MANUALplus 4110
Contents
1. H ke CC AH Jr CC XC TC 6 CC 422 174 2541 CC 424 1772541 480 121G Dimensions in mm 370 346 0 2 12 5 5 Be e E d 3 JOU JOO JOU LJ 3 1553 19 43 205 CS Y WY 258 0 2 4 346 0 2 Cutout in machine panel Mounting surface 25 17 3 3 33 HR 130 HR 150 Dimensions in mm Dimensions in mm HR 13x 4 5 HR 150 6 HR 410 Dimensions in mm Adapter Cable for HR 410 Dimensions 510 Dimensions in mm PL 510 550 139 PL 511 183 PE 512 227 Ba gt anaeezs saqoa UUUUUUU UUUUUUUUU UUUUUUU U J 9999999999 9999999999 9888999289 Line Drop Compensator for EnDat Interface Dimensions2. 10 sJ010 N 29S Ajddns samod 69X 918 GZE TE 8 GZE 092 Z9X 9L LOF OL Md OEL AN Je npoy 10 0W 4 10 sJ010 N 98S 69X 918 GCE 912 10 677 092 9L 10 677 097 Addins 17 Accessories WOE XX GLL 9 10 788 Z8S any asn i LE 0 HIOMJOU 19449433 E Is cesego 19u19u13 E pesodsue1 zesego 19u49u13 m Els m ZX XX XX GCL 995 LLX 97X ZEZ SH VT A 18 32 10 980 OLE 1 39 XX 6L OLE 63 HE XX 96 995 XX y8y 995 uid 6 20 96 292 1e1depy atv suwa mo JIN uid 6 10 86 292 1e1depy XX L90 152 OSL GX LX ddy XX ZLL 89 TA 4494 OLX 10 6 8 212 XX 997 966 186 TA A XX 69 962 017 HH s 10 699 LEZ XX 0t6 OVS 5 pue paay 10 HH 10 099 GLE 19 6 10128uuoo qns q XX 9 0 LLE XX 9 0 LLE LOOT Z0 9Z aq snw 5 jqe Bunoeuuoo Bunsixe Joy WOE Bunoeuuoo sjulod
3. Joy 2 qe9 uoisua1X3 18 MANUALplus 4110 The Versatile Contouring Control Lathes The MANUAL plus 4110 is versatile Conceived for single parts and short production runs Supports action oriented machining Made for the machinist Quickly learned requires minimum training time For new parts rework and repair of workpieces Features a wide machining spectrum from simple turned parts to complex CNC workpieces e Supports milling operations on the end face and lateral surface e Maximizes machine utilization rates Minimizes unit costs HEIDENHAIN The MANUALplus 4110 is suited for many different lathes Complete lathe setup spindle one slide X and Z axis C axis or positionable spindle and driven tool Cycle controlled lathes Lathes with simple tool holders Lathes with multiple tool carriers e g turret Lathes with driven tools and positionable spindle Lathes with driven tools and C axis Lathes with turning in front of the workpiece and turning behind the workpiece Vertical boring and turning lathes 19 Technical Description 5 Programming and display Traverse range Spindle Programming and display Spindle override Maximum speed Speed limiting Gear stages C axis operation 20 The MANUAL plus 4110 is contouring control for manual lathes with one spindle and compound rest X and 2 for tool movement Feed rate in mm min mm revol
4. 86 10 80420000 E Mail sales heidenhain com cn 364 189 24 5 4 2007 Printed in Germany Subject to change without notice CS CZ DK ES FI FR GB GR HK HR HU JP KR MK MX MY Serbia and Montenegro gt BG HEIDENHAIN s r o 106 00 Praha 10 Czech Republic o 420272658131 E Mail heidenhainQheidenhain cz TP TEKNIK A S 2670 Greve Denmark amp 45 70 100966 E Mail tp gruppen tp gruppen dk FARRESA ELECTRONICA S A 08028 Barcelona Spain 34 934092491 E Mail farresaQfarresa es HEIDENHAIN Scandinavia AB 02770 Espoo Finland 358 9 8676476 E Mail info heidenhain fi HEIDENHAIN FRANCE sarl 92310 S vres France 52 330141143000 E Mail info heidenhain fr HEIDENHAIN G B Limited Burgess Hill RH15 YRD United Kingdom 659 44 1444 247711 E Mail sales heidenhain co uk MB Milionis Vassilis 17341 Athens Greece 30 210 9336607 E Mail bmilioni otenet gr HEIDENHAIN LTD Kowloon Hong Kong 852 27591920 E Mail service heidenhain com hk Croatia gt SL HEIDENHAIN K pviselet 1239 Budapest Hungary amp 36 1 4210952 E Mail info heidenhain hu PT Servitama Era Toolsindo Jakarta 13930 Indonesia 62 21 46834111 E Mail ptset group gts co id NEUMO VARGUS MARKETING LTD Tel Aviv 61570 Israel 972 3 5373275 E Mail neumoQneumo vargus co l ASHOK amp LAL Chennai 60
5. 21 Commissioning ids Oscilloscope Logic diagram Table function Log TNCopt accessory TNCdiag accessory 28 The MANUAL plus 4110 features an integrated oscilloscope The following characteristic curves can be recorded and stored in four channels e Actual position value e Nominal position value e Following error e Actual velocity value e Nominal velocity value e Actual acceleration value e Nominal acceleration value e Performance e Torque e Actual value of shaft speed e Nominal value of shaft speed e ntegral current motor speed controller e Torque determining current Simultaneous graphic representation of the logic states of up to 16 operands markers words inputs outputs The current conditions of the markers words inputs and outputs are displayed in tables The conditions can be changed via the keyboard For the purposes of error diagnosis there is a log for all error messages PC software for commissioning digital control loops Functions e Commissioning of current controller e Automatic commissioning of speed controller e Automatic optimization of sliding friction compensation e Automatic optimization of reversal spike compensation e Automatic optimization of ky factor Requirements e Windows 95 98 or NT 4 0 or 2000 operating system e At least VGA XGA recommended e Atleast 16 MB RAM e At least 15 MB free hard disk space e Serial or Ethernet interface Th
6. P e Wire frame or cutting path graphics e Motion simulation erasing graphics The blank is displayed as a white surface which is machined during the simulation Side or face view or 2 D view of cylindrical surface e Display of programmed contours e Shifting and magnifying functions e Calculation of machining and idle machine time S Consideration of switching commands triggered by the Representation of single times per cycle or per tool change with DIN programs German English French Italian Spanish Dutch Danish Swedish Czech Polish Hungarian Finnish Russian Accessory Accessory Electronic handwheels PLC input output system PC software PLCdesignNT TNCopt TNCdiag KonfigPilot DataPilot 4110 MANUALplus 4110 Page e Connection of two HR 150 panel mounted handwheels for moving the slide 15 on a manual machine As a complement the HR 410 portable handwheel can be connected Or e Connection of one HR 130 panel mounted handwheel The PLC assigns the handwheel to an axis Modular external PL 510 1 0 system consisting of e Basic module with HEIDENHAIN PLC interface PLB 510 for 4 modules PLB 511 for 6 modules PLB 512 for 8 modules e PLD 16 8 module with 16 digital inputs and 8 digital outputs e PLA 4 4 Analog module with 4 analog inputs for 10 V and inputs for PT 100 thermistors 27 PLC development software with PLC basic program Software for commissi
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8. The untt fulfills the requirements for a Class A device in accordance with the specifications in EN 55022 and is intended for use primarily in industrially zoned areas Protect your equipment from interference by observing the rules and recommendations specified in the Technical Manual Noise is mainly produced by capacitive and inductive coupling from electrical conductors or from device inputs outputs such as e Strong magnetic fields from transformers or electric motors e Relays contactors and solenoid valves e High frequency equipment pulse equipment and stray magnetic fields from switch mode power supplies e Power lines and leads to the above equipment e Keep a minimum distance of 20 cm from the MC CC and its leads to devices that carry interference signals e Keep a minimum distance of 10 cm from the MC CC and its leads to cables that carry interference signals For cables in metallic ducting adequate decoupling can be achieved by using a grounded separation shield e Shielding according to EN 50 178 e Use potential compensating lines with a cross section of 6 mm Use only original HEIDENHAIN cables connectors and couplings 31 Overall Dimensions MC 420 422 Dimensions in mm 32 MC 420 5 position encoder inputs CC 422 6 control loops 100 0 2 XC
9. backlash is also possible The compensation values must be determined by the machine tool builder and entered in the parameter list Up to 100 compensation points can be defined with the corresponding compensation values for multipoint error compensation The error compensation is interpolated linearly between these points Errors 0 Pl P2 P3 PA P5 P6 P7 P8 Position Backlash For length measurements via spindle and rotary encoders the play between the table movement and the rotary encoder movement on direction changes can be compensated This backlash is outside the controlled system Reversal error The play between the table movement and the motor movement Is also compensated in length measurements In this case the backlash is within the controlled system Misalignment Misalignment compensation counteracts nonparallelism in the compensation compensation axes of a slide The compensation path for this axis is calculated per 100 mm traverse of the neighboring axis Thermal expansion compensate thermal expansion the machine expansion behavior must be known The temperature can be recorded via temperature measurement thermistors connected to the analog inputs of the MANUALplus 4110 The PLC evaluates the temperature information and transfers the compensation value to the NC 26 Integrated PLC PLC inputs PLC outputs PLC expansion Rated operating current per output Memory Cycle time PLC prog
10. in mm Variant 03 Connection for temperature sensor V 11 V 24 Adapter Dimensions in mm bc JI Y 21 0 5 78 0 2 60 1 Opening for mounting the adapter 37 USB Hub Dimensions in mm 38 Mounting cutout Documentation Technical documentation User documentation Other documentation The following are supplied with a control system e 1 MANUAL plus 4110 User s Manual 1 MANUAL plus 4110 Pilot brief programming guide This documentation Must be ordered separately in the language required Further documentation is available from HEIDENHAIN e HEIDENHAIN Technical Manual for MANUAL plus 4110 in English or German Technical Manual for Inverter Systems and Motors The Technical Manuals in loose leaf format in a ring binder Supplementary issues with update information and replacement sheets are sent when the software or hardware is updated MANUALplus 4110 User s Manual MANUALplus 4110 Pilot brief programming guide in German English French Italian Dutch Spanish Danish Czech Swedish Polish Finnish R
11. of missing coordinates intersections etc For multiple solutions graphic display of all solutions Chamfers rounding arcs and form elements can be entered along with the contour or added later Downloading of DXF files option e NC programming as per ISO 6983 Creation of DIN programs DIN macros e Programming with area clearance recessing recess turning drilling and milling cycles Simplified geometry programming calculation of missing data e Programming with variables Subprograms User Functions Tool programming Tool management Tool measurement Tool compensation Program verification graphics Machining time analysis Conversational languages See the MANUALplus 4110 brochure MANUALplus 4110 Page e able for 99 tools with tool descriptions e Transfer of cutting data feed rate shaft speed from the tool description e ool monitoring for lifetime of the insert tool tip or the number of workpieces produced e touching the workpiece e With a triggering touch probe option e By using an optical gauge option e Automatic tool tip and cutter radius compensation e Automatic tool tip position recognition in left right inward or outward direction of motion e Compensation of tool tip position in the X Z plane e High precision correction via handwheel capturing compensation values in the tool table Graphic simulation of the cycle process or of the cycle or ISO program
12. optional Tool datum preset and pallet tables Connection of HR electronic handwheels TS workpiece touch probes and TT tool touch probes Data interfaces Ethernet 100BaseT RS 232 C 24 RS 422 V 11 USB 1 1 Compact contouring control for milling drilling and boring machines Three or optionally four closed loop axes and one non controlled spindle Analog speed command interface Integrated keyboard and flat panel color display 15 inch Program memory 10 MB on Compact Flash memory card CFR Program input in HEIDENHAIN conversational language execution of ISO programs ain 1384 5 0YR FK free contour programming User aids Programming graphics verification graphics program run graphics Programming aids Milling drilling and boring cycles parametric programming coordinate transformation subprogramming Tool and reference point tables TS workpiece touch probe Data interfaces Ethernet 100BaseT RS 232 C V 24 USB 1 1 41 Subject Index A B E E Cable overview Cycle times Control panel D Data Data transfer Fate 4 Digte ed Documentation Electromagnetic compatibility Electronic handwheels EnDat interface Sl SNR F Fast Feed
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14. 512 can be connected to the control The maximum cable length to the last PLB 51x is 30 meters The 1 0 modules consist of one module with digital inputs outputs and one analog module For partially assembled basic modules the unused slots must be occupied by an empty housing module with 16 digital inputs and 8 digital outputs Total current Outputs 0107 lt 4A Outputs 0 to 3 410 7 lt 2 Simultaneity factor 2 outputs 2 each 4 outputs 1 A each 8 outputs 0 5 A each Weight 0 2 kg ID 360 916 01 Analog module with 4 analog inputs for PT 100 thermistors 4 analog inputs for x10 V Weight 0 2 kg ID 366 423 01 For unused slots ID 383 022 01 Electronic Handwheels Function HR 150 HR 410 HR 130 The standard MANUAL plus 4110 supports the use of electronic handwheels The following handwheels can be installed Two HR 150 panel mounted handwheels and one HR 410 portable handwheel Or One HR 130 panel mounted handwheel Moving the machine slide in selectable increments via PLC 1 um 10 um 100 um per increment Max velocity 9 999 mm min Positioning the slide to the starting position of MANUALplus cycles Fine adjustment of tool position Panel mounted handwheel with ergonomic control knob ID 257 061 09 Weight approx 0 7 kg Portable electronic handwheel with Keys for the selection of 5 axes e Keys for traverse direction e Keys for three preset feed rates e Key for actual pos
15. 73208 51 with max 6 control loops 1st additional axis Ath 354 139 01 2nd additional axis bth 354 140 01 With software options the features of the MC 420 can also be adapted retroactively to meet new requirements They are enabled by entering keywords based on the SIK number and are saved in the SIK component Please indicate your SIK number when ordering new software options DXF import 526 460 01 Tool measurement 534615 01 HDR hard disk SIK component 11 Controller Unit Controller unit CC 422 12 The CC 422 controller unit includes Speed controller Current controller nterfaces to the 1xx UR 2xx and 2xx power modules PWM outputs nterfaces to the shaft speed encoders nterfaces for power supply for controller unit and main computer supply 1xxD UE 2xxD UR 2 The 422 is available with max 6 digital control loops The MANUAL plus 4110 software supports max 5 control loops The number of enabled control loops is saved in the SIK see Main Computer The CC 422 controller unit is combined with the 420 main computer The position controllers and position encoder inputs are located on the MC 420 main computer version with 5 position encoder inputs CC 422 Max 6 digital control loops Shaft speed inputs 6x 1 Vpp or EnDat PWM outputs 6 Weight 4 0 kg ID 3596515 Control Panel BFT 121G operating panel Machi
16. HEIDENHAIN SISMO T l 04 50 36 81 18 Fa 04 50 36 97 49 www ratmo com al ET e ust n CI ATO 2 z rant z c tay ees NG Es Oe SEEST EE nae E ge uu ME 1 Ay SE ah ne UN E ge i E gt S Ak We ENT Arer 1 MTS 1 A re L Pur D lt T T wig ME ue e 1 ab i MANUAL plus 4110 The Versatile Contouring Control for Lathes EE m Td 91 113 4 Information for the Machine Manufacturer April 2007 MANUALplus 4110 Contouring Control with Inverter MANUALplus 4110 e Contouring control for lathes with 2 axes controlled spindle C axis and driven tools HEIDENHAIN inverter systems and motors TFT color flat panel display Hard disk System tests Expendable parts Standards Cycle programming for turning drilling and milling operations Free ICP contour programming for turning and milling contours DIN programming for turning drilling and milling operations BFT 121G control panel MC 420 CC 422 with modular inverter Controls motors and encoders from HEIDENHAIN are usually integrated as components in larger systems In these cases comprehensive tests of the complete system are required irrespective of the specifications of the individual devices In particular the following parts in control
17. ble for connection to HEIDENHAIN numerical controls With absolute encoders the position information is contained in several coded tracks Thus an absolute reference is available immediately after switch on Reference mark traverse is not necessary Additional incremental signals are output for highly dynamic control loops The MANUALplus 4110 is fitted with the serial EnDat interface the connection of absolute encoders Note he EnDat interface on HEIDENHAIN encoders differs in its pin assignment from the interface on Siemens motors with integrated absolute rotary encoders Special adapter cables are available Encoder inputs for Incremental and absolute linear angular or rotary encoders from position control HEIDENHAIN can be connected to all position encoder inputs of the MC 420 Inputs Signal level Input frequency Interface Incremental KHz 350 KAZ Absolute EnDat N Nop 33 2 350 kHz Switchable Encoder inputs for Incremental and absolute rotary encoders from HEIDENHAIN can speed control be connected to all speed encoder inputs of the CC 420 Inputs Signal level Input frequency Interface Incremental 350 kHz Absolute EnDat NA Bp 350 kHz Switchable 25 Compensation The MANUAL plus 4110 electronically compensates mechanical errors of the machine Axis error The MANUALplus 4110 compensates axis error in the linear axes X and Z in a linear manner Compensation of
18. e In 2 axes max 10 m Circle In 2 axes circle radius max x 100 m C axis Interpolation of X and Z linear axes with the C axis Axis feedback control With following error 21 22 23 e With feedforward With jerk limiting Feed rate mm min or mm revolution Constant cutting soeed Feed rate with chip breaking 60000 rom No of pole pairs of the motor 1 Cycle times e Position controller 3 ms 22 Speed controller 0 6 ms e Current controller at fpwm 3333 HZ 4166 Hz Maximum feed rate Screw pitch mm 5000 Hz 6666 Hz 8333 Hz 10000 Hz Maximum speed 60000 rpm for motors with two pole pairs 20 For more information see nverter Systems brochure 4 Specifications Monitoring functions Data interfaces Protocols Power supply Operating temperature Storage temperature Machine Interfacing Compensation Integral PLC PLC program RAM process memory RAM data memory PLC cycle time PLC inputs 24 PLC outputs 24 Vdc Analog inputs 10 V Analog outputs 10 V Inputs for thermistors MANUALplus 4110 Page During operation the control monitors the e Amplitude of the encoder signals e Actual position e Actual path traversed movement monitoring e Actual speed Supply voltage Motor current Motor temperature DC link voltage Supply voltage of the logic unit Temperature of the power module One RS 232 CN 24 with max 38 4 kbps One RS 422 C V 11 with max 38 4 kbps 100 BaseT Fast E
19. e TNCdiag software for PCs enables the service technician to make a simple and fast diagnosis of the drives It also permits the display and evaluation of the electronic ID labels TNCdiag works with the MANUAL plus 4110 as of software version 526488 04 The following diagnostic functions are available e Reading and displaying the electronic ID labels of motors with EON 1325 or ECN 1313 e Heading and displaying the electronic ID labels of the UVR 1xxD and UM 1xxD inverter modules e Displaying and evaluating the internal control conditions and the status signals of the inverter components e Displaying the analog values available to the drive controller e Automatic test for proper function of motors and inverters e Automatic test of position and speed encoders Oscillosrope curser 2 tursor setting ng slk ee 0 0 91 Nominal and actual position IPO MIT LESTIE Sai the ba 15T amv Sali 0 019 22 5 FR 22 5 _ 165 663 sais Analyzer mr Din Dome a S start Ip 1 1 0 eurite data AA te data LAMA Logic diagram PLC input 190 PLC input 147 PLC input 140 PLE inpet 199 1 itie EN i 1211114 nanan nu Monitoring Functions During operation the MANUALplus 4110 monitors e Amplitude of the encoder signals e Actual position e Actual path traversed mo
20. eave space for exchanging the HDR hard dek Y ial 50 Ci a LIDIEIEIDI O LILILIEICI O LIDIEIEIEIEIEIEIETEIEIETEJETES P1 ET ED ODEEEGOGGEH T COD rn 99999588995 Leave space for servicing and LIEIEIBIBIEIETETETE HHHH ui HHHHHBHE 5 connecting cables OOO d o a a pa UE UM MC 42x CC 42x 30 Mounting and electrical connection Degrees of protection Keep the following in mind during mounting and electrical connection e National regulations for power installations e Interference and noise immunity e Conditions of operation e Mounting attitude The following components fulfill the requirements for IP 54 dust protection and splash proof protection e Visual display unit when properly installed e Keyboard unit when properly installed e Handwheel Electromagnetic compatibility Intended area of application Likely sources of interference Protective measures
21. forward control FONOWING eara H 42 Incremental 5 24 Integrated inverters 24 Integrated e 27 J dE 23 L 23 Machine operating 13 Waffe eine ur 10 MG 10 Monitoring functions 29 ceci aware 30 P ST 14 36 PE 14 OT 14 PLC expansion ME 27 PEG le EEN 27 Bee 27 PLC aaa 27 14 Reference mark evaluation 24 Replacement control system 40 Reversal 26 TE 29 SE 29 S se RS 40 le 40 SIRCOMPORENL ie 11 T Technical sUPPON ess 40 Traverse ne pA mi 20 U Ee 29 USB N E 29 38 V V 11W 24 adapter eme 37 HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH Dr Johannes Heidenhain Stra e 5 83301 Traunreut Germany e 49 8669 31 0 49 8669 50 61 E Mail info heidenhain de www heidenhain de DE AR AT AU BE BG BR BY CA CH CN HEIDENHAIN Technisches Buro Nord 12681 Berlin Deutschland 030 54705 240 E Mail
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23. it CC 422 with 6 shaft speed inputs 4 2 10 420 with 5 position encoder inputs ID 51592 7 xx HDR Heard Disk SIK Component HDR hard disk SIK component Master keyword NC software license for MC 420 Auxiliary axes Software options The HDR hard disk is removable It contains the NC software and a slot for the SIK component HDR for MANUALplus 4110 MC 420 586 040 51 The SIK component contains the NC software license for enabling control loops and software options It gives the main computer an unambiguous ID code the SIK number The SIK component is ordered and shipped separately It must be inserted in a special slot in the HDR Additional control loops can be enabled later by entering a keyword HEIDENHAIN provides the keyword which is based on the SIK number When ordering please indicate the SIK number of your control When the keywords are entered in the control they are saved in the SIK component This enables and activates the options For commissioning the MANUALplus 4110 a master keyword can be used that will unlock all control loop options for a duration of two weeks After this period the control loop options will be active only through the correct keyword Should service become necessary the SIK component must be inserted in the replacement control to enable all required options SIK with software license and MANUALplus 4110 enabling for 3 control loops for CC 5
24. ition capture e Three keys with machine functions see below Two permissive buttons 24 V e Emergency Stop button 24 V e Magnetic holding pads e Weight approx 1 kg All keys are designed as snap on keys and can be replaced by keys with other symbols HR 410 NC start stop spindle start for PLC basic program Without detent ID 296469 55 With detent ID 535220 05 HR 410 spindle right left stop Without detent ID 296469 54 Connecting cable spiral cable to HR 410 3 m ID 312879 01 HR 410 MC 422 adapter cable ID 296466 xx Dummy plug for emergency stop circuit ID 271958 03 Panel mounted handwheel with ergonomic control knob It is connected to the logic unit directly or via extension cable Weight approx 0 7 kg HR 130 without detent ID 254040 05 HR 130 with detent ID 540940 01 15 Cable Overview saxy E me XX COE XX Q E 955 LO 7ZZ OLE ER NG 19 041u09 soe inu equa WG W E 2 10 922 OLE XX 6CL 695 XX 68 D NG 19110411U09 GEIER 10 922 OLE m 1 NG z m lt w09 o puids sexy 682 XX v8 w09 ES lt a WOE o puids sax GE 68 e dE LL ES 0 682 Ed SELVE BEE E XX L L OLE SIX s ndul uonisog ccv DIN SSSI L 28 602 ind
25. loaded with a total supply current greater than 0 5 A The maximum cable length for external USB units is 6 m without amplifiers For lengths from 7 m USB connecting cables with an integrated amplifier are required USB hub If you need further USB ports or if the supply current is not sufficient a USB hub is required The USB hub from HEIDENHAIN offers four free USB ports Power supply 24 Vdc max 300 mA ID 582 884 01 Cover The USB hub can be installed in the operating panel in such a way that two USB ports can be accessed from the outside An optionally available cover can be used to protect the ports from contamination ID 508 921 21 29 Mounting Instructions Mounting attitude When installing the 420 CC 422 UV R 1xx UM xxx UE 2xxB take note of the minimum spacing space needed for servicing and the appropriate length and location of the connecting cables j TU 77000 9 gt 90 Leave space air circulation Air outlet Temperatures of gt 150 may occur with the UE 21 with integrated braking resistor do not mount any temperature sensitive parts Leave space for servicing D D oe 2 DH P aie D Seef 7 mm mm mmm EH mmm EH i Leave space for air circulation NE and servicing m N Air inlet TD m gt 155 L
26. missioning MANUAL plus 4110 service Encoder service Special training for specific customers For more information on dates registration etc call in Germany 08669 31 2293 31 1695 08669 31 1999 E mail mtt amp heidenhain de www heidenhain de 40 Other HEIDENHAIN Controls 530 Contouring Control Information ITNC 530 brochure TNC 320 Contouring Control Information TNC 320 brochure e FK free contour programming e User aids Programming graphics verification graphics Five axis machining with TCPM and 3 D tool compensation e Subprogramming and fixed cycles e Machining with rotary tables option e Connection for one HR electronic handwheel and one Contouring control for milling drilling and boring machines and machining centers 11 closed loop axes and servo controlled spindle For digital drive control with HEIDENHAIN inverter systems Flat panel color display 15 inch Keyboard unit with alohanumeric keys Program memory on integrated hard disk Program input with smarT NC in HEIDENHAIN conversational format or according to ISO DXF file import External programming on CAD CAM systems or programming stations program run graphics Programming aids Milling drilling and boring cycles parametric programming coordinate transformation subprogramming Tilted working plane with PLANE function and machining with a rotary table HSC machining Collision monitoring
27. ne operating panel ID 326206 05 Weight approx 3 kg 10 4 inch flat panel color display Soft keys e Numeric keypad e Editing keys The machine tool builder designs the machine operating panel It should contain the following components e Handwheels e Axis direction buttons or joystick Emergency stop button Feed rate override Spindle override Cycle keys Spindle keys BFT 121G Handwheel resolution Cycle start Handwheel X Cycle stop Coolant Tool change Emergency stop Pho C Spindle start stop Handwheel Z Feed rate override Rapid traverse Axis direction keys Spindle jog Spindle override Proposal for a machine operating panel 13 Accessories PLC Inputs Outputs Basic module PLB 510 PLB 511 PLB 512 I O modules PLD 16 8 PLA 4 4 Empty housing 14 If the PLC inputs outputs of the MC are insufficient additional PL 510 input output units can be connected These external modular systems consist of a basic module and one or more input output modules Basic modules for 4 6 or 8 modules are available They are mounted on standard NS 35 rails DIN 46227 or EN 50022 Supply voltage 24 Vdc Power consumption approx 20 W Weight 0 36 kg bare Basic modules with HEIDENHAIN PLC interface Slots for 4 modules ID 358849 01 Slots for 6 modules ID 556941 01 Slots for 8 modules ID 557 125 01 Up to four PLB 510 and up to two PLB 511 or PLB
28. ng steps in alteration with manual machine operation e Thread repair thread reworking in a second workpiece setup Sequential linking of fixed cycles where each cycle 15 run immediately after Input 15 graphically simulated and subsequently saved e Cycle programs or DIN programs in single block or full sequence e Workpiece datum setting e Definition of tool change position e Definition of protection zone e Area clearance cycles for simple and complex contours as well as contours described with Interactive Contour Programming ICP Recessing cycles for simple complex and ICP contours with repetitions Recess turning cycles for simple and complex contours as well as contours described with Interactive Contour Programming ICP Undercut and parting cycles Threading cycles for single or multi start longitudinal taper API threads e Axial and radial drilling peck drilling and tapping cycles e Thread milling Axial and radial milling cycles for grooves figures single sides and polygons as well as complex ICP contours Helical slot milling Linear and circular patterns for milling drilling and boring Use of DIN macros in cycle programs Conversion of cycle programs to DIN programs Workpiece blank definition as rod pipe and contour Support graphics can be switched for inside and outside machining Contour definition with linear and circular contour elements Immediate display of entered contour elements Calculation
29. omentary nominal position and the actual position of the axis The velocity is calculated as follows Sa v velocity ky loop gain following error Feedforward control means that the speed and the acceleration feedforward control are preset according to the machine while taking the jerk limiting into account Together with the values calculated from the following error it forms the nominal value In this way the following error becomes very small in the range of a few um The cycle time for the position controller is defined as the time interval during which interpolation points on the path are calculated The speed controller cycle time is the time interval in which the actual speed value is compared to the calculated nominal speed value The cycle time for the current controller is defined as the time interval during which the actual current value is compared to the calculated nominal current value Position Speed Current controller controller controller MIC 420 3 ms 0 6 ms 0 1 ms CC 422 Position Fast Machining Look ahead The MANUAL plus 4110 calculates the geometry ahead of time in order to adjust the feed rate 20 blocks In this way directional changes are detected in time to accelerate or decelerate the appropriate NC axes Jerk Limiting Jerk Smoother jerk The derivative of acceleration is referred to as jerk A linear change in acceleration causes a jerk step This Jerk ca
30. oning digital control loops 28 Software for drive diagnosis contained in TNCopt got Configuration tool e Configuration of the parameters e Adjustment of M numbers Control software on PCs for xx e Programming and test runs e Program management Operating resources management e Data backup e Training See the Remote diagnosis with Teleservice Product Overview xx See the DataPilot 4110 CD HEIDENHAIN Control Systems The MANUALplus 4110 lathe machine control from HEIDENHAIN includes various components which can be selected and combined to fit the application Model Page omm Electronic handwheels HR 410 HR 150 or HR 130 15 MC 420 CC 422 MC 420 CC 422 with compact inverter with modular inverter Main Computer Main computer The MC 420 main computer includes Processor Celeron 400 MHz RAM memory 128 MB PLC Interface to the CC controller unit Interface to the control panel Interface to the handwheel Further interfaces PLC expansion Ethernet USB RS 232 C V 24 RS 422 V 11 To be ordered separately e HDR hard disk with the NC software e SIK component System Identification Key for enabling the control loops and software options Power supply The main computer is powered over the CC controller unit 420 The MC 420 main computer is available in versions with 5 position encoder inputs It offers up to 5 control loops Position inputs 5 x 1 Vpp or EnDat Controller un
31. ramming Hardware requirements Features Command set Format PLC test functions Logic Analyzer The machine tool builder provides the PLC software Machine specific functions are activated and monitored via PLC inputs outputs The number of PLC inputs outputs required depends on the complexity of the machine 56 freely assignable inputs 24 V 31 freely assignable outputs 24 V 100 mA and 1 control is ready output If the PLC inputs outputs of the logic unit are insufficient you can add PL 510 input output units Logic unit 0 1A PL 510 1 2 PLC program hard disk Process memory 512 RAM e Data memory 124 KB RAM 18 ms The PC program PLCdesignNT accessory can be used for easy creation of PLC programs Comprehensive examples of PLC programs are included Standard PC with Windows operating system 95 98 NT 2000 ME XP e At least 32 MB RAM Menu guided operation Modular programming method Compiling and linking of PLC source files Operand comments Comprehensive help system Data transmission to the control Compilation of the software file for the machine Bit byte and word commands Logical operations Arithmetic commands Comparisons Parenthetic calculations Jump commands Subprograms e 200 timers e 48 counters e Transfer commands Statement list Simultaneous representation of the logic states of up to 16 operands markers inputs outputs counters timers
32. ramming and Speed of the driven tool display e Constant shaft speed 1 to 19999 rpm e Constant cutting speed 1 to 2000 m min opeed limiting e The MANUAL plus monitors the actual speed e Speed limiting can be adjusted via parameter and in the feedrate spindle tool menu Digital Control Integrated inverter Position controllers speed controllers current controllers and inverters are integrated in the control HEIDENHAIN synchronous and asynchronous motors are connected to the MANUALplus 4110 position speed MURORUM ULM LM CD CDL REF Servo drive control Inverter Machine Velocity Acceleration feedforward feedforward Nominal Nominal velocity acceleration gt Motor with rotary Machine slide Position Speed Current shaft speed with linear or controller controller controller Power stage rotor position angle encoder Nominal Nominal Actual current Actual speed Actual position Axis feedback In the standard turning cycles the MANUAL plus 4110 operates control with feedforward control Feedforward control is turned off during certain threading cycles 21 Servo control with following error Servo control with velocity feedforward Control loop cycle times 22 The term following error denotes the distance between the m
33. s from HEIDENHAIN are subject to wear e Hard disk e Buffer battery e Fan Standards ISO EN etc apply only where explicitly stated in the catalog Contents Page Tables with Specifications Machine Interfacing 4 User Functions and Accessories Control Systems 9 Cable Overviews 16 Technical Description 20 Overall Dimensions 32 Documentation 39 Service 40 Subject Index 42 Please refer to the page references in the tables with the specifications The features and specifications described here apply for the following control and NC software version MANUALplus 4110 with NC software version V 6 4 as of ID 526488 07 Some of these specifications require particular machine configurations Please note also that for some functions a special PLC program must be created by the manufacturer This catalog supersedes all previous editions which thereby become invalid Subject to change without notice Specifications Operating panel BFT 121G e TFT color flat panel display e NC keyboard Inverter systems e Compact inverters i e Modular inverters Axes and spindles e 2 closed loop axes e Closed loop spindle switchable to C axis operation e Driven tool option Program memory At least 5 GB on hard disk Input resolution and display step e o 0 001 mm on linear axes 20 e o 0 001 on the C axis Position loop resolution e o 0 0001 mm on linear axes e o 0 000 1 on the C axis Interpolation Straight lin
34. thernet interface Two USB interfaces e Windows supported network protocols including e 3x 400 Vac for inverter with logic unit e 24 for color flat panel display and PLC 0 C to 40 C 35 C to 65 C MANUALplus 4110 Page Screw pitch error Backlash Slope angle misalignment compensation Tool nose cutting radius Milling tool radius On hard disk 512 KB 124 KB 18 ms 56 expandable by PL 31 expandable by PL 3 expandable by PL 6 3 expandable by PL Additional inputs outputs option Maximum four PL 510 external input output systems 14 Commissioning aids e External in the PLC programming system 28 PLC window on the screen e Integrated oscilloscope for checking traversed distances and the dynamic adjustment of the drives Logic Analyzer for chronological representation of digital inouts outputs and PLC interface signals e TNCopt PC software for commissioning digital control loops e TNCdiag PC software for diagnostics of digital drive systems User Functions User Functions Modes of operation Manual operation Teach in Program run Setup functions Programming Cycle programming Interactive Contour Programming ICP G code programming See the MANUALplus 4110 brochure MANUALplus 4110 Page e Manual slide movement through intermediate switch or electronic handwheel e Graphic support for entering and running cycles without saving the machini
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36. uses oscillations and leads to contour damage To prevent machine oscillations the jerk is limited to attain optimum path control The MANUALplus 4110 machines smooth surfaces at the highest possible feed rate and yet keeps the contour accurate The user sets the permissible tolerance via parameter 23 Encoders Incremental encoders Reference mark Reference mark evaluation Output signals Absolute encoders EnDat interface 24 For speed and position control of the axes and spindle HEIDENHAIN offers both incremental as well as absolute measuring systems Incremental encoders have as measuring standard a grating consisting of alternate lines and spaces Relative movement between the scanning head and the scale causes output of sinusoidal scanning signals The measured value is calculated from these signals When the machine is switched on the machine axes need to traverse a reference mark for an accurate reference to be established between measured value and machine position For encoders with distance coded reference marks the maximum travel until automatic reference mark evaluation for linear encoders is only 20 mm or 80 mm depending on the model or 10 or 20 for angle encoders The routine for traversing the reference marks can also be started for specific axes via the PLC during operation reactivation of parked axes Incremental encoders with sinusoidal output signals with levels N 1 Vpp are suita
37. ussian Motors brochure MANUALplus 4110 brochure DataPilot 4110 data sheet DataPilot 4110 CD ROM Inverter Systems brochure Training documents in German and English also suitable for private study ID 361 406 ID 208962 xx ID 354 267 xx ID 354 268 xx ID 208893 xx ID 355830 xx ID 364 321 xx ID 510703 xx ID 622 420 xx DataPilot 4110 on CD ROM 39 HEIDENHAIN Service Technical support HEIDENHAIN offers the machine manufacturer technical support to optimize the adaptation of the MANUAL plus to the machine including on site Replacement In the event of a fault HEIDENHAIN guarantees the rapid supply control system of a replacement control system usually within 24 hours in Europe Hotline Our service engineers are naturally at your disposal by telephone if you have any questions on the interfacing of the control or in the event of faults TNC support 49 86 69 31 31 01 E mail service nc support heidenhain de PLC programming 49 86 69 31 31 02 E mail service plc heidenhain de NC programming 49 8669 31 31 03 E mail service nc ogm heidenhain de Measuring systems 49 8669 31 31 04 E mail service ms support heidenhain de Lathe controls 49 7 11 95 2803 0 E mail service hst heidenhain de Seminars HEIDENHAIN provides technical customer training in the following subjects NC programming be av Tu PLC programming MANUAL plus 4110 mounting and com
38. ution Feed rate with chip breaking Feed rate override 0 to 150 e Maximum feed rate at 5000 Hz 60000 rom No of pole pairs of the motor screw pitch mm 9 999 9999 to 9999 9999 mm The machine tool builder defines the traverse range It is also possible the operator to limit the traverse range if he wishes to reduce the working space with software limit switches A protection zone for the spindle 7 can also be specified For machines featuring a higher level of automation you can switch the spindle to C axis operation for machining with driven tools Spindle speed e Constant shaft speed 1 to 19999 rom Constant cutting speed 1 to 2000 m min 50 to 150 _ fpwm 60000 rom mx NPP 5000 Hz fwm PWM frequency in Hz NPP number of pole pairs The MANUALplus monitors the actual speed Speed limiting can be adjusted via parameter and in the feedrate spindle tool menu A separate nominal speed is defined for each of the 4 gear ranges The gear code is output via the PLC The spindle is switched to C axis operation for milling drilling and boring cycles A separate servo drive for the C axis is activated Input resolution and display step 0 001 Driven ool The driven tool is used for drilling and tapping holes as well as for milling in M19 or C axis operation Programs for the driven tool can be input manually via cycles or in the DIN editor Prog
39. vement monitoring e Actual speed e Supply voltage e Motor current e Motor temperature e DC ink voltage e Supply voltage of the logic unit e Temperature of the power module In case of an error the MANUALplus 4110 reports this error If a hazardous error occurs an EMERGENCY STOP message is sent to the external electronics via the control is ready output Data Interfaces The MANUALplus 4110 is connected to other EDP systems such as PCs programming stations etc or integrated in networks via data interfaces Ethernet e 100 BaseT Fast Ethernet interface The MANUAL plus 4110 supports various Windows networks protocols TCP IP among others RS 232 C V 24 Data interface according to DIN 66020 or EIA standard RS 232 C Maximum transmission distance 20m RS 422 V 11 Data interface according to EIA standard RS 422 Maximum transmission distance 1 km Data transfer rate 36400 19200 9600 7200 4800 3600 2400 1200 600 300 baud Data transfer The data is transferred character by character The number of data bits stop bits the character parity and the software or hardware handshake Xon Xoff RTS CTS must be set by the user Adapter block For connecting the interface to the electrical cabinet or operating panel RS 232 C V 24 adapter 9 pin ID 363987 02 25 pin ID 310085 01 RS 422 V 11 adapter 9 pin ID 363 987 01 USB The two USB interfaces are available for connecting standard storage media They must not be
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