Siemens SINUMERIK 840D User manual

SINUMERIK
SINUMERIK 840D sl/828D
Milling
Operating Manual
Valid for
Control System
SINUMERIK 840D sl/840DE sl/828D
Software Version
CNC software for 840D sl/ 840DE sl/828D 2.6 SP1
with SINUMERIK Operate for PCU/PC 2.6 SP1
03/2010
6FC5398-7CP20-1BA0
Preface
Introduction
1
Setting up the machine
2
Execution in manual mode
3
Machining the workpiece
4
Simulating machining
5
Creating G code program
6
Creating a ShopMill program
7
Programming technological
functions (cycles)
8
Multi-channel view
9
User variables
10
Teaching in a program
11
Tool management
12
Program management
13
Setting up drives
14
HT 8
15
Easy Message (828D only)
16
Easy Extend (828D only)
17
Service Planner (828D only)
18
Ladder Viewer and Ladder
add-on (828D only)
19
A
larms, error messages, and
system alarms
20
Appendix
A

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the 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: 6FC5398-7CP20-1BA0
Ⓟ 05/2010
Copyright © Siemens AG 2010.
Technical data subject to change

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Operating Manual, 03/2010, 6FC5398-7CP20-1BA0 3
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 milling machines running the SINUMERIK
Operate software.
Benefits
The operating manual familiarizes users with the operator controls and operating commands.
It instructs users on how to respond to faults and take corrective action.
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.

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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 are given below in this documentation.
Program
A program is a sequence of instructions to the CNC which combine to produce a specific
workpiece on the machine.
Contour
The term contour refers generally to the outline of a workpiece. More specifically, it refers to
the section of the program that defines the outline of a workpiece comprising individual
elements.
Cycle
A cycle, e.g. milling a rectangular pocket, is a subprogram defined in SINUMERIK Operate
for executing a frequently repeated machining operation.
Technical Support
If you have any technical questions, please contact our hotline:
Europe/Africa
Phone [phone]
Fax [phone]
0.14 €/min. from German landlines, max. 0.42 €/min for calls from a mobile phone
Internet http://www.siemens.com/automation/support-request
Americas
Phone [phone]
Fax [phone]
E-mail mailto:[email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-mail mailto:support.asia.automatio[email protected]

Preface
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Operating Manual, 03/2010, 6FC5398-7CP20-1BA0 5
Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
http://www.automation.siemens.com/partner
Questions about the manual
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.............................................................................................................................................. 17
1.1 Product overview .........................................................................................................................17
1.2 Operator panel fronts ...................................................................................................................18
1.2.1 Overview ......................................................................................................................................18
1.2.2 Keys of the operator panel...........................................................................................................20
1.3 Machine control panels................................................................................................................26
1.3.1 Overview ......................................................................................................................................26
1.3.2 Controls on the machine control panel ........................................................................................26
1.4 User interface...............................................................................................................................29
1.4.1 Screen layout ...............................................................................................................................29
1.4.2 Status display...............................................................................................................................30
1.4.3 Actual value window ....................................................................................................................33
1.4.4 T,F,S window ...............................................................................................................................34
1.4.5 Current block display ...................................................................................................................35
1.4.6 Operation via softkeys and buttons .............................................................................................36
1.4.7 Entering or selecting parameters.................................................................................................37
1.4.8 Pocket calculator..........................................................................................................................40
1.4.9 Context menu...............................................................................................................................41
1.4.10 Touch operation ...........................................................................................................................42
1.4.11 Changing the user interface language.........................................................................................42
1.4.12 Entering Asian characters............................................................................................................43
1.4.13 Protection levels...........................................................................................................................45
1.4.14 Online help in SINUMERIK Operate............................................................................................47
2 Setting up the machine............................................................................................................................ 51
2.1 Switching on and switching off.....................................................................................................51
2.2 Approaching a reference point.....................................................................................................52
2.2.1 Referencing axes .........................................................................................................................52
2.2.2 User agreement ...........................................................................................................................53
2.3 Operating modes .........................................................................................................................55
2.3.1 General ........................................................................................................................................55
2.3.2 Modes groups and channels........................................................................................................57
2.3.3 Channel switchover......................................................................................................................57
2.4 Settings for the machine ..............................................................................................................58
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................58
2.4.2 Switching the unit of measurement..............................................................................................59
2.4.3 Setting the work offset .................................................................................................................60
2.5 Measuring the tool .......................................................................................................................62
2.5.1 Measuring a tool manually...........................................................................................................62
2.5.2 Measuring the tool length with the workpiece as reference point................................................63
2.5.3 Measuring radius or diameter ......................................................................................................64
2.5.4 Fixed point calibration ..................................................................................................................65
2.5.5 Measuring a tool with an electrical tool probe..............................................................................66

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2.5.6 Calibrating the electrical tool probe............................................................................................. 68
2.6 Measuring the workpiece zero .................................................................................................... 69
2.6.1 Overview ..................................................................................................................................... 69
2.6.2 Sequence of operations .............................................................................................................. 72
2.6.3 Examples with manual swivel ..................................................................................................... 73
2.6.4 Calibrating the electronic workpiece probe................................................................................. 74
2.6.5 Setting the edge .......................................................................................................................... 76
2.6.6 Edge measurement..................................................................................................................... 78
2.6.7 Measuring a corner ..................................................................................................................... 80
2.6.8 Measuring a pocket and hole...................................................................................................... 83
2.6.9 Measuring a spigot...................................................................................................................... 90
2.6.10 Aligning the plane........................................................................................................................ 95
2.6.11 Defining the measurement function selection............................................................................. 97
2.6.12 Corrections after measurement of the zero point ....................................................................... 98
2.7 Work offsets .............................................................................................................................. 100
2.7.1 Display active zero offset .......................................................................................................... 101
2.7.2 Displaying the work offset "overview" ....................................................................................... 102
2.7.3 Displaying and editing base zero offset .................................................................................... 103
2.7.4 Displaying and editing settable zero offset ............................................................................... 104
2.7.5 Displaying the zero offset details. ............................................................................................. 105
2.7.6 Deleting a work offset................................................................................................................ 106
2.7.7 Measuring the workpiece zero .................................................................................................. 107
2.8 Monitoring axis and spindle data .............................................................................................. 108
2.8.1 Specify working area limitations................................................................................................ 108
2.8.2 Editing spindle data................................................................................................................... 109
2.9 Displaying setting data lists....................................................................................................... 110
2.10 Handwheel assignment............................................................................................................. 111
2.11 MDA .......................................................................................................................................... 113
2.11.1 Loading an MDA program from the Program Manager ............................................................ 113
2.11.2 Saving an MDA program........................................................................................................... 114
2.11.3 Executing an MDA program...................................................................................................... 115
2.11.4 Deleting an MDA program......................................................................................................... 116
3 Execution in manual mode..................................................................................................................... 117
3.1 General...................................................................................................................................... 117
3.2 Selecting a tool and spindle ...................................................................................................... 117
3.2.1 T, S, M windows........................................................................................................................ 117
3.2.2 Selecting a tool.......................................................................................................................... 119
3.2.3 Starting and stopping a spindle manually ................................................................................. 120
3.2.4 Position spindle ......................................................................................................................... 121
3.3 Traversing axes......................................................................................................................... 122
3.3.1 Traverse axes by a defined increment...................................................................................... 122
3.3.2 Traversing axes by a variable increment .................................................................................. 124
3.4 Positioning axes ........................................................................................................................ 125
3.5 Swiveling ................................................................................................................................... 126
3.6 Simple face milling of workpiece...............................................................................................130
3.7 Default settings for manual mode ............................................................................................. 133
4 Machining the workpiece ....................................................................................................................... 135

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4.1 Starting and stopping machining................................................................................................135
4.2 Selecting a program...................................................................................................................136
4.3 Testing a program......................................................................................................................137
4.4 Displaying the current program block ........................................................................................138
4.4.1 Current block display .................................................................................................................138
4.4.2 Displaying a basic block.............................................................................................................139
4.4.3 Display program level ................................................................................................................140
4.5 Correcting a program .................................................................................................................141
4.6 Repositioning axes.....................................................................................................................142
4.7 Starting machining at a specific point ........................................................................................143
4.7.1 Use block search .......................................................................................................................143
4.7.2 Continuing program from search target .....................................................................................145
4.7.3 Simple search target definition...................................................................................................145
4.7.4 Defining an interruption point as search target..........................................................................146
4.7.5 Entering the search target via search pointer............................................................................147
4.7.6 Parameters for block search in the search pointer ....................................................................148
4.7.7 Block search mode ....................................................................................................................149
4.8 Intervening in the program sequence ........................................................................................151
4.8.1 Program control..........................................................................................................................151
4.8.2 Skip blocks.................................................................................................................................153
4.9 Overstore ...................................................................................................................................154
4.10 Editing a program.......................................................................................................................156
4.10.1 Searching in programs...............................................................................................................157
4.10.2 Replacing program text..............................................................................................................158
4.10.3 Copying/pasting/deleting a program block.................................................................................159
4.10.4 Renumber program....................................................................................................................160
4.10.5 Opening a second program .......................................................................................................160
4.10.6 Editor settings ............................................................................................................................162
4.11 Displaying G Functions and Auxiliary Functions........................................................................163
4.11.1 Selected G functions..................................................................................................................163
4.11.2 All G functions............................................................................................................................165
4.11.3 Auxiliary functions ......................................................................................................................166
4.12 Displaying the program runtime and counting workpieces........................................................169
4.13 Setting for automatic mode........................................................................................................170
5 Simulating machining............................................................................................................................. 173
5.1 Overview ....................................................................................................................................173
5.2 Simulation before machining of the workpiece ..........................................................................179
5.3 Simultaneous recording before machining of the workpiece .....................................................181
5.4 Simultaneous recording during machining of the workpiece .....................................................182
5.5 Different views of a workpiece ...................................................................................................183
5.5.1 Plan view....................................................................................................................................183
5.5.2 3D view ......................................................................................................................................183
5.5.3 Side views..................................................................................................................................184
5.6 Editing the simulation display.....................................................................................................185
5.6.1 Entering blank details.................................................................................................................185

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5.6.2 Showing and hiding the tool path.............................................................................................. 185
5.7 Program control during the simulation ...................................................................................... 186
5.7.1 Changing the feedrate............................................................................................................... 186
5.7.2 Simulating the program block by block ..................................................................................... 187
5.8 Changing and adapting a simulation graphic............................................................................ 188
5.8.1 Enlarging or reducing the graphical representation .................................................................. 188
5.8.2 Panning a graphical representation .......................................................................................... 189
5.8.3 Rotating the graphical representation....................................................................................... 190
5.8.4 Modifying the viewport .............................................................................................................. 191
5.8.5 Defining cutting planes.............................................................................................................. 192
5.9 Displaying simulation alarms..................................................................................................... 193
6 Creating G code program ...................................................................................................................... 195
6.1 Graphical programming............................................................................................................. 195
6.2 Program views .......................................................................................................................... 196
6.3 Program structure ..................................................................................................................... 199
6.4 Basics........................................................................................................................................ 200
6.4.1 Machining planes ...................................................................................................................... 200
6.4.2 Current planes in cycles and input screens .............................................................................. 200
6.4.3 Programming a tool (T) ............................................................................................................. 201
6.5 Generating a G code program .................................................................................................. 202
6.6 Blank input ................................................................................................................................ 203
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F)........................................................................................................................................ 205
6.8 Selection of the cycles via softkey ............................................................................................206
6.9 Calling technology functions ..................................................................................................... 211
6.9.1 Hiding cycle parameters............................................................................................................ 211
6.9.2 Setting data for cycles............................................................................................................... 211
6.9.3 Checking cycle parameters....................................................................................................... 212
6.9.4 Changing a cycle call ................................................................................................................ 212
6.9.5 Additional functions in the input screens................................................................................... 213
6.10 Measuring cycle support ........................................................................................................... 214
7 Creating a ShopMill program ................................................................................................................. 217
7.1 Program views .......................................................................................................................... 218
7.2 Program structure ..................................................................................................................... 222
7.3 Basic information....................................................................................................................... 223
7.3.1 Machining planes ...................................................................................................................... 223
7.3.2 Polar coordinates ...................................................................................................................... 224
7.3.3 Absolute and incremental dimensions ...................................................................................... 224
7.4 Creating a ShopMill program ....................................................................................................226
7.5 Program header ........................................................................................................................ 227
7.6 Generating program blocks....................................................................................................... 228
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) ........................................................ 229
7.8 Defining machine functions....................................................................................................... 231

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7.9 Call work offsets.........................................................................................................................233
7.10 Repeating program blocks.........................................................................................................233
7.11 Specifying the number of workpieces ........................................................................................235
7.12 Changing program blocks..........................................................................................................236
7.13 Changing program settings........................................................................................................237
7.14 Selection of the cycles via softkey .............................................................................................238
7.15 Calling technology functions ......................................................................................................242
7.15.1 Additional functions in the input screens ...................................................................................242
7.15.2 Checking input parameters........................................................................................................243
7.15.3 Setting data for technological functions .....................................................................................243
7.15.4 Changing a cycle call .................................................................................................................243
7.16 Measuring cycle support............................................................................................................244
7.17 Example, standard machining....................................................................................................246
7.17.1 Workpiece drawing ....................................................................................................................247
7.17.2 Programming..............................................................................................................................247
7.17.3 Results/simulation test ...............................................................................................................259
7.17.4 G code machining program........................................................................................................261
8 Programming technological functions (cycles)....................................................................................... 265
8.1 Drilling ........................................................................................................................................265
8.1.1 General ......................................................................................................................................265
8.1.2 Centering (CYCLE81) ................................................................................................................266
8.1.3 Drilling (CYCLE82).....................................................................................................................268
8.1.4 Reaming (CYCLE85) .................................................................................................................269
8.1.5 Deep-hole drilling (CYCLE83)....................................................................................................270
8.1.6 Boring (CYCLE86) .....................................................................................................................273
8.1.7 Tapping (CYCLE84, 840)...........................................................................................................275
8.1.8 Drill and thread milling (CYCLE78)............................................................................................280
8.1.9 Positioning and position patterns...............................................................................................283
8.1.10 Arbitrary positions (CYCLE802).................................................................................................284
8.1.11 Position pattern Line (HOLES1), Grid or Frame (CYCLE801) ..................................................285
8.1.12 Circle position pattern (HOLES2)...............................................................................................286
8.1.13 Repeating positions ...................................................................................................................288
8.2 Milling.........................................................................................................................................289
8.2.1 Face milling (CYCLE61) ............................................................................................................289
8.2.2 Rectangular pocket (POCKET3)................................................................................................292
8.2.3 Circular pocket (POCKET4).......................................................................................................295
8.2.4 Rectangular spigot (CYCLE76)..................................................................................................299
8.2.5 Circular spigot (CYCLE77).........................................................................................................301
8.2.6 Multi-edge (CYCLE79)...............................................................................................................303
8.2.7 Longitudinal groove (SLOT1).....................................................................................................305
8.2.8 Circumferential groove (SLOT2)................................................................................................308
8.2.9 Open groove (CYCLE899).........................................................................................................311
8.2.10 Long hole (LONGHOLE) - only for G code programs................................................................317
8.2.11 Thread milling (CYCLE70).........................................................................................................319
8.2.12 Engraving (CYCLE60) ...............................................................................................................323
8.3 Contour milling ...........................................................................................................................328
8.3.1 General ......................................................................................................................................328
8.3.2 Representation of the contour....................................................................................................328
8.3.3 Creating a new contour..............................................................................................................330

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8.3.4 Creating contour elements........................................................................................................ 332
8.3.5 Changing the contour................................................................................................................ 336
8.3.6 Contour call (CYCLE62) - only for G code program ................................................................. 337
8.3.7 Path milling (CYCLE72) ............................................................................................................ 338
8.3.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 342
8.3.9 Predrilling contour pocket (CYCLE64)...................................................................................... 344
8.3.10 Milling contour pocket (CYCLE63)............................................................................................ 347
8.3.11 Residual material contour pocket (CYCLE63) .......................................................................... 349
8.3.12 Milling contour spigot (CYCLE63)............................................................................................. 351
8.3.13 Residual material contour spigot (CYCLE63) ........................................................................... 353
8.4 Turning - only for G code programs .......................................................................................... 355
8.4.1 General...................................................................................................................................... 355
8.4.2 Stock removal (CYCLE951)...................................................................................................... 355
8.4.3 Groove (CYCLE930)................................................................................................................. 358
8.4.4 Undercut form E and F (CYCLE940) ........................................................................................ 360
8.4.5 Thread undercut (CYCLE940) .................................................................................................. 362
8.4.6 Thread turning (CYCLE99) .......................................................................................................365
8.4.7 Thread chain (CYCLE98).......................................................................................................... 373
8.4.8 Cut-off (CYCLE92).................................................................................................................... 376
8.5 Contour turning - only for G code programs ............................................................................. 378
8.5.1 General information................................................................................................................... 378
8.5.2 Representation of the contour................................................................................................... 379
8.5.3 Creating a new contour............................................................................................................. 380
8.5.4 Creating contour elements........................................................................................................ 382
8.5.5 Changing the contour................................................................................................................ 387
8.5.6 Contour call (CYCLE62)............................................................................................................ 388
8.5.7 Stock removal (CYCLE952)...................................................................................................... 390
8.5.8 Stock removal residual (CYCLE952) ........................................................................................ 394
8.5.9 Grooving (CYCLE952) .............................................................................................................. 396
8.5.10 Grooving residual material (CYCLE952)................................................................................... 398
8.5.11 Plunge turning (CYCLE952)......................................................................................................400
8.5.12 Plunge turning residual material (CYCLE952).......................................................................... 403
8.6 Further cycles and functions ..................................................................................................... 406
8.6.1 Swiveling plane/tool (CYCLE800)............................................................................................. 406
8.6.2 Swiveling tool (CYCLE800)....................................................................................................... 414
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800)....................... 414
8.6.2.2 Swiveling tool/orienting milling tools - only for G code program (CYCLE800).......................... 415
8.6.3 High-speed settings (CYCLE832)............................................................................................. 416
8.6.4 Subroutines ............................................................................................................................... 418
8.7 Further cycles and functions ShopMill ...................................................................................... 420
8.7.1 Transformations ........................................................................................................................ 420
8.7.2 Translation................................................................................................................................. 421
8.7.3 Rotation..................................................................................................................................... 422
8.7.4 Scaling....................................................................................................................................... 423
8.7.5 Mirroring .................................................................................................................................... 424
8.7.6 Straight or circular machining.................................................................................................... 425
8.7.7 Programming a straight line ...................................................................................................... 427
8.7.8 Programming a circle with known center point ......................................................................... 428
8.7.9 Programming a circle with known radius .................................................................................. 429
8.7.10 Helix .......................................................................................................................................... 430
8.7.11 Polar coordinates ...................................................................................................................... 431
8.7.12 Straight polar............................................................................................................................. 432
8.7.13 Circle polar ................................................................................................................................ 433

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8.7.14 Obstacle.....................................................................................................................................434
9 Multi-channel view ................................................................................................................................. 435
9.1 Multi-channel view .....................................................................................................................435
9.2 Multi-channel view in the "Machine" operating area..................................................................435
9.3 Setting the multi-channel view ...................................................................................................438
10 User variables........................................................................................................................................ 441
10.1 Overview ....................................................................................................................................441
10.2 R parameters .............................................................................................................................442
10.3 Global GUD................................................................................................................................443
10.4 Channel GUD.............................................................................................................................444
10.5 Local LUD ..................................................................................................................................445
10.6 Program PUD.............................................................................................................................446
10.7 Searching for user data..............................................................................................................447
10.8 Defining and activating user variables .......................................................................................447
11 Teaching in a program........................................................................................................................... 449
11.1 Overview ....................................................................................................................................449
11.2 General sequence......................................................................................................................449
11.3 Inserting a block.........................................................................................................................450
11.3.1 Input parameters for teach-in blocks .........................................................................................451
11.4 Teach-in via window ..................................................................................................................452
11.4.1 General ......................................................................................................................................452
11.4.2 Teach in rapid traverse G0 ........................................................................................................454
11.4.3 Teach in straight G1...................................................................................................................454
11.4.4 Teaching in circle intermediate and circle end point CIP...........................................................454
11.4.5 Teach-in A spline .......................................................................................................................455
11.5 Editing a block............................................................................................................................456
11.6 Selecting a block........................................................................................................................457
11.7 Deleting a block .........................................................................................................................458
12 Tool management.................................................................................................................................. 461
12.1 Lists for the tool management....................................................................................................461
12.2 Magazine management .............................................................................................................462
12.3 Tool types...................................................................................................................................463
12.4 Tool dimensioning......................................................................................................................465
12.5 Tool list.......................................................................................................................................472
12.5.1 Additional data ...........................................................................................................................474
12.5.2 Creating a new tool ....................................................................................................................475
12.5.3 Measuring the tool .....................................................................................................................477
12.5.4 Managing several cutting edges ................................................................................................477
12.5.5 Delete tool..................................................................................................................................478
12.5.6 Loading and unloading tools......................................................................................................479
12.5.7 Selecting a magazine.................................................................................................................480

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12.6 Tool wear................................................................................................................................... 482
12.6.1 Reactivating a tool..................................................................................................................... 484
12.7 Tool data OEM .......................................................................................................................... 485
12.8 Magazine................................................................................................................................... 486
12.8.1 Positioning a magazine............................................................................................................. 488
12.8.2 Relocating a tool ....................................................................................................................... 488
12.9 Sorting tool management lists................................................................................................... 490
12.10 Filtering the tool management lists ........................................................................................... 491
12.11 Specific search in the tool management lists............................................................................ 492
12.12 Displaying tool details ............................................................................................................... 493
12.13 Changing a tool type ................................................................................................................. 494
13 Program management ........................................................................................................................... 495
13.1 Overview ................................................................................................................................... 495
13.1.1 NC memory ............................................................................................................................... 498
13.1.2 Local drive................................................................................................................................. 498
13.1.3 USB drives ................................................................................................................................ 499
13.2 Opening and closing the program............................................................................................. 500
13.3 Executing a program................................................................................................................. 501
13.4 Creating a directory/program/job list/program list ..................................................................... 503
13.4.1 Creating a new directory ........................................................................................................... 503
13.4.2 Creating a new workpiece......................................................................................................... 504
13.4.3 Creating a new G code program............................................................................................... 505
13.4.4 Creating a new ShopMill program............................................................................................. 506
13.4.5 Storing any new file................................................................................................................... 506
13.4.6 Creating a Joblist ...................................................................................................................... 507
13.4.7 Creating a program list.............................................................................................................. 509
13.5 Creating templates .................................................................................................................... 510
13.6 Displaying the program in the Preview. .................................................................................... 511
13.7 Selecting several directories/programs..................................................................................... 511
13.8 Copying and pasting a directory/program................................................................................. 513
13.9 Deleting a program/directory..................................................................................................... 515
13.9.1 Deleting a program/directory..................................................................................................... 515
13.10 Renaming file and directory properties ..................................................................................... 516
13.11 EXTCALL .................................................................................................................................. 517
13.12 Backing up data ........................................................................................................................ 519
13.12.1 Generating an archive in the Program Manager....................................................................... 519
13.12.2 Generating the archive via series startup ................................................................................. 520
13.12.3 Reading in an archive ............................................................................................................... 522
13.13 Setup data................................................................................................................................. 523
13.13.1 Backing up setup data............................................................................................................... 523
13.13.2 Reading-in set-up data.............................................................................................................. 525
13.14 V24............................................................................................................................................ 527
13.14.1 Reading-in and reading-out archives ........................................................................................ 527
13.14.2 Setting V24 in the program manager........................................................................................ 529

Table of contents
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14 Setting up drives.................................................................................................................................... 531
14.1 Overview ....................................................................................................................................531
14.2 Setting up drives ........................................................................................................................532
15 HT 8....................................................................................................................................................... 535
15.1 HT 8 overview ............................................................................................................................535
15.2 Traversing keys..........................................................................................................................538
15.3 Machine control panel menu......................................................................................................539
15.4 Virtual keyboard .........................................................................................................................540
15.5 Calibrating the touch panel ........................................................................................................542
16 Easy Message (828D only).................................................................................................................... 543
16.1 Overview ....................................................................................................................................543
16.2 Activating Easy Message...........................................................................................................544
16.3 Creating/editing a user profile....................................................................................................545
16.4 Setting-up events .......................................................................................................................546
16.5 Logging an active user on and off..............................................................................................548
16.6 Displaying SMS logs ..................................................................................................................549
16.7 Making settings for Easy Message ............................................................................................550
17 Easy Extend (828D only)....................................................................................................................... 551
17.1 Overview ....................................................................................................................................551
17.2 Enabling a device.......................................................................................................................552
17.3 Activating and deactivating a device..........................................................................................553
17.4 Commissioning Easy Extend .....................................................................................................554
18 Service Planner (828D only).................................................................................................................. 555
18.1 Performing and monitoring maintenance tasks .........................................................................555
18.2 Set maintenance tasks...............................................................................................................557
19 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 559
19.1 PLC diagnostics .........................................................................................................................559
19.2 Structure of the user interface....................................................................................................560
19.3 Control options...........................................................................................................................561
19.4 Displaying PLC properties .........................................................................................................563
19.5 Displaying and editing NC/PLC variables ..................................................................................563
19.6 Displaying and editing PLC signals ...........................................................................................564
19.7 Displaying information on the program blocks...........................................................................565
19.8 Downloading a PLC user program.............................................................................................566
19.9 Editing the local variable table ...................................................................................................567
19.10 Creating a new block .................................................................................................................569

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16 Operating Manual, 03/2010, 6FC5398-7CP20-1BA0
19.11 Editing block properties............................................................................................................. 570
19.12 Inserting and editing networks .................................................................................................. 570
19.13 Editing network properties......................................................................................................... 572
19.14 Displaying and editing symbol tables........................................................................................ 573
19.15 Inserting/deleting a symbol table ..............................................................................................574
19.16 Searching for operands............................................................................................................. 575
19.17 Displaying the network symbol information table...................................................................... 576
19.18 Displaying/canceling the access protection .............................................................................. 577
19.19 Displaying cross references...................................................................................................... 577
20 Alarms, error messages, and system alarms......................................................................................... 579
20.1 Displaying alarms...................................................................................................................... 579
20.2 Displaying an alarm log............................................................................................................. 581
20.3 Displaying messages ................................................................................................................ 581
20.4 PLC and NC variables............................................................................................................... 582
20.4.1 Displaying and editing PLC and NC variables .......................................................................... 582
20.4.2 Saving and loading screen forms.............................................................................................. 586
20.4.3 Loading PLC symbols ............................................................................................................... 587
20.5 Version ...................................................................................................................................... 588
20.5.1 Displaying version data............................................................................................................. 588
20.5.2 Save information ....................................................................................................................... 589
20.6 Logbook..................................................................................................................................... 590
20.6.1 Displaying and editing the logbook ........................................................................................... 590
20.6.2 Making/searching for a logbook entry ....................................................................................... 591
20.7 Creating screenshots ................................................................................................................ 592
20.8 Remote diagnostics................................................................................................................... 593
20.8.1 Setting remote access............................................................................................................... 593
20.8.2 Permit modem........................................................................................................................... 595
20.8.3 Request remote diagnostics...................................................................................................... 595
20.8.4 Exit remote diagnostics............................................................................................................. 596
A Appendix................................................................................................................................................ 597
A.1 Feedback on the documentation............................................................................................... 597
A.2 Overview ................................................................................................................................... 599
Index...................................................................................................................................................... 601

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Operating Manual, 03/2010, 6FC5398-7CP20-1BA0 17
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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18 Operating Manual, 03/2010, 6FC5398-7CP20-1BA0
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.

Introduction
1.2 Operator panel fronts
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Operating Manual, 03/2010, 6FC5398-7CP20-1BA0 19
Operator controls and indicators
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(5)
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1 Status LED: POWER
2 Status LED: TEMP
(illuminated LEDs indicate increased wear)
3 Alphabetic key group
4 Numerical key group
5 Softkeys
6 Control key group
7 Hotkey group
8 Cursor key group
9 USB interface
10 Menu select key
11 Menu forward button
12 Machine area button
13 Menu back key
Figure 1-1 View of OP 010 operator panel front

Introduction
1.2 Operator panel fronts
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20 Operating Manual, 03/2010, 6FC5398-7CP20-1BA0
References
A more precise description as well as a view of the other operator panel fronts that can be
used may be found in the following reference:
Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl
1.2.2 Keys of the operator panel
The following keys and key combinations are available for operation of the control and the
machine tool.
Keys and key combinations
Key Function
<ALARM CANCEL>
Cancels alarms and messages that are marked with this
symbol.
<CHANNEL>
Advances for several channels.
<HELP>
Calls the context-sensitive online help for the selected window.
<NEXT WINDOW>
Toggles between the windows.
For a multi-channel view or for a multi-channel functionality,
switches within a channel gap between the upper and
lower window.
<PAGE UP>
Scrolls upwards by one page in a window.
+ <PAGE UP> + <SHIFT>
In the program manager and in the program editor from the
cursor position, selects directories or program blocks up to the
beginning of the window.
+ <PAGE UP> + <CTRL>
Positions the cursor to the topmost line of a window.