Siemens SINUMERIK 840D sl User manual

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SINUMERIK
SINUMERIK 840D sl/828D
Milling
Operating Manual
Valid for:
SINUMERIK 840D sl / 840DE sl / 828D controls
Software Software version
CNC for 840D sl / 840DE sl 4.5
SINUMERIK Operate for PCU/PC 4.5
02/2012
6FC5398-7CP40-3BA0
Preface
Introduction
1
Setting up the machine
2
Execution in manual mode
3
Machining the workpiece
4
Simulating machining
5
Generating a G code
program
6
Creating a ShopMill program
7
Programming technological
functions (cycles)
8
Multi-channel view
9
User variables
10
Teaching in a program
11
Working with Manual
Machine
12
Tool management
13
Managing programs
14
Setting up drives
15
HT 8
16
Continued on next page

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-7CP40-3BA0
Ⓟ 01/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Legal information

SINUMERIK 840D sl/828D
Milling
Operating Manual
Continuation
Ctrl-Energy
17
Easy Message (828D only)
18
Easy Extend (828D only)
19
Service Planner (828D only)
20
Ladder Viewer and Ladder
add-on (828D only)
21
Alarm, error, and system
messages
22
Appendix
A

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 relevant 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 product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
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 complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of 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
Order number: 6FC5398-7CP40-3BA0
Ⓟ 01/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved

Milling
Operating Manual, 02/2012, 6FC5398-7CP40-3BA0 5
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
[e-mail]
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer under:
● www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
● www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com

Preface
Milling
6 Operating Manual, 02/2012, 6FC5398-7CP40-3BA0
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This documentation is intended for users of milling machines running the SINUMERIK
Operate software.
Benefits
The operating manual helps users familiarize themselves with the control elements and
commands. Guided by the manual, users are capable of responding to problems and taking
corrective action.
Standard scope
This documentation describes the functionality of the standard scope. Extensions or changes
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.
Furthermore, for the sake of clarity, 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.
Terms
The meanings of some basic terms used in this documentation are given below.
Program
A program is a sequence of instructions to the CNC which combine to produce a specific
workpiece on the machine.
Contour
The term contour refers generally to the outline of a workpiece. More specifically, it refers to
the section of the program that defines the outline of a workpiece comprising individual
elements.
Cycle
A cycle, e.g. milling a rectangular pocket, is a subprogram defined in SINUMERIK Operate
for executing a frequently repeated machining operation.

Preface
Milling
Operating Manual, 02/2012, 6FC5398-7CP40-3BA0 7
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support

Preface
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8 Operating Manual, 02/2012, 6FC5398-7CP40-3BA0

Milling
Operating Manual, 02/2012, 6FC5398-7CP40-3BA0 9
Table of contents
Preface ...................................................................................................................................................... 5
1 Introduction.............................................................................................................................................. 21
1.1 Product overview .........................................................................................................................21
1.2 Operator panel fronts ...................................................................................................................22
1.2.1 Overview ......................................................................................................................................22
1.2.2 Keys of the operator panel...........................................................................................................23
1.3 Machine control panels ................................................................................................................33
1.3.1 Overview ......................................................................................................................................33
1.3.2 Controls on the machine control panel ........................................................................................33
1.4 User interface...............................................................................................................................36
1.4.1 Screen layout ...............................................................................................................................36
1.4.2 Status display...............................................................................................................................37
1.4.3 Actual value window ....................................................................................................................40
1.4.4 T,F,S window ...............................................................................................................................41
1.4.5 Current block display ...................................................................................................................43
1.4.6 Operation via softkeys and buttons .............................................................................................43
1.4.7 Entering or selecting parameters.................................................................................................45
1.4.8 Pocket calculator..........................................................................................................................47
1.4.9 Context menu...............................................................................................................................49
1.4.10 Touch operation ...........................................................................................................................49
1.4.11 Changing the user interface language.........................................................................................50
1.4.12 Entering Asian characters............................................................................................................51
1.4.13 Protection levels...........................................................................................................................53
1.4.14 Online help in SINUMERIK Operate............................................................................................55
2 Setting up the machine............................................................................................................................ 59
2.1 Switching on and switching off.....................................................................................................59
2.2 Approaching a reference point.....................................................................................................60
2.2.1 Referencing axes .........................................................................................................................60
2.2.2 User agreement ...........................................................................................................................61
2.3 Operating modes .........................................................................................................................63
2.3.1 General ........................................................................................................................................63
2.3.2 Modes groups and channels........................................................................................................65
2.3.3 Channel switchover......................................................................................................................65
2.4 Settings for the machine ..............................................................................................................67
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................67
2.4.2 Switching the unit of measurement..............................................................................................67
2.4.3 Setting the zero offset ..................................................................................................................68
2.5 Measuring the tool .......................................................................................................................71
2.5.1 Measuring a tool manually...........................................................................................................71
2.5.2 Measuring the tool length with the workpiece as reference point................................................72
2.5.3 Measuring radius or diameter ......................................................................................................73

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2.5.4 Fixed point calibration ................................................................................................................. 74
2.5.5 Measuring a tool with an electrical tool probe............................................................................. 75
2.5.6 Calibrating the electrical tool probe............................................................................................. 77
2.6 Measuring the workpiece zero .................................................................................................... 78
2.6.1 Overview ..................................................................................................................................... 78
2.6.2 Sequence of operations .............................................................................................................. 82
2.6.3 Examples with manual swivel ..................................................................................................... 83
2.6.4 Calibrating the electronic workpiece probe................................................................................. 84
2.6.5 Setting the edge .......................................................................................................................... 86
2.6.6 Edge measurement..................................................................................................................... 88
2.6.7 Measuring a corner ..................................................................................................................... 91
2.6.8 Measuring a pocket and hole...................................................................................................... 94
2.6.9 Measuring a spigot.................................................................................................................... 100
2.6.10 Aligning the plane...................................................................................................................... 106
2.6.11 Defining the measurement function selection........................................................................... 108
2.6.12 Corrections after measurement of the zero point ..................................................................... 109
2.7 Zero offsets ............................................................................................................................... 111
2.7.1 Display active zero offset .......................................................................................................... 112
2.7.2 Displaying the zero offset "overview"........................................................................................ 113
2.7.3 Displaying and editing base zero offset .................................................................................... 114
2.7.4 Displaying and editing settable zero offset ............................................................................... 115
2.7.5 Displaying and editing details of the zero offsets...................................................................... 115
2.7.6 Deleting a zero offset ................................................................................................................ 117
2.7.7 Measuring the workpiece zero .................................................................................................. 118
2.8 Monitoring axis and spindle data .............................................................................................. 119
2.8.1 Specify working area limitations................................................................................................ 119
2.8.2 Editing spindle data................................................................................................................... 120
2.9 Displaying setting data lists....................................................................................................... 121
2.10 Handwheel assignment............................................................................................................. 122
2.11 MDA .......................................................................................................................................... 124
2.11.1 Loading an MDA program from the Program Manager ............................................................ 124
2.11.2 Saving an MDA program........................................................................................................... 125
2.11.3 Executing an MDA program...................................................................................................... 126
2.11.4 Deleting an MDA program......................................................................................................... 126
3 Execution in manual mode..................................................................................................................... 127
3.1 General...................................................................................................................................... 127
3.2 Selecting a tool and spindle ...................................................................................................... 127
3.2.1 T, S, M windows........................................................................................................................ 127
3.2.2 Selecting a tool.......................................................................................................................... 129
3.2.3 Starting and stopping a spindle manually .................................................................................130
3.2.4 Position spindle ......................................................................................................................... 131
3.3 Traversing axes......................................................................................................................... 132
3.3.1 Traverse axes by a defined increment...................................................................................... 132
3.3.2 Traversing axes by a variable increment ..................................................................................133
3.4 Positioning axes ........................................................................................................................ 134
3.5 Swiveling ................................................................................................................................... 135

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3.6 Manual retraction .......................................................................................................................139
3.7 Simple face milling of the workpiece..........................................................................................141
3.8 Default settings for manual mode ..............................................................................................144
4 Machining the workpiece ....................................................................................................................... 145
4.1 Starting and stopping machining................................................................................................145
4.2 Selecting a program...................................................................................................................146
4.3 Testing a program......................................................................................................................147
4.4 Displaying the current program block ........................................................................................149
4.4.1 Current block display .................................................................................................................149
4.4.2 Displaying a basic block.............................................................................................................149
4.4.3 Display program level ................................................................................................................150
4.5 Correcting a program.................................................................................................................151
4.6 Repositioning axes.....................................................................................................................153
4.7 Starting machining at a specific point ........................................................................................155
4.7.1 Use block search .......................................................................................................................155
4.7.2 Continuing program from search target .....................................................................................157
4.7.3 Simple search target definition...................................................................................................157
4.7.4 Defining an interruption point as search target..........................................................................158
4.7.5 Entering the search target via search pointer ............................................................................159
4.7.6 Parameters for block search in the search pointer ....................................................................160
4.7.7 Block search mode ....................................................................................................................161
4.8 Controlling the program run .......................................................................................................163
4.8.1 Program control..........................................................................................................................163
4.8.2 Skip blocks.................................................................................................................................164
4.9 Overstore ...................................................................................................................................166
4.10 Editing a program.......................................................................................................................167
4.10.1 Searching in programs...............................................................................................................168
4.10.2 Replacing program text..............................................................................................................170
4.10.3 Copying/pasting/deleting a program block.................................................................................171
4.10.4 Renumber program....................................................................................................................172
4.10.5 Creating a program block...........................................................................................................173
4.10.6 Opening additional programs.....................................................................................................174
4.10.7 Editor settings ............................................................................................................................175
4.11 Mold making view ......................................................................................................................177
4.11.1 Starting the mold making view...................................................................................................179
4.11.2 Specifically jump to the program block ......................................................................................180
4.11.3 Searching for program blocks....................................................................................................180
4.11.4 Changing the view .....................................................................................................................181
4.11.4.1 Enlarging or reducing the graphical representation...................................................................181
4.11.4.2 Modifying the viewport ...............................................................................................................182
4.12 Displaying G Functions and Auxiliary Functions........................................................................183
4.12.1 Selected G functions..................................................................................................................183
4.12.2 All G functions............................................................................................................................185
4.12.3 Auxiliary functions ......................................................................................................................186

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4.13 Displaying the program runtime and counting workpieces ....................................................... 189
4.14 Setting for automatic mode ....................................................................................................... 191
5 Simulating machining............................................................................................................................. 193
5.1 Overview ................................................................................................................................... 193
5.2 Simulation before machining of the workpiece ......................................................................... 200
5.3 Simultaneous recording before machining of the workpiece .................................................... 201
5.4 Simultaneous recording during machining of the workpiece .................................................... 202
5.5 Different views of the workpiece ............................................................................................... 203
5.5.1 Plan view................................................................................................................................... 203
5.5.2 3D view...................................................................................................................................... 203
5.5.3 Side view................................................................................................................................... 204
5.6 Editing the simulation display.................................................................................................... 205
5.6.1 Blank display ............................................................................................................................. 205
5.6.2 Showing and hiding the tool path.............................................................................................. 205
5.7 Program control during the simulation ......................................................................................206
5.7.1 Changing the feedrate............................................................................................................... 206
5.7.2 Simulating the program block by block ..................................................................................... 207
5.8 Changing and adapting a simulation graphic............................................................................ 208
5.8.1 Enlarging or reducing the graphical representation .................................................................. 208
5.8.2 Panning a graphical representation .......................................................................................... 209
5.8.3 Rotating the graphical representation....................................................................................... 209
5.8.4 Modifying the viewport .............................................................................................................. 210
5.8.5 Defining cutting planes.............................................................................................................. 211
5.9 Displaying simulation alarms..................................................................................................... 212
6 Generating a G code program ............................................................................................................... 213
6.1 Graphical programming............................................................................................................. 213
6.2 Program views .......................................................................................................................... 214
6.3 Program structure ..................................................................................................................... 217
6.4 Fundamentals ........................................................................................................................... 218
6.4.1 Machining planes ...................................................................................................................... 218
6.4.2 Current planes in cycles and input screens .............................................................................. 218
6.4.3 Programming a tool (T) ............................................................................................................. 219
6.5 Generating a G code program .................................................................................................. 220
6.6 Blank input ................................................................................................................................ 221
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F)........................................................................................................................................ 223
6.8 Selection of the cycles via softkey ............................................................................................ 224
6.9 Calling technology functions ..................................................................................................... 229
6.9.1 Hiding cycle parameters............................................................................................................ 229
6.9.2 Setting data for cycles............................................................................................................... 229
6.9.3 Checking cycle parameters....................................................................................................... 230
6.9.4 Programming variables ............................................................................................................. 230

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6.9.5 Changing a cycle call .................................................................................................................231
6.9.6 Compatibility for cycle support...................................................................................................231
6.9.7 Additional functions in the input screens ...................................................................................232
6.10 Measuring cycle support ............................................................................................................233
7 Creating a ShopMill program ................................................................................................................. 235
7.1 Program views ...........................................................................................................................236
7.2 Program structure ......................................................................................................................240
7.3 Fundamentals ............................................................................................................................241
7.3.1 Machining planes .......................................................................................................................241
7.3.2 Polar coordinates .......................................................................................................................241
7.3.3 Absolute and incremental dimensions .......................................................................................242
7.4 Creating a ShopMill program .....................................................................................................244
7.5 Program header .........................................................................................................................245
7.6 Generating program blocks........................................................................................................247
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V).........................................................248
7.8 Defining machine functions........................................................................................................250
7.9 Call work offsets.........................................................................................................................252
7.10 Repeating program blocks .........................................................................................................253
7.11 Specifying the number of workpieces ........................................................................................255
7.12 Changing program blocks..........................................................................................................256
7.13 Changing program settings........................................................................................................257
7.14 Selection of the cycles via softkey .............................................................................................259
7.15 Calling technology functions ......................................................................................................263
7.15.1 Additional functions in the input screens ...................................................................................263
7.15.2 Programming variables ..............................................................................................................263
7.15.3 Checking input parameters........................................................................................................264
7.15.4 Setting data for technological functions .....................................................................................264
7.15.5 Changing a cycle call .................................................................................................................265
7.15.6 Compatibility for cycle support...................................................................................................265
7.16 Measuring cycle support ............................................................................................................266
7.17 Example, standard machining....................................................................................................267
7.17.1 Workpiece drawing ....................................................................................................................268
7.17.2 Programming..............................................................................................................................269
7.17.3 Results/simulation test ...............................................................................................................280
7.17.4 G code machining program........................................................................................................282
8 Programming technological functions (cycles)....................................................................................... 285
8.1 Drilling ........................................................................................................................................285
8.1.1 General ......................................................................................................................................285
8.1.2 Centering (CYCLE81)................................................................................................................286
8.1.2.1 Function .....................................................................................................................................286
8.1.3 Drilling (CYCLE82).....................................................................................................................288
8.1.3.1 Function .....................................................................................................................................288

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8.1.4 Reaming (CYCLE85) ................................................................................................................ 290
8.1.4.1 Function..................................................................................................................................... 290
8.1.5 Deep-hole drilling (CYCLE83)................................................................................................... 292
8.1.5.1 Function..................................................................................................................................... 292
8.1.6 Boring (CYCLE86) .................................................................................................................... 295
8.1.6.1 Function..................................................................................................................................... 295
8.1.7 Tapping (CYCLE84, 840).......................................................................................................... 297
8.1.7.1 Function..................................................................................................................................... 297
8.1.8 Drill and thread milling (CYCLE78) ........................................................................................... 303
8.1.8.1 Function..................................................................................................................................... 303
8.1.9 Positioning and position patterns .............................................................................................. 307
8.1.10 Arbitrary positions (CYCLE802)................................................................................................ 309
8.1.11 Position pattern line (HOLES1), grid or frame (CYCLE801)..................................................... 312
8.1.12 Circle position pattern (HOLES2).............................................................................................. 314
8.1.13 Displaying and hiding positions................................................................................................. 316
8.1.14 Repeating positions................................................................................................................... 317
8.2 Milling ........................................................................................................................................ 319
8.2.1 Face milling (CYCLE61)............................................................................................................ 319
8.2.1.1 Function..................................................................................................................................... 319
8.2.2 Rectangular pocket (POCKET3)............................................................................................... 322
8.2.3 Circular pocket (POCKET4)...................................................................................................... 325
8.2.4 Rectangular spigot (CYCLE76)................................................................................................. 330
8.2.5 Circular spigot (CYCLE77)........................................................................................................ 333
8.2.5.1 Function..................................................................................................................................... 333
8.2.6 Multi-edge (CYCLE79).............................................................................................................. 335
8.2.6.1 Function..................................................................................................................................... 335
8.2.7 Longitudinal groove (SLOT1).................................................................................................... 338
8.2.8 Circumferential groove (SLOT2) ............................................................................................... 341
8.2.9 Open groove (CYCLE899)........................................................................................................ 344
8.2.10 Long hole (LONGHOLE) - only for G code programs............................................................... 351
8.2.11 Thread milling (CYCLE70) ........................................................................................................ 353
8.2.12 Engraving (CYCLE60)............................................................................................................... 357
8.3 Contour milling .......................................................................................................................... 363
8.3.1 General...................................................................................................................................... 363
8.3.2 Representation of the contour................................................................................................... 363
8.3.3 Creating a new contour............................................................................................................. 365
8.3.4 Creating contour elements........................................................................................................ 367
8.3.5 Changing the contour................................................................................................................ 372
8.3.6 Contour call (CYCLE62) - only for G code program ................................................................. 373
8.3.7 Path milling (CYCLE72) ............................................................................................................ 374
8.3.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 378
8.3.9 Predrilling contour pocket (CYCLE64)...................................................................................... 380
8.3.10 Milling contour pocket (CYCLE63)............................................................................................ 383
8.3.11 Residual material contour pocket (CYCLE63) .......................................................................... 385
8.3.12 Milling contour spigot (CYCLE63)............................................................................................. 387
8.3.13 Residual material contour spigot (CYCLE63) ........................................................................... 389
8.4 Turning - only for G code programs .......................................................................................... 392
8.4.1 General...................................................................................................................................... 392
8.4.2 Stock removal (CYCLE951)...................................................................................................... 392
8.4.3 Groove (CYCLE930)................................................................................................................. 395
8.4.4 Undercut form E and F (CYCLE940) ........................................................................................ 398

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8.4.5 Thread undercut (CYCLE940) ...................................................................................................400
8.4.6 Thread turning (CYCLE99) ........................................................................................................403
8.4.7 Thread chain (CYCLE98)...........................................................................................................412
8.4.8 Cut-off (CYCLE92).....................................................................................................................416
8.5 Contour turning - only for G code programs ..............................................................................418
8.5.1 General information ...................................................................................................................418
8.5.2 Representation of the contour....................................................................................................419
8.5.3 Creating a new contour..............................................................................................................420
8.5.4 Creating contour elements.........................................................................................................422
8.5.5 Changing the contour.................................................................................................................428
8.5.6 Contour call (CYCLE62) ............................................................................................................429
8.5.7 Stock removal (CYCLE952).......................................................................................................430
8.5.8 Stock removal residual (CYCLE952) .........................................................................................436
8.5.9 Grooving (CYCLE952) ...............................................................................................................438
8.5.10 Grooving residual material (CYCLE952) ...................................................................................441
8.5.11 Plunge turning (CYCLE952) ......................................................................................................443
8.5.12 Plunge turning residual material (CYCLE952)...........................................................................447
8.6 Further cycles and functions ......................................................................................................450
8.6.1 Swivel plane/tool (CYCLE800)...................................................................................................450
8.6.2 Swiveling tool (CYCLE800)........................................................................................................459
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) .......................459
8.6.2.2 Swiveling aligning tool - only for G code program (CYCLE800)................................................460
8.6.3 High-speed settings (CYCLE832)..............................................................................................462
8.6.4 Subroutines................................................................................................................................465
8.7 Additional cycles and functions in ShopMill...............................................................................467
8.7.1 Transformations .........................................................................................................................467
8.7.2 Translation .................................................................................................................................468
8.7.3 Rotation......................................................................................................................................469
8.7.4 Scaling .......................................................................................................................................470
8.7.5 Mirroring.....................................................................................................................................471
8.7.6 Cylinder surface transformation.................................................................................................472
8.7.6.1 General programming................................................................................................................474
8.7.7 Straight or circular machining ....................................................................................................475
8.7.8 Programming a straight line.......................................................................................................477
8.7.9 Programming a circle with known center point ..........................................................................478
8.7.10 Programming a circle with known radius ...................................................................................479
8.7.11 Helix ...........................................................................................................................................480
8.7.12 Polar coordinates .......................................................................................................................481
8.7.13 Straight polar..............................................................................................................................482
8.7.14 Circle polar.................................................................................................................................483
8.7.15 Obstacle .....................................................................................................................................484
9 Multi-channel view ................................................................................................................................. 485
9.1 Multi-channel view .....................................................................................................................485
9.2 Multi-channel view in the "Machine" operating area..................................................................485
9.3 Multi-channel view for large operator panels.............................................................................489
9.4 Setting the multi-channel view ...................................................................................................490
10 User variables........................................................................................................................................ 493

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10.1 Overview ................................................................................................................................... 493
10.2 R parameters ............................................................................................................................ 494
10.3 Displaying global user data (GUD) ........................................................................................... 495
10.4 Displaying channel GUDs ......................................................................................................... 496
10.5 Displaying local user data (LUD) .............................................................................................. 497
10.6 Displaying program user data (PUD) ........................................................................................498
10.7 Searching for user variables ..................................................................................................... 499
10.8 Defining and activating user variables ...................................................................................... 499
11 Teaching in a program........................................................................................................................... 501
11.1 Overview ................................................................................................................................... 501
11.2 General sequence..................................................................................................................... 501
11.3 Inserting a block ........................................................................................................................ 502
11.3.1 Input parameters for teach-in blocks......................................................................................... 503
11.4 Teach-in via window.................................................................................................................. 504
11.4.1 General...................................................................................................................................... 504
11.4.2 Teach in rapid traverse G0........................................................................................................ 505
11.4.3 Teach in straight G1.................................................................................................................. 506
11.4.4 Teaching in circle intermediate and circle end point CIP.......................................................... 506
11.4.5 Teach-in A spline ...................................................................................................................... 507
11.5 Editing a block........................................................................................................................... 509
11.6 Selecting a block ....................................................................................................................... 510
11.7 Deleting a block......................................................................................................................... 511
12 Working with Manual Machine ............................................................................................................... 513
12.1 Measuring the tool..................................................................................................................... 514
12.2 Measuring the workpiece zero .................................................................................................. 514
12.3 Setting the zero offset ............................................................................................................... 515
12.4 Set limit stop.............................................................................................................................. 515
12.5 Simple workpiece machining..................................................................................................... 516
12.5.1 Traversing axes......................................................................................................................... 517
12.5.2 Angular milling........................................................................................................................... 518
12.5.3 Straight and circular machining................................................................................................. 519
12.5.3.1 Straight milling........................................................................................................................... 519
12.5.3.2 Circular milling........................................................................................................................... 520
12.6 More complex machining .......................................................................................................... 521
12.6.1 Drilling with Manual Machine .................................................................................................... 522
12.6.2 Milling with Manual Machine ..................................................................................................... 524
12.7 Simulation and simultaneous recording .................................................................................... 525
13 Tool management.................................................................................................................................. 527
13.1 Lists for the tool management................................................................................................... 527

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13.2 Magazine management .............................................................................................................529
13.3 Tool types...................................................................................................................................530
13.4 Tool dimensioning......................................................................................................................532
13.5 Tool list.......................................................................................................................................538
13.5.1 Additional data ...........................................................................................................................541
13.5.2 Creating a new tool ....................................................................................................................543
13.5.3 Measuring the tool .....................................................................................................................544
13.5.4 Managing several cutting edges ................................................................................................545
13.5.5 Delete tool..................................................................................................................................545
13.5.6 Loading and unloading tools......................................................................................................546
13.5.7 Selecting a magazine.................................................................................................................548
13.6 Tool wear ...................................................................................................................................549
13.6.1 Reactivating a tool .....................................................................................................................552
13.7 Tool data OEM...........................................................................................................................553
13.8 Magazine....................................................................................................................................554
13.8.1 Positioning a magazine..............................................................................................................556
13.8.2 Relocating a tool ........................................................................................................................556
13.8.3 Unload all tools...........................................................................................................................558
13.9 Graphic display ..........................................................................................................................559
13.10 Sorting tool management lists....................................................................................................561
13.11 Filtering the tool management lists ............................................................................................562
13.12 Specific search in the tool management lists.............................................................................563
13.13 Displaying tool details ................................................................................................................565
13.14 Changing a tool type ..................................................................................................................566
13.15 Settings for tool lists...................................................................................................................567
14 Managing programs............................................................................................................................... 569
14.1 Overview ....................................................................................................................................569
14.1.1 NC memory................................................................................................................................572
14.1.2 Local drive..................................................................................................................................572
14.1.3 USB drives .................................................................................................................................574
14.2 Opening and closing the program..............................................................................................575
14.3 Executing a program..................................................................................................................577
14.4 Creating a directory / program / job list / program list................................................................579
14.4.1 Creating a new directory............................................................................................................579
14.4.2 Creating a new workpiece..........................................................................................................580
14.4.3 Creating a new G code program................................................................................................581
14.4.4 Creating a new ShopMill program..............................................................................................582
14.4.5 Storing any new file....................................................................................................................582
14.4.6 Creating a job list .......................................................................................................................583
14.4.7 Creating a program list...............................................................................................................585
14.5 Creating templates.....................................................................................................................586
14.6 Searching directories and files...................................................................................................587

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14.7 Displaying the program in the Preview. ....................................................................................588
14.8 Selecting several directories/programs..................................................................................... 589
14.9 Copying and pasting a directory/program................................................................................. 591
14.10 Deleting a program/directory..................................................................................................... 593
14.10.1 Deleting a program/directory..................................................................................................... 593
14.11 Changing file and directory properties ...................................................................................... 594
14.12 Viewing PDF documents........................................................................................................... 595
14.13 EXTCALL .................................................................................................................................. 597
14.14 Backing up data ........................................................................................................................ 599
14.14.1 Generating an archive in the Program Manager....................................................................... 599
14.14.2 Generating an archive via the system data............................................................................... 600
14.14.3 Reading in an archive in the Program Manager ....................................................................... 602
14.14.4 Read in archive from system data ............................................................................................ 604
14.15 Setup data................................................................................................................................. 605
14.15.1 Backing up setup data............................................................................................................... 605
14.15.2 Reading-in set-up data.............................................................................................................. 608
14.16 RS-232-C .................................................................................................................................. 610
14.16.1 Reading-in and reading-out archives ........................................................................................ 610
14.16.2 Setting V24 in the program manager ........................................................................................ 612
14.17 Multiple clamping ...................................................................................................................... 614
14.17.1 Multiple clamping ...................................................................................................................... 614
14.17.2 Creating a multiple clamping program ...................................................................................... 615
15 Setting up drives.................................................................................................................................... 617
15.1 Overview ................................................................................................................................... 617
15.2 Setting up drives ....................................................................................................................... 618
16 HT 8....................................................................................................................................................... 621
16.1 HT 8 overview ........................................................................................................................... 621
16.2 Traversing keys......................................................................................................................... 624
16.3 Machine control panel menu..................................................................................................... 625
16.4 Virtual keyboard ........................................................................................................................ 626
16.5 Calibrating the touch panel ....................................................................................................... 628
17 Ctrl-Energy ............................................................................................................................................ 629
17.1 Overview ................................................................................................................................... 629
17.2 Displaying energy consumption ................................................................................................ 630
17.3 Measuring and saving the energy consumption ....................................................................... 631
17.4 Long-term measurement of the energy consumption............................................................... 632
17.5 Displaying measured curves..................................................................................................... 633
17.6 Using the energy-saving profile ................................................................................................ 634
18 Easy Message (828D only).................................................................................................................... 637

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18.1 Overview ....................................................................................................................................637
18.2 Activating Easy Message...........................................................................................................638
18.3 Creating/editing a user profile....................................................................................................639
18.4 Setting-up events .......................................................................................................................641
18.5 Logging an active user on and off..............................................................................................643
18.6 Displaying SMS logs ..................................................................................................................644
18.7 Making settings for Easy Message ............................................................................................645
19 Easy Extend (828D only) ....................................................................................................................... 647
19.1 Overview ....................................................................................................................................647
19.2 Enabling a device.......................................................................................................................648
19.3 Activating and deactivating a device..........................................................................................649
19.4 Commissioning Easy Extend .....................................................................................................650
20 Service Planner (828D only).................................................................................................................. 651
20.1 Performing and monitoring maintenance tasks .........................................................................651
20.2 Set maintenance tasks...............................................................................................................653
21 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 655
21.1 PLC diagnostics .........................................................................................................................655
21.2 Structure of the user interface....................................................................................................656
21.3 Control options...........................................................................................................................657
21.4 Displaying PLC properties .........................................................................................................659
21.5 Displaying and editing NC/PLC variables ..................................................................................660
21.6 Displaying and editing PLC signals ...........................................................................................661
21.7 Displaying information on the program blocks...........................................................................662
21.8 Downloading a PLC user program.............................................................................................664
21.9 Editing the local variable table ...................................................................................................665
21.10 Creating a new block .................................................................................................................666
21.11 Editing block properties..............................................................................................................667
21.12 Inserting and editing networks ...................................................................................................667
21.13 Editing network properties .........................................................................................................670
21.14 Displaying and editing symbol tables.........................................................................................671
21.15 Inserting/deleting a symbol table ...............................................................................................672
21.16 Searching for operands..............................................................................................................673
21.17 Displaying the network symbol information table.......................................................................674
21.18 Displaying/canceling the access protection ...............................................................................675
21.19 Displaying cross references.......................................................................................................675

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20 Operating Manual, 02/2012, 6FC5398-7CP40-3BA0
22 Alarm, error, and system messages ...................................................................................................... 677
22.1 Displaying alarms...................................................................................................................... 677
22.2 Displaying an alarm log............................................................................................................. 679
22.3 Displaying messages ................................................................................................................ 679
22.4 Sorting, alarms, faults and messages....................................................................................... 680
22.5 PLC and NC variables............................................................................................................... 681
22.5.1 Displaying and editing PLC and NC variables .......................................................................... 681
22.5.2 Saving and loading screen forms.............................................................................................. 684
22.5.3 Load symbols ............................................................................................................................ 686
22.6 Version ...................................................................................................................................... 687
22.6.1 Displaying version data............................................................................................................. 687
22.6.2 Save information ....................................................................................................................... 688
22.7 Logbook..................................................................................................................................... 689
22.7.1 Displaying and editing the logbook ........................................................................................... 689
22.7.2 Making a logbook entry ............................................................................................................. 690
22.8 Creating screenshots ................................................................................................................ 692
22.9 Remote diagnostics................................................................................................................... 693
22.9.1 Setting remote access............................................................................................................... 693
22.9.2 Permit modem........................................................................................................................... 695
22.9.3 Request remote diagnostics...................................................................................................... 695
22.9.4 Exit remote diagnostics............................................................................................................. 696
A Appendix................................................................................................................................................ 697
A.1 Overview ................................................................................................................................... 697
Index...................................................................................................................................................... 699