siemens 802D Operating Manual

Introduction 1

Turning On,

SINUMERIK 802D SINUMERIK 802D base line

Programming and Operating

Turning

Reference−Point Approach

Setting Up 3

Manually Controlled Mode 4

Automatic Mode 5

Part Programming 6

System 7

Programming 8

Valid for

Control system Software version

SINUMERIK 802D 2 SINUMERIK 802D base line 1

Cycles 9

08/05 Edition

Safety information

This Manual contains information which you should carefully observe to ensure your own personal safety and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on the degree of hazard, represented as shown below:

Danger

indicates that death or severe personal injury will result if proper precautions are not taken.

Warning

indicates that death or severe personal injury can result if proper precautions are not taken.

Caution

with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

Caution

without a warning triangle means that material damage can occur if the appropriate precautions are not taken.

Attention

indicates that an undesired event or status can occur if the appropriate note is not observed.

If several hazards of different degrees occur, the hazard with the highest degree must always be given preference. If a warning note with a warning triangle warns of personal injury, the same warning note can also contain a warning of material damage.

Qualified personnel

Start−up and operation of the device/equipment/system in question must only be performed using this documentation. The start−up and operation of a device/system must only be performed by qualified personnel. Qualified personnel as referred to in the safety guidelines in this documentation are those who are authorized to start up, earth and label units, systems and circuits in accordance with the relevant safety standards.

Proper use

Please note the following:

Warning

The device may only be used for the applications described in the Catalog and only in combination with the equipment, components and devices of other manufacturers as far as this is recommended or permitted by Siemens. It is assumed that this product be transported, stored and installed as intended and maintained and operated with care to ensure that the product functions correctly and properly.

Trademarks

All designations marked with the copyright notice ® are registered trademarks of Siemens AG. Other names in this publication might be trademarks whose use by a third party for its own purposes may violate the rights of the registered holder.

Disclaimer of liability

Although we have checked the contents of this publication for agreement with the hardware and software described, since differences cannot be totally ruled out. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions.

Siemens AG Automation and Drives Postfach 4848 90437 NÜRNBERG GERMANY

Siemens AG 2005 Subject to change without prior notice.

Preface

SINUMERIK Documentation The SINUMERIK Documentation is organized in 3 levels:

S General Documentation: S User Documentation S Manufacturer/Service Documentation:

For detailed information regarding further publications about SINUMERIK 802D, as well as for publications that apply for all SINUMERIK control systems (e.g. Universal Interface, Measuring Cycles...), please contact your Siemens branch office.

A monthly overview of publications with specification of the available languages can be found on the Internet at:

http://www.siemens.com/motioncontrol

Follow the menu items ”Support”/”Technical Documentation”/”Overview of Publications”. The Internet edition of DOConCD − DOConWEB − can be found at:

http://www.automation.siemens.com/doconweb

Addressees of the documentation

Standard scope

Hotline

The present documentation is aimed at the machine tool manufacturer. This publication provides detailed information required for the machine tool manufacturer to start up the SINUMERIK 802D control system.

The present Instruction Manual describes the functionality of the standard scope. Any amendments made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation can possibly also be performed on the control system. However, the customer is not entitled to demand these functions when the new equipment is supplied or servicing is carried out.

If you have any questions, do not hesitate to call our hotline:

A&D Technical Support Tel.: +49 (0) 180 / 5050 − 222 Fax: +49 (0) 180 / 5050 − 223 Internet: http://www.siemens.de/automation/support−request

If you have any questions (suggestions, corrections) regarding the Documentation, please send a fax to the following number or an e−mail to the following address:

Fax: +49 (0) 9131 / 98 − 63315 E−mail: motioncontrol.docu@siemens.com

Fax form: see return fax form at the end of this publication

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

iii

Preface

Internet address

http://www.siemens.com/motioncontrol

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition

6FC5 698−2AA00−1BP4

1 Introduction 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Screen layout 1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Operating areas 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Accessibility options 1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Calculator 1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Editing Chinese characters 1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Hotkeys 1-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 The help system 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Coordinate systems 1-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Turning On and Reference Point Approach 2-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Setting Up 3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Entering the tools and the tool offsets operating area”# 3-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Use this softkey to create a new tool. 3-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Determining the tool offsets (manually) 3-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Determining tool compensations using a probe 3-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.4 Determining the tool offsets using optical measuring instruments 3-37 . . . . . . . . . . . . . . . . . . . . .

3.1.5 Probe settings 3-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Tool monitoring 3-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Entering/modifying a work offset 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Determining the work offset 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Programming setting data - ”Parameter” operating area 3-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 R parameters − ”Offset/Parameter”operating area 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

4 Manually Controlled Mode 4-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Mode Jog - ”Position” operating area 4-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Assigning handwheels 4-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 MDA mode (Manual input) - ”Machine” operating area 4-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Face turning 4-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Automatic Mode 5-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Selecting / starting a part program - ”Machine” operating area 5-66 . . . . . . . . . . . . . . . . . . . . . . .

5.2 Block search - ”Machine” operating area 5-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Stopping / canceling a part program 5-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Reapproach after cancellation 5-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Repositioning after interruption 5-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Program execution from external source (RS232 interface) 5-70 . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Part Programming 6-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Entering a new program - ”Program” operating area 6-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Editing part programs - ”Program” operating area 6-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Blueprint programming 6-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Simulation 6-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Data transfer via the RS232 interface 6-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

Contents

7 System 7-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 PLC diagnosis represented as a ladder diagram 7-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Screen layout 7-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Operating options 7-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Programming 8-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Fundamentals of NC programming 8-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Program names 8-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.2 Program structure 8-131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.3 Word structure and address 8-132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.4 Block structure 8-133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.5 Character set 8-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.6 Overview of the instructions 8-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Positional data 8-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 Absolute / incremental dimensioning: G90, G91, AC, IC 8-148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 Dimensions in metric units and inches: G71, G70, G710, G700 8-149 . . . . . . . . . . . . . . . . . . . . . .

8.2.3 Radius / diameter dimensional notation: DIAMOF, DIAMON 8-150 . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.4 Programmable work offset: TRANS, ATRANS 8-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.5 Programmable scaling factor: SCALE, ASCALE 8-152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.6 Workpiece clamping − settable work offset:

G54 to G59, G500, G53, G153 8-154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.7 Programmable working area limitation:

G25, G26, WALIMON, WALIMOF 8-155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Axis movements 8-157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 Linear interpolation with rapid traverse: G0 8-157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.2 Linear interpolation with feedrate: G1 8-158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.3 Circular Interpolation: G2, G3 8-159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.4 Circular interpolation via intermediate point: CIP 8-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.5 Circle with tangential transition: CT 8-162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.6 Thread cutting with constant lead: G33 8-163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.7 Thread cutting with variable lead: G34, G35 8-166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.8 Thread Interpolation: G331, G332 8-167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.9 Fixed point approach: G75 8-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.10 Reference point approach: G74 8-168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.11 Measuring with touch−trigger probe: MEAS, MEAW 8-169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.12 Feedrate F 8-170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.13 Exact stop / continuous−path control mode: G9, G60, G64 8-171 . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.14 Acceleration pattern: BRISK, SOFT 8-173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.15 Percentage acceleration override: ACC 8-174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.16 Traversing with feedforward control: FFWON, FFWOF 8-175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.17 3rd and 4th axes 8-176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.18 Dwell Time: G4 8-176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.19 Travel to fixed stop 8-177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Spindle movements 8-181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1 Spindle speed S, directions of rotation 8-181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.2 Spindle speed limitation: G25, G26 8-181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.3 Spindle positioning: SPOS 8-182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.4 Gear stages 8-183

8.4.5 2nd spindle 8-183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Special turning functions 8-185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.1 Constant cutting rate: G96, G97 8-185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.2 Rounding, chamfer 8-187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5.3 Blueprint programming 8-188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Tool and tool offset 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.1 General notes 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.2 Tool T 8-191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.3 Tool offset number D 8-192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8.6.4 Selecting the tool radius compensation: G41, G42 8-196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.5 Corner behavior: G450, G451 8-197 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.6 Tool radius compensation OFF: G40 8-199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.7 Special cases of the tool radius compensation 8-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.8 Example of tool radius compensation 8-201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.9 Use of milling cutters 8-202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6.10 Special handling of tool compensation 8-204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7 Miscellaneous function (M) 8-205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8 H function 8-206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9 Arithmetic parameters R, LUD and PLC variables 8-207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.1 Arithmetic parameters R 8-207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.2 Local User Data (LUD) 8-208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9.3 Reading and writing PLC variables 8-210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10 Program jumps 8-211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.1 Jump destination for program jumps 8-211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.2 Unconditional program jumps 8-211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.3 Conditional program jumps 8-212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.10.4 Program example for jumps 8-214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11 Subroutine technique 8-215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11.1 General 8-215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.11.2 Calling machining cycles 8-217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12 Timers and workpiece counters 8-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12.1 Runtime timer 8-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12.2 Workpiece counter 8-219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13 Language commands for tool monitoring 8-221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13.1 Tool monitoring overview 8-221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13.2 Tool life monitoring 8-222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.13.3 Workpiece count monitoring 8-223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.14 Milling on turning machines 8-226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.14.1 Milling of the front face − TRANSMIT 8-226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.14.2 Milling of the peripheral surface − TRACYL 8-228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.15 G functions equivalent to the SINUMERIK 802S − Turning 8-233 . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

9 Cycles 9-235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Overview of cycles 9-235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Programming cycles 9-236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Graphical cycle support in the program editor 9-238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Drilling cycles 9-240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.1 General 9-240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.2 Prerequisites 9-241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.3 Drilling, centering – CYCLE81 9-242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.4 Drilling, counterboring – CYCLE82 9-245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.5 Deep hole drilling – CYCLE83 9-247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.6 Rigid tapping – CYCLE84 9-251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.7 Tapping with compensating chuck – CYCLE840 9-254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.8 Reaming1 (boring 1) – CYCLE85 9-258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.9 Boring (boring 2) – CYCLE86 9-261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.10 Boring with Stop 1 (boring 3) – CYCLE87 9-264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.11 Drilling with stop 2 (boring 4) – CYCLE88 9-267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.12 Reaming 2 (boring 5) – CYCLE89 9-269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.13 Row of holes – HOLES1 9-271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.14 Circle of holes – HOLES2 9-275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Turning cycles 9-278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

9.5.1 Prerequisites 9-278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.2 Grooving – CYCLE93 9-280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.3 Undercut (forms E and F to DIN) – CYCLE94 9-288 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.4 Machining with undercut – CYCLE95 9-292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.5 Thread undercut – CYCLE96 9-305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.6 Thread cutting – CYCLE97 9-309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.7 Chaining of threads – CYCLE98 9-315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Error Messages and Error Handling 9-322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.1 General notes 9-322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.2 Error handling in the cycles 9-322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.3 Overview of cycle alarms 9-322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6.4 Messages in the cycles 9-324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SINUMERIK 802D Key Definition

Clear key

Insert key

Tabulator

ENTER / Input key

”Position” operating area key

”Program” operating area key

”Parameter” operating area

”Program Manager” operating area

”Alarm/System” operating area

not assigned

”Recall” key

ETC key

”Acknowledge alarm” key

without function

Info key

Shift key

Controlkey

Altkey

SPACE

Backspace

PageUp / PageDown keys

Cursor keys

Selection key / toggle key

Alphanumeric keys

Double assignment on the Shift level

Numeric keys

Double assignment on the Shift level

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

External Machine Control Panel

Spindle override

User−defined key with LED

User−defined key without LED

INCREMENT

100

110

120

JOG

REFERENCE POINT

AUTOMATIC

6 2

100 110

120

SINGLE BLOCK

MANUAL DATA

SPINDLE START LEFT

SPINDLE STOP

RESET

NC STOP

NC START

EMERGENCY STOP

X axis

Z axis

SPINDLE START RIGHT

RAPID TRAVERSE OVERRIDE

Feedrate override

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Introduction

Note

The present Manual always uses ”802D bl” as an acronym for SINUMERIK 802D base line.

1.1 Screen layout

Status area

Applicationarea

Tip and softkey area

Fig. 1-1 Screen layout

The screen is divided into the following main areas:

S Status area S Applicationarea S Tip and softkey area

G function

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Introduction

MDA

System

1. Alarm number with alarm text, or

1.1 Screen layout

Status area

Fig. 1-2 Status area

Table 1-1 Explanation of the display elements in the status area

Screen Con-

trol

Display Meaning

Active operating area, active mode

Position

JOG; 1 INC, 10 INC, 100 INC, 1000 INC, VAR INC (evaluation by increments in the JOG mode) MDA

AUTOMATIC Offset Program Program Manager S

stem Alarm Marked as an ”external language” using G291

Alarm and message line

In addition, the following is displayed:

1. Alarm number with alarm text, or

2. Message text

Program status

RESET Program canceled / default status RUN Program running STOP Program stopped

Program controls in the AUTOMATIC mode

1-12

Reserved

NC messages

Selected part program (main program)

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Tip and softkey area

Fig. 1-3 Tip and softkey area

Introduction

1.1 Screen layout

Table 1-2 Explanation of the screen elements in the tip and softkey area

Screen Con-

trol

Display Meaning

Recall symbol

Pressing the Recall key lets you return to the next higher menu level.

Tip line

Displays tips for the operator

MMCstatus information ETC is possible (Pressing this key displays the horizontal softkey bar

providing further functions.)

Mixed notation active

Data transfer running

Connection to the PLC programming tool active

Softkey bar vertical and horizontal

Standard softkeys

Use this softkey to quit the screenform.

Use this softkey to cancel the input; the window is closed.

Selecting this softkey will complete your input and start the calculation.

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Introduction

1.2 Operating areas

Selecting this softkey will complete your input and accept the values you have entered.

This function is used to switch the screenform from diameter programming to radius programming.

1.2 Operating areas

The functions of the control system can be carried out in the following operating areas:

Position Machine operation

Offset/Parameters Input of offset values and setting data

Program Creation of part programs

Protection levels

Program Manager Part program directory

System Diagnosis, start−up

Alarm Alarm and message lists

To switch the operating area, use the relevant key (hard key).

The input and modification of vital data in the control system is protected by passwords. In the menus listed below the input and modification of data depends on the protection level

set:

S Tool offsets S Work offsets S Setting data S RS232 settings S Program creation / program correction

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1.3 Accessibility options

1.3.1 Calculator

The calculator function can be activated from any operating area using ”SHIFT” and ”=”. To calculate terms, the four basic arithmetic operations can be used, as well as the functions

”sine”, ”cosine”, ”squaring” and ”square root”. A bracket function is provided to calculate nested terms. The bracket depth is unlimited.

If the input field is already occupied by a value, the function will accept this value into the input line of the calculator.

When you press the Input key, the result is calculated and displayed in the calculator. Selecting the Accept softkey enters the result in the input field at the current cursor position

of the part program editor and closes the calculator automatically.

Introduction

1.3 Accessibility options

Note

If an input field is in the editing mode, it is possible to restore the original status using the ”Toggle” key.

Fig. 1-4 Calculator

Characters permitted for input

+, −, *, / Basic arithmetic operations S Sine function

The X value (in degrees) in front of the input cursor is replaced by the sin(X) value.

O Cosine function

The X value (in degrees) in front of the input cursor is replaced by the cos(X) value.

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Introduction

1.3 Accessibility options

Q Square function

The X value in front of the input cursor is replaced by the X

R Square root function

The X value in front of the input cursor is replaced by the √⎮ value.

( ) Bracket function (X+Y)*Z

Calculation examples

100 + (67*3) 100+67*3 −> 301 sin(45_) 45 S −> 0.707107 cos(45_) 45 C −> 0.707107

4 √4 4 R −> 2 (34+3*2)*10 (34+3*2)*10 −> 400

To calculate auxiliary points on a contour, the calculator offers the following functions:

S Calculating the tangential transition between a circle sector and a straight line S Moving a point in the plane

value.

Task Input −> Result

4 Q −> 16

Softkeys

S Converting polar coordinates to Cartesian coordinates S Adding the second end point of a straight line/straight line contour section given from an

angular relation

This function is used to calculate a point on a circle. The point results from the angle of the tangent created, as well as from the radius and the direction of rotation of the circle.

1-16

Fig. 1-5

Enter the circle center, the angle of the tangent and the circle radius.

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Introduction

1.3 Accessibility options

G2/G3

Use the G2 / G3 softkey to define the direction of rotation of the circle.

Use this softkey to calculate the abscissa and ordinate values. The abscissa is the first axis, and the ordinate is the second axis of the plane. The abscissa value is copied into the input field from which the calculator function has been called, and the value of the ordinate is copied into the next following input field. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

Example: Calculate the intersection point between the circle sector

and the straight line

in plane G18.

Given: Radius: 10

Circle center: Z 147 X 103 Connection angle of the straight line: −455

Result: Z = 154.071

X = 110.071

This function calculates the Cartesian coordinates of a point in the plane, which is to be connected to a point in the plane (PP) on a straight line. For calculation, the distance between the points and the slope angle (A2) of the new straight line to be created with reference to the slope (A1) of the given straight line must be known.

Fig. 1-6

Enter the following coordinates or angles:

S the coordinates of the given point (PP) S the slope angle of the straight line (A1) S the distance of the new point with reference to PP S the slope angle of the connecting straight line (A2) with reference to A1

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Introduction

1.3 Accessibility options

Use this softkey to calculate the Cartesian coordinates which are subsequently copied into two input fields following one after another. The abscissa value is copied into the input field from which the calculator function has been called, and the value of the ordinate is copied into the next following input field. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

This function converts the given polar coordinates into Cartesian coordinates.

Fig. 1-7

Enter the reference point, the vector length and the slope angle.

Use this function to calculate the missing end point of the straight line/straight line contour section whereby the second straight line stands vertically on the first straight line.

The following values of the straight line are known:

Straight line 1: Starting point and slope angle

Straight line 2: Length and one end point in the Cartesian coordinate system

1-18

Fig. 1-8

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Introduction

1.3 Accessibility options

This function is used to select the given coordinate of the end point. The ordinate value or the abscissa value is given.

The second straight line is rotated in the CW direction or in the CCW direction by 90 degrees relative to the first straight line.

The missing end point is calculated. The abscissa value is copied into the input field from which the calculator function has been called, and the value of the ordinate is copied into the next following input field. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

Example

Fig. 1-9

Add the drawing above by the value of the center circle in order to be able to calculate the intersection point between the circle sector of the straight line. The missing coordinate of the

center point is calculated using the calculator function

, since the radius in the tan-

gential transition stands vertically on the straight line.

Fig. 1-10

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1-19

Introduction

1.3 Accessibility options

Calculating M1 in section 1:

The radius stands at an angle of 90° turned CW on the straight−line defined by the angle.

Use the softkey

to select the appropriate direction of rotation. Use the softkey

to define the given end point.

Enter the coordinates of the pole, the slope angle of the straight line, the ordinate angle of the end point and the circle radius as the length.

Fig. 1-11

Result: X = 60

Z = −44.601

1.3.2 Editing Chinese characters

This function is only available in the Chinese language version. The control system provides a function for editing Chinese characters in the program editor

and in the PLC alarm text editor. After activation, type the phonetic alphabet of the searched character in the input field. The editor will then offer various characters for this sound, from which you can choose the desired one by entering either of the digits 1 to 9.

Fig. 1-12 Chinese editor

Alt S Is used to turn on / turn off the editor

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1.3.3 Hotkeys

This operator control can be used to select, copy, cut and delete texts using special key commands. These functions are available both for the part program editor and for input fields.

CTRL C Copy CTRL B Select CTRL X Cut CTRL V Paste Alt L Is used to switch to the mixed notation Alt H Help system or info key

Introduction

1.3 Accessibility options

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Introduction

1.4 The help system

To activate the help system, use the Info key. It offers a brief description for all important operating functions.

In addition, the help offers the following topics:

S Overview of the NC commands with a brief description S Cycle programming S Explanation of the drive alarms

Show

Go to topic

Fig. 1-13 Table of contents of the help system

This function opens the selected topic.

Fig. 1-14 Description for a help topic

Use this function to select cross references. A cross reference is marked by the characters

”>>....<<”. This softkey is only unhidden if a cross reference is displayed in the application

area.

1-22

Back to topic

If you select a cross reference, in addition, the Back to topic softkey is displayed. This function lets you return to the previous screenform.

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Introduction

1.4 The help system

Find

Use this function to search for a term in the table of contents. Type the term you are looking for and start the search process.

Help in the ”Program editor” area

The system offers an explanation for each NC instruction. To display the help text directly, position the cursor after the appropriate instruction and press the Info key.

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Introduction

1.5 Coordinate systems

For machine tools, right−handed, right−angled coordinate systems are used. The movements on the machine are described as a relative movement between tool and workpiece.

Fig. 1-15 Determination of the axis directions another to one; coordinate system for programming

when turning

Machine coordinate system (MCS)

How the coordinate system is located with reference to the machine, depends on the machine type concerned. It can be rotated in different positions.

Fig. 1-16 Machine coordinates/machine axes using the example of a turning machine

The origin of the coordinate system is the machine zero. This point only represents a reference point defined by the machine manufacturer. It need not be approachable.

The traversing range of the machine axes can by in the negative range.

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Workpiece coordinate system (WCS)

The coordinate system described above (see Fig. 1-15) is also used to describe the geometry of a workpiece in the workpiece program. The workpiece zero can be freely selected by the programmer in the Z axis. In the X axis, it lies in the turning center.

Introduction

1.5 Coordinate systems

Fig. 1-17 Workpiece coordinate system

Relative coordinate system

In addition to the machine and workpiece coordinate systems, the control system provides a relative coordinate system. This coordinate system is used for setting freely selected reference points which have no influence on the active workpiece coordinate system. All axis movements are displayed relative to these reference points.

Clamping the workpiece

For machining, the workpiece is clamped on the machine. The workpiece must be aligned such that the axes of the workpiece coordinate system run in parallel with those of the machine. Any resulting offset of the machine zero with reference to the workpiece zero is determined along the Z axis and entered in a data area intended for the settable work offset. In the NC program, this offset is activated, e.g. using a programmed G54 (see also Section

8.2.6).

Workpiece

W -workpiece zero

Workpiece

Machine

Fig. 1-18 Workpiece on the machine

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

e.g.

Workpiece

G54

Workpiece

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Introduction

1.5 Coordinate systems

Current workpiece coordinate system

The programmed work offset TRANS can be used to generate an offset with reference to the workpiece coordinate system resulting in the current workpiece coordinate system (see Section ”Programmable work offset: TRANS”).

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Turning On and Reference Point Approach

Note

When you turn on the SINUMERIK 802D and the machine, please also observe the Machine Documentation, since turning on and reference point approach are machine−dependent functions.

This documentation assumes an 802D standard machine control panel (MCP). Should you use a different MCP, the operation may be other than described herein.

Operating sequence

First, turn on the power supply of CNC and machine. After the control system has booted, you are in the ”Position” operating area, in the Jog mode.

The ”Reference point approach” window is active.

Fig. 2-1 The ”Jog−Ref” start screen

Use the Ref key on the machine control panel to activate ”reference point approach”. The ”Reference point approach” window (Fig. 2-1) displays whether the axes are referenced

(approached to their reference points).

Axis must be referenced

Axis has reached its reference point

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

...

-Z

Press a direction key.

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Turning On and Reference Point Approach

If you select the wrong approach direction, no motion will be carried out. Approach the reference points for each axis one after the other.

Quit the function by switching the mode (MDA, AUTOMATIC or Jog).

Note

”Reference point approach” is only possible in the Jog mode.

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Setting Up

Preliminary remarks

Before you can work with the CNC, set up the machine, the tools, etc. on the CNC as follows:

S Enter the tools and the tool offsets S Enter/modify the work offset S Enter the setting data

Menu tree

Tool List

Tool measure

Delete tool

Extend

Edges

Find

New tool

Tool life

Work offset

Measure workpiece

R vari− able

Find

Setting data

Work area limit.

Tim e counter

Misc.

User data

To o l measure

Delete tool

Extend

Edges

Find

New tool

Fig. 3-1 Menu tree ”Parameters” operating area

Note

The softkeys marked in Fig. 3-1 with an asterisk (”:”) are missing in the 802D bl.

SINUMERIK 802D, 802D bl Operartion and Programming Turning (BP−D), 08/05 Edition 6FC5 698−2AA00−1BP4

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Setting Up

3.1 Entering the tools and the tool offsets operating area”#

Functionality

The tool offsets consist of several data describing the geometry, the wear and the tool type. Depending on the tool type, each tool is assigned a defined number of parameters. Tools are identified by a number (T number).

See also Section 8.6 ”Tool and tool compensation”

Operating sequences

Use this softkey to open the ”Tool offset data” window which contains a list of the tools created. Use the cursor keys and the Page Up / Page Down keys to navigate in this list.

Tool List

Softkeys

Tool measure

Measure manual

Fig. 3-2 Tool list

Enter the offsets by positioning the

S cursor bar on the input field to be changed, S enter the value(s)

and either press Input or use a cursor key to confirm.

Extend

For special tools, the

softkey function is provided which offers a complete parameter

list which can be filled out.

Use this softkey to determine the tool compensation data.

Determining the tool offset data manually (see Section 3.1.2)

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+ 299 hidden pages

siemens 802D Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Contents

SINUMERIK 802D Key Definition

External Machine Control Panel

Introduction

1.1 Screen layout

1.2 Operating areas

1.3 Accessibility options

1.3.1 Calculator

1.3.2 Editing Chinese characters

1.3.3 Hotkeys

1.4 The help system

1.5 Coordinate systems

Turning On and Reference Point Approach

Setting Up

3.1 Entering the tools and the tool offsets operating area”#