Siemens SINUMERIK Operating Manual

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SINUMERIK SINUMERIK 802D sl Manual Machine Plus Turning

SINUMERIK

SINUMERIK 802D sl
Manual Machine Plus Turning

Programming and Operating Manual

Foreword

Description

_____________

Software interface

_____________

Turning On, Reference Point
Approach

_____________

Setting-up

_____________

Manual machining

_____________

Machining the machining
step program manually

_____________

Messages

_____________

Appendix

_____________

1

2

3

4

5

6

7

A

Valid for

Controller Software version
SINUMERIK 802D sl T/M 1.4 SP5

06/2009

6FC5398-6CP10-1BA0

Legal information

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

DANGER

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

WARNING

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

CAUTION

with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into

account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel

The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG

Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY

Ordernumber: 6FC5398-6CP10-1BA0
Ⓟ 05/2009

Copyright © Siemens AG 2009.
Technical data subject to change

Foreword

SINUMERIK documentation

The SINUMERIK documentation is organized in 3 parts:

● General documentation

● User documentation

● Manufacturer/Service documentation
An overview of publications, which is updated monthly and also provides information about

the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Follow menu items "Support" → "Technical Documentation" → "Ordering Documentation" →

"Printed Documentation".
The Internet version of DOConCD (DOConWEB) is available at:

Target group

Benefits

Standard scope

http://www.automation.siemens.com/doconweb
Information about training courses and FAQs (Frequently Asked Questions) can be found at

the following website:
http://www.siemens.com/motioncontrol under "Support".

This publication is intended for programmers, planning engineers, machine operators and
system operators.

With the Programming and Operating Manual, the target group can develop, write, test and
debug programs and software user interfaces.

It also contains the information required for the target group to operate the hardware and
software of a product/system (generally a machine).

This documentation only describes the functionality of the standard version. Additions or
revisions made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.

Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

Manual Machine Plus Turning
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3

Foreword

Technical support

If you have any technical questions, please contact our hotline:

Europe / Africa
Phone [phone]
Fax [phone]
Internet http://www.siemens.com/automation/support-request

America
Phone [phone]
Fax [phone]
E-Mail mailto:[e-mail]

Asia/Pacific
Phone [phone]
Fax [phone]
E-Mail mailto:[e-mail]

Note
Country-specific telephone numbers for technical support are provided under the following

Internet address:
http://www.siemens.com/automation/service&support

Calls are subject to charge, e.g. €0.14/min from a German landline. Tariffs of other phone
providers may differ.

Questions about this documentation

If you have any queries (suggestions, corrections) regarding this documentation, please
send a fax or email to the following address:

Fax [phone]
E-Mail [e-mail]

A fax form is available in the appendix of this document.

SINUMERIK Internet address

http://www.siemens.com/sinumerik

Manual Machine Plus Turning

4 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Foreword

EC Declaration of Conformity (only for hardware descriptions)

The EC Declaration of Conformity for the EMC Directive can be found/obtained:

● on the internet:
http://support.automation.siemens.com
under the product/order No. 15263595

● at the relevant regional office of the I DT MC Business Unit of Siemens AG.

Manual Machine Plus Turning
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5

Foreword

Manual Machine Plus Turning

6 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Table of contents

Foreword ...................................................................................................................................................

1 Description.................................................................................................................................................

1.1 Control and display elements.........................................................................................................

1.2 Error and status displays .............................................................................................................

1.3 Key definition of the full CNC keyboard (vertical format).............................................................

1.4 Key definition of the machine control panel .................................................................................

2 Software interface....................................................................................................................................

3 Turning On, Reference Point Approach...................................................................................................

3.1 Entry to the "Manual Machine Plus" operating area ....................................................................

3.2 Reference point approach............................................................................................................

4 Setting-up ................................................................................................................................................

4.1 Measuring tools............................................................................................................................

4.2 Limit stops ....................................................................................................................................

4.2.1 Setting and activating/deactivating limit stops .............................................................................

4.2.2 Turning against a stop .................................................................................................................

4.3 Setting the workpiece zero...........................................................................................................

5 Manual machining....................................................................................................................................

5.1 Fundamentals of manual machining............................................................................................

3
9

9
10
11
13
15
17
17
19
23
23
26

26
29

31
33
33

5.2 Display and operator control optios in the main screen for "Manual Machine Plus" ...................

5.2.1 Toggling the display .....................................................................................................................

5.2.2 Machining with the handwheels...................................................................................................

5.2.3 Setting the increment weighting for the handwheel.....................................................................

5.2.4 Machining with axis direction switch ............................................................................................

5.2.5 Spindle advance/reverse .............................................................................................................

5.2.6 Tool change .................................................................................................................................

5.2.7 Changing the feedrate/spindle value ...........................................................................................

5.2.8 Changing the feedrate/spindle type .............................................................................................

5.2.9 Change the speed limitation for constant cutting rate .................................................................

5.3 Manual machining with machining types .....................................................................................

5.3.1 Axis-parallel traversal...................................................................................................................

5.3.2 Manual taper turning ....................................................................................................................

5.3.3 Manual radius turning ..................................................................................................................

5.3.3.1 Radius turning type A...................................................................................................................

5.3.3.2 Radius turning type B...................................................................................................................

5.3.3.3 Radius turning type C ..................................................................................................................

5.4 Manual machining using cycles (functions) .................................................................................

5.4.1 Principle operating sequence.......................................................................................................

5.4.2 General parameters .....................................................................................................................

5.4.3 Manual drilling centered...............................................................................................................

5.4.4 Manual thread tapping .................................................................................................................

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34
38
39
39
39
40
41
43
44
46

47
47
48
49
52
52
53

54
54
58
60
62

7

Table of contents

5.4.5 Manual grooving/parting.............................................................................................................. 65

5.4.5.1 Groove cycle - single...................................................................................................................

5.4.5.2 Groove cycle - multiple................................................................................................................

5.4.5.3 Parting cycle - single ...................................................................................................................

5.4.5.4 Multiple tapping ...........................................................................................................................

5.4.5.5 Extended grooving ......................................................................................................................

5.4.5.6 Multiple extended grooving .........................................................................................................

5.4.6 Manual thread cutting..................................................................................................................

5.4.6.1 Thread cutting .............................................................................................................................

5.4.6.2 Thread recutting ..........................................................................................................................

5.4.6.3 Thread shaving after thread cutting ............................................................................................

5.4.7 Roughing cycles..........................................................................................................................

5.4.7.1 Roughing cycle A ........................................................................................................................

5.4.7.2 Roughing cycle B ........................................................................................................................

5.4.7.3 Roughing cycle C ........................................................................................................................

5.4.7.4 Roughing cycle D ........................................................................................................................

5.4.7.5 Roughing cycle E ........................................................................................................................

5.4.7.6 Roughing cycle F ........................................................................................................................

5.4.7.7 Roughing cycle, free contour: ...................................................................................................

5.4.7.8 Execute a roughing cycle..........................................................................................................

65
68
69
70
71
75
76
77
81
83
84
85
88
91
94
97

99
101
105

6 Machining the machining step program manually..................................................................................

6.1 Tool change in the machining step program.............................................................................

6.2 Teach In ....................................................................................................................................

6.3 Simulate machining...................................................................................................................

6.4 Executing the machining step program.....................................................................................

7 Messages ..............................................................................................................................................

7.1 Messages ..................................................................................................................................

A Appendix................................................................................................................................................

A.1 Feedback on the documentation...............................................................................................

A.2 Overview of documentation.......................................................................................................

Index......................................................................................................................................................

107
111
114
117
120
123
123
125
125
127
129

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8 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Description

1.1 Control and display elements

Operator control elements

The defined functions are called up via the horizontal and vertical softkeys. For a description,
please refer to this manual:

1

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Figure 1-1 CNC operator panel

+RUL]RQWDOVRIWNH\V

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9

Description

1.2 Error and status displays

1.2 Error and status displays

LED displays on the CNC operator panel (PCU)

The following LEDs are installed on the CNC operator panel.

(55 5'< 1& &)

The individual LEDs and their functions are described in the table below.

Table 1- 1 Status and error displays

LED Meaning
ERR (red) Serious error, remedy through power OFF/ON
RDY (green) Ready for operation
NC (yellow) Signoflife monitoring
CF (yellow) Reading from/writing to CF card

Reference

You can find information on error description in SINUMERIK 802D sl, Diagnostics Manual

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10 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Description

1.3 Key definition of the full CNC keyboard (vertical format)

1.3 Key definition of the full CNC keyboard (vertical format)

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Manual Machine Plus Turning
Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

11

Description

1.3 Key definition of the full CNC keyboard (vertical format)

Hot keys

In the part program editor and in the input fields of the HMI, the following functions can be
carried out with certain key combinations on the full CNC keyboard:

Keystroke combination Function
<CTRL> and <C> Copy selected text
<CTRL> and <B> Select text
<CTRL> and <X> Cut selected text
<CTRL> and <V> Paste copied text
<ALT> and <L> Changeover to small letters
<ALT> and <H> or <HELP> key Call help system

Manual Machine Plus Turning

12 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Description

1.4 Key definition of the machine control panel

1.4 Key definition of the machine control panel

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Manual Machine Plus Turning
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13

Description

1.4 Key definition of the machine control panel

Note
This documentation assumes an 802D standard machine control panel (MCP). Should you

use a different MCP, the operation may be other than described herein.

Manual Machine Plus Turning

14 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Software interface

This Programming and Operating Manual focuses primarily on the software interface of the
"Manual Machine Plus" system.

For descriptions of the software interface for the SINUMERIK 802D sl control system, please
refer to the SINUMERIK 802D sl Turning Programming and Operating Manual.

See Sections:

● Screen layout

● Standard softkeys

● Operating areas

● Help system

2

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15

Software interface

Manual Machine Plus Turning

16 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Turning On, Reference Point Approach

3.1 Entry to the "Manual Machine Plus" operating area

Operating sequences

Note
The operating area "Manual Machine Plus" runs only in Siemens mode, and not in ISO

mode.

Proceed as follows to open the "Manual Machine Plus" application:

Note
If the controller has already been preconfigured to "Manual Machine Plus" by the machine

manufacturer, items 1 to 3 can be ignored in the following description. The operating area
"Manual Machine Plus" is activated once the controller has been started up.

If you have not yet executed a reference point approach, you will be in the operating mode
Reference point approach (see Fig. Reference point approach) after start-up.

3

1. The NC boots into the JOG REF operating mode of the NC basic machine.

2. Select the JOG operating mode.
The interface can be seen in the screenshot below:

Figure 3-1 "Position" operating area

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17

Turning On, Reference Point Approach

3.1 Entry to the "Manual Machine Plus" operating area

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3. You can access the "Manual Machine Plus" area by clicking on softkey "Manual":

Note
If you have not yet executed a reference point approach, the JOG REF operating mode

will be reselected automatically when you press the "Manual" softkey.

Figure 3-2 Reference point approach

4. The operating area "Manual Machine Plus" can be exited with the "CNC" softkey, after
which the operating area of the NC basic machine is active again.

Note
The manual machine cannot be exited in the "Execute cycles" and "Execution window"

screen forms of the stepping program.

General operating information

If a screen (e.g. for the "thread tapping" function) contains input fields, then you can edit
them as follows:

● Select the input fields using the <cursor keys>.

● Enter data using the <numeric keys>.

● Accept the data using the <INPUT key>.

● Use the <Tab key> to switch between the input fields and the selection box during the
opening and saving of files.

● If you do not want to accept an input value,then exist the corresponding field using
<Cursor key> or change the screen form. Do not press the <INPUT> key.

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Note
The pictures in the parameterization screenforms depend on the setting of the machine data

by the machine manufacturer, i.e. display of the tool position before or behind the center of
rotation with regards to the turret head.

Turning On, Reference Point Approach

3.2 Reference point approach

3.2 Reference point approach

Functionality

The axes have not yet approached their reference points (see screenshot below).

Requirement

Figure 3-3 Reference point approach

Note
The meanings of the symbols in the axis display are as follows:

-> Axis still needs to be referenced.

-> Axis is referenced.

The following requirements must be fulfilled:

● There must be no NC alarms pending!

-> Clear any that are pending by pressing the "Reset" softkey.

● 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 in
front of the reference point.

DANGER

Before starting the reference point approach or switching off the machine, be sure to
move the machine slide to a position from which the reference point can be approached
in a positive axis direction.

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 cam before the start
of the reference point approach.

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19

Turning On, Reference Point Approach

3.2 Reference point approach

Operating sequence

1. Select the <JOG> operating mode.

Figure 3-4 Main screen for "Manual Machine Plus"

2. Select handwheel increment weighting using the <INCREMENT> key.

Figure 3-5 Handwheel increment weighting 100 INC

The current setting will appear on the top left of the screen (e.g.: 100 INC).

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20 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Turning On, Reference Point Approach

3.2 Reference point approach

3. Then use the handwheel to move the axes to a position from which they can approach

the reference point in a positive direction.

CAUTION

In this operating state, the axes can be moved only by means of the handwheel.
Traversing the axes using the axis traversing switch is inhibited. The spindle cannot be
started in this operating state.

4. Select the <JOG REF> operating mode.

;

5. Using the axis direction key, start the X axis in the positive direction (X+).

The reference point for the X axis is then approached automatically.
The axis stops automatically when it has completed this process.

The symbol

appears in front of the axis name in the display.

6. Repeat step 5 for the Z axis.

NOTICE

The axes must be referenced in this sequence, i.e., the X axis first, followed by the Z
axis. No other sequence will be accepted by the controller.

You have now referenced both axes.

Figure 3-6 Reference points reached

7. Select the <JOG> operating mode.

You are in the "Manual Machine Plus" operating area.

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21

Turning On, Reference Point Approach

3.2 Reference point approach

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Setting-up

4.1 Measuring tools

Functionality

You can measure tools manually in the "Manual Machine Plus" operating area. In this case,

Literature

the manual tool measurement function accesses the tool list data.

Note
You can access the tool list by pressing the operating area key <OFFSET/PARAM> and

softkey "Tool list".

Further methods of handling tools and tool offsets are described in the "SINUMERIK 802D sl
Turning Programming and Operating Manual".

DANGER

Notice: 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.

4

Requirement

Load the tool beforehand or enter the tool number in the "T" field. After confirming the input,
a dialog will prompt you to press the <NC Start> key. If the <NC Start> key is pressed, the

Manual Machine Plus Turning
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tool will be changed.

CAUTION

First approach a machine position where the tool change can be performed without danger.

23

Setting-up

4.1 Measuring tools

Operating sequences

Proceed as follows to measure the tool for the X axis of the loaded turning tool.

0HDV
WRRO

1. Press the "Meas. tool" softkey. The following screen appears:

Figure 4-1 Measure a turning tool

;

2. Press the "X" softkey.
The screen for measuring the X axis (L1) appears.

3. Check that the current tool number appears in the display field for the tool, since the
calibration operation will relate to this tool.

4. Carefully "scratch" a workpiece by an X handwheel infeed when the spindle is turning.

5. Move the slide slightly (without changing the X position) along the Z axis (longitudinal
turning) with the handwheel.

6. Switch the spindle off.

7. Enter the diameter measured on the workpiece in entry field "d1".

8. Accept the value by pressing the <INPUT> key.
The controller then automatically calculates the corresponding tool offset (in the radius)

and displays this as value "L1" in the screen form.

CAUTION

If you exit the screen form at this point, the new offset will not take effect.

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24 Programming and Operating Manual, 06/2009, 6FC5398-6CP10-1BA0

Setting-up

;

4.1 Measuring tools

6HW
OHQJWK

=

9. Press the "Set length" softkey.

The modified tool offset for the selected tool is applied in the X axis. Provided that the
"scratch position" in the X axis has not been moved, the measured diameter is now
displayed as the actual position in the position display of the tool measurement screen.

Figure 4-2 Measurement of turning tool in X axis completed

10. Press the "Z" softkey.

The screen for measuring the Z axis appears.

$ERUW

The Z axis can be measured in the same way as the X axis.
When measuring the tool in the Z axis, you may define a distance between the workpiece

and the turning tool tip in input field "a1" to avoid surface damage on the workpiece.

11. To return to the main screen for "Manual Machine Plus", select softkey "Abort".

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Setting-up

4.2 Limit stops

4.2 Limit stops

Functionality

Limit stops are used to stop the axes in a specific position.
If an axis stops in the limit stop position, it cannot be moved again until the triggering limit

stop is reset.
By setting the limit stops, in the "Manual Machine Plus" operating area, it is possible to turn

simple shoulders (including tapers) without the need for any further cycle parameterization.

Supplementary conditions

● The limit stop position is always an absolute dimension, which in turn always corresponds
to the position in the absolute actual value display on the "Manual Machine Plus"
interface. A relative limit stop position is not possible.

● A limit stop position can be entered/accepted only when the axes are stationary.
Otherwise, an error message appears.

4.2.1 Setting and activating/deactivating limit stops

Functionality

In the main screen "Manual Machine Plus" limit stops can be entered into the input fields "­X/-Z/+X/+Z".

In the following screen, the cursor (the field has a dark background) is located in the input
field "Endstop of axis X+".

Figure 4-3 Endstop of axis X+

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Setting-up

4.2 Limit stops

Parameter

Parameter Description
ON The limit stop is activated.
OFF The limit stop is deactivated.

- X Negative absolute position of the limit stop of the X axis.
The axis stops automatically if:

• The limit stop is active.

• The specified axis traverses in the negative direction and reaches the absolute limit stop position.

+X Positive absolute position of the limit stop of the X axis.

The axis stops automatically if:

• The limit stop is active.

• The specified axis traverses in the positive direction and reaches the absolute limit stop position.

-Z Negative absolute position of the limit stop of the Z axis.
The axis stops automatically if:

• The limit stop is active.

• The specified axis traverses in the negative direction and reaches the absolute limit stop position.

+Z Positive absolute position of the limit stop of the Z axis.

The axis stops automatically if:

• The limit stop is active.

• The specified axis traverses in the positive direction and reaches the absolute limit stop position.

All of the limit stops are set in the following screen.

Figure 4-4 All limit stops set

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Setting-up

4.2 Limit stops

Operating sequences

You can use the following methods to enter a limit stop position:

● Direct position entry:
– Select the input field of the relevant limit stop with the <Cursor keys>.
– Now use the <Numeric keys> to enter the absolute position you require.
– Press the <INPUT> key to accept the value.

● Accepting the current actual position:
– Select the input field of the relevant limit stop with the <Cursor keys>.

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X/+Z>).

– Press the "Set limit stop" softkey.

The current actual position of the relevant axis is transferred to the input field.

Activating/disabling limit stops

The limit stops are activated/de-activated individually using the <SELECT> key.
You can select between ON and OFF.

– Traverse to the required position using the axis direction switch (e.g. <-Z> or <+X/-

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Setting-up

4.2 Limit stops

4.2.2 Turning against a stop

Example:

The following example explains the operating principle of limit stops using the axis direction
keys.

You can also use the handwheel to perform the machining operation.

Task

The following shoulder with a finishing allowance of 0.2 mm must be turned:

● 100 mm in the Z direction

● 50 mm final diameter in the X direction
The end face starts at 0 mm int he Z direction. The blank diameter is 70 mm.

Operating sequences for infeeding to stop

1. Position the axes in front of the workpiece (e.g., X +75 mm/Z +5 mm).

2. Check the machining technology data.

3. Set the following limit stops:

– -X at 50.4 mm
– -Z at –99.8 mm (due to finishing allowance)
– +Z at +5 mm

4. Delete the limit stop for +X; it is not required.

5. Start the spindle.

6. Using the handwheel, infeed to the 1st depth of cut in the X direction.

7. Start machining in the Z axis in the negative direction using the axis direction switch.

When the limit stop position in Z –99.8 mm is reached, the Z axis stops automatically.
The message "Limit stop –Z reached" is displayed.

8. Switch-out the axis direction switch.

9. Using the handwheel, retract the tool from the workpiece in the X direction.

10. Using the axis direction switch and rapid traverse override, move the tool in a positive Z

direction towards the workpiece until the axis stops.
The message "Limit stop +Z reached" is displayed.

11. Switch-out the axis direction switch.

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Setting-up

4.2 Limit stops

12. Using the handwheel, infeed to the next depth of cut in the X direction.

13. Start machining in the Z axis in the negative direction using the axis direction switch.
Repeat the procedure until the depth of rough cut is reached.
The message "Limit stop -X reached" is displayed as the tool is fed in.
Once this cut has been completed, adjust the limit stops to the finished dimension,

provided that the axes are positioned in front of the workpiece.

Operating sequences for adjusting to finished dimension

1. Adjust the limit stops to the finished dimension: -X to 50.0 mm/-Z to –100.0 mm

2. Using the handwheel, infeed in the X direction until the "Limit stop -X reached" message
appears.

3. Start machining in the Z axis in the negative direction using the axis direction switch.
When the limit stop position in Z –100.0 mm is reached, the Z axis stops automatically.
The message "Limit stop –Z reached" is displayed.

4. Switch-out the axis direction switch in the Z direction and start in the positive X direction
(finishing the end face).

5. Switch-out the axis direction switch in the X direction as soon as the tool tip leaves the
workpiece.

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