Siemens SINUMERIK 828D Turning User manual

Turning
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SINUMERIK
SINUMERIK 840D sl/828D
Turning
Operating Manual
Valid for:
C
ontrollers
SINUMERIK 840D sl / 840DE sl / 828D
S
oftware version
Softwa
re CNC system for 840D sl/ 840DE sl V4.7 SP1
SINUMERIK Operate for PCU/PC
V4.7 SP1
01/2015
6FC5398
-8CP40-5BA2
Preface
Fundamental safety
instructions
1
Introduction
2
Setting up the machine
3
Working in manual mode
4
Machining the workpiece
5
Simulating machining
6
Creating a G code program
7
Creating a ShopTurn
program
8
Programming technology
functions (cycles)
9
Multi-channel machining
10
Collision avoidance
(only 840D sl)
11
Tool management
12
Managing programs
13
Alarm, error and system
messages
14
Working with Manual
Machine
15
Continued on next page

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-8CP40-5BA2
Ⓟ
02/2015 Subject to change
Copyright © Siemens AG 2008 - 2015.
All rights reserved

SINUMERIK 840D sl/828D
Turning
Operating Manual
Continuation
Working with a B axis
(only 840D sl)
16
Working with two tool
carriers
17
Teaching in a program
18
HT 8
19
Ctrl-Energy
20
Easy Message (828D only)
21
Easy Extend (828D only)
22
Service Planner (828D only)
23
Edit PLC user program
(828D only)
24
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-8CP40-5BA2
Ⓟ
02/2015 Subject to change
Copyright © Siemens AG 2008 - 2015.
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, 01/2015, 6FC5398-8CP40-5BA2 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
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6Operating Manual, 01/2015, 6FC5398-8CP40-5BA2
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This documentation is intended for users of turning 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, such as the tapping cycle, is a subprogram defined in SINUMERIK Operate for
executing a frequently repeated machining operation.

Preface
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Operating Manual, 01/2015, 6FC5398-8CP40-5BA2 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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Operating Manual, 01/2015, 6FC5398-8CP40-5BA2 9
Table of contents
Preface ................................................................................................................................................... 5
1 Fundamental safety instructions............................................................................................................ 23
1.1 General safety instructions .....................................................................................................23
1.2 Industrial security ....................................................................................................................24
2 Introduction........................................................................................................................................... 25
2.1 Product overview ....................................................................................................................25
2.2 Operator panel fronts ..............................................................................................................26
2.2.1 Overview .................................................................................................................................26
2.2.2 Keys of the operator panel......................................................................................................27
2.3 Machine control panels ...........................................................................................................37
2.3.1 Overview .................................................................................................................................37
2.3.2 Controls on the machine control panel ...................................................................................37
2.4 User interface..........................................................................................................................41
2.4.1 Screen layout ..........................................................................................................................41
2.4.2 Status display..........................................................................................................................42
2.4.3 Actual value window ...............................................................................................................45
2.4.4 T,F,S window ..........................................................................................................................47
2.4.5 Current block display ..............................................................................................................49
2.4.6 Operation via softkeys and buttons ........................................................................................49
2.4.7 Entering or selecting parameters............................................................................................51
2.4.8 Pocket calculator.....................................................................................................................53
2.4.9 Context menu..........................................................................................................................54
2.4.10 Touch operation ......................................................................................................................54
2.4.11 Changing the user interface language....................................................................................55
2.4.12 Entering Chinese characters ..................................................................................................55
2.4.12.1 Function - input editor .............................................................................................................55
2.4.12.2 Entering Asian characters.......................................................................................................57
2.4.12.3 Editing the dictionary...............................................................................................................58
2.4.13 Entering Korean characters ....................................................................................................60
2.4.14 Protection levels......................................................................................................................62
2.4.15 Online help in SINUMERIK Operate.......................................................................................64
3 Setting up the machine ......................................................................................................................... 67
3.1 Switching on and switching off................................................................................................67
3.2 Approaching a reference point................................................................................................68
3.2.1 Referencing axes ....................................................................................................................68
3.2.2 User agreement ......................................................................................................................69
3.3 Modes and mode groups ........................................................................................................70
3.3.1 General ...................................................................................................................................70
3.3.2 Modes groups and channels...................................................................................................72
3.3.3 Channel switchover.................................................................................................................73

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10 Operating Manual, 01/2015, 6FC5398-8CP40-5BA2
3.4 Settings for the machine ........................................................................................................ 74
3.4.1 Switching over the coordinate system (MCS/WCS) .............................................................. 74
3.4.2 Switching the unit of measurement........................................................................................ 75
3.4.3 Setting the zero offset ............................................................................................................ 76
3.5 Measuring the tool ................................................................................................................. 78
3.5.1 Measuring a tool manually ..................................................................................................... 78
3.5.2 Measuring a tool with a tool probe......................................................................................... 80
3.5.3 Calibrating the tool probe....................................................................................................... 82
3.5.4 Measuring a tool with a magnifying glass .............................................................................. 83
3.5.5 Logging tool measurement results......................................................................................... 84
3.6 Measuring the workpiece zero............................................................................................... 85
3.6.1 Measuring the workpiece zero............................................................................................... 85
3.6.2 Logging measurement results for the workpiece zero ........................................................... 87
3.7 Settings for the measurement result log ................................................................................ 88
3.8 Zero offsets ............................................................................................................................ 90
3.8.1 Display active zero offset ....................................................................................................... 91
3.8.2 Displaying the zero offset "overview"..................................................................................... 92
3.8.3 Displaying and editing base zero offset ................................................................................. 93
3.8.4 Displaying and editing settable zero offset ............................................................................ 94
3.8.5 Displaying and editing details of the zero offsets................................................................... 95
3.8.6 Deleting a zero offset ............................................................................................................. 97
3.8.7 Measuring the workpiece zero............................................................................................... 97
3.9 Monitoring axis and spindle data ........................................................................................... 98
3.9.1 Specify working area limitations............................................................................................. 98
3.9.2 Editing spindle data................................................................................................................ 99
3.9.3 Spindle chuck data............................................................................................................... 100
3.10 Displaying setting data lists.................................................................................................. 102
3.11 Handwheel assignment........................................................................................................ 103
3.12 MDA ..................................................................................................................................... 105
3.12.1 Loading an MDA program from the Program Manager ....................................................... 105
3.12.2 Saving an MDA program...................................................................................................... 106
3.12.3 Editing/executing a MDI program......................................................................................... 107
3.12.4 Deleting an MDA program ................................................................................................... 108
4 Working in manual mode .....................................................................................................................109
4.1 General ................................................................................................................................ 109
4.2 Selecting a tool and spindle ................................................................................................. 109
4.2.1 T,S,M window....................................................................................................................... 109
4.2.2 Selecting a tool..................................................................................................................... 111
4.2.3 Starting and stopping the spindle manually ......................................................................... 112
4.2.4 Positioning the spindle ......................................................................................................... 113
4.3 Traversing axes.................................................................................................................... 114
4.3.1 Traverse axes by a defined increment................................................................................. 114
4.3.2 Traversing axes by a variable increment ............................................................................. 115
4.4 Positioning axes ................................................................................................................... 116
4.5 Manual retraction ................................................................................................................. 117

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4.6 Simple stock removal of workpiece ......................................................................................118
4.7 Thread synchronizing............................................................................................................120
4.8 Default settings for manual mode .........................................................................................122
5 Machining the workpiece..................................................................................................................... 123
5.1 Starting and stopping machining ..........................................................................................123
5.2 Selecting a program..............................................................................................................124
5.3 Executing a trail program run................................................................................................125
5.4 Displaying the current program block ...................................................................................126
5.4.1 Current block display ............................................................................................................126
5.4.2 Displaying a basic block........................................................................................................126
5.4.3 Display program level ...........................................................................................................128
5.5 Correcting a program ............................................................................................................129
5.6 Repositioning axes................................................................................................................130
5.7 Starting machining at a specific point ...................................................................................131
5.7.1 Use block search ..................................................................................................................131
5.7.2 Continuing program from search target ................................................................................133
5.7.3 Simple search target definition .............................................................................................133
5.7.4 Defining an interruption point as search target.....................................................................134
5.7.5 Entering the search target via search pointer.......................................................................135
5.7.6 Parameters for block search in the search pointer ...............................................................136
5.7.7 Block search mode ...............................................................................................................137
5.8 Controlling the program run ..................................................................................................139
5.8.1 Program control ....................................................................................................................139
5.8.2 Skip blocks............................................................................................................................140
5.9 Overstore ..............................................................................................................................142
5.10 Editing a program..................................................................................................................144
5.10.1 Searching in programs..........................................................................................................145
5.10.2 Replacing program text.........................................................................................................146
5.10.3 Copying/pasting/deleting a program block............................................................................148
5.10.4 Renumbering a program.......................................................................................................149
5.10.5 Creating a program block .....................................................................................................150
5.10.6 Opening additional programs................................................................................................152
5.10.7 Editor settings .......................................................................................................................153
5.11 Display and edit user variables.............................................................................................156
5.11.1 Overview ...............................................................................................................................156
5.11.2 R parameters ........................................................................................................................157
5.11.3 Displaying global user data (GUD) .......................................................................................158
5.11.4 Displaying channel GUDs.....................................................................................................159
5.11.5 Displaying local user data (LUD) ..........................................................................................160
5.11.6 Displaying program user data (PUD)....................................................................................161
5.11.7 Searching for user variables .................................................................................................162
5.12 Displaying G functions and auxiliary functions .....................................................................164
5.12.1 Selected G functions.............................................................................................................164
5.12.2 All G functions.......................................................................................................................166
5.12.3 G functions for mold making .................................................................................................166

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5.12.4 Auxiliary functions ................................................................................................................ 168
5.13 Mold making view................................................................................................................. 170
5.13.1 Overview .............................................................................................................................. 170
5.13.2 Starting the mold making view ............................................................................................. 173
5.13.3 Specifically jump to the program block ................................................................................ 174
5.13.4 Searching for program blocks.............................................................................................. 174
5.13.5 Changing the view ............................................................................................................... 175
5.13.5.1 Enlarging or reducing the graphical representation ............................................................. 175
5.13.5.2 Modifying the viewport ......................................................................................................... 176
5.14 Displaying the program runtime and counting workpieces .................................................. 177
5.15 Setting for automatic mode .................................................................................................. 179
5.16 Working with DXF files......................................................................................................... 181
5.16.1 Overview .............................................................................................................................. 181
5.16.2 Displaying CAD drawings .................................................................................................... 181
5.16.2.1 Open a DXF file.................................................................................................................... 181
5.16.2.2 Cleaning a DXF file .............................................................................................................. 182
5.16.2.3 Enlarging or reducing the CAD drawing .............................................................................. 183
5.16.2.4 Modifying the section ........................................................................................................... 183
5.16.2.5 Rotating the view.................................................................................................................. 184
5.16.2.6 Displaying/editing information for the geometric data.......................................................... 185
5.16.3 Importing and editing a DXF file in the editor....................................................................... 186
5.16.3.1 General procedure ............................................................................................................... 186
5.16.3.2 Specifying a reference point ................................................................................................ 186
5.16.3.3 Setting the tolerance ............................................................................................................ 187
5.16.3.4 Transferring the drilling positions ......................................................................................... 188
5.16.3.5 Accepting contours .............................................................................................................. 191
6 Simulating machining...........................................................................................................................195
6.1 Overview .............................................................................................................................. 195
6.2 Simulation before machining of the workpiece .................................................................... 200
6.3 Simultaneous recording before machining of the workpiece ............................................... 201
6.4 Simultaneous recording during machining of the workpiece ............................................... 202
6.5 Different views of the workpiece .......................................................................................... 203
6.5.1 Side view.............................................................................................................................. 203
6.5.2 Half section .......................................................................................................................... 203
6.5.3 Face view ............................................................................................................................. 204
6.5.4 3D view ................................................................................................................................ 204
6.5.5 2-window .............................................................................................................................. 205
6.6 Graphical display.................................................................................................................. 205
6.7 Editing the simulation display............................................................................................... 206
6.7.1 Blank display ........................................................................................................................ 206
6.7.2 Showing and hiding the tool path......................................................................................... 208
6.8 Program control during the simulation ................................................................................. 208
6.8.1 Changing the feedrate ......................................................................................................... 208
6.8.2 Simulating the program block by block ................................................................................ 209
6.9 Editing and adapting a simulation graphic ........................................................................... 210

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6.9.1 Enlarging or reducing the graphical representation..............................................................210
6.9.2 Panning a graphical representation ......................................................................................211
6.9.3 Rotating the graphical representation...................................................................................211
6.9.4 Modifying the viewport ..........................................................................................................212
6.9.5 Defining cutting planes..........................................................................................................213
6.10 Displaying simulation alarms ................................................................................................214
7 Creating a G code program................................................................................................................. 215
7.1 Graphical programming ........................................................................................................215
7.2 Program views ......................................................................................................................215
7.3 Program structure .................................................................................................................218
7.4 Fundamentals .......................................................................................................................219
7.4.1 Machining planes ..................................................................................................................219
7.4.2 Current planes in cycles and input screens ..........................................................................219
7.4.3 Programming a tool (T) .........................................................................................................220
7.5 Generating a G code program ..............................................................................................221
7.6 Blank input ............................................................................................................................222
7.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL,
RP, SC, F).............................................................................................................................225
7.8 Selection of the cycles via softkey ........................................................................................226
7.9 Calling technology cycles .....................................................................................................231
7.9.1 Hiding cycle parameters .......................................................................................................231
7.9.2 Setting data for cycles...........................................................................................................231
7.9.3 Checking cycle parameters ..................................................................................................232
7.9.4 Programming variables .........................................................................................................232
7.9.5 Changing a cycle call ............................................................................................................233
7.9.6 Compatibility for cycle support..............................................................................................233
7.9.7 Additional functions in the input screens ..............................................................................234
7.10 Measuring cycle support .......................................................................................................234
8 Creating a ShopTurn program............................................................................................................. 235
8.1 Graphic program control, ShopTurn programs.....................................................................235
8.2 Program views ......................................................................................................................235
8.3 Program structure .................................................................................................................240
8.4 Fundamentals .......................................................................................................................241
8.4.1 Machining planes ..................................................................................................................241
8.4.2 Machining cycle, approach/retraction ...................................................................................243
8.4.3 Absolute and incremental dimensions..................................................................................245
8.4.4 Polar coordinates ..................................................................................................................246
8.4.5 Clamping the spindle ............................................................................................................247
8.5 Creating a ShopTurn program ..............................................................................................248
8.6 Program header ....................................................................................................................250
8.7 Generating program blocks ..................................................................................................253
8.8 Tool, offset value, feedrate and spindle speed (T, D, F, S, V)..............................................254

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14 Operating Manual, 01/2015, 6FC5398-8CP40-5BA2
8.9 Call work offsets................................................................................................................... 256
8.10 Repeating program blocks ................................................................................................... 257
8.11 Entering the number of workpieces ..................................................................................... 258
8.12 Changing program blocks .................................................................................................... 259
8.13 Changing program settings.................................................................................................. 260
8.14 Selection of the cycles via softkey ....................................................................................... 262
8.15 Calling technology functions ................................................................................................ 267
8.15.1 Additional functions in the input screens ............................................................................. 267
8.15.2 Checking cycle parameters.................................................................................................. 267
8.15.3 Programming variables ........................................................................................................ 268
8.15.4 Setting data for technological functions ............................................................................... 268
8.15.5 Changing a cycle call ........................................................................................................... 269
8.15.6 Compatibility for cycle support ............................................................................................. 269
8.16 Programming the approach/retraction cycle ........................................................................ 270
8.17 Measuring cycle support ...................................................................................................... 272
8.18 Example: Standard machining............................................................................................. 272
8.18.1 Workpiece drawing .............................................................................................................. 273
8.18.2 Programming........................................................................................................................ 274
8.18.3 Results/simulation test ......................................................................................................... 287
8.18.4 G code machining program.................................................................................................. 289
9 Programming technology functions (cycles) .........................................................................................293
9.1 Drilling .................................................................................................................................. 293
9.1.1 General ................................................................................................................................ 293
9.1.2 Centering (CYCLE81) .......................................................................................................... 294
9.1.3 Drilling (CYCLE82)............................................................................................................... 296
9.1.4 Reaming (CYCLE85) ........................................................................................................... 301
9.1.5 Boring (CYCLE86) ............................................................................................................... 303
9.1.6 Deep-hole drilling 1 (CYCLE83)........................................................................................... 306
9.1.7 Deep-hole drilling 2 (CYCLE830)......................................................................................... 312
9.1.8 Tapping (CYCLE84, 840)..................................................................................................... 322
9.1.9 Drill and thread milling (CYCLE78) ...................................................................................... 331
9.1.10 Positions and position patterns ............................................................................................ 335
9.1.11 Arbitrary positions (CYCLE802)........................................................................................... 336
9.1.12 Row position pattern (HOLES1)........................................................................................... 341
9.1.13 Grid or frame position pattern (CYCLE801)......................................................................... 343
9.1.14 Circle or pitch circle position pattern (HOLES2) .................................................................. 347
9.1.15 Displaying and hiding positions............................................................................................ 352
9.1.16 Repeating positions ............................................................................................................. 354
9.2 Rotate................................................................................................................................... 355
9.2.1 General ................................................................................................................................ 355
9.2.2 Stock removal (CYCLE951)................................................................................................. 355
9.2.3 Groove (CYCLE930)............................................................................................................ 358
9.2.4 Undercut form E and F (CYCLE940) ................................................................................... 361
9.2.5 Thread undercuts (CYCLE940) ........................................................................................... 363
9.2.6 Thread turning (CYCLE99) .................................................................................................. 366
9.2.7 Thread chain (CYCLE98)..................................................................................................... 382

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9.2.8 Cut-off (CYCLE92)................................................................................................................388
9.3 Contour turning .....................................................................................................................390
9.3.1 General information ..............................................................................................................390
9.3.2 Representation of the contour ..............................................................................................391
9.3.3 Creating a new contour.........................................................................................................392
9.3.4 Creating contour elements....................................................................................................394
9.3.5 Entering the master dimension .............................................................................................400
9.3.6 Changing the contour............................................................................................................402
9.3.7 Contour call (CYCLE62) - only for G code program .............................................................403
9.3.8 Stock removal (CYCLE952)..................................................................................................404
9.3.9 Stock removal rest (CYCLE952)...........................................................................................412
9.3.10 Plunge-cutting (CYCLE952) .................................................................................................415
9.3.11 Plunge-cutting rest (CYCLE952) ..........................................................................................420
9.3.12 Plunge-turning (CYCLE952) .................................................................................................423
9.3.13 Plunge-turning rest (CYCLE952) ..........................................................................................429
9.4 Milling....................................................................................................................................431
9.4.1 Face milling (CYCLE61) .......................................................................................................431
9.4.2 Rectangular pocket (POCKET3)...........................................................................................435
9.4.3 Circular pocket (POCKET4)..................................................................................................444
9.4.4 Rectangular spigot (CYCLE76) ............................................................................................454
9.4.5 Circular spigot (CYCLE77) ...................................................................................................461
9.4.6 Multi-edge (CYCLE79)..........................................................................................................468
9.4.7 Longitudinal groove (SLOT1)................................................................................................473
9.4.8 Circumferential groove (SLOT2)...........................................................................................482
9.4.9 Open groove (CYCLE899)....................................................................................................490
9.4.10 Long hole (LONGHOLE) - only for G code program ............................................................501
9.4.11 Thread milling (CYCLE70)....................................................................................................503
9.4.12 Engraving (CYCLE60) ..........................................................................................................507
9.5 Contour milling ......................................................................................................................514
9.5.1 General information ..............................................................................................................514
9.5.2 Representation of the contour ..............................................................................................514
9.5.3 Creating a new contour.........................................................................................................516
9.5.4 Creating contour elements....................................................................................................519
9.5.5 Changing the contour............................................................................................................524
9.5.6 Contour call (CYCLE62) - only for G code program .............................................................525
9.5.7 Path milling (CYCLE72) ........................................................................................................526
9.5.8 Contour pocket/contour spigot (CYCLE63/64) .....................................................................532
9.5.9 Predrilling contour pocket (CYCLE64)..................................................................................534
9.5.10 Milling contour pocket (CYCLE63)........................................................................................538
9.5.11 Contour pocket residual material (CYCLE63, option)...........................................................544
9.5.12 Milling contour spigot (CYCLE63).........................................................................................547
9.5.13 Contour spigot residual material (CYCLE63, option)............................................................552
9.6 Further cycles and functions.................................................................................................555
9.6.1 Swiveling plane / aligning tool (CYCLE800) .........................................................................555
9.6.2 Swiveling tool (CYCLE800) ..................................................................................................563
9.6.2.1 Aligning turning tools - only for G code program (CYCLE800).............................................563
9.6.2.2 Aligning milling tools - only for G code program (CYCLE800)..............................................566
9.6.2.3 Preloading milling tools - only for G code program (CYCLE800) .........................................567
9.6.3 High-speed settings (CYCLE832).........................................................................................568
9.6.4 Subroutines...........................................................................................................................572

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9.7 Additional cycles and functions in ShopTurn ....................................................................... 574
9.7.1 Drilling centric....................................................................................................................... 574
9.7.2 Thread centered................................................................................................................... 578
9.7.3 Transformations ................................................................................................................... 581
9.7.4 Translation ........................................................................................................................... 583
9.7.5 Rotation................................................................................................................................ 584
9.7.6 Scaling ................................................................................................................................. 585
9.7.7 Mirroring ............................................................................................................................... 586
9.7.8 Rotation C ............................................................................................................................ 587
9.7.9 Straight and circular machining............................................................................................ 588
9.7.10 Selecting a tool and machining plane .................................................................................. 589
9.7.11 Programming a straight line ................................................................................................. 591
9.7.12 Programming a circle with known center point .................................................................... 593
9.7.13 Programming a circle with known radius ............................................................................. 595
9.7.14 Polar coordinates ................................................................................................................. 597
9.7.15 Straight line polar ................................................................................................................. 598
9.7.16 Circle polar ........................................................................................................................... 600
9.7.17 Machining with movable counterspindle .............................................................................. 601
9.7.17.1 Programming example: Machining main spindle – Transfer workpiece – Machining
counterspindle...................................................................................................................... 602
9.7.17.2 Programming example: Machining counter-spindle – Transfer workpiece – Machining
main spindle ......................................................................................................................... 602
9.7.17.3 Programming example: Machining, counterspindle - without previous transfer .................. 603
9.7.17.4 Programming example: Machining bar material .................................................................. 603
9.7.18 Machining with fixed counterspindle .................................................................................... 609
10 Multi-channel machining ......................................................................................................................611
10.1 Multi-channel view ............................................................................................................... 611
10.1.1 Multi-channel view in the "Machine" operating area ............................................................ 611
10.1.2 Multi-channel view for large operator panels ....................................................................... 614
10.1.3 Setting the multi-channel view ............................................................................................. 615
10.2 Multi-channel support........................................................................................................... 617
10.2.1 Working with several channels ............................................................................................ 617
10.2.2 Creating a multi-channel program........................................................................................ 618
10.2.3 Entering multi-channel data ................................................................................................. 619
10.2.4 Multi-channel functionality for large operator panels ........................................................... 622
10.2.5 Editing the multi-channel program ....................................................................................... 625
10.2.5.1 Changing the job list ............................................................................................................ 625
10.2.5.2 Editing a G code multi-channel program ............................................................................. 626
10.2.5.3 Editing a ShopTurn multi-channel program ......................................................................... 628
10.2.5.4 Creating a program block..................................................................................................... 636
10.2.6 Setting the multi-channel function........................................................................................ 638
10.2.7 Synchronizing programs ...................................................................................................... 640
10.2.8 Insert WAIT marks ............................................................................................................... 643
10.2.9 Optimizing the machining time............................................................................................. 644
10.2.10 Automatic block building ...................................................................................................... 646
10.2.10.1 Creating automated program blocks.................................................................................... 646
10.2.10.2 Editing a converted program................................................................................................ 647
10.2.11 Simulating machining........................................................................................................... 648
10.2.11.1 Simulation ............................................................................................................................ 648
10.2.11.2 Different workpiece views for multi-channel support ........................................................... 650
10.2.12 Display/edit the multi-channel functionality in the "Machine" operating area ...................... 651

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10.2.12.1 Running-in a program ...........................................................................................................651
10.2.12.2 Block search and program control ........................................................................................652
10.2.13 Stock removal with 2 synchronized channels.......................................................................654
10.2.13.1 Job list...................................................................................................................................656
10.2.13.2 Stock removal .......................................................................................................................658
10.2.14 Synchronizing a counterspindle............................................................................................659
11 Collision avoidance (only 840D sl)....................................................................................................... 665
11.1 Activating collision avoidance ...............................................................................................665
11.2 Set collision avoidance .........................................................................................................667
12 Tool management ............................................................................................................................... 669
12.1 Lists for the tool management ..............................................................................................669
12.2 Magazine management ........................................................................................................670
12.3 Tool types .............................................................................................................................671
12.4 Tool dimensioning.................................................................................................................674
12.5 Tool list..................................................................................................................................679
12.5.1 Additional data ......................................................................................................................683
12.5.2 Creating a new tool ...............................................................................................................684
12.5.3 Measuring the tool ................................................................................................................686
12.5.4 Managing several cutting edges ...........................................................................................687
12.5.5 Delete tool.............................................................................................................................687
12.5.6 Loading and unloading tools.................................................................................................688
12.5.7 Selecting a magazine............................................................................................................690
12.5.8 Code carrier connection (only 840D sl) ................................................................................691
12.5.8.1 Overview ...............................................................................................................................691
12.5.9 Managing a tool in a file........................................................................................................694
12.6 Tool wear ..............................................................................................................................696
12.6.1 Reactivate tool ......................................................................................................................699
12.7 Tool data OEM......................................................................................................................700
12.8 Magazine ..............................................................................................................................702
12.8.1 Positioning a magazine.........................................................................................................704
12.8.2 Relocating a tool ...................................................................................................................704
12.8.3 Unload/load/relocate all tools................................................................................................705
12.9 Tool details............................................................................................................................707
12.9.1 Displaying tool details ...........................................................................................................707
12.9.2 Tool data ...............................................................................................................................708
12.9.3 Cutting edge data..................................................................................................................709
12.9.4 Monitoring data .....................................................................................................................711
12.10 Sorting tool management lists ..............................................................................................712
12.11 Filtering the tool management lists .......................................................................................713
12.12 Specific search in the tool management lists .......................................................................715
12.13 Changing the cutting edge position or tool type ...................................................................717
12.14 Settings for tool lists..............................................................................................................718
12.15 Working with multitool ...........................................................................................................720

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18 Operating Manual, 01/2015, 6FC5398-8CP40-5BA2
12.15.1 Tool list for multitool ............................................................................................................. 721
12.15.2 Create multitool.................................................................................................................... 722
12.15.3 Equipping multitool with tools............................................................................................... 724
12.15.4 Removing a tool from multitool ............................................................................................ 725
12.15.5 Delete multitool .................................................................................................................... 725
12.15.6 Loading and unloading multitool .......................................................................................... 726
12.15.7 Reactivating the multitool..................................................................................................... 727
12.15.8 Relocating a multitool........................................................................................................... 729
12.15.9 Positioning multitool ............................................................................................................. 730
13 Managing programs .............................................................................................................................731
13.1 Overview .............................................................................................................................. 731
13.1.1 NC memory .......................................................................................................................... 734
13.1.2 Local drive............................................................................................................................ 735
13.1.3 USB drives ........................................................................................................................... 736
13.1.4 FTP drive.............................................................................................................................. 737
13.2 Opening and closing the program........................................................................................ 738
13.3 Executing a program............................................................................................................ 740
13.4 Creating a directory / program / job list / program list .......................................................... 742
13.4.1 Creating a new directory ...................................................................................................... 742
13.4.2 Creating a new workpiece.................................................................................................... 743
13.4.3 Creating a new G code program.......................................................................................... 744
13.4.4 New ShopTurn program....................................................................................................... 744
13.4.5 Storing any new file.............................................................................................................. 745
13.4.6 Creating a job list ................................................................................................................. 746
13.4.7 Creating a program list......................................................................................................... 748
13.5 Creating templates............................................................................................................... 749
13.6 Searching directories and files............................................................................................. 750
13.7 Displaying the program in the Preview. ............................................................................... 751
13.8 Selecting several directories/programs................................................................................ 752
13.9 Copying and pasting a directory/program............................................................................ 754
13.10 Deleting a directory/program................................................................................................ 756
13.11 Changing file and directory properties ................................................................................. 757
13.12 Set up drives ........................................................................................................................ 758
13.12.1 Overview .............................................................................................................................. 758
13.12.2 Setting up drives .................................................................................................................. 759
13.13 Viewing PDF documents...................................................................................................... 765
13.14 EXTCALL ............................................................................................................................. 767
13.15 Execution from External Storage (EES) .............................................................................. 769
13.15.1 Overview .............................................................................................................................. 769
13.16 Backing up data ................................................................................................................... 770
13.16.1 Generating an archive in the Program Manager.................................................................. 770
13.16.2 Generating an archive via the system data ......................................................................... 771
13.16.3 Reading in an archive in the Program Manager .................................................................. 773
13.16.4 Read in archive from system data ....................................................................................... 774

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13.17 Setup data.............................................................................................................................776
13.17.1 Backing up setup data ..........................................................................................................776
13.17.2 Reading-in set-up data..........................................................................................................779
13.18 RS-232-C ..............................................................................................................................781
13.18.1 Reading-in and reading-out archives via a serial interface...................................................781
13.18.2 Setting V24 in the program manager....................................................................................783
14 Alarm, error and system messages ..................................................................................................... 785
14.1 Displaying alarms..................................................................................................................785
14.2 Displaying an alarm log.........................................................................................................787
14.3 Displaying messages ............................................................................................................788
14.4 Sorting, alarms, faults and messages...................................................................................789
14.5 Creating screenshots ............................................................................................................790
14.6 PLC and NC variables ..........................................................................................................791
14.6.1 Displaying and editing PLC and NC variables......................................................................791
14.6.2 Saving and loading screen forms .........................................................................................795
14.7 Version..................................................................................................................................796
14.7.1 Displaying version data.........................................................................................................796
14.7.2 Save information ...................................................................................................................797
14.8 Logbook ................................................................................................................................798
14.8.1 Displaying and editing the logbook .......................................................................................798
14.8.2 Making a logbook entry.........................................................................................................799
14.9 Remote diagnostics ..............................................................................................................801
14.9.1 Setting remote access ..........................................................................................................801
14.9.2 Permit modem.......................................................................................................................803
14.9.3 Request remote diagnostics .................................................................................................803
14.9.4 Exit remote diagnostics.........................................................................................................804
15 Working with Manual Machine............................................................................................................. 805
15.1 Manual Machine....................................................................................................................805
15.2 Measuring the tool ................................................................................................................806
15.3 Setting the zero offset...........................................................................................................806
15.4 Set limit stop .........................................................................................................................807
15.5 Simple workpiece machining ................................................................................................808
15.5.1 Traversing axes ....................................................................................................................808
15.5.2 Taper turning.........................................................................................................................809
15.5.3 Straight and circular machining ............................................................................................810
15.5.3.1 Straight turning......................................................................................................................810
15.5.3.2 Circular turning......................................................................................................................812
15.6 More complex machining ......................................................................................................813
15.6.1 Drilling with Manual Machine ................................................................................................814
15.6.2 Turning with manual machine...............................................................................................816
15.6.3 Contour turning with Manual machine ..................................................................................818
15.6.4 Milling with Manual Machine.................................................................................................819
15.7 Simulation and simultaneous recording................................................................................820

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20 Operating Manual, 01/2015, 6FC5398-8CP40-5BA2
16 Working with a B axis (only 840D sl) ....................................................................................................821
16.1 Lathes with B axis ................................................................................................................ 821
16.2 Tool alignment for turning .................................................................................................... 824
16.3 Milling with a B axis.............................................................................................................. 825
16.4 Swiveling .............................................................................................................................. 826
16.5 Approach/retraction.............................................................................................................. 828
16.6 Position pattern .................................................................................................................... 830
16.7 Tool selection for the manual mode..................................................................................... 832
16.8 Measuring a tool with the B axis .......................................................................................... 833
17 Working with two tool carriers...............................................................................................................835
17.1 Programming with two tool holders...................................................................................... 835
17.2 Measure tool ........................................................................................................................ 836
18 Teaching in a program .........................................................................................................................837
18.1 Overview .............................................................................................................................. 837
18.2 General sequence................................................................................................................ 837
18.3 Inserting a block................................................................................................................... 838
18.3.1 Input parameters for teach-in blocks.................................................................................... 839
18.4 Teach-in via Windows .......................................................................................................... 841
18.4.1 General ................................................................................................................................ 841
18.4.2 Teach in rapid traverse G0 .................................................................................................. 842
18.4.3 Teach in straight G1............................................................................................................. 842
18.4.4 Teaching in circle intermediate and circle end point CIP..................................................... 843
18.4.5 Teach-in A spline ................................................................................................................. 843
18.5 Editing a block...................................................................................................................... 845
18.6 Selecting a block.................................................................................................................. 846
18.7 Deleting a block.................................................................................................................... 847
18.8 Settings for teach-in ............................................................................................................. 848
19 HT 8 ....................................................................................................................................................849
19.1 HT 8 overview ...................................................................................................................... 849
19.2 Traversing keys.................................................................................................................... 852
19.3 Machine control panel menu................................................................................................ 853
19.4 Virtual keyboard ................................................................................................................... 854
19.5 Calibrating the touch panel .................................................................................................. 856
20 Ctrl-Energy ..........................................................................................................................................857
20.1 Overview .............................................................................................................................. 857
20.2 Displaying energy consumption........................................................................................... 858
20.3 Measuring and saving the energy consumption .................................................................. 860