SINUMERIK 802S base line 4
SINUMERIK 802C base line 4
2003.08 Edition
Cycles
9
SINUMERIK
®
Documentation
Key to editions
The editions listed below have been published prior to the current edition.
The column headed “Note” lists the amended sections, with reference to the previous edition.
Marking of edition in the “Note” column:
A ... ...New documentation.
B ... ...Unchanged reprint with new order number.
C ... ...Revised edition of new issue.
EditionOrder No.Note
1999.02 6FC5598-2AA10-0BP1A
2000.04 6FC5598-3AA10-0BP1A
2002.01 6FC5598-3AA10-0BP2C
2003.08 6FC5598-4AA11-0BP0A
Trademarks
SIMATIC
®
, SIMATIC HMI®, SIMATIC NET®, SIMODRIVE®, SINUMERIK®, and SIMOTION® are registered
trademarks of SIEMENS AG.
Other names in this publication might be trademarks whose use by a third party for his own purposes may violate
the registered holder.
Copyright Siemens AG 2003. All right reserved
The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will
be liable for damages. All rights, including rights created by patent
grant or registration of a utility model, are reserved.
Exclusion of liability
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences
might exist and we cannot therefore guarantee that they are completely identical. The information contained in this document is reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
Siemens-Aktiengesellschaft.SINUMERIK 802S/802C base line
Safety Guidelines
This Manual contains notices intended to ensure your personal safety , as well
as to protect products and connected equipment against damage. Safety
notices are highlighted by a warning triangle and presented in the following
categories depending on the degree of risk involved:
!
Indicates an imminently hazardous situation which, if not avoided, will result in
!
Indicates a potentially hazardous situation which, if not avoided, could result in
!
Used with safety alert symbol indicates a potentially hazardous situation which,
Used without safety alert symbol indicates a potentially hazardous situation
Danger
death or serious injury or in substantial property damage.
Warning
death or serious injury or in substantial property damage.
Caution
if not avoided, may result in minor or moderate injury or in property damage.
Caution
which, if not avoided, may result in property damage.
Indicates important information relating to the product or highlights part of the
Qualified person
Proper use
The unit may be used only for the applications described in the catalog or the
!
This product must be transported, stored and installed as intended, and
Please observe the following:
Notice
documentation for special attention.
The unit may only be started up and operated by qualified person or persons.
Qualified personnel as referred to in the safety notices provided in this
document are those who are authorized to start up, earth and label units,
systems and circuits in accordance with relevant safety standards.
Warning
technical description, and only in combination with the equipment, components
and devices of other manufacturers as far as this is recommended or p ermitted
by Siemens.
maintained and operated with care to ensure that it functions correctly and
safely.
Contents
Contents
SINUMERIK 802S/C base line Operator Panel OP
1.Introduction
1.1Screen Layout 1-1
1.2Operating areas 1-4
1.3Overview of the most important softkey functions 1-5
1.4Pocket calculator 1-6
1.5Basic principles 1-12
III
1-1
2.Turning On and Reference Point Approach
2-1
3.Setup
3.1Entering tools and tool offsets 3-1
3.1.1Creating a new tool 3-3
3.1.2Tool compensation data 3-4
3.1.3Determining the tool offsets 3-5
3.2Entering/modifying zero offsets 3-7
3.2.1Determining the zero offset 3-9
3.3Programming the setting data – “Parameters” operating area 3-11
3.4R parameters – “Parameters” operating area 3-13
3-1
4.Manually Operated Mode
4.1Jog mode – “Machine” operating area 4-1
4.1.1Assigning handwheels 4-4
4.2MDA Mode (Manual Data Input) – “Machine” operating area 4-5
5.Automatic Mode
5.1Selecting/starting a part program – “Machine” operating area 5-4
5.2Block search – “Machine” operating area 5-5
5.3Stopping/cancelling a part program – “Machine” operating area 5-6
5.4Repositioning after interruption 5-7
5.5Program execution from external (RS232 interface) 5-8
5.6Teach In 5-9
4-1
5-1
6.Part Programming
6.1Entering a new program – “Program” operating area 6-3
6.2Editing part programs – “Program” operating area 6-4
6.3Programming support 6-7
6.3.1Vertical menu 6-7
6.3.2Cycles 6-8
6.3.3Contour 6-9
6.3.4Free softkey assignment 6-24
6-1
7. Services and Diagnosis
7.1Data transfer via the RS232 Interface 7-1
7.1.1Interface parameters 7-4
7.1.2Special functions 7-5
7.1.3Interface parameterization 7-5
7.2Diagnosis and start-up – “Diagnostics” operating area 7-7
7-1
8.Programming
8.1Fundamentals of NC programming 8-1
8.1.1Program structure 8-1
8.1.2Word structure and address 8-2
8.1.3Block structure 8-3
8.1.4Character set 8-4
8.1.5Overview of instructions 8-5
8-1
SINUMERIK 802S/C base line
Operation and Programming Milling
8.6.4Selection of tool radius offset: G41, G42 8-44
8.6.5Behavior at corners: G450, G451 8-46
8.6.6Tool radius compensation OFF: G40 8-48
8.6.7Special cases of tool radius compensation 8-49
8.6.8Example of tool radius compensation 8-51
8.7Miscellaneous function M 8-52
8.8Arithmetic parameters R 8-53
8.9Program branches 8-55
8.9.1Labels - destination for program branches 8-55
8.9.2Unconditional program branches 8-56
8.9.3Conditional branches 8-57
8.9.4Example of program with branches 8-59
8.10Subroutine technique 8-60
9.Cycles
9.1General information about standard cycles 9-1
9.1.1Overview of cycles 9-1
9.1.2Error messages and error handling cycles 9-2
9.2Drilling cycles 9-4
9.2.1Drilling, spot facing - LCYC82 9-4
9.2.2Deep hole drilling - LCYC83 9-6
9.2.3Tapping without compensating chuck - LCYC84 9-10
9.2.4Tapping with compensating chuck - LCYC840 9-13
9.2.5Boring - LCYC85 9-15
9.3Drilling patterns 9-17
9.3.1Drilling a row of holes - LCYC60 9-17
9.3.2Hole circle - LCYC61 9-21
9.4Milling cycles 9-24
9.4.1Cutting square pockets, slots and circular pockets - LCYC75 9-24
II
SINUMERIK 802S/C base line
Operation and Programming
9-1
Milling
SINUMERIK 802S/C base line Operator Panel OP
Contents
NC keyboard area (left side):
Softkey
Machine area key
Recall key
ETC key
Area switchover key
Cursor UP
with shift: page up
Cursor LEFT
Delete key (backspace)
Numerical keys shift for
alternative assignment
Vertical menu
Acknowledge alarm
Selection key/toggle key
ENTER / input key
Shift key
Cursor DOWN
with shift: page down
Cursor RIGHT
SPACE (INSERT)
Alphanumeric keys shift for
alternative assignment
SINUMERIK 802S/C base line
Operation and Programming Milling
III
Contents
Machine Control Panel area (right side):
RESET
NC STOP
NC START
User-defined key with LED
…
User-defined key without LED
INCREMENT
JOG
REFERENCE POINT
AUTOMATIC
SINGLE BLOCK
SPINDLE STOP
RAPID TRAVERSE OVERLAY
X axis
Y axis
+Y-Y
Z axis
Feedrate override plus with LED
Feedrate override 100% without
LED
Feedrate override minus with LED
Spindle speed override plus with
LED
Spindle speed override 100%
without LED
MANUAL DATA
SPINDLE START LEFT
Counterclockwise direction
SPINDLE START RIGHT
Clockwise direction
Spindle speed override minus with
LED
IV
SINUMERIK 802S/C base line
Operation and Programming
Turning
Introduction
1.1 Screen Layout
1
Fig.1-1 Screen layout
The abbreviations on the screen stand for the following:
Table 1–1 Explanation of display elements
Display ElementAbbreviationMeaning
MAMachine
Active operating
area
Program status
Operating mode
PAParameter
PRProgramming
DIServices
DGDiagnosis
STOPProgramm stopped
RUNProgram running
RESETProgram aborted
JogManual traverse
MDAManual input with automatic function
AutoAutomatic
SINUMERIK 802S/C base line
Operation and Programming Milling
1-1
Introduction
Display ElementAbbreviationMeaning
SKPSkip block
Program blocks marked by a slash in front of the block
number are ignored during program execution.
DRYDry run feed
Traversing movements are executed at the feed specified in
the Dry Run Feed setting data.
ROVRapid traverse override
The feed override also applies to rapid feed mode.
SBLSingle block with stop after each block
When this function is active, the part program blocks are
processed separately in the following manner:
Each block is decoded separately, the program is stopped at
the end of each block. The only exception are thread blocks
without dry run feed. In this case, the program is stopped
only when the end of the current thread block is reached.
SBL can only be selected in the RESET state.
When this function is active, the program is stopped at each
block in which the miscellaneous function M01 is
programmed.
In this case, the message “5 stop M00/M01 active” appears
on the screen.
Incremental mode
If the control is in the Jog mode, incremental dimension is
displayed instead of the active program control function.
Stop: No NC Ready
Stop: EMERGENCY STOP active
Stop: Alarm active with stop
Stop: M0/M01 sctive
Stop: Block ended in SBL mode
Stop: NC STOP active
Wait: Read-in enable missing
Wait: Feed enable missing
Wait: Dwell time active
Wait: Auxiliary function acknowl. missing
Wait: Axis enable missing
Wait: Exact stop not reached
Wait: For spindle
Wait: Feed override to 0%
Stop: NC block incorrect
Wait: Block search active
Wait: No spindle enable
Wait: Axis feed value 0
Program name
1-2
SINUMERIK 802S/C base line
Operation and Programming
Milling
Introduction
Display ElementAbbreviationMeaning
Alarm line
Working window
Recall symbol
Menu extension
The alarm line is only displayed if an NC or PLC alarm is
active. The alarm line contains the alarm number and reset
criterion of the most recent alarm.
Working window and NC display
This symbol is displayed above the softkey bar when the
operator is in a lower-level menu.
When the Recall key is pressed, you can return to the nexthigher menu without saving data.
ETC is possible If this symbol appears above the softkey
bar, further menu functions are provided. These functions
can be activated by the ETC key.
Softkey bar
If this symbol is displayed above the softkey bar, further
Vertical menu
menu functions are provided. When the VM key is pressed,
these functions appear on the screen and can be selected
by Cursor UP and Cursor DOWN.
Here the current actual feedrate override is shown.
Feedrate
override
Gear box
Spindel speed
override
Here the current spindle gear stage 1…5 is shown.
Here the current spindel speed override is shown.
SINUMERIK 802S/C base line
Operation and Programming Milling
1-3
Introduction
1.2 Operating areas
The basic functions are grouped in the CNC into the following operating areas:
MachineParameterProgramServices
Executing
part
programs
Manual
control
Editing
program data
Creating
part
programs
Data
import /
export
Diagnosis
Alarm display
Start-up
Fig.1-2 SINUMERIK 802S base line operating areas
Switching between
the operating areas
Press the “Machine area” key for direct access to the “Machine” operating
area.
Use the area switching key to return from any operating area to the main
menu.
Press the area switching key twice to return to the previous operating area.
After turning on the control system, you will always find yourself in the Machine
operating area.
Protection levels
Sensible points of the control system are password-protected against entering
and modifying data.
However, the operator can alter the classes of protection in the “Machine data
display” menu in the “Diagnosis” operating area.
Default: protection level 3.
In the following menus, entering and modifying data depends on the set
protection class:
tool offsets
z
zero offsets
z
setting data
z
RS232 setting
z
1-4
Operation and Programming
SINUMERIK 802S/C base line
Milling
Introduction
1.3 Overview of the most important softkey functions
MachineParameterProgramServicesDiagnosis
Alarms
Display
bright.
Data In
Start
ProgramsCyclesSelectionOpen
R
Parameter
Data Out
Start
NewCopyDeleteRename
Tool
correction
Service
display
Display
darker
RS232
setting
Execut. f.
ext.
Setting
data
Start-up
Change
lang.
Error logshow
Zero
offset
Machine
data
Memory
info
Program
control
Axis feed.
Axis feed.
Hand wheelAxis feed.
SINUMERIK 802S/C base line
Operation and Programming Milling
Zoom blockSearch
Execut.f.
ext.
Zoom block
Act.val
WC
Zoom G
funct
Act.val
WC
Zoom G
funct
Act.val
WC
Zoom
act.val
Zoom M
funct
Zoom
act.val
Zoom M
funct
Zoom
act.val.
1-5
Introduction
1.4 Pocket calculator
This function can be activated for all input fields intended for entry of numerical
values by means of the “=” character. To calculate the required value, you can
use the four basic arithmetic operations, and the functions sine, cosine,
squaring, as well as the square root function.
If the input field is already loaded with a value, this function writes the value in
the input line of the pocket calculator.
Fig.1-3 Pocket calculator
Permissible
character
+ Value X plus value Y
- Value X minus value Y
* Value X multiplied with value Y
/ Value X divided by value Y
S Sine function
C Cosine function
Q Square function
R Square root function
The following characters are permitted for input:
he value X in front of the input cursor is replaced by the value sin(X).
The value X in front of the input cursor is replaced by the value cos(X).
The value X in front of the input cursor is replaced by the value X
The value X in front of the input cursor is replaced by the value ¥;
2.
Calculation examples
TaskInput
100 + (67*3)100+67*3
sin(45_)45 S -> 0.707107
cos(45_)45 C -> 0.707107
2
4
4 Q -> 16
¥4 R -> 2
The calculation is carried out when the Input key is pressed. The function
writes the result to the input field and automatically closes the pocket
calculator.
To calculate auxiliary points on a contour, the pocket calculator provides the
following functions:
calculating the tangential transition between a circle sector and a straight
z
line
moving a point in a plane
z
converting polar coordinates into Cartesian coordinates
z
1-6
Operation and Programming
SINUMERIK 802S/C base line
Milling
Introduction
adding the second end point of a contour section ‘straight line - straight
z
line’ given via angular interrelation.
These functions are directly linked with the input fields of the programming
support. Any values in this input field are written by the pocket calculator into
the input line, and the result is automatically copied into the input fields of the
programming support.
Softkeys
This function is used to calculate a point on a circle. The point results from the
angle of the created tangent and the direction of rotation of the circle.
Fig.1-4 calculation of a point on a circle
Enter the circle center, the angle of the tangent and the radius of the circle.
Use the softkeys G2 / G3 to define the direction of rotation of the circle.
The values of abscissa and ordinate are calculated. The abscissa is the first
axis of the plane, and the ordinate the second axis of the plane.
Example
If plane G17 is active, the abscissa is the X axis, and the ordinate the Y axis.
The value of the abscissa is copied into that input field from which the pocket
calculator function has been called, and the ordinate value into the next
following input field.
Example
Calculating the intersection point between the circle sector and the
straight line
.
Given:Radius: 10
Circle center point: X 20 Y20
Ongoing angle of the straight line: 45°
SINUMERIK 802S/C base line
Operation and Programming Milling
1-7
Introduction
Result:X = 12.928
Y = 27.071
The function calculates the Cartesian coordinates from a straight line specified
by length and rise angle.
Fig.1-5 Conversion of the polar coordinates into Cartesian coordinates
Enter the pole point (PP) as both an abscissa and ordinate value, the length
and the rise angle of the straight line.
The values of abscissa and ordinate are calculated.
The abscissa value is copied into the input field from which the pocket
calculator function has been called, and the ordinate value into the next
following input field.
Example
1-8
Operation and Programming
Calculating the end point of the straight line . The straight line is defined by
the angle A=45° and its length..
SINUMERIK 802S/C base line
Milling
Introduction
Result: X = 51.981
Y = 43.081
This function can be used to move a point in the plane. The point is on a
straight line defined by its rise angle.
Fig.1-6 Moving a point in the plane
Enter the rise angle of the straight line and the coordinates of the point.
Enter line shift and rotation of the point with refer to the straight line in the fields
“line shift” and “rotation”.
The values of abscissa and ordinate are calculated.
The pocket calculator copies the abscissa value into the input field from which
the pocket calculator function has been called, and the ordinate value into the
next following input field.
Example
Calculating the end point of the straight line . The straight line stands
vertical on the end point of the straight line
43.081). The length of the straight line is also given.
(coordinates: X = 51.981, Y =
SINUMERIK 802S/C base line
Operation and Programming Milling
1-9
Introduction
Result: X = 68.668
Y = 26.393
This function calculates the missing end point of the contour section straight
line - straight line, with the second straight line standing vertically on the first
straight line.
The following values of the straight line are known:
Straight line 1:Starting point and rise angle
Straight line 2:Length and one end point in the Cartesian coordinate system
Fig.1-7
This function chooses the given coordinate of the end position.
The value of ordinate and/or abscissa is given.
The second straight line is rotated in clockwise direction or, with refer to the
first straight line, rotated by 90 degrees in counter-clockwise direction. The
function chosses the appropriate setting.
The missing end position is calculated. The value of the abscissa is copied into
that input field from which the pocket calculator function has been called, and
the ordinate value into the next following input field.
1-10
SINUMERIK 802S/C base line
Operation and Programming
Milling
Introduction
Example
The drawing above must be added by the values of the of the circle center
points to be able to calculate the intersection points between the contour
sections. Calculating the missing coordinates of the center points is carried out
with the pocket calculator function
transition stands vertical on the straight line.
Calculating M1 in section 1:
In this section, the radius stands on the straight line section in counter-
clockwise direction.
, since the radius in the tangential
Use the softkeys
Enter the coordinates, the pole point P1, the rise angle of the straight line, the
given ordinate value and the circle radius as the length.
Result:X = -19.449
Y = 30
Calculating M2 in section 2:
In this section, the radius stands on the straight line section rotated in
clockwise direction. Use the softkeys to select the given constellation.
Enter the parameters in the screen form.
and to select the given constellation.
ResultX = 21.399
Y = 30
SINUMERIK 802S/C base line
Operation and Programming Milling
1-11
Introduction
1.5 Basic principles
Coordinate system
Fig.1-8 Specification of mutual relationship between axis directions
Machine coordinate
system (MCS)
Right-handed, rectangular coordinate systems are used for machine tools.
Such systems describe the movements on the machine as a relative motion
between tool and workpiece.
The orientation of the coordinate system on the machine tool depends on the
particular machine type. It can be turned to various positions.
Fig.1-9 Example of machine coordinates/axes
The origin of the coordinate system is the machine zero.
All axes are in zero position at this point. This point is merely a reference point
determined by the machine manufacturer. It needs not to be approachable.
The traversing range of the machine axes can be negative.
1-12
Operation and Programming
SINUMERIK 802S/C base line
Milling
Introduction
Workpiece coordInate system (WCS)
The definition of the directions is based on the assumption that the workpiece
The workpiece coordinate system described above (see Fi g. 1–8) is also used
to describe the geometry of a workpiece in the workpiece program.
The workpiece zero can be freely selected by the programmer. The programmer
need not know the real movement conditions on the machine, i.e. whether the
workpiece or the tool moves; this can be different in the individual axes.
does not move and the tool moves.
Z
Y
W
Fig.1-10 Workpiece coordinate system
Current workpiece
coordinate system
The use of the programmable zero offset provides a completely new current
from another zero than the initially selected zero (workpiece zero), he can
W= workpiece zero
If the programmer feels that it is better to continue his geometrical descriptions
define a new zero using the programmable zero offset. Reference is always
made to the original zero.
workpiece coordinate system. The current workpiece coordinate system can
also be turned to the original workpiece coordinate system (see Section
“Programmable Zero Offset and Rotation”).
X
Programmable offset G158
Z
W
Fig.1-11
Workpiece
clamping
SINUMERIK 802S/C base line
Operation and Programming Milling
be aligned such that the axes of the workpiece coordinate system run in
W= workpiece zero
To machine the workpiece, it is clamped on the m ach ine. Th e workpi ece must
parallel with the machine axes. Any resultant offset of the machine zero is
determined for each axis and entered into the intended data areas for the
settable zero offset. This offset is activated during the NC program execution
by means, for example, of a programmable G54 (see Section “Workpiece
Clamping - Settable Zero Offset ...”).
Y
X
Z
Current
Y
X
1-13
Introduction
Z
Machine
Z
Workpiece
W=workpi ece zero
M=machine zero
Y
W
z.B.
G54
Fig.1-12 Workpiece on the machine
M
X
Y
Machine
X
Machine
1-14
SINUMERIK 802S/C base line
Operation and Programming
Milling
Turning On and Reference
2
Point Approach
Note
Before you switch on the SINUMERIK and the machines, you should also have
read the machine documentation, since turning on and reference point
approach are machine-dependent functions.
Operating sequence
First switch on the power supply of the CNC and of the machine. After the
control system has booted, you are in the “Machine” operating area, in the Jog
operating mode.
The Reference point approach window is active.
Fig.2-1 Jog Ref basic screen
Reference-point approach can only be executed in the Jog mode.
Activate the “Approach reference point” function by selecting the Ref key on
the machine control panel area.
In the “Reference point approach” window (Fig. 2–1), it is displayed whether or
not the axes have to be referenced.
Axis has to be referenced
SINUMERIK 802S/C base line
Operation and Programming
Axis has reached the reference point
Milling
2-1
Turning On and Reference Point Approach
Press the direction keys.
The axis does not move if you select the wrong direction.
Approach the reference point in each axis successively.
You can quit the function by selecting another operating mode (MDA,
Automatic or Jog).
2-2
SINUMERIK 802S/C base line
Operation and Programming
Milling
Setup
3
Preliminary remarks
Before you can use the CNC, set up the machine, tools, etc. on the CNC by:
entering the tools and tool offsets
z
entering/modifying the zero offset
z
entering the setting data
z
3.1 Entering tools and tool offsets
Functionality
Each tool has a defined number of parameters depending on the tool type.
Each tool is identified by its own tool number (T number).
See also Section 8.6 “Tool and Tool Offset”.
Operating sequences
Parameter
Tool
Corr.
The tool offsets consist of several data that describe the geometry, wear and
tool type.
This function opens the
offset values of the currently active tool. If you select another tool using the
or
softkeys, the setting remains when you quit the window.
T>>
Tool Compensation Data
window, which contains the
<<T
Fig.3-1 Tool list
Softkeys
<< D
D >>
SINUMERIK 802S/C base line
Operation and Programming Milling
Select next lower or next higher edge number.
3-1
Setup
<< T
T >>
Search
Pressing this softkey opens the dialog box and the overview of the tool
numbers assigned. Enter the tool number you search for in the input window
and start search with OK. If the searched tool exists, the search function opens
the tool offset data box.
Press the ETC key to extend the softkey functions.
Select next lower or next higher tool.
Reset
edge
New
edge
The new edge is created for the currently displayed tool; it is automatically
All edge compensation values are reset to zero.
Creates a new edge and loads it with the appropriate parameters.
assigned the next higher edge number (D1 – D9).
Max. 30 edges (in total) can be stored in the memory.
Delete
tool
Deletes the tool compensation data of all edges of the selected tool.
New
Creates new tool compensation data for a new tool.
tool
Get
Comp.
Note: Max. 20 tools can be created.
Determines the length compensation values.
3-2
SINUMERIK 802S/C base line
Operation and Programming
Milling
Setup
3.1.1 Creating a new tool
Operating sequence
Press this softkey to create a new tool.
Pressing this softkey opens the input window and an overview of the tool
New
tool
Fig.3-2 New Tool window
numbers assigned.
… Enter the new T number (maximal only three digits) and specify the tool type.
Press OK to confirm your entry; the Tool Compensation Data window is
OK
opened.
SINUMERIK 802S/C base line
Operation and Programming Milling
3-3
Setup
3.1.2 Tool compensation data
The tool compensation data are divided into length and radius compensation
data.
The list is structured according to the tool type.
Fig. 3-3 Tool compensation d ata
Operating sequence
positioning the cursor on the input field to be modified,
… entering value(s)
Enter the offsets by
and confirming your entry by pressing Input or a cursor selection.
3-4
SINUMERIK 802S/C base line
Operation and Programming
Milling
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