Siemens SINUMERIK 840D sl User manual

Milling
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SINUMERIK
SINUMERIK 840D sl / 828D
Milling
Operating Manual
Valid for:
Controller
SINUMERIK 840D sl / 840DE sl / 828D
Software version
CNC software for 840D sl / 840DE sl 4.5 SP2
SINUMERIK O
p
erate for PCU
/
PC 4.5 SP2
03/2013
6FC5398-7CP40-3BA1
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 (only
840D sl)
9
Collision avoidance (only
840D sl)
10
Tool management
11
Managing programs
12
Alarm, error, and system
messages
13
Working with Manual
Machine
14
Teaching in a program
15
HT 8
16
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
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-7CP40-3BA1
Ⓟ 04/2013 Technical data subject to change
Copyright © Siemens AG 2008 - 2013.
All rights reserved
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
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
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.

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Operating Manual, 03/2013, 6FC5398-7CP40-3BA1 3
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
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4 Operating Manual, 03/2013, 6FC5398-7CP40-3BA1
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
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Operating Manual, 03/2013, 6FC5398-7CP40-3BA1 5
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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Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction.............................................................................................................................................. 19
1.1 Product overview .........................................................................................................................19
1.2 Operator panel fronts ...................................................................................................................20
1.2.1 Overview ......................................................................................................................................20
1.2.2 Keys of the operator panel...........................................................................................................21
1.3 Machine control panels ................................................................................................................31
1.3.1 Overview ......................................................................................................................................31
1.3.2 Controls on the machine control panel ........................................................................................31
1.4 User interface...............................................................................................................................34
1.4.1 Screen layout ...............................................................................................................................34
1.4.2 Status display...............................................................................................................................35
1.4.3 Actual value window ....................................................................................................................38
1.4.4 T,F,S window ...............................................................................................................................40
1.4.5 Current block display ...................................................................................................................42
1.4.6 Operation via softkeys and buttons .............................................................................................43
1.4.7 Entering or selecting parameters.................................................................................................44
1.4.8 Pocket calculator..........................................................................................................................47
1.4.9 Context menu...............................................................................................................................48
1.4.10 Touch operation ...........................................................................................................................49
1.4.11 Changing the user interface language.........................................................................................49
1.4.12 Entering Asian characters............................................................................................................50
1.4.13 Protection levels...........................................................................................................................52
1.4.14 Online help in SINUMERIK Operate............................................................................................54
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..............................................................................................68
2.4.3 Setting the zero offset ..................................................................................................................69
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 .............................................................................................................. 83
2.6.3 Examples with manual swivel ..................................................................................................... 84
2.6.4 Calibrating the electronic workpiece probe ................................................................................. 85
2.6.5 Setting the edge .......................................................................................................................... 87
2.6.6 Edge measurement..................................................................................................................... 89
2.6.7 Measuring a corner ..................................................................................................................... 91
2.6.8 Measuring a pocket and hole...................................................................................................... 95
2.6.9 Measuring a spigot.................................................................................................................... 101
2.6.10 Aligning the plane...................................................................................................................... 108
2.6.11 Defining the measurement function selection........................................................................... 110
2.6.12 Corrections after measurement of the zero point ..................................................................... 111
2.7 Zero offsets ............................................................................................................................... 113
2.7.1 Display active zero offset .......................................................................................................... 114
2.7.2 Displaying the zero offset "overview"........................................................................................ 115
2.7.3 Displaying and editing base zero offset .................................................................................... 116
2.7.4 Displaying and editing settable zero offset ............................................................................... 117
2.7.5 Displaying and editing details of the zero offsets...................................................................... 118
2.7.6 Deleting a zero offset ................................................................................................................ 119
2.7.7 Measuring the workpiece zero .................................................................................................. 120
2.8 Monitoring axis and spindle data .............................................................................................. 121
2.8.1 Specify working area limitations................................................................................................ 121
2.8.2 Editing spindle data................................................................................................................... 122
2.9 Displaying setting data lists....................................................................................................... 123
2.10 Handwheel assignment............................................................................................................. 123
2.11 MDA .......................................................................................................................................... 126
2.11.1 Loading an MDA program from the Program Manager ............................................................ 126
2.11.2 Saving an MDA program........................................................................................................... 127
2.11.3 Executing an MDA program...................................................................................................... 128
2.11.4 Deleting an MDA program......................................................................................................... 128
3 Execution in manual mode..................................................................................................................... 129
3.1 General...................................................................................................................................... 129
3.2 Selecting a tool and spindle ...................................................................................................... 129
3.2.1 T, S, M windows........................................................................................................................ 129
3.2.2 Selecting a tool.......................................................................................................................... 131
3.2.3 Starting and stopping a spindle manually .................................................................................132
3.2.4 Position spindle ......................................................................................................................... 133
3.3 Traversing axes......................................................................................................................... 134
3.3.1 Traverse axes by a defined increment...................................................................................... 134
3.3.2 Traversing axes by a variable increment ..................................................................................135
3.4 Positioning axes ........................................................................................................................ 136
3.5 Swiveling ................................................................................................................................... 137

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3.6 Manual retraction .......................................................................................................................142
3.7 Simple face milling of the workpiece..........................................................................................144
3.8 Default settings for manual mode ..............................................................................................147
4 Machining the workpiece ....................................................................................................................... 149
4.1 Starting and stopping machining................................................................................................149
4.2 Selecting a program...................................................................................................................151
4.3 Testing a program......................................................................................................................152
4.4 Displaying the current program block ........................................................................................153
4.4.1 Current block display .................................................................................................................153
4.4.2 Displaying a basic block.............................................................................................................154
4.4.3 Display program level ................................................................................................................155
4.5 Correcting a program .................................................................................................................156
4.6 Repositioning axes.....................................................................................................................157
4.7 Starting machining at a specific point ........................................................................................158
4.7.1 Use block search .......................................................................................................................158
4.7.2 Continuing program from search target .....................................................................................160
4.7.3 Simple search target definition...................................................................................................161
4.7.4 Defining an interruption point as search target..........................................................................162
4.7.5 Entering the search target via search pointer ............................................................................163
4.7.6 Parameters for block search in the search pointer ....................................................................164
4.7.7 Block search mode ....................................................................................................................165
4.8 Controlling the program run .......................................................................................................167
4.8.1 Program control..........................................................................................................................167
4.8.2 Skip blocks.................................................................................................................................168
4.9 Overstore ...................................................................................................................................170
4.10 Editing a program.......................................................................................................................172
4.10.1 Searching in programs...............................................................................................................173
4.10.2 Replacing program text..............................................................................................................174
4.10.3 Copying/pasting/deleting a program block.................................................................................176
4.10.4 Renumber program....................................................................................................................177
4.10.5 Creating a program block...........................................................................................................178
4.10.6 Opening additional programs.....................................................................................................179
4.10.7 Editor settings ............................................................................................................................181
4.11 Display and edit user variables..................................................................................................183
4.11.1 Overview ....................................................................................................................................183
4.11.2 R parameters .............................................................................................................................184
4.11.3 Displaying global user data (GUD) ............................................................................................185
4.11.4 Displaying channel GUDs..........................................................................................................186
4.11.5 Displaying local user data (LUD) ...............................................................................................187
4.11.6 Displaying program user data (PUD).........................................................................................188
4.11.7 Searching for user variables ......................................................................................................189
4.12 Displaying G Functions and Auxiliary Functions........................................................................191
4.12.1 Selected G functions..................................................................................................................191
4.12.2 All G functions............................................................................................................................193
4.12.3 G functions for mold making ......................................................................................................194

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4.12.4 Auxiliary functions ..................................................................................................................... 196
4.13 Mold making view...................................................................................................................... 198
4.13.1 Starting the mold making view .................................................................................................. 201
4.13.2 Specifically jump to the program block ..................................................................................... 202
4.13.3 Searching for program blocks ................................................................................................... 202
4.13.4 Changing the view..................................................................................................................... 203
4.13.4.1 Enlarging or reducing the graphical representation.................................................................. 203
4.13.4.2 Modifying the viewport .............................................................................................................. 204
4.14 Displaying the program runtime and counting workpieces ....................................................... 205
4.15 Setting for automatic mode ....................................................................................................... 207
5 Simulating machining............................................................................................................................. 209
5.1 Overview ................................................................................................................................... 209
5.2 Simulation before machining of the workpiece ......................................................................... 216
5.3 Simultaneous recording before machining of the workpiece .................................................... 217
5.4 Simultaneous recording during machining of the workpiece .................................................... 218
5.5 Different views of the workpiece ............................................................................................... 219
5.5.1 Plan view................................................................................................................................... 219
5.5.2 3D view...................................................................................................................................... 219
5.5.3 Side view................................................................................................................................... 220
5.6 Editing the simulation display.................................................................................................... 221
5.6.1 Blank display ............................................................................................................................. 221
5.6.2 Showing and hiding the tool path.............................................................................................. 221
5.7 Program control during the simulation ......................................................................................222
5.7.1 Changing the feedrate............................................................................................................... 222
5.7.2 Simulating the program block by block ..................................................................................... 223
5.8 Changing and adapting a simulation graphic............................................................................ 224
5.8.1 Enlarging or reducing the graphical representation .................................................................. 224
5.8.2 Panning a graphical representation .......................................................................................... 225
5.8.3 Rotating the graphical representation....................................................................................... 225
5.8.4 Modifying the viewport .............................................................................................................. 226
5.8.5 Defining cutting planes.............................................................................................................. 227
5.9 Displaying simulation alarms..................................................................................................... 228
6 Generating a G code program ............................................................................................................... 229
6.1 Graphical programming............................................................................................................. 229
6.2 Program views .......................................................................................................................... 230
6.3 Program structure ..................................................................................................................... 233
6.4 Fundamentals ........................................................................................................................... 234
6.4.1 Machining planes ...................................................................................................................... 234
6.4.2 Current planes in cycles and input screens .............................................................................. 235
6.4.3 Programming a tool (T) ............................................................................................................. 235
6.5 Generating a G code program .................................................................................................. 237
6.6 Blank input ................................................................................................................................ 238

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6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F).........................................................................................................................................240
6.8 Selection of the cycles via softkey .............................................................................................241
6.9 Calling technology functions ......................................................................................................245
6.9.1 Hiding cycle parameters ............................................................................................................245
6.9.2 Setting data for cycles................................................................................................................246
6.9.3 Checking cycle parameters........................................................................................................246
6.9.4 Programming variables ..............................................................................................................246
6.9.5 Changing a cycle call .................................................................................................................247
6.9.6 Compatibility for cycle support...................................................................................................247
6.9.7 Additional functions in the input screens ...................................................................................248
6.10 Measuring cycle support ............................................................................................................248
7 Creating a ShopMill program ................................................................................................................. 249
7.1 Program views ...........................................................................................................................250
7.2 Program structure ......................................................................................................................254
7.3 Fundamentals ............................................................................................................................255
7.3.1 Machining planes .......................................................................................................................255
7.3.2 Polar coordinates .......................................................................................................................256
7.3.3 Absolute and incremental dimensions .......................................................................................256
7.4 Creating a ShopMill program .....................................................................................................258
7.5 Program header .........................................................................................................................259
7.6 Generating program blocks........................................................................................................261
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V).........................................................262
7.8 Defining machine functions........................................................................................................264
7.9 Call work offsets.........................................................................................................................266
7.10 Repeating program blocks .........................................................................................................266
7.11 Specifying the number of workpieces ........................................................................................268
7.12 Changing program blocks..........................................................................................................269
7.13 Changing program settings........................................................................................................270
7.13.1 Parameters.................................................................................................................................271
7.14 Selection of the cycles via softkey .............................................................................................273
7.15 Calling technology functions ......................................................................................................277
7.15.1 Additional functions in the input screens ...................................................................................277
7.15.2 Programming variables ..............................................................................................................278
7.15.3 Checking input parameters........................................................................................................278
7.15.4 Setting data for technological functions .....................................................................................279
7.15.5 Changing a cycle call .................................................................................................................279
7.15.6 Compatibility for cycle support...................................................................................................280
7.16 Measuring cycle support ............................................................................................................280
7.17 Example, standard machining....................................................................................................281
7.17.1 Workpiece drawing ....................................................................................................................282
7.17.2 Programming..............................................................................................................................282

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7.17.3 Results/simulation test .............................................................................................................. 294
7.17.4 G code machining program....................................................................................................... 296
8 Programming technological functions (cycles)....................................................................................... 299
8.1 Drilling ....................................................................................................................................... 299
8.1.1 General...................................................................................................................................... 299
8.1.2 Centering (CYCLE81) ............................................................................................................... 300
8.1.2.1 Function..................................................................................................................................... 300
8.1.3 Drilling (CYCLE82).................................................................................................................... 302
8.1.3.1 Function..................................................................................................................................... 302
8.1.4 Reaming (CYCLE85) ................................................................................................................ 304
8.1.4.1 Function..................................................................................................................................... 304
8.1.5 Deep-hole drilling (CYCLE83)................................................................................................... 305
8.1.5.1 Function..................................................................................................................................... 305
8.1.6 Boring (CYCLE86) .................................................................................................................... 309
8.1.6.1 Function..................................................................................................................................... 309
8.1.7 Tapping (CYCLE84, 840).......................................................................................................... 311
8.1.7.1 Function..................................................................................................................................... 311
8.1.8 Drill and thread milling (CYCLE78) ........................................................................................... 317
8.1.8.1 Function..................................................................................................................................... 317
8.1.9 Positioning and position patterns .............................................................................................. 321
8.1.10 Arbitrary positions (CYCLE802)................................................................................................ 323
8.1.11 Position pattern line (HOLES1), grid or frame (CYCLE801)..................................................... 327
8.1.12 Circle position pattern (HOLES2).............................................................................................. 329
8.1.13 Displaying and hiding positions................................................................................................. 331
8.1.14 Repeating positions................................................................................................................... 332
8.2 Milling ........................................................................................................................................ 334
8.2.1 Face milling (CYCLE61)............................................................................................................ 334
8.2.1.1 Function..................................................................................................................................... 334
8.2.2 Rectangular pocket (POCKET3)............................................................................................... 337
8.2.3 Circular pocket (POCKET4)...................................................................................................... 341
8.2.4 Rectangular spigot (CYCLE76)................................................................................................. 347
8.2.5 Circular spigot (CYCLE77)........................................................................................................ 350
8.2.6 Multi-edge (CYCLE79).............................................................................................................. 353
8.2.6.1 Parameter.................................................................................................................................. 354
8.2.7 Longitudinal groove (SLOT1).................................................................................................... 355
8.2.8 Circumferential groove (SLOT2) ............................................................................................... 360
8.2.9 Open groove (CYCLE899)........................................................................................................ 363
8.2.10 Long hole (LONGHOLE) - only for G code programs............................................................... 371
8.2.11 Thread milling (CYCLE70) ........................................................................................................ 373
8.2.12 Engraving (CYCLE60)............................................................................................................... 377
8.3 Contour milling .......................................................................................................................... 383
8.3.1 General...................................................................................................................................... 383
8.3.2 Representation of the contour................................................................................................... 383
8.3.3 Creating a new contour............................................................................................................. 385
8.3.4 Creating contour elements........................................................................................................ 387
8.3.5 Changing the contour................................................................................................................ 392
8.3.6 Contour call (CYCLE62) - only for G code program ................................................................. 393
8.3.7 Path milling (CYCLE72) ............................................................................................................ 394
8.3.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 398
8.3.9 Predrilling contour pocket (CYCLE64)...................................................................................... 400

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8.3.10 Milling contour pocket (CYCLE63).............................................................................................403
8.3.11 Residual material contour pocket (CYCLE63) ...........................................................................406
8.3.12 Milling contour spigot (CYCLE63)..............................................................................................408
8.3.13 Residual material contour spigot (CYCLE63) ............................................................................410
8.4 Turning - only for G code programs...........................................................................................412
8.4.1 General ......................................................................................................................................412
8.4.2 Stock removal (CYCLE951).......................................................................................................412
8.4.2.1 Function .....................................................................................................................................412
8.4.3 Groove (CYCLE930)..................................................................................................................417
8.4.3.1 Function .....................................................................................................................................417
8.4.4 Undercut form E and F (CYCLE940) .........................................................................................422
8.4.4.1 Function .....................................................................................................................................422
8.4.5 Thread undercut (CYCLE940) ...................................................................................................426
8.4.5.1 Function .....................................................................................................................................426
8.4.6 Thread turning (CYCLE99) ........................................................................................................429
8.4.6.1 Function .....................................................................................................................................429
8.4.7 Thread chain (CYCLE98)...........................................................................................................438
8.4.7.1 Function .....................................................................................................................................438
8.4.8 Cut-off (CYCLE92).....................................................................................................................441
8.5 Contour turning- only for G code programs ...............................................................................443
8.5.1 General information ...................................................................................................................443
8.5.2 Representation of the contour....................................................................................................444
8.5.3 Creating a new contour..............................................................................................................445
8.5.4 Creating contour elements.........................................................................................................447
8.5.5 Changing the contour.................................................................................................................453
8.5.6 Contour call (CYCLE62) ............................................................................................................454
8.5.6.1 Function .....................................................................................................................................454
8.5.7 Stock removal (CYCLE952).......................................................................................................455
8.5.7.1 Function .....................................................................................................................................455
8.5.8 Stock removal residual (CYCLE952) .........................................................................................461
8.5.8.1 Function .....................................................................................................................................461
8.5.9 Grooving (CYCLE952) ...............................................................................................................464
8.5.9.1 Function .....................................................................................................................................464
8.5.10 Grooving residual material (CYCLE952) ...................................................................................467
8.5.11 Plunge turning (CYCLE952) ......................................................................................................469
8.5.12 Plunge turning residual material (CYCLE952)...........................................................................472
8.6 Further cycles and functions ......................................................................................................475
8.6.1 Swivel plane/tool (CYCLE800)...................................................................................................475
8.6.2 Swiveling tool (CYCLE800)........................................................................................................485
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) .......................485
8.6.2.2 Swiveling aligning tool - only for G code program (CYCLE800)................................................487
8.6.3 High-speed settings (CYCLE832)..............................................................................................488
8.6.4 Subroutines................................................................................................................................491
8.7 Additional cycles and functions in ShopMill...............................................................................493
8.7.1 Transformations .........................................................................................................................493
8.7.2 Translation .................................................................................................................................494
8.7.3 Rotation......................................................................................................................................495
8.7.4 Scaling .......................................................................................................................................496
8.7.5 Mirroring.....................................................................................................................................497
8.7.6 Cylinder surface transformation.................................................................................................498

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8.7.6.1 General programming ............................................................................................................... 499
8.7.7 Straight or circular machining.................................................................................................... 501
8.7.8 Programming a straight line ...................................................................................................... 503
8.7.9 Programming a circle with known center point ......................................................................... 504
8.7.10 Programming a circle with known radius ..................................................................................505
8.7.11 Helix .......................................................................................................................................... 506
8.7.12 Polar coordinates ...................................................................................................................... 507
8.7.13 Straight polar............................................................................................................................. 508
8.7.14 Circle polar ................................................................................................................................ 509
8.7.15 Obstacle .................................................................................................................................... 510
9 Multi-channel view (only 840D sl) .......................................................................................................... 511
9.1 Multi-channel view..................................................................................................................... 511
9.2 Multi-channel view in the "Machine" operating area ................................................................. 511
9.3 Multi-channel view for large operator panels ............................................................................ 514
9.4 Setting the multi-channel view .................................................................................................. 516
10 Collision avoidance (only 840D sl)......................................................................................................... 519
10.1 Collision monitoring in the machine operator area: .................................................................. 519
10.2 Switching the collision avoidance on and off ............................................................................ 520
11 Tool management.................................................................................................................................. 523
11.1 Lists for the tool management................................................................................................... 523
11.2 Magazine management............................................................................................................. 524
11.3 Tool types.................................................................................................................................. 525
11.4 Tool dimensioning ..................................................................................................................... 527
11.5 Tool list...................................................................................................................................... 534
11.5.1 Additional data .......................................................................................................................... 537
11.5.2 Creating a new tool ................................................................................................................... 538
11.5.3 Measuring the tool..................................................................................................................... 540
11.5.4 Managing several cutting edges ............................................................................................... 540
11.5.5 Delete tool ................................................................................................................................. 541
11.5.6 Loading and unloading tools ..................................................................................................... 542
11.5.7 Selecting a magazine................................................................................................................ 544
11.5.8 Code carrier connection (only 840D sl)..................................................................................... 545
11.6 Tool wear................................................................................................................................... 548
11.6.1 Reactivating a tool..................................................................................................................... 551
11.7 Tool data OEM .......................................................................................................................... 552
11.8 Magazine................................................................................................................................... 553
11.8.1 Positioning a magazine............................................................................................................. 555
11.8.2 Relocating a tool ....................................................................................................................... 555
11.8.3 Unload all tools.......................................................................................................................... 557
11.9 Graphic display ......................................................................................................................... 558
11.10 Sorting tool management lists................................................................................................... 560
11.11 Filtering the tool management lists ........................................................................................... 561

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11.12 Specific search in the tool management lists.............................................................................563
11.13 Displaying tool details ................................................................................................................564
11.14 Displaying all tool details............................................................................................................566
11.15 Changing a tool type ..................................................................................................................567
11.16 Settings for tool lists...................................................................................................................568
12 Managing programs............................................................................................................................... 571
12.1 Overview ....................................................................................................................................571
12.1.1 NC memory................................................................................................................................574
12.1.2 Local drive..................................................................................................................................575
12.1.3 USB drives .................................................................................................................................576
12.1.4 FTP drive....................................................................................................................................577
12.2 Opening and closing the program..............................................................................................578
12.3 Executing a program..................................................................................................................580
12.4 Creating a directory / program / job list / program list................................................................581
12.4.1 Creating a new directory............................................................................................................581
12.4.2 Creating a new workpiece..........................................................................................................582
12.4.3 Creating a new G code program................................................................................................583
12.4.4 Creating a new ShopMill program..............................................................................................584
12.4.5 Storing any new file....................................................................................................................585
12.4.6 Creating a job list .......................................................................................................................586
12.4.7 Creating a program list...............................................................................................................587
12.5 Creating templates.....................................................................................................................589
12.6 Searching directories and files...................................................................................................590
12.7 Displaying the program in the Preview. .....................................................................................591
12.8 Selecting several directories/programs......................................................................................592
12.9 Copying and pasting a directory/program..................................................................................594
12.10 Deleting a program/directory......................................................................................................596
12.10.1 Deleting a program/directory......................................................................................................596
12.11 Changing file and directory properties .......................................................................................597
12.12 Set up drives ..............................................................................................................................599
12.12.1 Overview ....................................................................................................................................599
12.12.2 Setting up drives ........................................................................................................................599
12.13 Viewing PDF documents............................................................................................................603
12.14 EXTCALL ...................................................................................................................................604
12.15 Backing up data .........................................................................................................................607
12.15.1 Generating an archive in the Program Manager........................................................................607
12.15.2 Generating an archive via the system data ...............................................................................608
12.15.3 Reading in an archive in the Program Manager ........................................................................610
12.15.4 Read in archive from system data .............................................................................................612
12.16 Setup data..................................................................................................................................613
12.16.1 Backing up setup data ...............................................................................................................613
12.16.2 Reading-in set-up data...............................................................................................................616

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16 Operating Manual, 03/2013, 6FC5398-7CP40-3BA1
12.17 RS-232-C .................................................................................................................................. 618
12.17.1 Reading-in and reading-out archives ........................................................................................ 618
12.17.2 Setting V24 in the program manager ........................................................................................ 620
12.18 Multiple clamping ...................................................................................................................... 622
12.18.1 Multiple clamping ...................................................................................................................... 622
12.18.2 Program header setting, "Clamping"......................................................................................... 623
12.18.3 Creating a multiple clamping program ...................................................................................... 624
13 Alarm, error, and system messages ...................................................................................................... 627
13.1 Displaying alarms...................................................................................................................... 627
13.2 Displaying an alarm log............................................................................................................. 629
13.3 Displaying messages ................................................................................................................ 630
13.4 Sorting, alarms, faults and messages....................................................................................... 631
13.5 PLC and NC variables............................................................................................................... 632
13.5.1 Displaying and editing PLC and NC variables .......................................................................... 632
13.5.2 Saving and loading screen forms.............................................................................................. 636
13.5.3 Load symbols ............................................................................................................................ 637
13.6 Version ...................................................................................................................................... 638
13.6.1 Displaying version data............................................................................................................. 638
13.6.2 Save information ....................................................................................................................... 639
13.7 Logbook..................................................................................................................................... 640
13.7.1 Displaying and editing the logbook ........................................................................................... 641
13.7.2 Making a logbook entry ............................................................................................................. 642
13.8 Creating screenshots ................................................................................................................ 643
13.9 Remote diagnostics................................................................................................................... 644
13.9.1 Setting remote access............................................................................................................... 644
13.9.2 Permit modem........................................................................................................................... 646
13.9.3 Request remote diagnostics...................................................................................................... 647
13.9.4 Exit remote diagnostics............................................................................................................. 648
14 Working with Manual Machine ............................................................................................................... 649
14.1 Measuring the tool..................................................................................................................... 650
14.2 Measuring the workpiece zero .................................................................................................. 650
14.3 Setting the zero offset ............................................................................................................... 651
14.4 Set limit stop.............................................................................................................................. 652
14.5 Simple workpiece machining..................................................................................................... 653
14.5.1 Traversing axes......................................................................................................................... 653
14.5.2 Angular milling........................................................................................................................... 654
14.5.3 Straight and circular machining................................................................................................. 655
14.5.3.1 Straight milling........................................................................................................................... 655
14.5.3.2 Circular milling........................................................................................................................... 657
14.6 More complex machining .......................................................................................................... 658
14.6.1 Drilling with Manual Machine .................................................................................................... 660
14.6.2 Milling with Manual Machine ..................................................................................................... 661
14.6.3 Contour milling with manual machine ....................................................................................... 662

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14.7 Simulation and simultaneous recording.....................................................................................663
15 Teaching in a program........................................................................................................................... 665
15.1 Overview ....................................................................................................................................665
15.2 General sequence......................................................................................................................665
15.3 Inserting a block.........................................................................................................................666
15.3.1 Input parameters for teach-in blocks .........................................................................................667
15.4 Teach-in via window ..................................................................................................................669
15.4.1 General ......................................................................................................................................669
15.4.2 Teach in rapid traverse G0 ........................................................................................................670
15.4.3 Teach in straight G1...................................................................................................................670
15.4.4 Teaching in circle intermediate and circle end point CIP...........................................................671
15.4.5 Teach-in A spline .......................................................................................................................671
15.5 Editing a block............................................................................................................................673
15.6 Selecting a block........................................................................................................................674
15.7 Deleting a block .........................................................................................................................675
16 HT 8....................................................................................................................................................... 677
16.1 HT 8 overview ............................................................................................................................677
16.2 Traversing keys..........................................................................................................................680
16.3 Machine control panel menu......................................................................................................681
16.4 Virtual keyboard .........................................................................................................................682
16.5 Calibrating the touch panel ........................................................................................................684
17 Ctrl-Energy ............................................................................................................................................ 685
17.1 Overview ....................................................................................................................................685
17.2 Displaying energy consumption.................................................................................................686
17.3 Measuring and saving the energy consumption ........................................................................687
17.4 Long-term measurement of the energy consumption................................................................688
17.5 Displaying measured curves......................................................................................................689
17.6 Using the energy-saving profile .................................................................................................690
18 Easy Message (828D only).................................................................................................................... 693
18.1 Overview ....................................................................................................................................693
18.2 Activating Easy Message...........................................................................................................694
18.3 Creating/editing a user profile....................................................................................................695
18.4 Setting-up events .......................................................................................................................697
18.5 Logging an active user on and off..............................................................................................699
18.6 Displaying SMS logs ..................................................................................................................700
18.7 Making settings for Easy Message ............................................................................................701

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18 Operating Manual, 03/2013, 6FC5398-7CP40-3BA1
19 Easy Extend (828D only) ....................................................................................................................... 703
19.1 Overview ................................................................................................................................... 703
19.2 Enabling a device...................................................................................................................... 704
19.3 Activating and deactivating a device......................................................................................... 704
19.4 Commissioning Easy Extend .................................................................................................... 705
20 Service Planner (828D only).................................................................................................................. 707
20.1 Performing and monitoring maintenance tasks......................................................................... 707
20.2 Set maintenance tasks.............................................................................................................. 709
21 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 711
21.1 PLC diagnostics ........................................................................................................................ 711
21.2 Structure of the user interface................................................................................................... 711
21.3 Control options .......................................................................................................................... 712
21.4 Displaying PLC properties......................................................................................................... 714
21.5 Displaying and editing NC/PLC variables ................................................................................. 715
21.6 Displaying and editing PLC signals........................................................................................... 716
21.7 Displaying information on the program blocks.......................................................................... 717
21.8 Loading modified PLC user program ........................................................................................ 719
21.9 Editing the local variable table .................................................................................................. 720
21.10 Creating a new block................................................................................................................. 722
21.11 Editing block properties subsequently ...................................................................................... 723
21.12 Inserting and editing networks .................................................................................................. 724
21.13 Editing network properties......................................................................................................... 726
21.14 Displaying and editing symbol tables........................................................................................ 727
21.15 Inserting/deleting a symbol table .............................................................................................. 728
21.16 Searching for operands............................................................................................................. 729
21.17 Displaying the network symbol information table...................................................................... 730
21.18 Displaying/canceling the access protection .............................................................................. 731
21.19 Displaying cross references...................................................................................................... 731
A Appendix................................................................................................................................................ 733
A.1 840D sl documentation overview .............................................................................................. 733
Index...................................................................................................................................................... 735

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Operating Manual, 03/2013, 6FC5398-7CP40-3BA1 19
Introduction 1
1.1 Product overview
The SINUMERIK controller is a CNC (Computerized Numerical Controller) for machine tools.
You can use the CNC to implement the following basic functions in conjunction with a
machine tool:
● Creation and adaptation of part programs
● Execution of part programs
● Manual control
● Access to internal and external data media
● Editing of data for programs
● Management of tools, zero points and further user data required in programs
● Diagnostics of controller and machine
Operating areas
The basic functions are grouped in the following operating areas in the controller:
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Introduction
1.2 Operator panel fronts
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20 Operating Manual, 03/2013, 6FC5398-7CP40-3BA1
1.2 Operator panel fronts
1.2.1 Overview
Introduction
The display (screen) and operation (e.g. hardkeys and softkeys) of the SINUMERIK Operate
user interface use the operator panel front.
In this example, the OP 010 operator panel front is used to illustrate the components that are
available for operating the controller and machine tool.
Operator controls and indicators
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1 Status LED: POWER
2 Status LED: TEMP
(illuminated LEDs indicate increased wear)
3 Alphabetic key group
4 Numerical key group
5 Softkeys