Siemens SINUMERIK 802D sl User manual

SINUMERIK SINUMERIK 802D sl Manual Machine Plus Turning
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Foreword
Description
1
Software interface
2
Turning On, Reference Point
Approach
3
Setting-up
4
Manual machining
5
Machining the machining
step program manually
6
Messages
7
Appendix
A
SINUMERIK
SINUMERIK 802D sl
Manual Machine Plus Turning
Programming and Operating Manual
06/2009
6FC5398-6CP10-1BA0
Valid for
Controller Software version
SINUMERIK 802D sl T/M 1.4 SP5

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ordernumber: 6FC5398-6CP10-1BA0
Ⓟ 06/2009
Copyright © Siemens AG 2009.
Technical data subject to change

Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 3
Foreword
SINUMERIK documentation
The SINUMERIK documentation is organized in 3 parts:
● General documentation
● User documentation
● Manufacturer/Service documentation
An overview of publications, which is updated monthly and also provides information about
the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Follow menu items "Support" → "Technical Documentation" → "Ordering Documentation" →
"Printed Documentation".
The Internet version of DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb
Information about training courses and FAQs (Frequently Asked Questions) can be found at
the following website:
http://www.siemens.com/motioncontrol under "Support".
Target group
This publication is intended for programmers, planning engineers, machine operators and
system operators.
Benefits
With the Programming and Operating Manual, the target group can develop, write, test and
debug programs and software user interfaces.
It also contains the information required for the target group to operate the hardware and
software of a product/system (generally a machine).
Standard scope
This documentation only describes the functionality of the standard version. Additions or
revisions made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

Foreword
Manual Machine Plus Turning
4 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
Technical support
If you have any technical questions, please contact our hotline:
Europe / Africa
Phone [phone]
Fax [phone]
Internet http://www.siemens.com/automation/support-request
America
Phone [phone]
Fax [phone]
E-Mail mailto:[email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-Mail mailto:adsupport.a[email protected]
Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
http://www.siemens.com/automation/service&support
Calls are subject to charge, e.g. €0.14/min from a German landline. Tariffs of other phone
providers may differ.
Questions about this documentation
If you have any queries (suggestions, corrections) regarding this documentation, please
send a fax or email to the following address:
Fax [phone]
E-Mail [e-mail]
A fax form is available in the appendix of this document.
SINUMERIK Internet address
http://www.siemens.com/sinumerik

Foreword
Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 5
EC Declaration of Conformity (only for hardware descriptions)
The EC Declaration of Conformity for the EMC Directive can be found/obtained:
● on the internet:
http://support.automation.siemens.com
under the product/order No. 15263595
● at the relevant regional office of the I DT MC Business Unit of Siemens AG.

Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 7
Table of contents
Foreword ................................................................................................................................................... 3
1 Description................................................................................................................................................. 9
1.1 Control and display elements.........................................................................................................9
1.2 Error and status displays .............................................................................................................10
1.3 Key definition of the full CNC keyboard (vertical format).............................................................11
1.4 Key definition of the machine control panel .................................................................................13
2 Software interface.................................................................................................................................... 15
3 Turning On, Reference Point Approach................................................................................................... 17
3.1 Entry to the "Manual Machine Plus" operating area ....................................................................17
3.2 Reference point approach............................................................................................................19
4 Setting-up ................................................................................................................................................ 23
4.1 Measuring tools............................................................................................................................23
4.2 Limit stops....................................................................................................................................26
4.2.1 Setting and activating/deactivating limit stops .............................................................................26
4.2.2 Turning against a stop .................................................................................................................29
4.3 Setting the workpiece zero...........................................................................................................31
5 Manual machining.................................................................................................................................... 33
5.1 Fundamentals of manual machining............................................................................................33
5.2 Display and operator control optios in the main screen for "Manual Machine Plus" ...................34
5.2.1 Toggling the display .....................................................................................................................38
5.2.2 Machining with the handwheels...................................................................................................39
5.2.3 Setting the increment weighting for the handwheel.....................................................................39
5.2.4 Machining with axis direction switch ............................................................................................39
5.2.5 Spindle advance/reverse .............................................................................................................40
5.2.6 Tool change .................................................................................................................................41
5.2.7 Changing the feedrate/spindle value ...........................................................................................43
5.2.8 Changing the feedrate/spindle type .............................................................................................44
5.2.9 Change the speed limitation for constant cutting rate .................................................................46
5.3 Manual machining with machining types .....................................................................................47
5.3.1 Axis-parallel traversal...................................................................................................................47
5.3.2 Manual taper turning ....................................................................................................................48
5.3.3 Manual radius turning ..................................................................................................................49
5.3.3.1 Radius turning type A...................................................................................................................52
5.3.3.2 Radius turning type B...................................................................................................................52
5.3.3.3 Radius turning type C ..................................................................................................................53
5.4 Manual machining using cycles (functions) .................................................................................54
5.4.1 Principle operating sequence.......................................................................................................54
5.4.2 General parameters .....................................................................................................................58
5.4.3 Manual drilling centered...............................................................................................................60
5.4.4 Manual thread tapping .................................................................................................................62

Table of contents
Manual Machine Plus Turning
8 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
5.4.5 Manual grooving/parting.............................................................................................................. 65
5.4.5.1 Groove cycle - single................................................................................................................... 65
5.4.5.2 Groove cycle - multiple................................................................................................................ 68
5.4.5.3 Parting cycle - single ................................................................................................................... 69
5.4.5.4 Multiple tapping ........................................................................................................................... 70
5.4.5.5 Extended grooving ...................................................................................................................... 71
5.4.5.6 Multiple extended grooving ......................................................................................................... 75
5.4.6 Manual thread cutting.................................................................................................................. 76
5.4.6.1 Thread cutting ............................................................................................................................. 77
5.4.6.2 Thread recutting .......................................................................................................................... 81
5.4.6.3 Thread shaving after thread cutting ............................................................................................ 83
5.4.7 Roughing cycles.......................................................................................................................... 84
5.4.7.1 Roughing cycle A ........................................................................................................................ 85
5.4.7.2 Roughing cycle B ........................................................................................................................ 88
5.4.7.3 Roughing cycle C ........................................................................................................................ 91
5.4.7.4 Roughing cycle D ........................................................................................................................ 94
5.4.7.5 Roughing cycle E ........................................................................................................................ 97
5.4.7.6 Roughing cycle F ........................................................................................................................ 99
5.4.7.7 Roughing cycle, free contour: ................................................................................................... 101
5.4.7.8 Execute a roughing cycle.......................................................................................................... 105
6 Machining the machining step program manually.................................................................................. 107
6.1 Tool change in the machining step program............................................................................. 111
6.2 Teach In .................................................................................................................................... 114
6.3 Simulate machining................................................................................................................... 117
6.4 Executing the machining step program..................................................................................... 120
7 Messages .............................................................................................................................................. 123
A Appendix................................................................................................................................................ 125
A.1 Feedback on the documentation............................................................................................... 125
A.2 Overview of documentation....................................................................................................... 127
Index...................................................................................................................................................... 129

Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 9
Description 1
1.1 Control and display elements
Operator control elements
The defined functions are called up via the horizontal and vertical softkeys. For a description,
please refer to this manual:
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Figure 1-1 CNC operator panel

Description
1.2 Error and status displays
Manual Machine Plus Turning
10 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
1.2 Error and status displays
LED displays on the CNC operator panel (PCU)
The following LEDs are installed on the CNC operator panel.
(55 5'< 1& &)
The individual LEDs and their functions are described in the table below.
Table 1- 1 Status and error displays
LED Meaning
ERR (red) Serious error, remedy through power OFF/ON
RDY (green) Ready for operation
NC (yellow) Signoflife monitoring
CF (yellow) Reading from/writing to CF card
Reference
You can find information on error description in SINUMERIK 802D sl, Diagnostics Manual

Description
1.3 Key definition of the full CNC keyboard (vertical format)
Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 11
1.3 Key definition of the full CNC keyboard (vertical format)
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Description
1.3 Key definition of the full CNC keyboard (vertical format)
Manual Machine Plus Turning
12 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
Hot keys
In the part program editor and in the input fields of the HMI, the following functions can be
carried out with certain key combinations on the full CNC keyboard:
Keystroke combination Function
<CTRL> and <C> Copy selected text
<CTRL> and <B> Select text
<CTRL> and <X> Cut selected text
<CTRL> and <V> Paste copied text
<ALT> and <L> Changeover to small letters
<ALT> and <H> or <HELP> key Call help system

Description
1.4 Key definition of the machine control panel
Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 13
1.4 Key definition of the machine control panel
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Description
1.4 Key definition of the machine control panel
Manual Machine Plus Turning
14 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
Note
This documentation assumes an 802D standard machine control panel (MCP). Should you
use a different MCP, the operation may be other than described herein.

Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 15
Software interface 2
This Programming and Operating Manual focuses primarily on the software interface of the
"Manual Machine Plus" system.
For descriptions of the software interface for the SINUMERIK 802D sl control system, please
refer to the SINUMERIK 802D sl Turning Programming and Operating Manual.
See Sections:
● Screen layout
● Standard softkeys
● Operating areas
● Help system

Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 17
Turning On, Reference Point Approach 3
3.1 Entry to the "Manual Machine Plus" operating area
Operating sequences
Note
The operating area "Manual Machine Plus" runs only in Siemens mode, and not in ISO
mode.
Proceed as follows to open the "Manual Machine Plus" application:
Note
If the controller has already been preconfigured to "Manual Machine Plus" by the machine
manufacturer, items 1 to 3 can be ignored in the following description. The operating area
"Manual Machine Plus" is activated once the controller has been started up.
If you have not yet executed a reference point approach, you will be in the operating mode
Reference point approach (see Fig. Reference point approach) after start-up.
1. The NC boots into the JOG REF operating mode of the NC basic machine.
2. Select the JOG operating mode.
The interface can be seen in the screenshot below:
Figure 3-1 "Position" operating area

Turning On, Reference Point Approach
3.1 Entry to the "Manual Machine Plus" operating area
Manual Machine Plus Turning
18 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
3. You can access the "Manual Machine Plus" area by clicking on softkey "Manual":
Note
If you have not yet executed a reference point approach, the JOG REF operating mode
will be reselected automatically when you press the "Manual" softkey.
Figure 3-2 Reference point approach
4. The operating area "Manual Machine Plus" can be exited with the "CNC" softkey, after
which the operating area of the NC basic machine is active again.
Note
The manual machine cannot be exited in the "Execute cycles" and "Execution window"
screen forms of the stepping program.
General operating information
If a screen (e.g. for the "thread tapping" function) contains input fields, then you can edit
them as follows:
● Select the input fields using the <cursor keys>.
● Enter data using the <numeric keys>.
● Accept the data using the <INPUT key>.
● Use the <Tab key> to switch between the input fields and the selection box during the
opening and saving of files.
● If you do not want to accept an input value,then exist the corresponding field using
<Cursor key> or change the screen form. Do not press the <INPUT> key.
Note
The pictures in the parameterization screenforms depend on the setting of the machine data
by the machine manufacturer, i.e. display of the tool position before or behind the center of
rotation with regards to the turret head.
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Turning On, Reference Point Approach
3.2 Reference point approach
Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0 19
3.2 Reference point approach
Functionality
The axes have not yet approached their reference points (see screenshot below).
Figure 3-3 Reference point approach
Note
The meanings of the symbols in the axis display are as follows:
-> Axis still needs to be referenced.
-> Axis is referenced.
Requirement
The following requirements must be fulfilled:
● There must be no NC alarms pending!
-> Clear any that are pending by pressing the "Reset" softkey.
● All machine axes must be in a position from which the reference point can be reached in
a positive traversing direction.
-> In manual mode, use the handwheels to move the axes to the appropriate position in
front of the reference point.
DANGER
Before starting the reference point approach or switching off the machine, be sure to
move the machine slide to a position from which the reference point can be approached
in a positive axis direction.
If the machine manufacturer has not fitted an axis limit switch, there is a risk of a
mechanical collision if the axis is on the wrong side of the reference cam before the start
of the reference point approach.

Turning On, Reference Point Approach
3.2 Reference point approach
Manual Machine Plus Turning
20 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0
Operating sequence
1. Select the <JOG> operating mode.
Figure 3-4 Main screen for "Manual Machine Plus"
2. Select handwheel increment weighting using the <INCREMENT> key.
Figure 3-5 Handwheel increment weighting 100 INC
The current setting will appear on the top left of the screen (e.g.: 100 INC).