)

Display of the active tool and the (next) replacement tool

2.4 Status Displays

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Tool measurement (TT tab)

The TNC only displays the TT tab if the function is active on your machine.

Soft key Meaning

No direct selection possible

Number of the tool to be measured

2.4 Status Displays

Coordinate transformations (TRANS tab)

Soft key Meaning

Display whether the tool radius or the tool length is being measured

MIN and MAX values of the individual cutting edges and the result of measuring the rotating tool (DYN = dynamic measurement)

Cutting edge number with the corresponding measured value. If the measured value is followed by an asterisk, the allowable tolerance in the tool table was exceeded The TNC displays the measured values of up to 24 teeth.

Name of the active datum table

Active datum number (#), comment from the active line of the active datum number (DOC) from Cycle 7

Active datum shift (Cycle 7); The TNC displays an active datum shift in up to 8 axes

Mirrored axes (Cycle 8)

Active basic rotation

Active rotation angle (Cycle 10)

Active scaling factor/factors (Cycles 11 / 26); The TNC displays an active scaling factor in up to 6 axes

Scaling datum

For further information, refer to the User's Manual for Cycles, "Coordinate Transformation Cycles."

88 Introduction

Global program settings 1 (GPS1 tab, software option)

The TNC only displays the tab if the function is active on your machine.

Soft key Meaning

No direct selection possible

Swapped axes

Superimposed datum shift

Superimposed mirroring

Global program settings 2 (GPS2 tab, software option)

The TNC only displays the tab if the function is active on your machine.

Soft key Meaning

No direct selection possible

Locked axes

Superimposed basic rotation

Superimposed rotation

Active feed rate factor

2.4 Status Displays

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Adaptive Feed Control (AFC tab, software option)

The TNC only displays the AFC tab if the function is active on your machine.

Soft key Meaning

No direct selection possible

Active mode in which adaptive feed control is running

2.4 Status Displays

Active tool (number and name)

Cut number

Current factor of the feed potentiomenter in percent

Active spindle load in percent

Reference load of the spindle

Current spindle speed

Current deviation of the speed

Current machining time

Line diagram, in which the current spindle load and the value commanded by the TNC for the feed-rate override are shown

90 Introduction

2.5 Window Manager

The machine tool builder determines the scope of function and behavior of the window manager. The machine tool manual provides further information.

The TNC features the Xfce window manager. Xfce is a standard application for UNIX-based operating systems, and is used to manage graphical user interfaces. The following functions are possible with the window manager:

 Display a task bar for switching between various applications (user

interfaces).

 Manage an additional desktop, on which special applications from

your machine tool builder can run.

 Control the focus between NC-software applications and those of

the machine tool builder.

 The size and position of pop-up windows can be changed. It is also

possible to close, minimize and restore the pop-up windows.

The TNC shows a star in the upper left of the screen if an application of the window manager or the window manager itself has caused an error. In this case, switch to the window manager and correct the problem. If required, refer to your machine manual.

2.5 Window Manager

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Soft-key row

In the task bar you can choose different workspaces by mouse click. The iTNC provides the following workspaces:

 Workspace 1: Active mode of operation  Workspace 2: Active programming mode  Workspace 3: Manufacturer's applications (optionally available), e.g.

remote control of a Windows computer

In the task bar you can also select other applications that you have started together with the TNC (switch for example to the PDF viewer or TNCguide)

Click the green HEIDENHAIN symbol to open a menu in which you can get information, make settings or start applications. The following

2.5 Window Manager

functions are available:

 About Xfce: Information on the Windows manager Xfce  About HeROS: Information about the operation system of the TNC  NC Control: Start and stop the TNC software. Only permitted for

diagnostic purposes

 Web Browser: Start Mozilla Firefox  Diagnostics: Available only to authorized specialists to start

diagnostic functions

 Settings: Configuration of miscellaneous settings

 Date/Time: Set the date and time  Language: Language setting for the system dialogs. During startup

the TNC overwrites this setting with the language setting of MP 7230

 Network: Network setting  Reset WM-Conf: Restore basic settings of the Windows Manager

May also reset settings implemented by your machine manufacturer

 Screensaver: Settings for the screen saver; several are available  Shares: Configure network connections

 Tools: Only for authorized users. The applications available under

Tools can be started directly by selecting the pertaining file type in the file management of the TNC (see “Additional tools for management of external file types” on page 139)

92 Introduction

2.6 SELinux security software

SELinux is an extension for Linux-based operating systems. SELinux

is an additional security software package based on Mandatory Access Control (MAC) and protects the system against the running of unauthorized processes or functions and therefore protects against viruses and other malware.

MAC means that each action must be specifically permitted otherwise the TNC will not run it. The software provides additional protection to the normal access restrictions of Linux. Specific processes and actions are performed only if permitted by the standard functions and SELinux access control.

The SELinux installation of the TNC is prepared to permit running of only those programs installed with the HEIDENHAIN NC software. You cannot run other programs with the standard installation.

The SELinux access control in HeROS 5 is regulated as follows:

 The TNC runs only those applications installed with the

HEIDENHAIN NC software.

 Files concerning the security of the software (SELinux system files,

HeROS 5 boot files, etc.) may only be changed by explicitly selected programs.

 Files created anew by other programs must basically not be run.  There are only two procedures permitted to run new files:

 Starting a software update

A HEIDENHAIN software update can replace or change system files.

 Starting the SELinux configuration

The configuration of SELinux is usually password-protected by your machine tool builder. Refer here to the relevant machine tool manual.

2.6 SELinux security software

HEIDENHAIN basically recommends activating SELinux, because this provides additional protection against external access.

HEIDENHAIN iTNC 530 93

2.7 Accessories: HEIDENHAIN 3-D Touch Probes and Electronic Handwheels

3-D touch probes

With the various HEIDENHAIN 3-D touch probe systems you can:

 Automatically align workpieces  Quickly and precisely set datums  Measure the workpiece during program run  Measure and inspect tools

All of the touch probe functions are described in the User’s Manual for Cycles. Please contact HEIDENHAIN if you require a copy of this User’s Manual. ID: 670 388-xx.

Note that HEIDENHAIN generally does not accept liability for the function of the touch probe cycles unless you use HEIDENHAIN touch probes!

TS 220, TS 640 and TS 440 touch trigger probes

These touch probes are particularly effective for automatic workpiece alignment, datum setting and workpiece measurement. The TS 220 transmits the triggering signals to the TNC via cable and is a costeffective alternative for applications where digitizing is not frequently required.

The TS 640 (see figure) and the smaller TS 440 feature infrared transmission of the triggering signal to the TNC. This makes them highly convenient for use on machines with automatic tool changers.

Principle of operation: HEIDENHAIN triggering touch probes feature a wear resisting optical switch that generates an electrical signal as soon as the stylus is deflected. This signal is transmitted to the control, which stores the current position of the stylus as the actual value.

2.7 Accessories: HEIDENHAIN 3-D Touch Probes and Electronic Handwheels

94 Introduction

TT 140 tool touch probe for tool measurement

The TT 140 is a triggering 3-D touch probe for tool measurement and inspection. Your TNC provides three cycles for this touch probe with which you can measure the tool length and radius automatically either with the spindle rotating or stopped. The TT 140 features a particularly rugged design and a high degree of protection, which make it insensitive to coolants and swarf. The triggering signal is generated by a wear-resistant and highly reliable optical switch.

HR electronic handwheels

Electronic handwheels facilitate moving the axis slides precisely by hand. A wide range of traverses per handwheel revolution is available. Apart from the HR130 and HR150 integral handwheels, HEIDENHAIN also offers the HR 520 and HR 550 FS portable handwheels. You will find a detailed description of HR 520 in Chapter 14 of this manual (see “Traversing with electronic handwheels” on page 548).

HEIDENHAIN iTNC 530 95

2.7 Accessories: HEIDENHAIN 3-D Touch Probes and Electronic Handwheels

96 Introduction

Programming: Fundamentals, File Management

3.1 Fundamentals

X (Z,Y)

Position encoders and reference marks

The machine axes are equipped with position encoders that register the positions of the machine table or tool. Linear axes are usually equipped with linear encoders, rotary tables and tilting axes with angle encoders.

When a machine axis moves, the corresponding position encoder generates an electrical signal. The TNC evaluates this signal and calculates the precise actual position of the machine axis.

3.1 Fundamentals

If there is a power interruption, the calculated position will no longer correspond to the actual position of the machine slide. To recover this association, incremental position encoders are provided with reference marks. The scales of the position encoders contain one or more reference marks that transmit a signal to the TNC when they are crossed over. From that signal the TNC can re-establish the assignment of displayed positions to machine positions. For linear encoders with distance-coded reference marks the machine axes need to move by no more than 20 mm, for angle encoders by no more than 20°.

With absolute encoders, an absolute position value is transmitted to the control immediately upon switch-on. In this way the assignment of the actual position to the machine slide position is re-established directly after switch-on.

Reference system

A reference system is required to define positions in a plane or in space. The position data are always referenced to a predetermined point and are described through coordinates.

The Cartesian coordinate system (a rectangular coordinate system) is based on the three coordinate axes X, Y and Z. The axes are mutually perpendicular and intersect at one point called the datum. A coordinate identifies the distance from the datum in one of these directions. A position in a plane is thus described through two coordinates, and a position in space through three coordinates.

Coordinates that are referenced to the datum are referred to as absolute coordinates. Relative coordinates are referenced to any other known position (reference point) you define within the coordinate system. Relative coordinate values are also referred to as incremental coordinate values.

98 Programming: Fundamentals, File Management

Reference system on milling machines

W+

C+

B+

V+

A+

U+

When using a milling machine, you orient tool movements to the Cartesian coordinate system. The illustration at right shows how the Cartesian coordinate system describes the machine axes. The figure illustrates the right-hand rule for remembering the three axis directions: the middle finger points in the positive direction of the tool axis from the workpiece toward the tool (the Z axis), the thumb points in the positive X direction, and the index finger in the positive Y direction.

The iTNC 530 can control up to 18 axes. The axes U, V and W are secondary linear axes parallel to the main axes X, Y and Z, respectively. Rotary axes are designated as A, B and C. The illustration at lower right shows the assignment of secondary axes and rotary axes to the main axes.

In addition, the machine tool builder can define any number of auxiliary axes identified by lowercase letters

3.1 Fundamentals

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Polar coordinates

0°

If the production drawing is dimensioned in Cartesian coordinates, you also write the NC program using Cartesian coordinates. For parts containing circular arcs or angles it is often simpler to give the dimensions in polar coordinates.

While the Cartesian coordinates X, Y and Z are three-dimensional and can describe points in space, polar coordinates are two-dimensional and describe points in a plane. Polar coordinates have their datum at a circle center (CC), or pole. A position in a plane can be clearly defined by the:

 Polar Radius, the distance from the circle center CC to the position,

3.1 Fundamentals

and the

 Polar Angle, the size of the angle between the reference axis and

the line that connects the circle center CC with the position

Setting the pole and the angle reference axis

The pole is set by entering two Cartesian coordinates in one of the three planes. These coordinates also set the reference axis for the polar angle PA.

Coordinates of the pole (plane)

X/Y +X

Y/Z +Y

Z/X +Z

Reference axis of the angle

100 Programming: Fundamentals, File Management

heidenhain iTNC 530 Programming Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Controls of the TNC

Keys on visual display unit

Alphanumeric keyboard

Machine operating modes

Program/file management, TNC functions

Navigation keys

Potentiometer for feed rate and spindle speed

Programming modes

Cycles, subprograms and program section repeats

Tool functions

Coordinate axes and numbers: Entering and editing

Programming path movements

Special functions / smarT.NC

About this Manual

Would you like any changes, or have you found any errors?

TNC Model, Software and Features

Software options

Feature content level (upgrade functions)

Intended place of operation

Legal information

New functions 606 42x-01 since the predecessor versions 340 49x-05

New Functions with 606 42x-02

Changed functions 606 42x-01 since the predecessor versions 340 49x-06

Changed functions with 606 42x-02

1 First Steps with the iTNC 530 ..... 51

2 Introduction ..... 73

3 Programming: Fundamentals, File Management ..... 97

4 Programming: Programming Aids ..... 149

5 Programming: Tools ..... 171

6 Programming: Programming Contours ..... 213

7 Programming: Data Transfer from DXF Files or Plain-language Contours ..... 267

8 Programming: Subprograms and Program Section Repeats ..... 287

9 Programming: Q-Parameters ..... 303

10 Programming: Miscellaneous Functions ..... 367

11 Programming: Special Functions ..... 391

12 Programming: Multiple Axis Machining ..... 467

13 Programming: Pallet Editor ..... 521

14 Manual Operation and Setup ..... 541

15 Positioning with Manual Data Input ..... 603

16 Test Run and Program Run ..... 609

17 MOD Functions ..... 641

18 Tables and Overviews ..... 679

19 Industrial PC 6341 with Windows 7 (Option) ..... 711

First Steps with the iTNC 530

1.1 Overview

Acknowledge the power interruption and move to the reference points

1.2 Machine Switch-On

Select the correct operating mode

The most important TNC keys

1.3 Programming the First Part

Create a new program/file management

Define a workpiece blank

Program layout

Program a simple contour

Create a cycle program

Selecting the correct operating mode

Select the tool table for the test run

1.4 Graphically Testing the First Program

Choose the program you want to test

Select the screen layout and the view

Start the program test

Selecting the correct operating mode

1.5 Tool Setup

Prepare and measure tools

The tool table TOOL.T

The pocket table TOOL_P.TCH

Selecting the correct operating mode

1.6 Workpiece Setup

Clamp the workpiece

Align the workpiece with a 3-D touch probe system

Set the datum with a 3-D touch probe

Selecting the correct operating mode

Choose the program you want to run

Start the program

1.7 Running the First Program

Introduction