Siemens SINUMERIK 808D ADVANCED Programming And Operating Manual
SINUMERIK
SINUMERIK 808D ADVANCED
Programming and Operating Manual (Turning)
User Manual
Legal information
Warning notice system
DANGER
will
WARNING
may
CAUTION
NOTICE
Qualified Personnel
personnel qualified
Proper use of Siemens products
WARNING
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.
indicates that death or severe personal injury
indicates that death or severe personal injury
indicates that minor personal injury can result if proper precautions are not taken.
indicates that property damage can result if proper precautions are not taken.
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.
The product/system described in this documentation may be operated only by
the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their
training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
Note the following:
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 complied with. The information in the relevant documentation must be observed.
result if proper precautions are not taken.
result if proper precautions are not taken.
for the specific task in accordance with
© Siemens AG 2015. All rights reserved
6FC5398-5DP10-0BA2, 06/2015
1
Preface
Applicable software versions for turning
Applicable products
Control system
Software version
Preface
Documentation components and target groups
Document
Recommended target group
My Documentation Manager (MDM)
Standard scope
Technical support
Country
Hotline
Further service contact information:
http://www.siemens.com.cn/808D
EC Declaration of Conformity
67385845
This manual is applicable to the following control system:
SINUMERIK 808D ADVANCED T (Turning) V4.7
Programming and Operating Manual (Turning) Programmers and operators of turning machines
Programming and Operating Manual (Milling) Programmers and operators of milling machines
Diagnostics Manual Mechanical and electrical designers, commissioning engi-
neers, machine operators, and service and maintenance
personnel
Under the following link you will find information to individually compile your documentation based on the Siemens content:
www.siemens.com/mdm
This manual only describes the functionality of the standard version. Extensions or changes made by the machine tool
manufacturer are documented by the machine tool manufacturer.
Germany +49 911 895 7222
China +86 400 810 4288
1)
You can find more hotline information at the global Web site given above.
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://www.siemens.com/automation/service&support.
Here, enter the number
Programming and Operating Manual (Turning)
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1)
• Global Web site:
https://support.industry.siemens.com/sc/us/en/sc/list-of-countries/oid2044
• Chinese Web site:
as the search term or contact your local Siemens office.
Table of contents
Preface ................................................................................................................................................................... 2
1 Fundamental safety instructions .............................................................................................................................. 7
2 Introduction............................................................................................................................................................. 8
3 Turning on, reference point approach .................................................................................................................... 15
4 Setting-up ............................................................................................................................................................. 16
5 Part programming ................................................................................................................................................. 30
6 Automatic machining ............................................................................................................................................. 36
7 Data backup ......................................................................................................................................................... 49
1.1 General safety instructions ...................................................................................................................... 7
1.2 Industrial security .................................................................................................................................... 7
2.1 CNC operator panels ............................................................................................................................... 8
2.1.1 Panel Processing Unit (PPU) versions .................................................................................................... 8
2.1.2 Control elements on the PPU161.3 ......................................................................................................... 8
2.2 Machine control panels .......................................................................................................................... 10
2.2.1 Machine Control Panel (MCP) versions ................................................................................................. 10
2.2.2 Control elements on the MCP ............................................................................................................... 10
2.3 Screen layout ........................................................................................................................................ 12
2.4 Protection levels .................................................................................................................................... 13
2.5 Setting user interface language ............................................................................................................. 14
4.1 Coordinate systems ............................................................................................................................... 16
4.2 Setting up tools ...................................................................................................................................... 18
4.2.1 Creating a new tool................................................................................................................................ 18
4.2.2 Activating the tool .................................................................................................................................. 20
4.2.3 Assigning the handwheel ....................................................................................................................... 21
4.2.4 Activating the spindle............................................................................................................................. 22
4.2.5 Measuring the tool (manually) ............................................................................................................... 23
4.2.6 Verifying the tool offset result in "MDA" mode ....................................................................................... 27
4.2.7 Entering/modifying the tool wear data ................................................................................................... 28
4.3 Operating area overview ....................................................................................................................... 29
5.1 Creating a part program ........................................................................................................................ 31
5.2 Editing part programs ............................................................................................................................ 31
5.3 Managing part programs ....................................................................................................................... 33
6.1 Simulating machining ............................................................................................................................ 37
6.1.1 Simulation prior to machining of the workpiece ..................................................................................... 37
6.1.2 Simultaneous recording prior to machining of the workpiece ................................................................ 39
6.1.3 Simultaneous recording during machining of the workpiece .................................................................. 39
6.2 Program control ..................................................................................................................................... 40
6.3 Program test .......................................................................................................................................... 41
6.4 Starting and stopping/interrupting a part program ................................................................................. 43
6.5 Executing/transferring a part program through the Ethernet connection ............................................... 44
6.5.1 Configuring the network drive ................................................................................................................ 44
6.5.2 Executing from external (through Ethernet connection)......................................................................... 46
6.5.3 Transferring from external (through Ethernet connection) ..................................................................... 47
6.6 Machining at a specific point ................................................................................................................. 48
7.1 Internal data backup .............................................................................................................................. 49
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8 Programming principles .........................................................................................................................................53
7.2 External data backup ............................................................................................................................ 50
7.2.1 External data backup in a data archive ................................................................................................. 50
7.2.2 Exernal data backup of separate files ................................................................................................... 52
8.1 Fundamentals of programming ............................................................................................................. 53
8.1.1 Program names .................................................................................................................................... 53
8.1.2 Program structure ................................................................................................................................. 53
8.2 Positional data ...................................................................................................................................... 53
8.2.1 Programming dimensions ..................................................................................................................... 53
8.2.2 Absolute/incremental dimensioning: G90, G91, AC, IC ......................................................................... 54
8.2.3 Dimensions in metric units and inches: G71, G70, G710, G700 ........................................................... 55
8.2.4 Radius/diameter dimensions: DIAMOF, DIAMON, DIAM90 .................................................................. 56
8.2.5 Programmable work offset: TRANS, ATRANS ...................................................................................... 56
8.2.6 Programmable scaling factor: SCALE, ASCALE ................................................................................... 59
8.2.7 Workpiece clamping - settable work offset: G54 to G59, G500, G53, G153 ......................................... 60
8.2.8 Kinematic transformation ...................................................................................................................... 61
8.2.8.1 Milling on turned parts (TRANSMIT) ..................................................................................................... 61
8.2.8.2 Cylinder surface transformation (TRACYL) ........................................................................................... 63
8.3 Linear interpolation................................................................................................................................ 69
8.3.1 Linear interpolation with rapid traverse: G0 ........................................................................................... 69
8.3.2 Feedrate F ............................................................................................................................................ 70
8.3.3 Linear interpolation with feedrate: G1 ................................................................................................... 71
8.4 Circular interpolation ............................................................................................................................. 71
8.4.1 Circular interpolation: G2, G3 ................................................................................................................ 71
8.4.2 Circular interpolation via intermediate point: CIP .................................................................................. 74
8.4.3 Circle with tangential transition: CT ....................................................................................................... 75
8.5 Thread cutting ....................................................................................................................................... 75
8.5.1 Thread cutting with constant lead: G33 ................................................................................................. 75
8.5.2 Programmable run-in and run-out path for G33: DITS, DITE ................................................................ 78
8.5.3 Thread cutting with variable lead: G34, G35 ......................................................................................... 79
8.5.4 Thread interpolation: G331, G332 ......................................................................................................... 80
8.6 Fixed point approach............................................................................................................................. 81
8.6.1 Fixed point approach: G75 .................................................................................................................... 81
8.6.2 Reference point approach: G74 ............................................................................................................ 81
8.7 Acceleration control and exact stop/continuous path ............................................................................ 82
8.7.1 Exact stop/continuous-path control mode: G9, G60, G64 ..................................................................... 82
8.7.2 Acceleration pattern: BRISK, SOFT ...................................................................................................... 84
8.7.3 Dwell Time: G4 ..................................................................................................................................... 84
8.8 The third axis ........................................................................................................................................ 85
8.9 Spindle movements............................................................................................................................... 85
Spindle speed S, directions of rotation .................................................................................................. 85
8.9.1
8
.9.2 Spindle positioning ................................................................................................................................ 86
8.9.2.1 Spindle positioning (SPOS, SPOSA, M19, M70, WAITS) ..................................................................... 86
8.9.2.2 Spindle positioning (SPOS, SPOSA, M19, M70, WAITS): Further information ..................................... 90
8.9.3 Gear stages .......................................................................................................................................... 92
8.10 Special turning functions ....................................................................................................................... 92
8.10.1 Constant cutting rate: G96, G97 ........................................................................................................... 92
8.10.2 Rounding, chamfer ................................................................................................................................ 93
8.10.3 Contour definition programming ............................................................................................................ 96
8.11 Tool and tool offset................................................................................................................................ 97
8.11.1 General information (turning) ................................................................................................................ 97
8.11.2 Tool T (turning) ..................................................................................................................................... 98
8.11.3 Tool offset number D (turning) .............................................................................................................. 98
8.11.4 Selecting the tool radius compensation: G41, G42 ............................................................................. 101
8.11.5 Corner behavior: G450, G451 ............................................................................................................. 103
8.11.6 Tool radius compensation OFF: G40 .................................................................................................. 103
8.11.7 Special cases of the tool radius compensation ................................................................................... 104
8.11.8 Example of tool radius compensation (turning) ................................................................................... 105
8.11.9 Special handling of tool compensation (turning) ................................................................................. 105
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9 Cycles ................................................................................................................................................................ 119
10 Typical turning programs ..................................................................................................................................... 189
A Appendix ............................................................................................................................................................ 194
8.12 Miscellaneous function M .................................................................................................................... 106
8.13 H function ............................................................................................................................................ 107
8.14 Arithmetic parameters, LUD and PLC variables .................................................................................. 107
8.14.1 Arithmetic parameter R ........................................................................................................................ 107
8.14.2 Local User Data (LUD) ........................................................................................................................ 108
8.14.3 Reading and writing PLC variables ..................................................................................................... 109
8.15 Program jumps .................................................................................................................................... 110
8.15.1 Unconditional program jumps .............................................................................................................. 110
8.15.2 Conditional program jumps .................................................................................................................. 111
8.15.3 Program example for jumps ................................................................................................................ 112
8.15.4 Jump destination for program jumps ................................................................................................... 113
8.16 Subroutine technique........................................................................................................................... 113
8.16.1 General information ............................................................................................................................. 113
8.16.2 Calling machining cycles (turning) ....................................................................................................... 115
8.16.3 Executing external subroutines (EXTCALL) ........................................................................................ 115
8.17 Timers and workpiece counters ........................................................................................................... 116
8.17.1 Runtime timer ...................................................................................................................................... 116
8.17.2 Workpiece counter............................................................................................................................... 118
9.1 Overview of cycles............................................................................................................................... 119
9.2 Programming cycles ............................................................................................................................ 120
9.3 Graphical cycle support in the program editor ..................................................................................... 121
9.4 Drilling cycles ...................................................................................................................................... 122
9.4.1 General information ............................................................................................................................. 122
9.4.2 Requirements ...................................................................................................................................... 122
9.4.3 Drilling, centering - CYCLE81 .............................................................................................................. 125
9.4.4 Drilling, counterboring - CYCLE82....................................................................................................... 127
9.4.5 Deep-hole drilling - CYCLE83 ............................................................................................................. 129
9.4.6 Rigid tapping - CYCLE84 .................................................................................................................... 133
9.4.7 Tapping with compensating chuck - CYCLE840 ................................................................................. 137
9.4.8 Reaming1 - CYCLE85 ......................................................................................................................... 141
9.4.9 Boring - CYCLE86 ............................................................................................................................... 143
9.5 Turning cycles ..................................................................................................................................... 145
9.5.1 Requirements ...................................................................................................................................... 145
9.5.2 Cutoff - CYCLE92 ................................................................................................................................ 147
9.5.3 Groove - CYCLE93.............................................................................................................................. 149
9.5.4 Undercut (forms E and F to DIN) - CYCLE94 ...................................................................................... 156
9.5.5 Cutting with relief cut - CYCLE95 ........................................................................................................ 159
9.5.6 Thread undercut - CYCLE96 ............................................................................................................... 173
9.5.7 Thread chaining - CYCLE98 ................................................................................................................ 176
9.5.8 Thread cutting - CYCLE99 .................................................................................................................. 181
9.6 Error messages and error handling ..................................................................................................... 188
9.6.1 General Information ............................................................................................................................. 188
9.6.2 Error handling in the cycles ................................................................................................................. 188
9.6.3 Overview of cycle alarms ..................................................................................................................... 188
9.6.4 Messages in the cycles ....................................................................................................................... 188
A.1 Creating a new cutting edge ................................................................................................................ 194
A.2 Setting up the workpiece ..................................................................................................................... 195
A.2.1 Measuring the workpiece ..................................................................................................................... 195
A.2.2 Entering/modifying work offsets ........................................................................................................... 197
A.3 Entering/modifying the setting data ..................................................................................................... 197
A.4 Setting R parameters........................................................................................................................... 201
A.5 Setting user data ................................................................................................................................. 202
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A.6 Other settings in "JOG" mode ............................................................................................................. 202
A.6.1 Setting the relative coordinate system (REL) ...................................................................................... 204
A.6.2 Setting the JOG data ........................................................................................................................... 204
A.7 Activating the contour handwheel via the NC program ....................................................................... 205
A.8 Notes on part programs in "MDA" mode ............................................................................................. 207
A.9 The help system .................................................................................................................................. 207
A.10 Operation wizard ................................................................................................................................. 210
A.11 Editing Chinese characters ................................................................................................................. 211
A.12 Pocket calculator ................................................................................................................................. 212
A.13 Calculating contour elements .............................................................................................................. 213
A.14 Free contour programming .................................................................................................................. 217
A.14.1 Programming a contour ....................................................................................................................... 219
A.14.2 Defining a start point ........................................................................................................................... 219
A.14.3 Programming contour element ............................................................................................................ 220
A.14.4 Parameters for contour elements ........................................................................................................ 223
A.14.5 Undercuts for turning technology ........................................................................................................ 226
A.14.6 Specifying contour elements in polar coordinates ............................................................................... 226
A.14.7 Cycle support ...................................................................................................................................... 229
A.14.8 Programming example for turning application ..................................................................................... 229
A.15 Word structure and address ................................................................................................................ 233
A.16 Character set ...................................................................................................................................... 234
A.17 Block format ........................................................................................................................................ 235
A.18 List of instructions ............................................................................................................................... 236
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1
Fundamental safety instructions
1.1
General safety instructions
WARNING
Risk of death if the safety instructions and remaining risks are not carefully observed
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization
1.2
Industrial security
Note
Industrial security
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
If the safety instructions and residual risks are not observed in the associated hardware documentation, accidents involving
severe injuries or death can occur.
• Observe the safety instructions given in the hardware documentation.
• Consider the residual risks for the risk evaluation.
As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.
• Protect the parameterization (parameter assignments) against unauthorized access.
• Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF).
Siemens provides products and solutions with industrial security functions that support the secure operation of plants,
solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept.
With this in mind, Siemens’ products and solutions undergo continuous development. Siemens recommends strongly that
you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell
protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party
products that may be in use should also be considered. For more information about industrial security, visit this address
(http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product-specific newsletter. For more information, visit
this address (http://support.automation.siemens.com).
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in
your installation which can result in death, severe injuries and/or material damage.
• Keep the software up to date.
You will find relevant information and newsletters at this address (http://support.automation.siemens.com).
• Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the
installation or machine.
You will find further information at this address (http://www.siemens.com/industrialsecurity).
• Make sure that you include all installed products into the holistic industrial security concept.
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2
Introduction
2.1
CNC operator panels
2.1.1
Panel Processing Unit (PPU) versions
PPU version
Panel layout
Applicable control system
2.1.2
Control elements on the PPU161.3
Vertical and horizontal softkeys
Return key
Menu extension key
Alphabetic and numeric keys
Control keys
Alarm cancellation key
On-board wizard key
Help key
Cursor keys
Operating area keys
USB interface
Status LEDs
PPU161.3 Horizontal, English version SINUMERIK 808D ADVANCED T (Turning)/M (Milling)
Horizontal, Chinese version
①
Calls specific menu functions
②
Returns to the next higher-level menu
③
Opens the next lower-level menu or navigate between the menus of the same level
④
⑤
⑥
Cancels alarms and messages that are marked with this symbol
⑦
Provides step-by-step guides on basic commissioning and operation procedures
⑧
Calls help information
⑨
⑩
⑪
⑫
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Keys with icons
Further information
The icon on the key is a hint that you can press both <CTRL> and this key as shortcuts for capturing
screens.
The icon on the key is a hint that you can press both <CTRL> and this key as shortcuts for saving
start-up archives and action logs to a USB stick.
The icon on the key is a hint that you can press both <CTRL> and this key as shortcuts for displaying
pre-defined slides on the screen or both <ALT> and this key as shortcuts for saving action logs to a
USB stick.
The icon on the key is a hint that you can press this key to call the calculator function.
The icon on the key is a hint that this key can be used together with another key to function as a key
combination.
To enter the upper character on an alphabetic/numeric/operating area key, keep this key pressed.
• Toggles between entries in the input field
• Enters the "Set-up menu" dialog at NC start-up
To open the system data management operating area, press the following key combination:
USB interface Connects to a USB device, for example:
Status LEDs
LED "POK" Solid green: The power supply for the CNC is switched on.
LED "RDY"
LED "TEMP"
Backlight brightness control
+
Enables user-defined extension applications, for example, generation of user dialogs with the
EasyXLanguage function.
For more information about this function, see the SINUMERIK 808D/SINUMERIK 808D ADVANCED
Function Manual.
• An external USB memory stick, to transfer data between the USB stick and the CNC
• An external USB keyboard which functions as an external NC keyboard
• Solid green: The CNC is ready and the PLC is in running mode.
• Solid red: The CNC is in stop mode.
• Solid orange: The PLC is in stop mode.
• Flashing orange: The PLC is in power-up mode.
• Off: The CNC temperature is within the specified range.
• Solid orange: The CNC temperature is out of range.
Pressing <CTRL> and the cursor keys sets the screen backlight brightness by an increment of 10%
(brightness range: 10% to 100%).
Note that after you release the key combination, the HMI saves your brightness settings and the
brightness bar disappears after three seconds.
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2.2
Machine control panels
2.2.1
Machine Control Panel (MCP) versions
MCP version
Applicable control system
Vertical MCP with an override switch for the spindle, Chinese version
2.2.2
Control elements on the MCP
①
Reserved hole for emergency stop button
⑦
Axis traversing keys
②
Handwheel key
⑧
Spindle override switch
for the handwheel)
③
Tool number display
Displays the current tool number
⑨
Spindle state keys
④
Operating mode keys
⑩
Feedrate override switch
override
⑤
Program control keys
⑪
Keys for program start, stop, and reset
⑥
User-defined keys
⑫
Reserved slot for the handwheel
• Horizontal MCP, English version
• Horizontal MCP, Chinese version
• Vertical MCP with a reserved slot for the handwheel, English version
• Vertical MCP with a reserved slot for the handwheel, Chinese version
• Vertical MCP with an override switch for the spindle, English version
•
SINUMERIK 808D ADVANCED T (Turning)/M
(Milling)
Controls the axis movement with external handwheels
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(unavailable for the vertical MCP with a reserved slot
Traverses the selected axis at the specified feedrate
User-defined keys
Pre-defined insertion strips
Pressing this in any operating mode switches on/off the lamp.
LED on: The lamp is switched on.
LED off: The lamp is switched off.
Pressing this key in any operating mode switches on/off the coolant supply.
LED on: The coolant supply is switched on.
LED off: The coolant supply is switched off.
Pressing this key starts sequential tool changes (active only in "JOG" mode).
LED on: The machine starts sequential tool changes
LED off: The machine stops sequential tool changes
Pressing this key in any operating mode activates the chuck to clamp/unclamp the workpiece.
LED on: Activates the chuck to clamp the workpiece
LED off: Activates the chuck to unclamp the workpiece
Pressing this key only when the spindle stops operation.
LED on: Activates the external chuck to clamp the workpiece inwards
LED off: Activates the internal chuck to clamp the workpiece outwards
Pressing this key in any operating mode advances/retracts the tailstock.
LED on: Advances the tailstock towards the workpiece until it firmly engages with the end of the workpiece
The MCP package includes two sets (six pieces each) of pre-defined insertion strips. One set is for the turning variant of the
control system and is pre-inserted on the back of the MCP. The other set is for the milling variant of the control system.
If your control system is a milling variant of the control system, replace the pre-inserted strips with the milling-specific
insertion strips.
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Customized insertion strips
Note
2.3
Screen layout
Display of variable increments in the status area
The MCP package also includes an A4-sized blank plastic sheet with detachable strips. You can customize insertion strips if
the pre-defined strips cannot meet your needs.
In the \examples\SINUMERIK_808D_ADVANCED\MCP folder of the Toolbox DVD for the control system, there is a symbol
library file and an insertion strip template file. To make customized insertion strips, follow the steps below:
1. Copy the desired symbols from the symbol library file to the desired locations in the insertion strip template.
2. Print the template to the A4-sized blank plastic sheet.
3. Detach the insertion strips from the blank plastic sheet.
4. Pull out the pre-inserted strips from the MCP.
5. Insert the customized strips on the back of the MCP.
This manual assumes a SINUMERIK 808D ADVANCED standard MCP. Should you use a different MCP, the operation
may be other than described herein.
Displays the variable increment if it is defined in the standard subroutine program
• Value ≤ five digits: displays the complete value
• Value > five digits: displays the first four digits plus ".."
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Alarms and messages
Displays active alarms with alarm text
Displays messages from NC programs
2.4
Protection levels
Overview
Note
Protection level
Locked by
Area
0
1
2
3-6
7
Protection level 1
Protection level 3-6
The alarm number is displayed in white lettering on a red background. The associated alarm text is shown in red lettering. An
arrow indicates that several alarms are active. The number to
the right of the arrow indicates the total number of active
alarms. When more than one alarm is active, the display scrolls
through the alarms in sequence. An acknowledgement symbol
indicates the alarm cancel criterion.
Messages from NC programs do not have numbers and appear
in green lettering.
The control system provides a concept of protection levels for enabling data areas. Different protection levels control
different access rights.
The control system delivered by Siemens is set by default to the lowest protection level 7 (without password). If the
password is no longer known, the control system must be reinitialized with the default machine/drive data. All passwords are
then reset to default passwords for this software release.
Before you boot the control system with default machine/drive data, make sure that you have backed up your machine/drive
data; otherwise, all data are lost after rebooting with default machine/drive data.
Siemens password Siemens, reserved
Manufacturer password Machine manufacturers
Reserved
End user password
(Default password: "CUSTOMER")
No password End users
Protection level 1 requires a manufacturer password. With this password entry, you can perform the following operations:
● Entering or changing part of the machine data and drive data
● Conducting NC and drive commissioning
Protection level 3-6 requires an end user password. With this password entry, you can perform the following operations:
● Entering or changing part of the machine data
● Editing programs
● Setting offset values
● Measuring tools
End users
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Protection level 7
USER_CLASS
Setting password
2.5
Setting user interface language
Operating sequence
Note:
Protection level 7 is set automatically if no password is set and no protection level interface signal is set. The protection level
7 can be set from the PLC user program by setting the bits in the user interface.
In the menus listed below the input and modification of data depends on the set protection level:
● Tool offsets
● Work offsets
● Setting data
● Program creation/program correction
The number of machine data and drive data which can be read or modified depends on the protection level. You can set the
protection level for these function areas with the display machine data (
You can set the desired password through the following operating area:
+
+
→
1. Select the desired operating area.
2. Press this softkey to open the user interface language selection window.
...).
3. Use the cursor keys to select the desired language.
4. Press this softkey to confirm your selection.
The HMI (Human Machine Interface) is automatically restarted when a new language is
selected.
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3
Turning on, reference point approach
Note
Operating sequence
d, the symbol is always visible in the current (machining) operating
When turning on the CNC and the machine, also observe the machine tool manufacturer's documentation, since turning-on
and reference point approach are machine-dependent functions.
1. Switch on the power supply for the control system and the machine.
2. Release all emergency stop buttons on the machine.
By default, the control system is in the "REF.POINT" window after booting.
The symbol
If an axis is not reference
area.
3. Press the corresponding axis traversing keys on the MCP to traverse each axis to the reference point.
Note that axis traversing directions and axis key functions are defined by the machine man-
If the axis is referenced, a symbol (
in the "REF.POINT" window.
ufacturer.
shown next to the axis identifier indicates that the axis is not yet referenced.
) appears next to the axis identifier and is visible only
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4
Setting-up
4.1
Coordinate systems
Machine coordinate system (MCS)
As a rule, a coordinate system is formed from three mutually perpendicular coordinate axes. The positive directions of the
coordinate axes are defined using the so-called "3-finger rule" of the right hand. The coordinate system is related to the
workpiece and programming takes place independently of whether the tool or the workpiece is being traversed. When
programming, it is always assumed that the tool traverses relative to the coordinate system of the workpiece, which is
intended to be stationary.
The figure below illustrates how to determine the axis directions.
The orientation of the coordinate system relative to the machine depends on the machine type. It can be rotated in different
positions.
The directions of the axes follow the "3-finger rule" of the right hand. Seen from the front of the machine, the middle finger of
the right hand points in the opposite direction to the infeed of the spindle.
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machine zero.
machine axes
Workpiece coordinate system (WCS)
workpiece zero
Relative coordinate system (REL)
Clamping the workpiece
settable work
offset
G54
The figure below shows an example of the machine coordinate system of a turning machine.
The origin of this coordinate system is the
This point is only a reference point which is defined by the machine manufacturer. It does not have to be approachable.
The traversing range of the
To describe the geometry of a workpiece in the workpiece program, a right-handed, right-angled coordinate system is also
used.
The
The figure below shows an example of the workpiece coordinate system.
In addition to the machine and workpiece coordinate systems, the control system provides a relative coordinate system. This
coordinate system is used to set reference points that can be freely selected and have no influence on the active workpiece
coordinate system. All axis movements are displayed relative to these reference points.
can be freely selected by the programmer in the Z axis. In the X axis, it lies in the turning center.
can be in the negative range.
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
. In the NC program, this offset is activated during program execution, for example, using a programmed
command.
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Current workpiece coordinate system
4.2
Setting up tools
4.2.1
Creating a new tool
Note
Operating sequence
The figure below shows an example of the workpiece clamped on the machine.
The programmed work offset TRANS (Page 56) can be used to generate an offset with reference to the workpiece
coordinate system, resulting in the current workpiece coordinate system.
The control system supports a maximum of 64 tools or 128 cutting edges.
1. Select the desired operating area.
2. Open the tool list window.
3. Open the lower-level menu for tool type selection.
4. Select a desired tool type with the corresponding softkey.
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5. Enter the tool number (value range: 1 to 31999; preferentially enter a value less than 100)
and select the corresponding tool edge position code according to the actual tool point direction in the following windows:
• Available edge positions for turning tool and grooving tool: 1, 2, 3 and 4 (taking new
turning tool as an example)
• Available edge positions for drilling tool, tapping tool and milling tool: 5, 6, 7 and 8
(taking new milling tool as an example)
6. Use this softkey to confirm your settings. The window below shows the information of the
new tool created.
① Tool type
② Tool number
③ Tool offset number
④ Tool offset number
⑤ Tool length in the X and Z axes
⑥ Tool radius
⑦ Clearance angle
⑧ Tip width of the cutting edge, which is only active for the grooving tool
⑨ Cutting edge direction
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Note:
4.2.2
Activating the tool
Operating sequence
7. Enter the tool radius data or tool tip width as desired and confirm your settings.
1. Select the desired operating area.
2. Switch to "JOG" mode.
3. Open the "T, S, M" window.
4. Enter the desired tool number (for example, 1) in the "T, S, M" window.
• Column ④ is invisible in Siemens mode. The function of activating the compensation
data via the "H" column is active only in ISO dialect mode.
• Column
40000H. By default, MD19730 = 0H. Note that MD19730 is visible only with the
manufacturer password. For more information about the clearance angle, see the
SINUMERIK 808D/SINUMERIK 808D ADVANCED Function Manual.
⑦ is visible only when you set bit 18 of MD19730 to 1, that is, MD19730 =
5. Use this key or move the cursor to confirm your entries.
6. Press this key on the MCP to activate the tool.
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4.2.3
Assigning the handwheel
Method 1: Assigning through the PPU
ey to activate the value change. Note that the control system restarts
1. Select the desired operating area.
+
2. Open the machine data window.
3. Press this softkey to open the basic machine data list.
4. Use the cursor keys or the following softkey to search for the general machine data "14512
5. Select bit 7 by using the following key and cursor keys:
USER_DATA_HEX[16]".
Press the following softkey to confirm your input.
6. Press this vertical softk
to accept the new value.
7. After the control system has booted, select the desired operating area.
8. Press this key on the MCP.
9. Press this key to view more menu options.
10. Open the handwheel assignment window.
11. Select the desired handwheel number with the cursor keys.
12. Press the desired vertical softkey (<X> ... <MZ1>) or the following key for the handwheel
assignment.
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Select the required override increment with the following axis traversing keys on the MCP to
Method 2: Assigning through the MCP
Precondition:
4.2.4
Activating the spindle
Operating sequence
The axis identifier (for example, "X") which appears in the window indicates that you have
assigned the handwheel to the selected axis.
13.
move the selected axis.
The override increment is 0.001 mm.
The override increment is 0.010 mm.
The override increment is 0.100 mm.
MD14512[16].7 = 0 (factory default)
1. Select the desired operating area.
2. Press this key on the MCP to control the axis movement with external handwheels.
3. Press the desired axis traversing keys to assign the handwheel.
1. Select the desired operating area.
2. Switch to "JOG" mode.
3. Open the "T, S, M" window.
4. Enter the desired value for the spindle speed in the "T, S, M" window.
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4.2.5
Measuring the tool (manually)
Overview
5. Press this key to select the spindle direction.
6. Use this key or move the cursor to confirm your entries.
7. Press this key on the MCP to activate the spindle.
The geometries of the machining tool must be taken into consideration when you execute a part program. These are stored
as tool offset data in the tool list. Each time the tool is called, the control considers the tool offset data.
You can determine the tool offset data, including the length, radius and diameter by either measuring the tool or entering the
values in the tool list (for more information, see Section "Creating a new tool (Page 18)").
As per the actual position of the point F (the machine coordinate) and the reference point, the control system can calculate
the offset value assigned to the lengths for the X and Z axes.
See the following illustration for determining the length offsets using the example of a turning tool:
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Operating sequence
Measuring the tool in the X direction
See the following illustration for determining the length offsets using the example of a drill: Length 1/Z axis
See the following illustration for determining the length offsets using the example of a milling tool:
1. Select the desired operating area.
2. Switch to "JOG" mode.
3. Open the manual tool measurement window.
4. Press this vertical softkey to measure the tool in the X direction.
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override feedrate, and then use the handwheel to move the tool to scratch
Note:
Save the length value in the X axis. The tool diameter, radius, and cutting edge position are
...
5. Move the tool to approach the workpiece in the X direction.
6. Switch to handwheel control mode.
7. Select a suitable
the required workpiece edge (or the edge of the setting block, if it is used).
8. Enter the workpiece diameter in the "Ø" field (for example, 50).
For a milling tool with edge position 5 or 7, the radius of the tool itself is displayed in the
following window:
9.
all taken in to account.
10. Press this softkey and you can see that the compensation data values have been automatically added to the tool data.
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Measuring the tool in the Z direction
Select a suitable override feedrate, and then use the handwheel to move the tool to scratch
1. Select the desired operating area.
2. Switch to "JOG" mode.
3. Open the manual tool measurement window.
4. Press this vertical softkey to measure the tool in the Z direction.
5. Move the tool to approach the workpiece in the Z direction.
...
6. Switch to handwheel control mode.
7.
the required workpiece edge (or the edge of the setting block, if it is used).
8. Enter the distance between the tool tip and the workpiece edge in the "Z0" field, for example, "0". (This value is the thickness of a setting block if it is used.)
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Note:
4.2.6
Verifying the tool offset result in "MDA" mode
Operating sequence
Note:
Further softkey functions in "MDA" mode
9. Save the length value in the Z axis.
10. Press this softkey and you can see that the compensation data values have been automati-
Repeat the above operations for other tools and make sure you measure all the tools before machining, which also eases
the tool changing process.
In order to ensure the machine safety and correctness, you must test the results of the tool offset appropriately.
For a milling tool with edge position 6 or 8, the radius of the tool itself is displayed in the
following window:
cally added to the tool data.
1. Select the desired operating area.
2. Switch to "MDA" mode.
3. Press this softkey on the PPU.
4. Enter the test program, for example: G500 T1 D1 G00 X0 Z5.
You can alternatively load an existing part program from a system directory using the follow-
ing softkey if desired:
5. Press this key to ensure the "ROV" function is active (LED on).
The "ROV" function activates the feedrate override switch under the G00 function.
6. Press this key on the MCP.
Increase the feedrate override gradually to avoid accidents caused by an axis moving too
fast and observe whether the axis moves to the set position.
This window displays important G functions whereby each G function is assigned to a group and
has a fixed position in the window. To close the window, press this softkey once again.
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This window displays the auxiliary and M functions currently active. To close the window, press this
a name and a storage medium for
Note:
4.2.7
Entering/modifying the tool wear data
Note
Operating sequence
To display additional G functions, use the corresponding keys.
softkey once again.
This softkey opens the file saving window where you can specify
the program displayed in the MDA window. To save your program, either enter a new program
name in the input field or select an existing program for overwriting.
If you do not save with this softkey, the program edited in "MDA" mode is actually a temporary file.
Pressing this softkey deletes all the blocks displayed in the MDA window.
This softkey opens a window where you can select an existing program file from a system directory
to load into the MDA buffer.
For the explanation of other softkeys in this mode, see Section "Other settings in "JOG" mode (Page 202)".
For the explanation of part programming in "MDA" mode, see Section "Notes on part programs in "MDA" mode (Page 207)".
You must distinguish the direction of tool wear compensation clearly.
1. Select the desired operating area.
2. Open the tool wear window.
3. Use the cursor keys to select the required tools and their edges.
4. Enter the tool length wear parameter of axis X and axis Z as well as the tool radius wear
parameter.
Positive value: The tool moves away from the workpiece.
Negative value: The tool moves closer to the workpiece.
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4.3
Operating area overview
Softkey functions
①
Displays and modifies the tool offsets
②
Displays and modifies the tool wear data
③
Displays and modifies the work offsets
④
Displays and modifies the R variables
⑤
Configures and displays lists of setting data
⑥
Displays the defined user data
⑦
Measures the tool manually
⑧
For more information, see Section "Creating a new tool (Page 18)".
⑨
For more information, see Section "Creating a new cutting edge (Page 194)".
⑩
Removes the currently selected tool from the tool list
⑪
Searches for your desired tool with the tool number
5. Press this key or move the cursor to activate the compensation.
When working with the CNC, you need to set up the machine and the tools, etc. as follows:
● Create the tools and cutting edges.
● Enter/modify the tool and work offsets.
● Enter the setting data.
Pressing this key on the PPU allows you to open the following window:
Creates a new tool
Opens a lower-level menu for cutting edge settings
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5
Part programming
Softkey functions
The control system can store a maximum of 300 part programs which include those created by the control system for certain
functions such as MM+, TSM, and so on.
Pressing this key on the PPU allows you to open the following window:
Stores the NC programs for subsequent operations
①
Manages and transfers the manufacturer cycles
②
Reads in/out files via the USB drive and executes the program from the external storage media
③
Reads in/out files via the Ethernet interface and executes the program from an external PC
④
Backs up manufacturer files
⑤
Backs up user files
⑥
Shows the recently accessed files
⑦
Executes the selected file. No editing is allowed in the execution process.
⑧
Creates new files or directories
⑨
Searches for files
⑩
Selects all files for the subsequent operations
⑪
Copies the selected file(s) to the clipboard
⑫
Pastes the selected file(s) from the clipboard to the current directory
⑬
Restores the deleted file(s)
⑭
Opens the lower-level menu for more options:
⑮
• Rename the part programs
• Cut the part programs
Note: Softkeys
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② and ⑤ are visible only with the manufacturer password.
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