Brief details of this edition and previous editions are listed below.
The status of each edition is indicated by the code in the "Remarks" column.
Status code in the "Remarks" column:
A .... New documentation.
B .... Unrevised reprint with new order number
C .... Revised edition with new status
Edition Order No. Remarks
04/2005---
Trademarks
SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK® and SIMODRIVE® are registered
trademarks of Siemens AG. Other names used in this publication may be trademarks, which, if used by third
parties for their own means, may violate the rights of their owners.
A
Additional information is available in the Internet at:
http://www.siemens.com/motioncontrol
This publication has been produced using WinWord V 8.0,
Designer V 7.0 and the DocuTool AutWinDoc.
Other functions not described in this documentation may be
executable in the control
obligation to supply such functions with a new control or when
servicing.
We have checked the contents of this manual for agreement with the
hardware and software described. Nevertheless, differences might
exist and we cannot, therefore, guarantee that they are completely
identical. However, the data in this manual are reviewed regularly and
any necessary corrections included in subsequent editions.
Suggestions for improvement are welcome.
Technical data subject to change.
Siemens Aktiengesellschaft
. This does not, however, represent an
04/2005Preface
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in 3 parts:
• General documentation
• User documentation
• Manufacturer/Service documentation
Please contact your local Siemens office for more detailed information about other
SINUMERIK 802D publications.
An overview of publications that is updated monthly is provided in a number of
languages in the Internet at:
http://www.siemens.com/motioncontrol
Follow menu items "Support" Æ "Technical Documentation" Æ "Overview of
Documents".
The Internet version of the DOConCD (DOConWEB) is available at:
http://www.automation.siemens.com/doconweb
Target readership
This Manual is intended for machine-tool users. This publication provides detailed
information that the user requires for operating the SINUMERIK 810D and 840D
controls.
Standard scope
This Operator’s Guide describes the functionality of the standard scope.
Extensions or changes made by the machine tool manufacturer are documented by
the machine tool manufacturer.
Other functions not described in this documentation may be executable in the
control. This does not, however, represent an obligation to supply such functions
with a new module or when servicing.
Fax form: See the reply form at the end of the document.
SINUMERIK Internet address
http://www.siemens.com/motioncontrol
Safety notes
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 The warnings are shown below in decreasing
order of danger.
!
!
!
Danger
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury or in substantial property damage.
Warning
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury or in substantial property damage.
Caution
Used with the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury or in property
damage.
Used without safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
Notice
Used without the safety alert symbol indicates a potential situation which, if not
avoided, may result in an undesirable result or state.
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 device/system must only be
commissioned and operated 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
!
Note the following:
Warning
The device must 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.
This notice indicates important facts that must be taken into consideration.
Note
This symbol always appears in this documentation where further, explanatory
information is provided.
Machine manufacturer
This pictorial symbol always appears in this document to indicate that the
machine manufacturer can affect or modify the function described. Note the
machine manufacturer’s instructions.
Unless the machine manufacturer has set it up differently, the controller powers up
automatically when the power supply is switched on. Internal test routines are
performed during the power-up process. Once they have been successfully
completed, the controller opens and displays the Reference Point screen form.
2.2 Reference point approach
Once the controller has powered up, the Reference Point screen form appears:
Fig. 2-1: Reference point approach
!
Note
Before starting the reference point approach, be sure to move the machine slide
to a position from which the reference point can be approached in a positive axis
direction.
2.2.1 Preparations for reference point approach
Before you can approach the reference points for the two axes, the following
conditions must be met:
Prerequisite
• There must be no NC alarms pending!
→ Clear any that are pending by pressing the "Reset" function key.
• All machine axes must be in a position from which the reference point can be
reached in a positive traversing direction.
→ In manual mode, use the handwheels to move the axes to the appropriate
position ahead of the reference point.
In this operating mode the axes can only be approached using the handwheel.
Use of the 4-way switch or axis direction keys to move the axes is blocked. In
addition, the spindle cannot be started in this mode.
• Press the “Refer. Axes” function key to switch back to “Reference point
approach” mode.
2.2.3 Reference point approach
Displays
Axis has not yet been referenced
Axis has already reached the reference point (is referenced)
Once all the conditions have been met (→ Preparations for reference point
approach), reference point approach can be started for each axis as follows:
• Using the 4-way switch or axis direction key, start the X axis in the positive
direction (X+). The reference point for the X axis is then approached
automatically.
• At the end of this process the axis stops automatically and the symbol is
displayed in front of the axis name.
• Once the X axis has reached its reference point, the same process can be
repeated for the Z axis (Z+).
!
Note
The axes must be referenced in this sequence, i.e. the X axis first, followed by
the Z axis. Any other sequence will not be accepted by the controller.
Caution
If the machine manufacturer has not fitted an axis limit switch, there is a risk of a
mechanical collision if the axis is on the wrong side of the reference point cam
before the start of the reference point approach.
→ Preparations for reference point approach.
• Press the "End Refpkt." function key once both axes have been referenced to
Manual workpiece machining is carried out in this operating mode.
Here the cross-slide is controlled either
• By means of the handwheels for the X and Z axis (→ Machining with the
handwheels) or
• By means of the 4-way switch or the axis direction keys (X+/X-/Z+/Z-)
(→ Machining with the 4-way switch/axis direction keys)
The spindle is controlled by means of
• The spindle joystick or the individual spindle advance and spindle reverse keys
(→ Spindle advance/reverse).
Machining technology data such as spindle speed, cutting speed and feedrate
must be set via special screen forms.
→ Machining technology data.
!
Note
Generally speaking the relevant machining technology data must be entered
before starting manual machining.
Caution
The maximum permissible spindle speed, which depends on the chucking device
fitted, must be entered in the Machining Technology Data screen form!
Failure to pay sufficient attention to this point can lead to serious damage as a
result of the chucking device speed being exceeded.
→ Machining technology data.
2.3.1 Displays on the main "Manual Machining" screen:
Actual-value
display:
The current actual position for the X and Z axis is shown here.
If the abbreviation "Abs" appears after the position value, the
display shows the absolute machine position. If the
abbreviation "Rel" appears here, however, it is a relative
position reflecting the distance traversed since the display was
last reset.
→Toggling the display.
Traversing
direction:
If the axis is moving, the current traversing direction is indicated
by the appropriate sign (+/-) in front of the axis letter (X/Z).
S value:The programmed value for either the spindle speed (Rev/min)
or the cutting speed (m/min) is shown here. The display
corresponds to the settings for the machining technology data.
→Machining technology data.
F value:The programmed feedrate is displayed here in either "m/min" or
"mm/Rev", depending on the settings for the machining
technology data.
→Machining technology data.
T value:The tool offset used by the controller is shown here.
→Tool change.
INC value:Indicates the handwheel pulse weighting currently set.
The handwheels for the X and Z axis are not mechanically connected to the feed
screws. Electronic pulse generators mounted on the handwheels generate the
information needed by the controller to execute the required traversing movement.
The handwheels are only active when the 4-way switch is in the zero position and
the individual axis control keys are disabled.
The distance traversed per handwheel pulse depends on the handwheel valuation
setting.
→ Handwheel valuation setting.
!
Note
If the handwheel valuation is set to "0" or if the feedrate override switch is in the
"0" position, the handwheels are disabled.
2.3.4 Handwheel valuation setting
Press the “Toggle key for handwheel valuation” in the main “Manual Machining”
screens to set the handwheel valuation.
The current setting will appear on the top-right of the screen (e.g., 100 INC).
If you are unable to adjust the handwheel valuation setting, it will be because the
controller's internal mode is incompatible with this process. Press the “JOG” key
once to resolve the problem.
Caution
An incorrect handwheel valuation setting can result in damage to the workpiece,
tool and machine.
2.3.5 Machining with the 4-way switch/axis direction keys
The axis can be traversed in the desired direction by turning the 4-way switch or
pressing the appropriate axis direction key. The feedrate at which the axis is
traversed depends on the settings in the Machining Technology Data screen form.
The axis feedrate is also influenced by the feedrate override switch setting and,
depending on the option selected in the Machining Technology Data screen form
(Rev. feedrate/cutting speed), by the spindle override switch.
If rapid traverse overlay is also actuated, the axis is moved at the maximum
possible speed unless a different value has been set at the feedrate override
switch.
!
Note
If the feedrate override switch is set to "0", any type of axis movement is blocked.
With the "Rev. feedrate" and "cutting speed" settings, the feed is blocked until the
spindle reaches the setpoint speed.
2.3.6 Spindle advance/reverse
The spindle is started in the appropriate direction (spindle advance/reverse) by
moving the spindle joystick or actuating the corresponding spindle direction key,
provided that the chuck guard switch is enabled (chuck guard closed).
!
Note
The spindle cannot be started unless the chuck guard switch is enabled.
→ Close the chuck guard.
Caution
Handling the chuck guard/chuck guard switch can lead to injury or mechanical
damage and should be avoided.
When the spindle is switched off it brakes and comes to a halt. If a spindle brake is
fitted, it is applied. If there is no spindle brake or it is switched off, the spindle can
be rotated freely once it has stopped.
If "Spindle Positi." is selected in the "Spindle Positioning" screen form, the spindle
is moved to the specified position after being switched off.
The spindle brake, if fitted, is then applied.
→ Spindle positioning.
The programmed spindle speed can be controlled by means of an appropriate
spindle override switch setting (e.g. 50%).
2.3.7 Jog spindle
The jog spindle key (if provided by the machine manufacturer) can be used to
rotate the spindle at low speed, for example to move a workpiece to a specific
angular position.
In the case of conventional/cycle-controlled machines of this order of magnitude,
with just a few exceptions, a manual tool change will generally be required. For this
reason, the correct tool number (tool compensation) must be notified to the control
by hand once the real tool change has taken place at the machine.
This is done as follows:
• Press function key "T" in the main Manual Machining screen form.
• The entry field for the T value is highlighted.
• Use the numeric keypad to enter the required tool number (tool offset)
(permissible values 1-15).
• Press "Enter" to complete the process.
If no further messages appear, the controller has completed the tool change.
!
Note
The tool number (tool offset) can only be changed, if all axes and the spindle are
stationary.
Caution
The tool number (tool offset) entered in the T value field must correspond to the
tool fitted in the machine. Otherwise, the tool will have to be re-calibrated (→ Tool
calibration). An uncalibrated or incorrectly calibrated tool can lead to dimensional
errors or to incorrect cutting values.
If machining technology data settings for the tool number (tool offset) to be
activated are found in the “Tool Data” screen form (→ Entering tool technology
data), the following message appears (relating to T4, in this example):
The question can be answered by pressing one of these function keys:
"OK"The tool offsets for the X and Z axis corresponding to the last tool
calibration operation are applied. The actual-value display changes,
if necessary.
The previous machining technology data is also overwritten by the
tool technology data (which has been saved for this tool) (feedrate,
spindle speed, cutting speed)
→Entering tool technology data.
“Abort”The tool offsets for the X and Z axis corresponding to the last tool
calibration operation are applied. The actual-value display changes,
if necessary.
The previous machining technology data is retained.
2.3.9 Machining technology data
Machining technology data, such as spindle speed, cutting speed and feedrate,
defines the settings that the controller needs for the machining of workpieces.
!
Note
The machining technology data can only be changed, if all axes and the spindle
are stationary.
There are two ways of changing the machining technology data:
• Simple changes to the spindle and feedrate values (S value/F value) can be
made directly in the "Manual Machining" screen form.
→ Changing the spindle/feedrate value
• A separate screen form is provided for entering the full set of machining
technology data.
→ Entering machining technology data
2.3.10 Changing the spindle/feedrate value
This method of adapting technology data can be used to change values quickly
during machining.
The values are changed using the appropriate function keys in the "Manual
Machining" screen form.
However, it is not possible to switch between "m/min" and "rev/min" (spindle) or
"mm/min" and "mm/rev" (axis) here (→ Entering machining technology data).
Changing
the S
value:
Changing
the F
value:
!
Note
The S value or F value can only be changed if all axes and the spindle are
stationary.
Press function key "S" to highlight the display field showing the
current programmed spindle value. The programmed value can now
be changed via the numeric keypad. Then press Enter to accept
(activate) the change. The entry field is deselected and the process
is complete.
To abort the change, press function key "S" or the Alarm reset key
instead of Enter. In this case the entry field is again deselected, the
new value is cleared and the previously programmed spindle value
is restored.
You cannot switch between "m/min" and "rev/min" here.
Press function key "F" to highlight the display field showing the
current programmed feedrate value. The programmed value can
now be changed via the numeric keypad. Then press Enter to
accept (activate) the change. The entry field is deselected and the
process is complete.
To abort the change, press function key "F" or the Alarm reset key
instead of Enter. In this case the entry field is again deselected, the
new value is cleared and the previously programmed feedrate value
is restored.
You cannot switch between "mm/min" and "mm/rev" here.
To open the screen form for machining technology data, press the "Spindle"
function key in "Manual Machining".
The following screen form appears:
Fig. 2-7: Machining technology data input
When the screen form appears, the last entry field to have been edited is
highlighted and a new value can be entered. To change a value in a different entry
field, use the cursor keys to move to that field. Enter the value via the numeric
keypad and then press Enter to accept (activate) the value. To abort the change
and restore the previous entry value, use the cursor keys to move to a different
entry field or exit the screen form (by pressing the "Back" function key), without
pressing Enter.
The meanings of the individual entry fields are defined as follows:
Const. Spindle
Speed
This entry value defines the programmed spindle speed for
machining with "Spindle speed + Time feed" or "Spindle
speed + Rev. feedrate". The value is only fully reached if no
reduction is specified via the spindle override valuation or the
spindle speed limit parameter ("Max. spindle speed").
Const. cutting
Speed
Cutting speed entry value for machining with "Cutting speed +
Rev. feedrate". The spindle speed is adjusted to the
machining diameter of the workpiece so that uniform cutting
conditions are achieved. Since the spindle would theoretically
have to rotate at an "infinitely high" speed at the rotational
center point in this mode, it has to be limited via the "Max.
spindle speed" parameter. The constant cutting speed can
also be influenced by means of the feedrate and spindle
override valuation settings.
It is vital to enter the maximum permissible spindle speed
here. The spindle speed is then limited to this value under all
circumstances, so that the permissible chucking device
speed, for example, cannot be exceeded.
Time feedIf Time feed is selected, the axes are moved at the speed
entered here (mm/min) (unless rapid traverse override is
activated). It can be influenced by the feedrate override
switch setting.
Feedrate per
rev.
The value entered here determines the axis velocity in
“Spindle speed + Rev. feedrate” or “Const. cutting speed +
Rev. feedrate” modes (if no rapid traverse override is set). It
is influenced directly by the feedrate override valuation setting
and indirectly by the spindle override valuation setting.
Caution
In the entry field for the maximum permissible spindle speed, you must enter the
value specified by the manufacturer for the chucking device that is fitted!
Failure to pay sufficient attention to this point can lead to serious damage as a
result of the chucking device speed being exceeded.
• To select the desired machining mode, press the "Spindle Feed" function key
The Spindle positioning function is intended purely for stopping the spindle in a
specific position to facilitate fitting of the chuck guard. It is not intended for positionrelated machining.
If the Spindle positioning function is selected, the spindle is switched off and then
moved to the position specified in the "Set spindle pos." entry field. If fitted, a
spindle brake is then applied.
To open the “Spindle Positioning” screen form, press the "Spindle Positi." function
key in the "Machining Technology Data" screen form.
The following screen form appears:
Fig. 2-8: Spindle positioning
When the screen form appears, there are two ways to enter the position:
• Use the numeric keypad to enter the position directly in the highlighted entry
field for the "Set spindle pos.". Then press Enter to accept the value. Only
values from 0 to 359.9 are permitted; otherwise, an error message appears and
the value is not accepted.
• After switching off the spindle, rotate it manually into the required position and
press Enter. The current spindle position is displayed in the "Set spindle pos."
entry field and automatically accepted. If the spindle has not completed a full
rotation since the controller was last powered up, the spindle is not yet
synchronized and the position will therefore not be accepted. In this case, a
corresponding message is displayed.
The controller is supplied with a tool list for 15 tools as standard. However, the
individual tools must be calibrated prior to initial use.
→ Tool calibration.
Caution
An uncalibrated or incorrectly calibrated tool can lead to dimensional errors or to
incorrect cutting values! If the values entered are very different from the actual
tool values, there is a risk that the tool may break or the mechanism or workpiece
may be damaged.
To open the "Tool Data Overview", press the "Tool" function key in the main
"Manual Machining" screen form.
The following screen form appears:
Fig. 3-1: Tool data overview
The active offsets for each tool, known as the tool offsets for the X and Z axis, are
displayed in this screen form. Experienced lathe operators can use this screen
form to enter the tool offsets, as on CNC controllers. Other operators should simply
refer to this screen form for information about the current offsets. The actual tool
measuring process takes place in the "Tool Measuring" screen form.
→ Tool calibration.
Data can be entered in the "Tool Data Overview" as follows:
• Use the cursor keys to select the required field (field is highlighted)
• Select the required tool type (turning tool or drilling tool) by pressing the
"Turn-/Boretool" function key
• Enter the values and press Enter to accept. The actual value display on the
machine (in "Manual Machining") is now updated to reflect the change. If you do
not wish to accept the value entered, either use the cursor key to leave the
entry field or switch to another screen form without pressing Enter.