Siemens SINUMERIK 840D sl User manual

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SINUMERIK
SINUMERIK 840D sl/828D
Milling
Operating Manual
Valid for:
Controller
SINUMERIK 840D sl / 840DE sl / 828D
Software Version
CNC software for 840D sl / 840DE sl 4.4
SINUMERIK Operate for PCU/PC 4.4
09/2011
6FC5398-7CP40-2BA0
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
Ctrl Energy
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
A
larms, 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: 6FC5398-7CP40-2BA0
Ⓟ 04/2011
Copyright © Siemens AG 2011.
Technical data subject to change

Milling
Operating Manual, 09/2011, 6FC5398-7CP40-2BA0 3
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
[e-mail]
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer under:
● www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
● www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com

Preface
Milling
4 Operating Manual, 09/2011, 6FC5398-7CP40-2BA0
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This documentation is intended for users of milling machines running the SINUMERIK
Operate software.
Benefits
The operating manual helps users familiarize themselves with the control elements and
commands. Guided by the manual, users are capable of responding to problems and taking
corrective action.
Standard scope
This documentation describes the functionality of the standard scope. Extensions or changes
made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
Furthermore, for the sake of clarity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.
Terms
The meanings of some basic terms used in this documentation are given below.
Program
A program is a sequence of instructions to the CNC which combine to produce a specific
workpiece on the machine.
Contour
The term contour refers generally to the outline of a workpiece. More specifically, it refers to
the section of the program that defines the outline of a workpiece comprising individual
elements.
Cycle
A cycle, e.g. milling a rectangular pocket, is a subprogram defined in SINUMERIK Operate
for executing a frequently repeated machining operation.

Preface
Milling
Operating Manual, 09/2011, 6FC5398-7CP40-2BA0 5
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support

Preface
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Milling
Operating Manual, 09/2011, 6FC5398-7CP40-2BA0 7
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 ................................................................................................................31
1.3.1 Overview ......................................................................................................................................31
1.3.2 Controls on the machine control panel ........................................................................................31
1.4 User interface...............................................................................................................................34
1.4.1 Screen layout ...............................................................................................................................34
1.4.2 Status display...............................................................................................................................35
1.4.3 Actual value window ....................................................................................................................38
1.4.4 T,F,S window ...............................................................................................................................39
1.4.5 Current block display ...................................................................................................................41
1.4.6 Operation via softkeys and buttons .............................................................................................41
1.4.7 Entering or selecting parameters.................................................................................................43
1.4.8 Pocket calculator..........................................................................................................................45
1.4.9 Context menu...............................................................................................................................47
1.4.10 Touch operation ...........................................................................................................................47
1.4.11 Changing the user interface language.........................................................................................48
1.4.12 Entering Asian characters............................................................................................................49
1.4.13 Protection levels...........................................................................................................................51
1.4.14 Online help in HMI sl....................................................................................................................53
2 Setting up the machine............................................................................................................................ 57
2.1 Switching on and switching off.....................................................................................................57
2.2 Approaching a reference point.....................................................................................................58
2.2.1 Referencing axes .........................................................................................................................58
2.2.2 User agreement ...........................................................................................................................59
2.3 Operating modes .........................................................................................................................61
2.3.1 General ........................................................................................................................................61
2.3.2 Modes groups and channels........................................................................................................63
2.3.3 Channel switchover......................................................................................................................63
2.4 Settings for the machine ..............................................................................................................65
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................65
2.4.2 Switching the unit of measurement..............................................................................................66
2.4.3 Setting the work offset .................................................................................................................67
2.5 Measuring the tool .......................................................................................................................69
2.5.1 Measuring a tool manually...........................................................................................................69
2.5.2 Measuring the tool length with the workpiece as reference point................................................70
2.5.3 Measuring radius or diameter ......................................................................................................71

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2.5.4 Fixed point calibration ................................................................................................................. 72
2.5.5 Measuring a tool with an electrical tool probe............................................................................. 73
2.5.6 Calibrating the electrical tool probe............................................................................................. 75
2.6 Measuring the workpiece zero .................................................................................................... 76
2.6.1 Overview ..................................................................................................................................... 76
2.6.2 Sequence of operations .............................................................................................................. 80
2.6.3 Examples with manual swivel ..................................................................................................... 81
2.6.4 Calibrating the electronic workpiece probe................................................................................. 82
2.6.5 Setting the edge .......................................................................................................................... 84
2.6.6 Edge measurement..................................................................................................................... 86
2.6.7 Measuring a corner ..................................................................................................................... 89
2.6.8 Measuring a pocket and hole...................................................................................................... 92
2.6.9 Measuring a spigot...................................................................................................................... 98
2.6.10 Aligning the plane...................................................................................................................... 104
2.6.11 Defining the measurement function selection........................................................................... 106
2.6.12 Corrections after measurement of the zero point ..................................................................... 107
2.7 Work offsets .............................................................................................................................. 109
2.7.1 Display active zero offset .......................................................................................................... 110
2.7.2 Displaying the work offset "overview" ....................................................................................... 111
2.7.3 Displaying and editing base zero offset .................................................................................... 112
2.7.4 Displaying and editing settable zero offset ............................................................................... 113
2.7.5 Displaying the zero offset details. ............................................................................................. 114
2.7.6 Deleting a work offset................................................................................................................ 115
2.7.7 Measuring the workpiece zero .................................................................................................. 116
2.8 Monitoring axis and spindle data .............................................................................................. 117
2.8.1 Specify working area limitations................................................................................................ 117
2.8.2 Editing spindle data................................................................................................................... 118
2.9 Displaying setting data lists....................................................................................................... 119
2.10 Handwheel assignment............................................................................................................. 119
2.11 MDA .......................................................................................................................................... 122
2.11.1 Loading an MDA program from the Program Manager ............................................................ 122
2.11.2 Saving an MDA program........................................................................................................... 123
2.11.3 Executing an MDA program...................................................................................................... 124
2.11.4 Deleting an MDA program......................................................................................................... 124
3 Execution in manual mode..................................................................................................................... 125
3.1 General...................................................................................................................................... 125
3.2 Selecting a tool and spindle ...................................................................................................... 125
3.2.1 T, S, M windows........................................................................................................................ 125
3.2.2 Selecting a tool.......................................................................................................................... 127
3.2.3 Starting and stopping a spindle manually .................................................................................127
3.2.4 Position spindle ......................................................................................................................... 128
3.3 Traversing axes......................................................................................................................... 130
3.3.1 Traverse axes by a defined increment...................................................................................... 130
3.3.2 Traversing axes by a variable increment ..................................................................................131
3.4 Positioning axes ........................................................................................................................ 132
3.5 Swiveling ................................................................................................................................... 133

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3.6 Simple face milling of workpiece................................................................................................137
3.7 Default settings for manual mode ..............................................................................................140
4 Machining the workpiece ....................................................................................................................... 141
4.1 Starting and stopping machining................................................................................................141
4.2 Selecting a program...................................................................................................................142
4.3 Testing a program......................................................................................................................143
4.4 Displaying the current program block ........................................................................................145
4.4.1 Current block display .................................................................................................................145
4.4.2 Displaying a basic block.............................................................................................................145
4.4.3 Display program level ................................................................................................................146
4.5 Correcting a program.................................................................................................................148
4.6 Repositioning axes.....................................................................................................................149
4.7 Starting machining at a specific point ........................................................................................150
4.7.1 Use block search .......................................................................................................................150
4.7.2 Continuing program from search target .....................................................................................152
4.7.3 Simple search target definition...................................................................................................153
4.7.4 Defining an interruption point as search target..........................................................................153
4.7.5 Entering the search target via search pointer ............................................................................154
4.7.6 Parameters for block search in the search pointer ....................................................................155
4.7.7 Block search mode ....................................................................................................................156
4.8 Intervening in the program sequence ........................................................................................158
4.8.1 Program control..........................................................................................................................158
4.8.2 Skip blocks.................................................................................................................................159
4.9 Overstore ...................................................................................................................................161
4.10 Editing a program.......................................................................................................................162
4.10.1 Searching in programs...............................................................................................................163
4.10.2 Replacing program text..............................................................................................................164
4.10.3 Copying/pasting/deleting a program block.................................................................................165
4.10.4 Renumber program....................................................................................................................166
4.10.5 Creating a program block...........................................................................................................167
4.10.6 Opening additional programs.....................................................................................................168
4.10.7 Editor settings ............................................................................................................................169
4.11 Mold making view ......................................................................................................................171
4.11.1 Starting the mold making view...................................................................................................173
4.11.2 Specifically jump to the program block ......................................................................................174
4.11.3 Searching for program blocks....................................................................................................174
4.11.4 Changing the view .....................................................................................................................175
4.11.4.1 Enlarging or reducing the graphical representation...................................................................175
4.11.4.2 Modifying the viewport ...............................................................................................................176
4.12 Displaying G Functions and Auxiliary Functions........................................................................177
4.12.1 Selected G functions..................................................................................................................177
4.12.2 All G functions............................................................................................................................179
4.12.3 Auxiliary functions ......................................................................................................................180
4.13 Displaying the program runtime and counting workpieces........................................................183

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4.14 Setting for automatic mode ....................................................................................................... 185
5 Simulating machining............................................................................................................................. 187
5.1 Overview ................................................................................................................................... 187
5.2 Simulation before machining of the workpiece ......................................................................... 194
5.3 Simultaneous recording before machining of the workpiece .................................................... 195
5.4 Simultaneous recording during machining of the workpiece .................................................... 196
5.5 Different views of a workpiece .................................................................................................. 197
5.5.1 Plan view................................................................................................................................... 197
5.5.2 3D view...................................................................................................................................... 197
5.5.3 Side view................................................................................................................................... 198
5.6 Editing the simulation display.................................................................................................... 199
5.6.1 Blank display ............................................................................................................................. 199
5.6.2 Showing and hiding the tool path.............................................................................................. 199
5.7 Program control during the simulation ......................................................................................200
5.7.1 Changing the feedrate............................................................................................................... 200
5.7.2 Simulating the program block by block ..................................................................................... 201
5.8 Changing and adapting a simulation graphic............................................................................ 202
5.8.1 Enlarging or reducing the graphical representation .................................................................. 202
5.8.2 Panning a graphical representation .......................................................................................... 203
5.8.3 Rotating the graphical representation....................................................................................... 203
5.8.4 Modifying the viewport .............................................................................................................. 204
5.8.5 Defining cutting planes.............................................................................................................. 205
5.9 Displaying simulation alarms..................................................................................................... 206
6 Creating G code program ...................................................................................................................... 207
6.1 Graphical programming............................................................................................................. 207
6.2 Program views .......................................................................................................................... 208
6.3 Program structure ..................................................................................................................... 211
6.4 Basics........................................................................................................................................ 211
6.4.1 Machining planes ...................................................................................................................... 211
6.4.2 Current planes in cycles and input screens .............................................................................. 212
6.4.3 Programming a tool (T) ............................................................................................................. 213
6.5 Generating a G code program .................................................................................................. 214
6.6 Blank input ................................................................................................................................ 215
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F)........................................................................................................................................ 217
6.8 Selection of the cycles via softkey ............................................................................................ 218
6.9 Calling technology functions ..................................................................................................... 222
6.9.1 Hiding cycle parameters............................................................................................................ 222
6.9.2 Setting data for cycles............................................................................................................... 222
6.9.3 Checking cycle parameters....................................................................................................... 223
6.9.4 Changing a cycle call ................................................................................................................ 223
6.9.5 Compatibility for cycle support .................................................................................................. 224