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

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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
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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
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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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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

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6.9.6 Additional functions in the input screens ...................................................................................224
6.10 Measuring cycle support ............................................................................................................225
7 Creating a ShopMill program ................................................................................................................. 227
7.1 Program views ...........................................................................................................................228
7.2 Program structure ......................................................................................................................232
7.3 Basic information .......................................................................................................................233
7.3.1 Machining planes .......................................................................................................................233
7.3.2 Polar coordinates .......................................................................................................................233
7.3.3 Absolute and incremental dimensions .......................................................................................234
7.4 Creating a ShopMill program .....................................................................................................236
7.5 Program header .........................................................................................................................237
7.6 Generating program blocks........................................................................................................239
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V).........................................................240
7.8 Defining machine functions........................................................................................................242
7.9 Call work offsets.........................................................................................................................244
7.10 Repeating program blocks .........................................................................................................245
7.11 Specifying the number of workpieces ........................................................................................247
7.12 Changing program blocks..........................................................................................................248
7.13 Changing program settings........................................................................................................249
7.14 Selection of the cycles via softkey .............................................................................................250
7.15 Calling technology functions ......................................................................................................254
7.15.1 Additional functions in the input screens ...................................................................................254
7.15.2 Checking input parameters........................................................................................................254
7.15.3 Setting data for technological functions .....................................................................................255
7.15.4 Changing a cycle call .................................................................................................................255
7.15.5 Compatibility for cycle support...................................................................................................256
7.16 Measuring cycle support ............................................................................................................256
7.17 Example, standard machining....................................................................................................257
7.17.1 Workpiece drawing ....................................................................................................................258
7.17.2 Programming..............................................................................................................................258
7.17.3 Results/simulation test ...............................................................................................................270
7.17.4 G code machining program........................................................................................................272
8 Programming technological functions (cycles)....................................................................................... 275
8.1 Drilling ........................................................................................................................................275
8.1.1 General ......................................................................................................................................275
8.1.2 Centering (CYCLE81)................................................................................................................276
8.1.2.1 Function .....................................................................................................................................276
8.1.3 Drilling (CYCLE82).....................................................................................................................278
8.1.3.1 Function .....................................................................................................................................278
8.1.4 Reaming (CYCLE85) .................................................................................................................279
8.1.4.1 Function .....................................................................................................................................279
8.1.5 Deep-hole drilling (CYCLE83)....................................................................................................281

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8.1.5.1 Function..................................................................................................................................... 281
8.1.6 Boring (CYCLE86) .................................................................................................................... 284
8.1.6.1 Function..................................................................................................................................... 284
8.1.7 Tapping (CYCLE84, 840).......................................................................................................... 286
8.1.7.1 Function..................................................................................................................................... 286
8.1.8 Drill and thread milling (CYCLE78) ........................................................................................... 291
8.1.8.1 Function..................................................................................................................................... 291
8.1.9 Positioning and position patterns .............................................................................................. 295
8.1.10 Arbitrary positions (CYCLE802)................................................................................................ 297
8.1.11 Position pattern Line (HOLES1), Grid or Frame (CYCLE801).................................................. 300
8.1.12 Circle position pattern (HOLES2).............................................................................................. 302
8.1.13 Displaying and hiding positions................................................................................................. 304
8.1.14 Repeating positions................................................................................................................... 305
8.2 Milling ........................................................................................................................................ 307
8.2.1 Face milling (CYCLE61)............................................................................................................ 307
8.2.1.1 Function..................................................................................................................................... 307
8.2.2 Rectangular pocket (POCKET3)............................................................................................... 310
8.2.3 Circular pocket (POCKET4)...................................................................................................... 313
8.2.4 Rectangular spigot (CYCLE76)................................................................................................. 318
8.2.5 Circular spigot (CYCLE77)........................................................................................................ 321
8.2.5.1 Function..................................................................................................................................... 321
8.2.6 Multi-edge (CYCLE79).............................................................................................................. 323
8.2.6.1 Function..................................................................................................................................... 323
8.2.7 Longitudinal groove (SLOT1).................................................................................................... 326
8.2.8 Circumferential groove (SLOT2) ............................................................................................... 329
8.2.9 Open groove (CYCLE899)........................................................................................................ 332
8.2.10 Long hole (LONGHOLE) - only for G code programs............................................................... 339
8.2.11 Thread milling (CYCLE70) ........................................................................................................ 341
8.2.12 Engraving (CYCLE60)............................................................................................................... 344
8.3 Contour milling .......................................................................................................................... 351
8.3.1 General...................................................................................................................................... 351
8.3.2 Representation of the contour................................................................................................... 351
8.3.3 Creating a new contour............................................................................................................. 353
8.3.4 Creating contour elements........................................................................................................ 355
8.3.5 Changing the contour................................................................................................................ 360
8.3.6 Contour call (CYCLE62) - only for G code program ................................................................. 361
8.3.7 Path milling (CYCLE72) ............................................................................................................ 362
8.3.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 366
8.3.9 Predrilling contour pocket (CYCLE64)...................................................................................... 368
8.3.10 Milling contour pocket (CYCLE63)............................................................................................ 371
8.3.11 Residual material contour pocket (CYCLE63) .......................................................................... 373
8.3.12 Milling contour spigot (CYCLE63)............................................................................................. 375
8.3.13 Residual material contour spigot (CYCLE63) ........................................................................... 377
8.4 Turning - only for G code programs .......................................................................................... 380
8.4.1 General...................................................................................................................................... 380
8.4.2 Stock removal (CYCLE951)...................................................................................................... 380
8.4.3 Groove (CYCLE930)................................................................................................................. 383
8.4.4 Undercut form E and F (CYCLE940) ........................................................................................ 386
8.4.5 Thread undercut (CYCLE940) .................................................................................................. 388
8.4.6 Thread turning (CYCLE99) ....................................................................................................... 391
8.4.7 Thread chain (CYCLE98).......................................................................................................... 400

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8.4.8 Cut-off (CYCLE92).....................................................................................................................403
8.5 Contour turning - only for G code programs ..............................................................................406
8.5.1 General information ...................................................................................................................406
8.5.2 Representation of the contour....................................................................................................407
8.5.3 Creating a new contour..............................................................................................................408
8.5.4 Creating contour elements.........................................................................................................411
8.5.5 Changing the contour.................................................................................................................417
8.5.6 Contour call (CYCLE62) ............................................................................................................418
8.5.7 Stock removal (CYCLE952).......................................................................................................419
8.5.8 Stock removal residual (CYCLE952) .........................................................................................424
8.5.9 Grooving (CYCLE952) ...............................................................................................................426
8.5.10 Grooving residual material (CYCLE952) ...................................................................................430
8.5.11 Plunge turning (CYCLE952) ......................................................................................................432
8.5.12 Plunge turning residual material (CYCLE952)...........................................................................435
8.6 Further cycles and functions ......................................................................................................438
8.6.1 Swiveling plane/tool (CYCLE800)..............................................................................................438
8.6.2 Swiveling tool (CYCLE800)........................................................................................................448
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) .......................448
8.6.2.2 Swiveling aligning tool - only for G code program (CYCLE800)................................................449
8.6.3 High-speed settings (CYCLE832)..............................................................................................451
8.6.4 Subroutines................................................................................................................................453
8.7 Further cycles and functions ShopMill .......................................................................................455
8.7.1 Transformations .........................................................................................................................455
8.7.2 Translation .................................................................................................................................456
8.7.3 Rotation......................................................................................................................................457
8.7.4 Scaling .......................................................................................................................................458
8.7.5 Mirroring.....................................................................................................................................459
8.7.6 Cylinder surface transformation.................................................................................................460
8.7.6.1 General programming................................................................................................................462
8.7.7 Straight or circular machining ....................................................................................................463
8.7.8 Programming a straight line.......................................................................................................465
8.7.9 Programming a circle with known center point ..........................................................................466
8.7.10 Programming a circle with known radius ...................................................................................467
8.7.11 Helix ...........................................................................................................................................468
8.7.12 Polar coordinates .......................................................................................................................469
8.7.13 Straight polar..............................................................................................................................470
8.7.14 Circle polar.................................................................................................................................471
8.7.15 Obstacle .....................................................................................................................................472
9 Multi-channel view ................................................................................................................................. 473
9.1 Multi-channel view .....................................................................................................................473
9.2 Multi-channel view in the "Machine" operating area..................................................................473
9.3 Multi-channel view for large operator panels.............................................................................476
9.4 Setting the multi-channel view ...................................................................................................478
10 User variables........................................................................................................................................ 481
10.1 Overview ....................................................................................................................................481
10.2 R parameters .............................................................................................................................482

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10.3 Global GUD............................................................................................................................... 483
10.4 Channel GUD............................................................................................................................ 484
10.5 Local LUD.................................................................................................................................. 485
10.6 Program PUD............................................................................................................................ 486
10.7 Searching for user data............................................................................................................. 487
10.8 Defining and activating user variables ...................................................................................... 487
11 Teaching in a program........................................................................................................................... 489
11.1 Overview ................................................................................................................................... 489
11.2 General sequence..................................................................................................................... 489
11.3 Inserting a block ........................................................................................................................ 490
11.3.1 Input parameters for teach-in blocks......................................................................................... 491
11.4 Teach-in via window.................................................................................................................. 492
11.4.1 General...................................................................................................................................... 492
11.4.2 Teach in rapid traverse G0........................................................................................................ 494
11.4.3 Teach in straight G1.................................................................................................................. 494
11.4.4 Teaching in circle intermediate and circle end point CIP.......................................................... 494
11.4.5 Teach-in A spline ...................................................................................................................... 495
11.5 Editing a block........................................................................................................................... 497
11.6 Selecting a block ....................................................................................................................... 498
11.7 Deleting a block......................................................................................................................... 499
12 Tool management.................................................................................................................................. 501
12.1 Lists for the tool management................................................................................................... 501
12.2 Magazine management............................................................................................................. 502
12.3 Tool types.................................................................................................................................. 503
12.4 Tool dimensioning ..................................................................................................................... 505
12.5 Tool list...................................................................................................................................... 512
12.5.1 Additional data .......................................................................................................................... 515
12.5.2 Creating a new tool ................................................................................................................... 516
12.5.3 Measuring the tool..................................................................................................................... 518
12.5.4 Managing several cutting edges ............................................................................................... 518
12.5.5 Delete tool ................................................................................................................................. 519
12.5.6 Loading and unloading tools ..................................................................................................... 520
12.5.7 Selecting a magazine................................................................................................................ 521
12.6 Tool wear................................................................................................................................... 523
12.6.1 Reactivating a tool..................................................................................................................... 525
12.7 Tool data OEM .......................................................................................................................... 527
12.8 Magazine................................................................................................................................... 528
12.8.1 Positioning a magazine............................................................................................................. 530
12.8.2 Relocating a tool ....................................................................................................................... 530
12.9 Sorting tool management lists................................................................................................... 532

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12.10 Filtering the tool management lists ............................................................................................533
12.11 Specific search in the tool management lists.............................................................................534
12.12 Displaying tool details ................................................................................................................535
12.13 Changing a tool type..................................................................................................................536
13 Program management ........................................................................................................................... 537
13.1 Overview ....................................................................................................................................537
13.1.1 NC memory................................................................................................................................540
13.1.2 Local drive..................................................................................................................................540
13.1.3 USB drives .................................................................................................................................541
13.2 Opening and closing the program..............................................................................................542
13.3 Executing a program..................................................................................................................544
13.4 Creating a directory/program/job list/program list......................................................................545
13.4.1 Creating a new directory............................................................................................................545
13.4.2 Creating a new workpiece..........................................................................................................546
13.4.3 Creating a new G code program................................................................................................547
13.4.4 Creating a new ShopMill program..............................................................................................548
13.4.5 Storing any new file....................................................................................................................549
13.4.6 Creating a Joblist .......................................................................................................................550
13.4.7 Creating a program list...............................................................................................................551
13.5 Creating templates.....................................................................................................................552
13.6 Searching directories and files...................................................................................................553
13.7 Displaying the program in the Preview. .....................................................................................554
13.8 Selecting several directories/programs......................................................................................555
13.9 Copying and pasting a directory/program..................................................................................557
13.10 Deleting a program/directory......................................................................................................559
13.10.1 Deleting a program/directory......................................................................................................559
13.11 Renaming file and directory properties ......................................................................................560
13.12 EXTCALL ...................................................................................................................................562
13.13 Backing up data .........................................................................................................................564
13.13.1 Generating an archive in the Program Manager........................................................................564
13.13.2 Generating an archive via the system data ...............................................................................565
13.13.3 Reading in an archive in the Program Manager ........................................................................567
13.13.4 Read in archive from system data .............................................................................................569
13.14 Setup data..................................................................................................................................570
13.14.1 Backing up setup data ...............................................................................................................570
13.14.2 Reading-in set-up data...............................................................................................................573
13.15 V24.............................................................................................................................................575
13.15.1 Reading-in and reading-out archives.........................................................................................575
13.15.2 Setting V24 in the program manager.........................................................................................577
14 Setting up drives.................................................................................................................................... 579
14.1 Overview ....................................................................................................................................579

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14.2 Setting up drives ....................................................................................................................... 580
15 HT 8....................................................................................................................................................... 583
15.1 HT 8 overview ........................................................................................................................... 583
15.2 Traversing keys......................................................................................................................... 586
15.3 Machine control panel menu..................................................................................................... 587
15.4 Virtual keyboard ........................................................................................................................ 588
15.5 Calibrating the touch panel ....................................................................................................... 590
16 Ctrl Energy............................................................................................................................................. 591
16.1 Overview ................................................................................................................................... 591
16.2 Displaying energy consumption ................................................................................................ 592
16.3 Measuring and saving the energy consumption ....................................................................... 593
16.4 Displaying measured curves..................................................................................................... 594
16.5 Using the energy-saving profile ................................................................................................ 594
17 Easy Message (828D only).................................................................................................................... 597
17.1 Overview ................................................................................................................................... 597
17.2 Activating Easy Message.......................................................................................................... 598
17.3 Creating/editing a user profile ................................................................................................... 599
17.4 Setting-up events ...................................................................................................................... 600
17.5 Logging an active user on and off............................................................................................. 602
17.6 Displaying SMS logs ................................................................................................................. 603
17.7 Making settings for Easy Message ........................................................................................... 604
18 Easy Extend (828D only) ....................................................................................................................... 605
18.1 Overview ................................................................................................................................... 605
18.2 Enabling a device...................................................................................................................... 606
18.3 Activating and deactivating a device......................................................................................... 606
18.4 Commissioning Easy Extend .................................................................................................... 607
19 Service Planner (828D only).................................................................................................................. 609
19.1 Performing and monitoring maintenance tasks......................................................................... 609
19.2 Set maintenance tasks.............................................................................................................. 610
20 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 613
20.1 PLC diagnostics ........................................................................................................................ 613
20.2 Structure of the user interface................................................................................................... 614
20.3 Control options .......................................................................................................................... 615
20.4 Displaying PLC properties......................................................................................................... 616
20.5 Displaying and editing NC/PLC variables ................................................................................. 617

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20.6 Displaying and editing PLC signals ...........................................................................................618
20.7 Displaying information on the program blocks...........................................................................619
20.8 Downloading a PLC user program.............................................................................................621
20.9 Editing the local variable table ...................................................................................................622
20.10 Creating a new block .................................................................................................................623
20.11 Editing block properties..............................................................................................................624
20.12 Inserting and editing networks ...................................................................................................625
20.13 Editing network properties .........................................................................................................627
20.14 Displaying and editing symbol tables.........................................................................................628
20.15 Inserting/deleting a symbol table ...............................................................................................629
20.16 Searching for operands..............................................................................................................630
20.17 Displaying the network symbol information table.......................................................................631
20.18 Displaying/canceling the access protection ...............................................................................632
20.19 Displaying cross references.......................................................................................................632
21 Alarms, error messages, and system alarms......................................................................................... 635
21.1 Displaying alarms.......................................................................................................................635
21.2 Displaying an alarm log..............................................................................................................637
21.3 Displaying messages .................................................................................................................637
21.4 Sorting, alarms, faults and messages........................................................................................638
21.5 PLC and NC variables ...............................................................................................................639
21.5.1 Displaying and editing PLC and NC variables...........................................................................639
21.5.2 Saving and loading screen forms ..............................................................................................643
21.5.3 Load symbols.............................................................................................................................644
21.6 Version.......................................................................................................................................645
21.6.1 Displaying version data..............................................................................................................645
21.6.2 Save information ........................................................................................................................646
21.7 Logbook .....................................................................................................................................647
21.7.1 Displaying and editing the logbook ............................................................................................648
21.7.2 Making a logbook entry..............................................................................................................648
21.8 Creating screenshots .................................................................................................................650
21.9 Remote diagnostics ...................................................................................................................651
21.9.1 Setting remote access ...............................................................................................................651
21.9.2 Permit modem............................................................................................................................653
21.9.3 Request remote diagnostics ......................................................................................................653
21.9.4 Exit remote diagnostics..............................................................................................................654
A Appendix................................................................................................................................................ 655
A.1 Overview ....................................................................................................................................655
Index...................................................................................................................................................... 657

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Introduction 1
1.1 Product overview
The SINUMERIK controller is a CNC (Computerized Numerical Controller) for machine tools.
You can use the CNC to implement the following basic functions in conjunction with a
machine tool:
● Creation and adaptation of part programs
● Execution of part programs
● Manual control
● Access to internal and external data media
● Editing of data for programs
● Management of tools, zero points and further user data required in programs
● Diagnostics of controller and machine
Operating areas
The basic functions are grouped in the following operating areas in the controller:
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Introduction
1.2 Operator panel fronts
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20 Operating Manual, 09/2011, 6FC5398-7CP40-2BA0
1.2 Operator panel fronts
1.2.1 Overview
Introduction
The display (screen) and operation (e.g. hardkeys and softkeys) of the SINUMERIK Operate
user interface use the operator panel front.
In this example, the OP 010 operator panel front is used to illustrate the components that are
available for operating the controller and machine tool.
Operator controls and indicators
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