Siemens SINUMERIK 840D sl User manual

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Turning
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SINUMERIK
SINUMERIK 840D sl/828D
Turning
Operating Manual
Valid for:
SINUMERIK 828D with CNC system software
Version 4.3
CNC software for 840D sl/ 840DE sl Version 2.6 SP1
SINUMERIK Operate Version 2.6 SP1
for PCU/PC
07/2010
6FC5398-8CP40-0BA0
Preface
Introduction
1
Setting up the machine
2
Working in manual mode
3
Machining the workpiece
4
Simulating a machining
operation
5
Creating G code program
6
Creating a ShopTurn
program
7
Programming technology
functions (cycles)
8
Multi-channel support
9
User data
10
Teaching in a program
11
Working with a B axis
12
Tool management
13
Program management
14
Setting up drives
15
HT 8
16
Easy Message (828D only)
17
Easy Extend (828D only)
18
Service Planner (828D only)
19
Ladder Viewer and Ladder
add-on (828D only)
20
Alarms, error messages, and
system alarms
21
Appendix
A

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
order number: 6FC5398-8CP40-0BA0
Ⓟ 06/2010
Copyright © Siemens AG 2010.
Technical data subject to change

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Preface
Structure of the documentation
The SINUMERIK documentation is organized in three parts:
● General documentation
● User documentation
● Manufacturer/service documentation
Information on the following topics is available at
http://www.siemens.com/motioncontrol/docu
● Ordering documentation
Here you can find an up-to-date overview of publications.
● Downloading documentation
Links to more information for downloading files from Service & Support.
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWEB.
● Compiling individual documentation on the basis of Siemens contents with the My
Documentation Manager (MDM), refer to http://www.siemens.com/mdm.
My Documentation Manager provides you with a range of features for generating your
own machine documentation.
● Training and FAQs
Information on our range of training courses and FAQs (frequently asked questions) is
available via the page navigation.
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.

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Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
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.
For the sake of simplicity, this documentation does not contain all detailed information about
all types of the product and cannot cover every conceivable case of installation, operation, or
maintenance.
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.
Technical Support
If you have any technical questions, please contact our hotline:
Europe/Africa
Telephone [phone]
Fax [phone]
0.14 €/min from a German landline; cell phone charges may vary.
Internet http://www.siemens.com/automation/support-request
Americas
Telephone [phone]
Fax [phone]
E-mail mailto:[email protected]

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Asia/Pacific
Telephone [phone]
Fax [phone]
E-mail mailto:support.asia.automatio[email protected]
Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
http://www.automation.siemens.com/partner
Questions on
If you have any queries (suggestions, corrections) in relation to this documentation, please
fax or e-mail us:
Fax [phone]
E-mail mailto:[email protected]m
A fax form is available in the appendix of this document.
Internet address
http://www.siemens.com/motioncontrol

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...........................................................................................................22
1.3 Machine control panels ................................................................................................................28
1.3.1 Overview ......................................................................................................................................28
1.3.2 Controls on the machine control panel ........................................................................................28
1.4 User interface...............................................................................................................................31
1.4.1 Screen layout ...............................................................................................................................31
1.4.2 Status display...............................................................................................................................32
1.4.3 Actual value window ....................................................................................................................35
1.4.4 T,F,S window ...............................................................................................................................36
1.4.5 Current block display ...................................................................................................................37
1.4.6 Operation via softkeys and buttons .............................................................................................38
1.4.7 Entering or selecting parameters.................................................................................................39
1.4.8 Pocket calculator..........................................................................................................................42
1.4.9 Context menu...............................................................................................................................43
1.4.10 Touch operation ...........................................................................................................................44
1.4.11 Changing the user interface language.........................................................................................44
1.4.12 Entering Asian characters............................................................................................................45
1.4.13 Protection levels...........................................................................................................................47
1.4.14 Online help in SINUMERIK Operate............................................................................................49
2 Setting up the machine............................................................................................................................ 53
2.1 Switching on and switching off.....................................................................................................53
2.2 Approaching a reference point.....................................................................................................54
2.2.1 Referencing axes .........................................................................................................................54
2.2.2 User agreement ...........................................................................................................................56
2.3 Modes and mode groups .............................................................................................................58
2.3.1 General ........................................................................................................................................58
2.3.2 Modes groups and channels........................................................................................................60
2.3.3 Channel switchover......................................................................................................................61
2.4 Settings for the machine ..............................................................................................................62
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................62
2.4.2 Switching the unit of measurement..............................................................................................62
2.4.3 Setting the work offset .................................................................................................................63
2.5 Measuring the tool .......................................................................................................................66
2.5.1 Measuring a tool manually...........................................................................................................66
2.5.2 Measuring a tool with a tool probe...............................................................................................68
2.5.3 Calibrating the tool probe.............................................................................................................70
2.6 Measuring the workpiece zero.....................................................................................................71

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2.7 Work offsets ................................................................................................................................ 73
2.7.1 Display active zero offset ............................................................................................................ 74
2.7.2 Displaying the work offset "overview" ......................................................................................... 75
2.7.3 Displaying and editing base zero offset ...................................................................................... 76
2.7.4 Displaying and editing settable zero offset ................................................................................. 77
2.7.5 Displaying the zero offset details. ............................................................................................... 78
2.7.6 Deleting a work offset.................................................................................................................. 79
2.7.7 Measuring the workpiece zero .................................................................................................... 80
2.8 Monitoring axis and spindle data ................................................................................................ 81
2.8.1 Specify working area limitations.................................................................................................. 81
2.8.2 Editing spindle data..................................................................................................................... 82
2.8.3 Spindle chuck data...................................................................................................................... 83
2.9 Displaying setting data lists......................................................................................................... 86
2.10 Handwheel assignment............................................................................................................... 87
2.11 MDA ............................................................................................................................................ 89
2.11.1 Loading an MDA program from the Program Manager .............................................................. 89
2.11.2 Saving an MDA program............................................................................................................. 90
2.11.3 Executing an MDA program........................................................................................................ 91
2.11.4 Deleting an MDA program........................................................................................................... 91
3 Working in manual mode ......................................................................................................................... 93
3.1 General........................................................................................................................................ 93
3.2 Selecting a tool and spindle ........................................................................................................ 94
3.2.1 T,S,M window.............................................................................................................................. 94
3.2.2 Selecting a tool............................................................................................................................ 95
3.2.3 Starting and stopping the spindle manually ................................................................................ 96
3.2.4 Positioning the spindle ................................................................................................................ 97
3.3 Traversing axes........................................................................................................................... 98
3.3.1 Traverse axes by a defined increment........................................................................................ 98
3.3.2 Traversing axes by a variable increment .................................................................................... 99
3.4 Positioning axes ........................................................................................................................ 101
3.5 Simple stock removal of workpiece........................................................................................... 102
3.6 Thread synchronizing................................................................................................................ 104
3.7 Default settings for manual mode ............................................................................................. 106
4 Machining the workpiece ....................................................................................................................... 107
4.1 Starting and stopping machining............................................................................................... 107
4.2 Selecting a program.................................................................................................................. 109
4.3 Executing a trail program run.................................................................................................... 110
4.4 Displaying the current program block .......................................................................................112
4.4.1 Current block display................................................................................................................. 112
4.4.2 Displaying a basic block............................................................................................................ 112
4.4.3 Display program level................................................................................................................ 113
4.5 Correcting a program ................................................................................................................ 115
4.6 Repositioning axes.................................................................................................................... 116
4.7 Starting machining at a specific point ....................................................................................... 117
4.7.1 Use block search....................................................................................................................... 117

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4.7.2 Continuing program from search target .....................................................................................119
4.7.3 Simple search target definition...................................................................................................119
4.7.4 Defining an interruption point as search target..........................................................................120
4.7.5 Entering the search target via search pointer ............................................................................121
4.7.6 Parameters for block search in the search pointer ....................................................................122
4.7.7 Block search mode ....................................................................................................................123
4.8 Intervening in the program sequence ........................................................................................125
4.8.1 Program control..........................................................................................................................125
4.8.2 Skip blocks.................................................................................................................................127
4.9 Overstore ...................................................................................................................................129
4.10 Editing a program.......................................................................................................................131
4.10.1 Searching in programs...............................................................................................................131
4.10.2 Exchanging program text...........................................................................................................133
4.10.3 Copying/pasting/deleting a program block.................................................................................134
4.10.4 Renumbering a program............................................................................................................135
4.10.5 Opening a second program .......................................................................................................136
4.10.6 Editor settings ............................................................................................................................137
4.11 Displaying G functions and auxiliary functions ..........................................................................139
4.11.1 Selected G functions..................................................................................................................139
4.11.2 All G functions............................................................................................................................141
4.11.3 Auxiliary functions ......................................................................................................................142
4.12 Displaying the program runtime and counting workpieces........................................................145
4.13 Setting for automatic mode........................................................................................................147
5 Simulating a machining operation.......................................................................................................... 149
5.1 Overview ....................................................................................................................................149
5.2 Simulation before machining of the workpiece ..........................................................................153
5.3 Simultaneous recording before machining of the workpiece.....................................................155
5.4 Simultaneous recording during machining of the workpiece .....................................................156
5.5 Different views of a workpiece ...................................................................................................157
5.5.1 Side view....................................................................................................................................157
5.5.2 Half section ................................................................................................................................157
5.5.3 Face view...................................................................................................................................158
5.5.4 3D view ......................................................................................................................................158
5.5.5 2-window....................................................................................................................................159
5.6 Graphical display .......................................................................................................................160
5.7 Editing the simulation display.....................................................................................................161
5.7.1 Entering blank details.................................................................................................................161
5.7.2 Showing and hiding the tool path...............................................................................................161
5.8 Program control during the simulation.......................................................................................162
5.8.1 Changing the feedrate ...............................................................................................................162
5.8.2 Simulating the program block by block ......................................................................................163
5.9 Editing and adapting a simulation graphic.................................................................................164
5.9.1 Enlarging or reducing the graphical representation...................................................................164
5.9.2 Panning a graphical representation ...........................................................................................165
5.9.3 Rotating the graphical representation........................................................................................165
5.9.4 Modifying the viewport ...............................................................................................................166
5.9.5 Defining cutting planes...............................................................................................................167

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5.10 Displaying simulation alarms..................................................................................................... 168
6 Creating G code program ...................................................................................................................... 169
6.1 Graphical programming............................................................................................................. 169
6.2 Program views .......................................................................................................................... 170
6.3 Program structure ..................................................................................................................... 173
6.4 Basic information....................................................................................................................... 174
6.4.1 Machining planes ...................................................................................................................... 174
6.4.2 Current planes in cycles and input screens .............................................................................. 174
6.4.3 Programming a tool (T) ............................................................................................................. 175
6.5 Generating a G code program .................................................................................................. 176
6.6 Blank input ................................................................................................................................ 177
6.6.1 Function..................................................................................................................................... 177
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F)........................................................................................................................................ 179
6.8 Selection of the cycles via softkey ............................................................................................ 180
6.9 Calling technology cycles.......................................................................................................... 186
6.9.1 Hiding cycle parameters............................................................................................................ 186
6.9.2 Setting data for cycles............................................................................................................... 186
6.9.3 Checking cycle parameters....................................................................................................... 187
6.9.4 Changing a cycle call ................................................................................................................ 187
6.9.5 Additional functions in the input screens................................................................................... 188
6.10 Measuring cycle support ........................................................................................................... 189
7 Creating a ShopTurn program ............................................................................................................... 191
7.1 Graphic program control, ShopTurn programs ......................................................................... 191
7.2 Program views .......................................................................................................................... 192
7.3 Program structure ..................................................................................................................... 195
7.4 Basic information....................................................................................................................... 196
7.4.1 Machining planes ...................................................................................................................... 196
7.4.2 Machining cycle, approach/retraction ....................................................................................... 198
7.4.3 Absolute and incremental dimensions ......................................................................................200
7.4.4 Polar coordinates ...................................................................................................................... 202
7.4.5 Entering the master dimension ................................................................................................. 203
7.5 Creating a ShopTurn program .................................................................................................. 204
7.6 Program header ........................................................................................................................ 206
7.7 Generating program blocks....................................................................................................... 208
7.8 Tool, offset value, feedrate and spindle speed (T, D, F, S, V).................................................. 209
7.9 Call work offsets........................................................................................................................ 212
7.10 Repeating program blocks ........................................................................................................ 213
7.11 Entering the number of workpieces .......................................................................................... 215
7.12 Changing program blocks ......................................................................................................... 216
7.13 Changing program settings....................................................................................................... 217
7.14 Selection of the cycles via softkey ............................................................................................ 219

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7.15 Calling technology functions ......................................................................................................225
7.15.1 Additional functions in the input screens ...................................................................................225
7.15.2 Checking cycle parameters........................................................................................................225
7.15.3 Setting data for technological functions .....................................................................................226
7.15.4 Changing a cycle call .................................................................................................................226
7.16 Programming the approach/retraction cycle..............................................................................227
7.17 Measuring cycle support ............................................................................................................229
7.18 Example: Standard machining...................................................................................................231
7.18.1 Workpiece drawing ....................................................................................................................232
7.18.2 Programming..............................................................................................................................232
7.18.3 Results/simulation test ...............................................................................................................246
7.18.4 G code machining program........................................................................................................248
8 Programming technology functions (cycles) .......................................................................................... 251
8.1 Drilling ........................................................................................................................................251
8.1.1 General ......................................................................................................................................251
8.1.2 Centering (CYCLE81) ................................................................................................................252
8.1.3 Drilling (CYCLE82).....................................................................................................................254
8.1.4 Reaming (CYCLE85) .................................................................................................................255
8.1.5 Deep-hole drilling (CYCLE83)....................................................................................................257
8.1.6 Boring (CYCLE86) .....................................................................................................................260
8.1.7 Tapping (CYCLE84, 840)...........................................................................................................261
8.1.8 Drill and thread milling (CYCLE78)............................................................................................266
8.1.9 Positioning and position patterns...............................................................................................269
8.1.9.1 Approach/retraction....................................................................................................................270
8.1.10 Arbitrary positions (CYCLE802).................................................................................................271
8.1.11 Position pattern line (HOLES1), grid or frame (CYCLE801)......................................................273
8.1.12 Circle position pattern (HOLES2)...............................................................................................276
8.1.13 Repeating positions ...................................................................................................................279
8.2 Rotate.........................................................................................................................................280
8.2.1 General ......................................................................................................................................280
8.2.2 Stock removal (CYCLE951).......................................................................................................280
8.2.3 Groove (CYCLE930)..................................................................................................................283
8.2.4 Undercut form E and F (CYCLE940) .........................................................................................286
8.2.5 Thread undercuts (CYCLE940) .................................................................................................288
8.2.6 Thread turning (CYCLE99) ........................................................................................................291
8.2.7 Thread chain (CYCLE98)...........................................................................................................300
8.2.8 Cut-off (CYCLE92).....................................................................................................................302
8.3 Contour turning ..........................................................................................................................305
8.3.1 General information ...................................................................................................................305
8.3.2 Representation of the contour....................................................................................................306
8.3.3 Creating a new contour..............................................................................................................307
8.3.4 Creating contour elements.........................................................................................................309
8.3.5 Changing the contour.................................................................................................................314
8.3.6 Contour call (CYCLE62) - only for G code program ..................................................................315
8.3.7 Stock removal (CYCLE952).......................................................................................................316
8.3.8 Stock removal rest (CYCLE952)................................................................................................321
8.3.9 Plunge-cutting (CYCLE952).......................................................................................................323
8.3.10 Plunge-cutting rest (CYCLE952)................................................................................................326
8.3.11 Plunge-turning (CYCLE952) ......................................................................................................328
8.3.12 Plunge-turning rest (CYCLE952) ...............................................................................................331
8.4 Milling.........................................................................................................................................333

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8.4.1 Face milling (CYCLE61)............................................................................................................ 333
8.4.2 Rectangular pocket (POCKET3)............................................................................................... 336
8.4.3 Circular pocket (POCKET4)...................................................................................................... 340
8.4.4 Rectangular spigot (CYCLE76)................................................................................................. 345
8.4.5 Circular spigot (CYCLE77)........................................................................................................ 348
8.4.6 Multi-edge (CYCLE79).............................................................................................................. 351
8.4.7 Longitudinal groove (SLOT1).................................................................................................... 353
8.4.8 Circumferential groove (SLOT2) ............................................................................................... 357
8.4.9 Open groove (CYCLE899)........................................................................................................ 361
8.4.10 Long hole (LONGHOLE) - only for G code program................................................................. 368
8.4.11 Thread milling (CYCLE70) ........................................................................................................ 370
8.4.12 Engraving (CYCLE60)............................................................................................................... 373
8.5 Contour milling .......................................................................................................................... 380
8.5.1 General information................................................................................................................... 380
8.5.2 Representation of the contour................................................................................................... 380
8.5.3 Creating a new contour............................................................................................................. 382
8.5.4 Creating contour elements........................................................................................................ 384
8.5.5 Changing the contour................................................................................................................ 389
8.5.6 Contour call (CYCLE62) - only for G code program ................................................................. 390
8.5.7 Path milling (CYCLE72) ............................................................................................................ 391
8.5.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 395
8.5.9 Predrilling contour pocket (CYCLE64)...................................................................................... 397
8.5.10 Milling contour pocket (CYCLE63)............................................................................................ 401
8.5.11 Contour pocket residual material (CYCLE63, option)............................................................... 404
8.5.12 Milling contour spigot (CYCLE63)............................................................................................. 406
8.5.13 Contour spigot residual material (CYCLE63, option)................................................................ 409
8.6 Further cycles and functions ..................................................................................................... 412
8.6.1 Swiveling plane/tool (CYCLE800)............................................................................................. 412
8.6.2 Swiveling tool (CYCLE800)....................................................................................................... 420
8.6.2.1 Orienting turning tools - only for G code program (CYCLE800) ............................................... 420
8.6.2.2 Orienting milling tools - only for G code program (CYCLE800)................................................ 421
8.6.2.3 Preloading milling tools - only for G code program (CYCLE800) ............................................. 422
8.6.3 High-speed settings (CYCLE832)............................................................................................. 424
8.6.4 Subroutines ............................................................................................................................... 425
8.7 Further cycles and functions ShopTurn .................................................................................... 428
8.7.1 Drilling centric............................................................................................................................ 428
8.7.2 Thread centered........................................................................................................................ 430
8.7.3 Transformations ........................................................................................................................ 432
8.7.4 Translation................................................................................................................................. 434
8.7.5 Rotation..................................................................................................................................... 435
8.7.6 Scaling....................................................................................................................................... 436
8.7.7 Mirroring .................................................................................................................................... 437
8.7.8 Rotation C ................................................................................................................................. 438
8.7.9 Straight and circular machining................................................................................................. 439
8.7.10 Selecting a tool and machining plane ....................................................................................... 440
8.7.11 Programming a straight line ...................................................................................................... 442
8.7.12 Programming a circle with known center point ......................................................................... 444
8.7.13 Programming a circle with known radius ..................................................................................446
8.7.14 Polar coordinates ...................................................................................................................... 448
8.7.15 Straight line polar ...................................................................................................................... 449
8.7.16 Circle polar ................................................................................................................................ 451
8.7.17 Machining with the counterspindle............................................................................................ 452
8.7.17.1 Programming example: Machining main spindle – Transfer workpiece – Machining
counterspindle........................................................................................................................... 454

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8.7.17.2 Programming example: Machining, counterspindle - without previous transfer ........................454
8.7.17.3 Programming example: Machining bar material ........................................................................455
8.7.17.4 Parameters, counterspindle.......................................................................................................455
9 Multi-channel support ............................................................................................................................ 459
9.1 Working with several channels ..................................................................................................459
9.2 Multi-channel view .....................................................................................................................460
9.2.1 Multi-channel view in the "Machine" operating area..................................................................460
9.2.2 Setting the multi-channel view ...................................................................................................463
9.3 Multi-channel editor....................................................................................................................465
9.3.1 Creating a multi-channel program..............................................................................................465
9.3.2 Entering multi-channel data .......................................................................................................466
9.3.3 Editing the multi-channel program .............................................................................................468
9.3.3.1 Changing the job list ..................................................................................................................468
9.3.3.2 Editing a G code multi-channel program ...................................................................................469
9.3.3.3 Editing a ShopTurn multi-channel program ...............................................................................471
9.3.3.4 Creating a program block...........................................................................................................478
9.3.4 Synchronizing programs ............................................................................................................481
9.3.5 Optimizing the machining time...................................................................................................484
9.4 Simulating a machining operation..............................................................................................486
9.4.1 Simulation ..................................................................................................................................486
9.4.2 Different workpiece views for multi-channel support .................................................................487
9.5 Display / edit the multi-channel functionality in the "Machine" operating area ..........................489
9.5.1 Running-in a program ................................................................................................................489
9.5.2 Block search and program control .............................................................................................490
9.6 Setting the multi-channel function..............................................................................................492
10 User data............................................................................................................................................... 495
10.1 Overview ....................................................................................................................................495
10.2 R parameters .............................................................................................................................496
10.3 Global GUD................................................................................................................................497
10.4 Channel GUD.............................................................................................................................499
10.5 Local LUD ..................................................................................................................................500
10.6 Program PUD.............................................................................................................................501
10.7 Searching for user data..............................................................................................................502
10.8 Defining and activating user data...............................................................................................503
11 Teaching in a program........................................................................................................................... 505
11.1 Overview ....................................................................................................................................505
11.2 General sequence......................................................................................................................506
11.3 Inserting a block.........................................................................................................................507
11.3.1 Input parameters for teach-in blocks .........................................................................................508
11.4 Teach-in via Windows................................................................................................................510
11.4.1 General ......................................................................................................................................510
11.4.2 Teach in rapid traverse G0 ........................................................................................................511
11.4.3 Teach in straight G1...................................................................................................................511
11.4.4 Teaching in circle intermediate and circle end point CIP...........................................................512

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11.4.5 Teach-in A spline ...................................................................................................................... 512
11.5 Editing a block........................................................................................................................... 514
11.6 Selecting a block ....................................................................................................................... 515
11.7 Deleting a block......................................................................................................................... 516
11.8 Settings for teach-in .................................................................................................................. 517
12 Working with a B axis ............................................................................................................................ 519
12.1 Lathes with B axis ..................................................................................................................... 519
12.2 Tool alignment for turning ......................................................................................................... 522
12.3 Milling with a B axis................................................................................................................... 523
12.4 Swiveling ................................................................................................................................... 524
12.5 Approach/retraction................................................................................................................... 526
12.6 Position pattern ......................................................................................................................... 528
12.7 Tool selection for the manual mode.......................................................................................... 530
12.8 Measure tool ............................................................................................................................. 531
13 Tool management.................................................................................................................................. 533
13.1 Lists for the tool management................................................................................................... 533
13.2 Magazine management............................................................................................................. 535
13.3 Tool types.................................................................................................................................. 536
13.4 Tool dimensioning ..................................................................................................................... 539
13.5 Tool list...................................................................................................................................... 544
13.5.1 Other data ................................................................................................................................. 547
13.5.2 Creating a new tool ................................................................................................................... 548
13.5.3 Measuring the tool..................................................................................................................... 549
13.5.4 Managing several cutting edges ............................................................................................... 550
13.5.5 Delete tool ................................................................................................................................. 551
13.5.6 Loading and unloading tools ..................................................................................................... 551
13.5.7 Selecting a magazine................................................................................................................ 553
13.6 Tool wear................................................................................................................................... 555
13.6.1 Reactivate tool .......................................................................................................................... 557
13.7 Tool data OEM .......................................................................................................................... 559
13.8 Magazine................................................................................................................................... 560
13.8.1 Positioning a magazine............................................................................................................. 562
13.8.2 Relocating a tool ....................................................................................................................... 562
13.9 Sorting tool management lists................................................................................................... 564
13.10 Filtering the tool management lists ........................................................................................... 565
13.11 Specific search in the tool management lists............................................................................ 566
13.12 Displaying tool details ............................................................................................................... 568
13.13 Changing the cutting edge position or tool type........................................................................ 570
13.14 Working with multitool ............................................................................................................... 571
13.14.1 Tool list for multitool .................................................................................................................. 571
13.14.2 Create multitool ......................................................................................................................... 572

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13.14.3 Equipping multitool with tools.....................................................................................................574
13.14.4 Removing a tool from multitool ..................................................................................................575
13.14.5 Deleting multitool .......................................................................................................................576
13.14.6 Loading and unloading multitool ................................................................................................576
13.14.7 Reactivating multitool.................................................................................................................577
13.14.8 Relocating a multitool.................................................................................................................579
13.14.9 Positioning multitool ...................................................................................................................580
14 Program management ........................................................................................................................... 581
14.1 Overview ....................................................................................................................................581
14.1.1 NC memory................................................................................................................................584
14.1.2 Local drive..................................................................................................................................584
14.1.3 USB drives .................................................................................................................................585
14.2 Opening and closing the program..............................................................................................586
14.3 Executing a program..................................................................................................................588
14.4 Creating a directory/program/joblist/program list.......................................................................590
14.4.1 Creating a new directory............................................................................................................590
14.4.2 Creating a new workpiece..........................................................................................................591
14.4.3 Creating a new G code program................................................................................................592
14.4.4 New ShopTurn program.............................................................................................................593
14.4.5 Storing any new file....................................................................................................................593
14.4.6 Creating a Joblist .......................................................................................................................595
14.4.7 Creating a program list...............................................................................................................596
14.5 Creating templates.....................................................................................................................598
14.6 Displaying the program in the Preview. .....................................................................................599
14.7 Selecting several directories/programs......................................................................................600
14.8 Copying and pasting a directory/program..................................................................................602
14.9 Deleting a directory/program......................................................................................................604
14.10 Renaming file and directory properties ......................................................................................605
14.11 EXTCALL ...................................................................................................................................606
14.12 Backing up data .........................................................................................................................608
14.12.1 Generating an archive in the Program Manager........................................................................608
14.12.2 Generating the archive via series startup ..................................................................................609
14.12.3 Reading in an archive ................................................................................................................611
14.13 Setup data..................................................................................................................................612
14.13.1 Backing up setup data ...............................................................................................................612
14.13.2 Reading-in set-up data...............................................................................................................614
14.14 V24.............................................................................................................................................616
14.14.1 Reading-in and reading-out archives.........................................................................................616
14.14.2 Setting V24 in the program manager.........................................................................................618
15 Setting up drives.................................................................................................................................... 621
15.1 Overview ....................................................................................................................................621
15.2 Setting up drives ........................................................................................................................622
16 HT 8....................................................................................................................................................... 625
16.1 HT 8 overview ............................................................................................................................625

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16.2 Traversing keys......................................................................................................................... 628
16.3 Machine control panel menu..................................................................................................... 629
16.4 Virtual keyboard ........................................................................................................................ 631
16.5 Calibrating the touch panel ....................................................................................................... 633
17 Easy Message (828D only).................................................................................................................... 635
17.1 Overview ................................................................................................................................... 635
17.2 Activating Easy Message.......................................................................................................... 637
17.3 Creating/editing a user profile ................................................................................................... 638
17.4 Setting-up events ...................................................................................................................... 640
17.5 Logging an active user on and off............................................................................................. 642
17.6 Displaying SMS logs ................................................................................................................. 643
17.7 Making settings for Easy Message ........................................................................................... 644
18 Easy Extend (828D only) ....................................................................................................................... 645
18.1 Overview ................................................................................................................................... 645
18.2 Enabling a device...................................................................................................................... 646
18.3 Activating and deactivating a device......................................................................................... 647
18.4 Commissioning Easy Extend .................................................................................................... 648
19 Service Planner (828D only).................................................................................................................. 649
19.1 Performing and monitoring maintenance tasks......................................................................... 649
19.2 Set maintenance tasks.............................................................................................................. 651
20 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 653
20.1 PLC diagnostics ........................................................................................................................ 653
20.2 Structure of the user interface................................................................................................... 654
20.3 Control options .......................................................................................................................... 656
20.4 Displaying PLC properties......................................................................................................... 658
20.5 Displaying information on the program blocks.......................................................................... 659
20.6 Displaying and editing NC/PLC variables ................................................................................. 661
20.7 Downloading a PLC user program............................................................................................662
20.8 Editing the local variable table .................................................................................................. 663
20.9 Creating a new block................................................................................................................. 665
20.10 Editing block properties............................................................................................................. 666
20.11 Inserting and editing networks .................................................................................................. 667
20.12 Editing network properties......................................................................................................... 669
20.13 Displaying/canceling the access protection .............................................................................. 670
20.14 Displaying and editing symbol tables........................................................................................ 671
20.15 Searching for operands............................................................................................................. 672

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20.16 Inserting/deleting a symbol table ...............................................................................................674
20.17 Displaying the network symbol information table.......................................................................675
20.18 Displaying and editing PLC signals ...........................................................................................676
20.19 Displaying cross references.......................................................................................................677
21 Alarms, error messages, and system alarms......................................................................................... 679
21.1 Displaying alarms.......................................................................................................................679
21.2 Displaying an alarm log..............................................................................................................681
21.3 Displaying messages .................................................................................................................682
21.4 PLC and NC variables ...............................................................................................................683
21.4.1 Displaying and editing PLC and NC variables...........................................................................683
21.4.2 Saving and loading screen forms ..............................................................................................686
21.4.3 Loading PLC symbols ................................................................................................................687
21.5 Version.......................................................................................................................................689
21.5.1 Displaying version data..............................................................................................................689
21.5.2 Save information ........................................................................................................................690
21.6 Logbook .....................................................................................................................................692
21.6.1 Displaying and editing the logbook ............................................................................................692
21.6.2 Making/searching for a logbook entry........................................................................................693
21.7 Creating screenshots .................................................................................................................695
21.8 Remote diagnostics ...................................................................................................................696
21.8.1 Setting remote access ...............................................................................................................696
21.8.2 Permit modem............................................................................................................................698
21.8.3 Request remote diagnostics ......................................................................................................698
21.8.4 Exit remote diagnostics..............................................................................................................699
A Appendix................................................................................................................................................ 701
A.1 Feedback on the documentation................................................................................................701
A.2 Overview ....................................................................................................................................703
Index...................................................................................................................................................... 705

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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, 07/2010, 6FC5398-8CP40-0BA0
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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