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Siemens SINUMERIK 802D Training Manual

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SINUMERIK 802D solution line
Machine Controller Milling Handbook
Training Manual
Edition 2006.7
Training Material

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  Summary of Contents for Siemens SINUMERIK 802D

  • Page 1 SINUMERIK 802D solution line Machine Controller Milling Handbook Training Manual Edition 2006.7 Training Material...
  • Page 3 SINUMERIK 802D sl Operating, Programming and Service Milling Valid for Control Software SINUMERIK 802D sl 1.2 Edition 07.2006...
  • Page 5 Module content for end users. Operating and Programming Service CNC Basic Principles Milling C102 Pushbutton test (MCP) Basic Program Structure LED Diagnosis Drive Modality (preparatory functions) LED Diagnosis HMI Commonly used G functions - M MCPA signal test Basic Miscellaneous Codes Save Data Backup Additional G functions - M Restore Data Backup...
  • Page 7 Geometric relationships of the component to the machine are achieved with (Tool and component) numeric compensations. These compensations mathematically compensate the difference between component, Tool and machine. Module Content: • Fundamentals of CNC Machines Fundamentals of CNC Machines Section 2 C102 C102 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 8 CNC modules should help explain the myth of CNC. ITS ONLY NUMBERS. No magic !! Reference position Z Reference position X Zero Offset Tool Offset Zero Offset C102 C102 SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 9 Module content: • Basic structure • Basic structure for turning • Basic structure for milling Basic structure Section 2 Basic structure for Section 3 turning Basic structure for Section 4 milling SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 10 This will be the same for ever tool that is written in the NC program If you keep to a good basic structure, this will make the program safer to run and easier to perform a block search. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 11 N210 G00 X0.0 Z2.0 N220 G01 Z-25.0 F0.25 Geometry for component N230 G00 Z2.0 N240 G00 G40 Z2.0 N250 X0.0 Z200.0 Safe position for tool change N260 M30 End of program SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 12 N230 X20.0 Geometry for component N240 X30.0 N250 X40.0 N260 X50.0 N270 MCALL N280 G00 G40 Z50.0 N290 X0.0 Y200.0 Z200.0 Safe position for tool change N300 M30 End of program SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 13 NC program. Module content: • G function overview • G function window display G function overview Section 2 G function window dis- play Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 14 G54 S1000 M03 use this function again X0.0 Y0.0 Z50.0 you must type it in again G01 Z0.0 F200 in another block. G04 F10.0 G00 Z50.0 SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 15 Plane selection 3rd - 1st geometry axis Plane selection 2nd - 3rd geometry axis Default for turning * / default for milling # M = milling / T = turning SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 16 Continuous – path mode Group 11: Exact stop, non-modal Name Meaning Machine Velocity reduction, exact positioning Default for turning * / default for milling # M = milling / T = turning SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 17 CFTCP Constant feed in tool center point (center-point path) Constant feed at internal radius, acceleration at exter- CFIN nal radius Default for turning * / default for milling # M = milling / T = turning SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 18 G function window display To look at the active G-codes, you can activate a window called G FUNCTION. PRESS Softkey G function PRESS This “G function” softkey is present in modes: SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 19 Use the button Page Page Down to scroll down or up to search for the required G-code group. The slide bar has This is the window now moved. that is shown. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 20 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 21 G functions in detail • Example contour program • Example drilling program G functions in detail Section 2 Example contour pro- Section 3 gram Example drilling pro- Section 4 gram SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 22 Programming G02/G03 X.. Y.. Z.. I=AC(..) J-AC(..) K=AC(..) absolute centre point G02/G03 X.. Y.. Z.. I.. J.. K.. Incremental centre point G02/G03 X.. Y.. Z.. CR=.. Circle radius CR= ————————————————————————————————— SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 23 F = Time G4 S.. S = Rotations ————————————————————————————————— Plane selection G17 Function To select the infeed feed axis when milling or drilling, this is the de- fault G function. Programming ————————————————————————————————— SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 24 Programming Tool radius compensation G42 Function To activate tool compensation, with the tool operating to the right of the contour in the machining direction. Programming ————————————————————————————————— SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 25 Programming G54 to G59 ————————————————————————————————— Absolute dimension G90 Function With the G90 command all dimensions are related from your active zero offset. Programming X.. Y.. Z.. ————————————————————————————————— SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 26 With G64, the object is to avoid deceleration at the end of the block. Programming ; Exact stop - non-modal ; Exact stop - modally effective ; Continuous path-control mode SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 27 ;coordinates for contour G00 G40 Z50.0 ;rapid to safe height cancel cut comp X0.0 Y200.0 Z200.0 ;safe tool change position ;end of program Note: G94 are being used in this contour example SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 28 Section 3 Example contour program Notes This is the same program typed into the control: The same program run in simulation: SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 29 ;rapid out of hole G00 G40 Z50.0 ;rapid to safe height X0.0 Y200.0 Z200.0 ;safe tool change position ;end of program Note: G95 are being used in this contour example SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 30 Section 4 Example drilling program Notes This is the same program typed into the control: The same program run in simulation: SINUMERIK 802D sl Operating and Service Training Manual Page 10...
  • Page 31 • M, H, window display Miscellaneous codes Section 2 Miscellaneous func- Section 3 tions (M) T, D, F, S, window dis- Section 4 play M, H, window display Section 5 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 32 If no D word is written, D1 is automatically in effect. If D0 is programmed, the offset for the tool is inactive. Programming D… ; tool offset number: 1 … 9 ; no offset active SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 33 The spindle speed is programmed in r.p.m. under the address S, provided that there is a controlled spindle on the machine. Programming S1000 M03 ; Spindle accelerates Clock—wise to 1000rpm …. S500 ; speed change SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 34 M01 is conditional, can be activated or deactivated in the “AUTO” page, under softkey “program control” Then pressing softkey “Condit stop” softkey “program control” will allow you to select softkey “Condit. stop” to activate and deactivate M01 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 35 Programming tool change for a milling machine SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 36 Coolant ON/OFF (M08 - M09) Function To switch ON and OFF of coolant system on machine. Programming ; switch on of coolant system ; switch off of coolant system ————————————————————————————————— SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 37 T, D, F, S, val- ues that are being used in the NC program at that point in time. This “T,D,F,S,” window is available in all these three modes: SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 38 This screen will show you all active M and H values that are being used in the NC program at that point in time. This window is available in all these three modes: SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 39 We use G functions to instruct a machine what to do, but a structure should be kept to. Module content: • Additional G functions in more detail • Example program Additional G functions in more detail Section 2 Example program Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 40 If only one of the end points is known for a straight line, and an angu- lar dimension is given on the drawing, this can be used for the straight line path. Programming ; angle value for defining a straight line SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 41 ; jump backwards to label N10 IF R1==1 GOTOF LABEL1 … N90 LABEL1: N100 IF R1>1 GOTOF LABEL2 … N150 LABEL2: … N800 LABEL3: … N1000 IF R45==R7+1 GOTOB LABEL3 SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 42 Additional G functions in more detail Notes Milling on peripheral surface - TRACYL This function is only available for SINUMERIK 802D sl plus and pro. Function This transformation function TRACYL allows convenient program- ming milling/drilling on the peripheral surface of turned parts.
  • Page 43 G00 G54 X25.0 Y0.0 Z50.0 Z10.0 MCALL CYCLE82( 10.00000, 0.00000, 2.00000, -10.00000, 0.00000, 0.10000) HOLES2( 0.00000, 0.00000, 25.00000, 0.00000, 90.00000, 3) MCALL G00 G40 X150.0 Y150.0 Z150.0 R1=R1+1 GOTOB TOP END: SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 44 SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 45 Creating a work plan Section 2 Creating a list of tools Section 3 Define the program Section 4 structure Create example pro- Section 5 gram in editor Simulate the program Section 6 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 46 End mill D60mm Slot milling Slot mill D6mm The slot mill can cut on the side and on the face, it is therefore good for the complete machining of slots. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 47 The speeds and feeds have to be adapted dependant upon the workpiece material. Spindle Tool / Feed Speed T-Nr. direction Coolant Operation mm/min M3/M4 End mill D60mm Surface milling End mill D60mm Contour milling Slot mill D6mm 4200 Slot milling SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 48 Program spindle speed and direction • Program feedrate • Switch coolant on • Slot milling • Retract tool • Stop spindle and coolant • Return to home position • Program end SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 49 The program should be given the name PLATE1. After generating a new program in the editor, the blocks for the surface milling, contour milling and the slot milling have to be typed in. SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 50 ; Infeed top slot N300 X30 F563 N310 G0 Z2 ; Top slot finished N320 Z100 M5 M9 ; Retract tool N330 X-200 Y150 ; Home position N340 M30 ; Program end SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 51 The program can be tested in the Simulation mode. The necessary tools have to exist in the tool list in order to simulate the program. Sequence of operation for Simulation: SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 52 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 53 Module content: • Graphical cycles support • Milling cycles • Drilling cycles Graphical cycles support Section 2 Milling cycles Section 3 Drilling cycles Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 54 “drilling” or “milling”. Here you can choose from milling or drilling cycles. Once you have chosen a cycle here you can choose from the different types of cycles. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 55 Input screenforms for parameter assignment for Cycle 81 drilling. Parameter assign- ments for the cycle At any time you can press help the button which will give you an explana- tion for each of the parameters required. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 56 You are given the task to face and machine the pocket on your work piece. We would create a basic program so that we can add the facing and pocket cycles. First of all we will create the basic start of the program. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 57 Section 3 Milling cycles Notes Then we will add the first milling cycle. Push milling fol- lowed by face milling PRESS Enter data taken from your drawing, then press OK. PRESS SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 58 2: parallel to 2nd axis, unidirectional 3: parallel to 1st axis, changing direction 4: parallel to 2nd axis, changing direction 1 & 2 3 & 4 _FDP1 Distance of overhang by cutter along direction of SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 59 You can also press the online help button, which will give you a written explanation of each of the parame- ters. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 60 Your program should now look as above. We have now created a program to face off the component. See if you can now create the rest of the program to machine the pocket. SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 61 Section 3 Milling cycles Notes To create the rest of the program, you will have to use POCKET4 (Circular Pocket). Final program and simulation. SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 62 You are given the task to drill and tap 4 holes in your work piece. We would create a basic program to CENTER DRILL, DRILL and TAP. First of all we will create the basic start of the program. SINUMERIK 802D sl Operating and Service Training Manual Page 10...
  • Page 63 Then we will add the first drilling cycle. Push drilling fol- lowed by center drilling PRESS Enter data taken from your drawing, then press modal call, so that the cycle is made modal. PRESS SINUMERIK 802D sl Operating and Service Training Manual Page 11...
  • Page 64 If you look below, as you cursor down the parameter windows you will get a prompt with text, which relates to the picture guide. SINUMERIK 802D sl Operating and Service Training Manual Page 12...
  • Page 65 You now need to give the coordinates for the posi- tions of the holes. You can use for this exercise hole pattern and circle pattern PRESS Enter data taken from your drawing PRESS SINUMERIK 802D sl Operating and Service Training Manual Page 13...
  • Page 66 Section 4 Drilling cycles Notes Because the drilling cycle was a modal call, you have to deactivate the call PRESS PRESS SINUMERIK 802D sl Operating and Service Training Manual Page 14...
  • Page 67 Your program should now look as above. We have now created a program to center drill 4 holes. See if you can now create the rest of the program to drill and tap the 4 holes. SINUMERIK 802D sl Operating and Service Training Manual Page 15...
  • Page 68 To create the rest of the program, you will have to use CYCLE81 and CY- CLE84 and HOLES2, remembering to make the correct CYCLES modal and non-modal. Final program. For Centre Drill, Drill and Tap. SINUMERIK 802D sl Operating and Service Training Manual Page 16...
  • Page 69 G00 G54 X60.0 Y0.0 Z50.0 MCALL CYCLE84( 0.00000, 0.00000, 2.00000, -18.00000, 0.00000, 0.10000, 3, 1.00000, , ,800.00000, 800.00000) HOLES2( 0.00000, 0.00000, 60.00000, 0.00000, 90.00000, 4) MCALL G00 G40 X0.0 Y150.0 Z200. SINUMERIK 802D sl Operating and Service Training Manual Page 17...
  • Page 70 SINUMERIK 802D sl Operating and Service Training Manual Page 18...
  • Page 71 This module describes the usage of the card in the control. Module content: • Copying data to and from the card Copying data to and Section 2 from the card SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 72 CF card should be inserted into the controller, as can be seen below: Data can be transferred to the card in the “Program Manager” area of the control, also in the “System area”. Program Manager File functions CF Card SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 73 Highlight the file which should be copied With the COPY softkey, the file is copied to the buffer of the control. With paste the file is copied to the destination. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 74 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 75 It is not necessary to reference axis which have an absolute measuring system. Module content: • Switch on the control • Referencing the axis Switch on the control Section 2 Referencing the axis Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 76 NOTE: Please take care to follow the switching on guidelines of the machine manufacturer Once that the controller is running, all E-Stop switches should normally be released. Please follow the guidelines of the machine manufacturer. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 77 „Cycle Start“ Or by pressing the axis direction key. Care to be taken with override switch. When the axis are successfully referenced, the referenced symbol will ap- pear as shown below. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 78 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 79 We use Axis Control/Jog to move axis, that we can setup tools, change tools / inserts, and gain approved access to the workpiece. Module content: • • Jog INC/VAR • Handwheel Section 2 Jog INC/VAR Section 3 Handwheel Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 80 If you press the rapid override button at the same time as the selected axis, the axis will move at rapid speed until the buttons are released. The use of the feed override switch allows you to regulate the feed of the chosen axis. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 81 Active INC mode is shown here Use the axis pushbutton for the required axis, and direction to be moved. When pressed the chosen axis will move by 1 increment per press. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 82 The following screen will be seen: (with VAR INC shown) JOG VAR INC mode is shown here Use the SETTINGS softkey to set the VARIABLE value PRESS SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 83 Section 3 Jog VAR Notes Cursor down to VARIABLE INCREMENT using button Variable Increment SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 84 Type 500 using the numerical buttons PRESS Screen below will be seen: VAR INC 500 is shown here When you use the push buttons, the axis will JOG at 0.5 increment per press. SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 85 First put the control into JOG INC mode. PRESS PRESS The following screen will be seen: JOG 1 INC mode is shown here PRESS This will show a small window to activate the Hand wheel. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 86 Select the axis you wish to move using the hand wheel i.e. X axis PRESS A tick box will now be shown by the side of the axis, in the hand wheel window. SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 87 HAND WHEEL screen is shown here with axis When the hand wheel is used the X axis will move at 0.001mm per increment. To change the axis Use the soft keys SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 88 This will allow you to choose how many microns are used with the hand wheel JOG 1000 INC mode is shown here HAND WHEEL screen is shown here with axis SINUMERIK 802D sl Operating and Service Training Manual Page 10...
  • Page 89 This will show the axis as Enabling the operator to see the difference between WCS and MCS systems Shown here with MCS pressed HAND WHEEL screen is shown here in MCS SINUMERIK 802D sl Operating and Service Training Manual Page 11...
  • Page 90 SINUMERIK 802D sl Operating and Service Training Manual Page 12...
  • Page 91 This module describes navigating these menus. Module content: • Overview of operating areas • Functionality of the operating areas. Overview of operating areas Section 2 Functionality of the Section 3 operating areas. SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 92 Managing the NC program memo- Operating area Program- ry and the CF-Card, Program se- Manager lection, Edit functions List of active alarms Operating area System / Alarm Machine builder specific Operating area customer SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 93 Section 3 Functionality of the operating areas Notes 3.1 Functionality of the operating areas Overview of the softkeys in JOG Overview of the softkeys in MDA SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 94 Section 3 Functionality of the operating areas. Notes Overview of the Softkeys in AUTOMATIC Overview of the Softkeys in PROGRAM SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 95 NC program. Module content: • Functionality of MDA • Save MDA to program • Face milling Functionality of MDA Section 2 Save MDA to program Section 3 Face milling Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 96 M02 as this will have the effect of resetting the given spindle speed and direction. After NC start you can return to Jog and position the axis accordingly. Example program for MDA: X0 Y0 S2000 M3 SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 97 The destination can be determined with the select key: NC(Drive N:), the CF-card (Drive D:) or the RCS-connection can be selected. The data will be saved with the OK key SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 98 4.1 Face milling The “Face milling” function is used for surface preparation prior to machin- ing in Automatic. The return plane and safety distance should be entered in the Settings dia- log. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 99 Notes The type of machining can be selected in the “Mach“ dialog: Rough Roughing with more passes Fine Finishing The values in the above dialog are for the following example: SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 100 Section 4 Face milling Notes With the OK key the contents of the dialog will be accepted. And with the cycle start key, activated. SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 101 (G codes). This module explains this relationship, which is important when using driven tools. Module content: • Workplane selection • Tool types for milling/drilling Workplane selection Section 2 Tool types for milling/ Section 3 drilling SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 102 • The index finger points in the +Y direction • The middle finger points in the +Z direction Turning coordinate system. Appling the right hand rule to a turning machine. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 103 Drilling & milling operations at the peripheral surface of the turned part are programmed in the G19 plane that the offset is applied correctly When plane G19 is programmed, the length compensation L1 is applied to the X axis. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 104 L3 is there- With G19 on a turning machine, there is no Y axis, in the case of a turning tool L2 is then assigned to the Z axis. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 105 (X Default axis infeed direction) plane The same planes apply when milling, the first part of any drilling or milling cycle is the infeed direction (or movement). SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 106 When creating a drilling / milling tool you have to be aware of the tool type that you choose, because the tool type goes hand in hand with the workplane. PRESS PRESS Softkey to choose drilling and milling tools SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 107 Soft key to choose the different types If you wish to drill in the End Face of your turned component, you would choose the top softkey as your tool type chosen soft key SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 108 X axis offset Shown below is a typical program for drilling on the End Face of your turned component using G17 Selected plane Default plane acti- vated at end of cycle SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 109 Note: this tool type is chosen as long as the configuration of the machine is set with the turret behind the spindle centre line. SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 110 Z axis offset Shown below is a typical program for drilling on the peripheral surface of your turned component using G19 Selected plane Default plane acti- vated at end of cycle SINUMERIK 802D sl Operating and Service Training Manual Page 10...
  • Page 111 When choosing the tool type for Milling, the only difference is the graphi- cal representation. Soft key to choose milling tools Soft key to choose the different planes for milling SINUMERIK 802D sl Operating and Service Training Manual Page 11...
  • Page 112 SINUMERIK 802D sl Operating and Service Training Manual Page 12...
  • Page 113 Tool setting on the machine • Drilling tools Tool geometry and workplanes Section 2 New milling tool Section 3 Tool setting on the ma- Section 4 chine Drilling Tools Section 5 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 114 The G18 or G19 plane can be selected when a spindle attachment (rotary head etc.) is used which places the orientation of the spindle into the X or Y axis. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 115 Tool offset for milling tools The tool length offset is applied to the axis dependent upon the plane which is active, with G17: Length 1: - Calculated in the Z direction Radius: - XY-plane SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 116 After this procedure the tool appears in the tool list. The length and radius of the tool can now be entered in the left geometry fields. Example: Important: After each value is input the input key must be pressed! SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 117 Using the above key changes the size of the INC to be used: Pressing the VAR key repeatly,can change size of the INC can be selec- ted, as can be seen above: SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 118 You have to select the mode (length or diameter) first with the respective softkeys. Measuring mode selection: With set length or set diameter the measuring is completed. The value calculated can then be checked in the Offset/param area. SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 119 A difference between milling and drilling tools exists in the control, drills have only a length. The length can be determined with the same steps as in the last section. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 120 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 121 Zero offset page in the control • Setting the zero offset Overview of the coordi- nate system Section 2 Zero offset page in the Section 3 control Setting the zero offset Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 122 The G code G153 can be used blockwise to perform a move in the MCS at any time in the program. NOTE: The instruction G153 is only blockwise active! SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 123 G58 - 5th. Zero Offset G59 - 6th. Zero Offset Example: Programmed G0 G153 X0 Y0 Z0 Typically the following position will be reached, dependant upon the machi- ne builder. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 124 Section 2 Overview of the coordinate system Notes Programmed G0 G54 X0 Y0 Z0 The following position will be reached: SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 125 All values can be edited on the offset page. To simplify the input a pocket calculator is integrated into the control: By pressing the equals key in the respective input field, the calculator will start. SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 126 The calculation takes place when the INPUT key is pressed. And with The calculated value will be transferred into the input field. With the parameter field A coordinate rotation can also be input. SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 127 Z zero offset: T1 ; manual 3D-Dial indicator Drive to the surface of the work- piece until indication. The height of a slip guage can be put in the distance field. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 128 , you can determine the memory location With the of the stored value. The value will be stored with the following key: This should then be repeated for the X and Y axis respectively. SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 129 This module describes the steps which have to be taken to select and run an NC part program. Module content: • Select part program • Starting a program Select part program Section 2 Starting a program Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 130 Firstly the relevant directory has to be opened. The required directory can be highlighted with the cursor keys. The directory can be opened with the following key, and the required pro- gram highlighted . SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 131 Section 2 Select part program Notes Select program After pressing the following key: The mode will change to Automatic and the relevant program is selected.. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 132 The feedrate override can be used additionally to control the velocity af the axis. NC-Start Taking care of the above mentioned functions you can continue with the Cycle Start key. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 133 Transfer data from the controller • Transfer data to the controller Principle of operation Section 2 Transfer data from the controller Section 3 Transfer data to the controller Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 134 Start RCS 802 Click to start RCS 802 application The following screen can be seen: Activate online con- nection on/off toggle Connection type Explorer Settings and type window connection status SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 135 SHIFT+ ALARM, the following screen will be displayed: Online status change and RS232C settings Online status with PLC softkey Press softkey PLC to enter the following picture and configure interface. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 136 Interface is active and can be deacti- vated with “Connect OFF” Symbol RS232C active Configure interface RCS802 Tool. Click the online symbol to config- ure and attain an online connection SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 137 Drag the required file from the displayed directory simply to your LOCAL drive. NC programs stored on CNC: can be copy and paste to destina- tion or drag & drop SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 138 Drag the required file from the displayed LOCAL directory simply to your DESTINATION CNC drive. NC programs stored LOCALLY: can be copy and paste to destina- tion or drag & drop SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 139 Module description: ISO Dialect allows a non-Siemens NC program to be run with in the control. This module describes the functionality offered by standard functions. Differences and additions implemented by the machine tool manufacturer are documented by the machine-tool manufacturer.
  • Page 140 It is not possible to use a mixture of ISO Dialect code and Sie- mens code in the same NC block. • If further Siemens functions are to be used, it will be necessary to switch to Siemens mode first. SINUMERIK 802D sl Operating and Service Training Manual...
  • Page 141 Section 3 Switch Over to ISO Dialect Notes Switch Over The following two G functions are used to switch between Siemens Mode and ISO dialect Mode: • G290 - Siemens NC programming language active • G291 - ISO Dialect NC programming language active...
  • Page 142 NC program, the control will revert back to Sie- mens mode, as G290 is the default code. The above program in AUTO mode, showing G291 in red text. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 143 These are the different addresses that are used in ISO dialect. Address Meaning Feed G94 (mm/inch per min) Feed G95 (mm/inch per rev) Thread pitch Chamfer Radius I, J, K Interpolation parameters G4 Time unit Contour Angle SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 144 In the feed per minute mode (G94) the dwell time unit is in seconds, while in the feed per revolution (G95) the dwell time unit is in spindle revolutions. Programming G4 G94 X.. X = Time G4 G95 X.. X = Rotations SINUMERIK 802D sl Operating...
  • Page 145 When using canned cycles, the retraction level for the Z axis is deter- mined through G98/G99. G98/G99 are modal G codes. G98 is usu- ally set as power-on default. Programming G85 G98 Z… R… F... G85 G99 Z… R… F... SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 146 Counterbore drilling cycle Countersink drilling cycle Deep hole drilling cycle with swarf removal Clockwise tapping cycle Drilling cycle Drilling cycle, retract using G00 Back boring cycle Drilling cycle, retract using G01 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 147 • linear interpolation and linear interpolation • linear interpolation and circular interpolation • circular interpolation and linear interpolation • circular interpolation and Circular interpolation Programming C… ;chamfering R… ;corner rounding SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 148 Section 7 Basic ISO Dialect program Notes Basic ISO Dialect program An ISO Dialect program using the same basic structure as a Siemens pro- gram, but using instead an ISO Dialect drilling cycle (G81). Drilling cycle (G81) The above program running in auto mode : note the G291 in red text.
  • Page 149 Transfer, edit and execute program • Program Example Mold&Die short description Section 2 Mold&Die Section 3 commands Transfer, edit and exe- Section 4 cute a program Program Example Section 5 C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 150 When defining the tolerance value for smoothing the contour, the operator must have knowledge of the subsequent CAM program. C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 151 The look ahead function also means that the control system is able to round the corners it detects. The programmed corner points are therefore not appro- ached exactly. Sharp corners are rounded. Insertion of Circle or Spline elements. Corner Rounding G642 C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 152 The axis slides travel with constant acceleration until the feedrate is reached. SOFT acceleration enables higher path accuracy and less wear and tear on the machine. C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 153 Feedforward control FFWON reduces speed - dependent following er- rors when contouring almost to zero. Traversing with feedforward control permits higher path accuracy and thus improved machining re- sults. C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 154 • G Code Group30 — COMPRESSOR ON/OFF COMPOF / COMPON / COMPCURV / COMPCAD This function is only available for SINUMERIK 802D sl pro. Recommended function : COMPCAD CAD/CAM systems usually deliver linear blocks which observe the parameterized accuracy. With complex contours, this results in a substantial data quantity and –...
  • Page 155 This tolerance value should be the same or a a little bit higher 10- 20%, than the chord tolerance band of the CAM system. Freeform Surface: Chordal Error Ideal Cutter Path Linearized Cutter Path Tolerance Band C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 156 Note: The NC Memory for the operator on the 802Dsl pro is max 3MB. Programs larger than 3MB could only be stored and executed from the CF Card. C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 157 PC. Programs in the NC Directory Note: To Open a program you have two choices. Press Open or the INPUT button C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 9...
  • Page 158 With 802Dsl pro it is possible to execute a program in two ways . Execute from the controller NC Memory and execute from CF Card Execute from NC - Directory NC - Memory Execute from CF- Card C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 10...
  • Page 159 Program Example Notes 5.1 Program Roughing Short Description: Tool : End Mill 6mm CAM Chordal Tolerance : 0.05 mm Program Size : 186 KB - 7778 lines Program Header: C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 11...
  • Page 160 Program Example Notes 5.2 Program Finishing Short Description: Tool : Ball Nose 3mm CAM Chordal Tolerance : 0.005 mm Program Size : 1,35 MB - 50338 lines Program Header: C104 C104 SINUMERIK 802D sl Operating and Service Training Manual Page 12...
  • Page 161 LED's. Module content: • Locating the Status LED's • Status of CNC Controller LED's Locating the Status LED's Section 2 Status of CNC Control- Section 3 ler LED's SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 162 In the case where a fault diagnosis is not possible a status of the LED´s should be given to the OEM or to Siemens service personnel. SINUMERIK 802D sl Operating and Service Training Manual...
  • Page 163 MCPA board itself. Module content: • Identification of MCPA in the system • Analogue spindle interface test Identification of MCPA in the system Section 2 Analogue spindle inter- Section 3 face test SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 164 Due to the use of a 9 pin D sub connector the voltages can only be tested at the drive end of the cable. To generate a setpoint voltage e.g.S500 M3 should be pro- grammed in MDI mode. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 165 All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory (Flash memory) and will not be lost upon dissipation of the GoldCap. Module content: • Performing a Data Save Performing a Data Save Section 2 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 166 On NC Keyboard — Press the key SHIFT + ALARM Keyboard (upright) Keyboard (broad) To perform a “Save Data” the password “CUSTOMER” has to be set. Password CUSTOMER To Save Data SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 167 Performing a Save Data Notes Confirm with OK to save data.. To Save Data Confirm with OK It is also possible to see in the above picture, which data will be saved. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 168 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 169 This module describes the methods of restoring the previously saved data. See hand book module C17 Save data Module content: • Performing a Restore of saved data Performing a Restore of saved data Section 2 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 170 The alarm 004062 indicates to the operator that “saved data” has been loaded, this alarm can be acknowledged with the reset key. CUSTOMER Password set EVENING—SUNRISE Password set SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 171 Module content: • Saving all data to CF Card • Restoring data from CF card Saving all data to CF Section 2 Card Restoring data from Section 3 CF card SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 172 The SYSTEM area of the control is reached by pressing the key : SHIFT + ALARM. The entry point for saving data is through softkey Start-up files, see picture below: Entry for sav- ing data SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 173 SK Copy The destination should now be selected and the Paste function can be used to save the files to the respective card. The destination is the “Customer CF card” SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 174 To reflect the newest changes this process should be carried out on a regular basis. Both archives saved to CF, card can now be re- moved and stored safely. SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 175 You should see the message “004060 Standard machine data is loaded”. Using copy from CF card and paste to CNC the backup data can be re- stored to the control. See the following diagrams: SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 176 Section 3 Restoring All data from Compact flash card Notes Select HMI archive and with COPY soft- key prepare for paste operation to CNC Select HMI directory and press “paste” softkey SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 177 Upon completion of this process the machine should be functional again. Note: The HMI archive should be read in first because the specific PLC alarms are in the NC/PLC archive. SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 178 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 179 • Searching • Cross referencing Locating the PLC Pro- gram displays Section 2 Navigating the displays Section 3 Program status ON/ Section 4 Searching Section 5 Cross referencing Section 6 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 180 “Program list” picture. This function is explained in the hand book module C33. The PLC Program displays can be found by pressing the softkey “PLC Program” The following picture can be seen: SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 181 Section 3 Navigating the displays Notes 3.1 Navigating the displays Project name, Version , Cycle time, Processing time. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 182 Section 3 Navigating the displays Notes Status >> Bits, Bytes, Words, DWords with the possibility to change Overview Input, Output, Marker area with the possibility to change SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 183 Section 3 Navigating the displays Notes Status >> logic online/offline Define which block with softkey “Program block” Status >> logic online/offline as Window 1 Define which block with softkey “Program block” SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 184 Program status ON/OFF 4.1 Program status ON/OFF With Program status ON, a real-time picture can be seen of the logic con- trolling the machine. switch OFF to conserve proces- sor resources SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 185 PLC program or cross reference table. Section 6 Cross referencing 6.1 Cross referencing Find all occurrences of operands in the PLC program SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 186 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 187 Module content: • Structure of an alarm • Function of alarm • Cross referencing Structure of an alarm Section 2 Function of alarm Section 3 Cross referencing Section 4 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 188 Floating point number is displayed PLC Signal The alarm 700000 is generated with the corresponding PLC signal, the reaction from the NC is defined in the NC machine data 14516[index]. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 189 Bit 1 Read-in disable Bit 2 Feed disable for all axis Bit 3 Emergency stop Bit 4 PLC Stop Bit 5 Bit 6 Cancel with Delete key Bit 7 Power on SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 190 A logic condition generates the alarm, the logic condition has to be found in the PLC program and diagnosed using status. To find the logic, the cross reference function should be used. See the following picture: Result SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 191 Locate the alarm display • Find the alarm description in the diagnostic guide Locate the alarm dis- play Section 2 Find the alarm descrip- Section 3 tion in the diagnostic guide SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 192 Section 3 Find the description in the diagnostic guide 3.1 Find the description in the diagnostic guide A description of the alarm can be found in the 802D sl Diagnostic Guide. SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 193 • Setting password • Changing machine data + data save Location of NC ma- chine data Section 2 Setting password Section 3 Changing machine Section 4 data + data save SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 194 Machine data area: Machine data entry point General MD 10000-19800 Channel MD 20050-29000 Note: Axis MD Drive machine data should only be changed under 30100-38000 supervision from experts SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 195 = after pressing Reset key on machine control panel = after powering on = immediately After making changes to the machine data, it is important to make a new backup see hand book module’s C19 and C17 SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 196 SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 197 It is often in the case of an axis alarm that a fault in the drive may be the cause. Module content: • Location of drive diagnostic parameters • Setting password Location of drive diag- nostic parameters Section 2 Setting password Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 198 “SHIFT + ALARM”. The following de- scribes graphically how to enter the Machine data area and how to navi- gate to the drive diagnostic area: Status 0 = No drive error existing SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 199 Further important diagnostic parameters can be found under the softkey “Parameter displays”. The most important parameters can be seen in the following table, and the values can be passed to the relevant service personnel upon request: SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 200 Setting password Notes 3.1 Setting password In order to see the data, the correct password should be set. Enter new password level Change stan- dard password Password cancelled Keyswitch active SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 201 / LED on the machine control is defect. Module content: • Hardware identification • Hardware interface Hardware identification Section 2 Hardware interface Section 3 SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 202 MCP variants • It is not possible to differentiate without looking into the control cabi- net itself. Identification of MCP connected to MCPA interface module. MCPA Board SINUMERIK 802D sl Operating and Service Training Manual Page 2...
  • Page 203 Section 2 Hardware identification Notes Identification of MCP connected to PLC periphery board. Periphery Board PP72/48 SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 204 This mnemonic is used to trace the signal flow of the keys and lamps. [VAR] Ref Point Auto Single Block Spindle Left Spindle Stop Spindle Right Reset Rapid Cycle Stop SINUMERIK 802D sl Operating and Service Training Manual Page 4...
  • Page 205 The machine control panel will be connected to the first of a possible 3 periphery boards. The start address of this board is 0. Periphery board PP72/48 Machine control panel X111 X1201 X222 X1202 X333 SINUMERIK 802D sl Operating and Service Training Manual Page 5...
  • Page 206 In the case where all keys and lamps are not working the MCPA board should be tested, or the periphery board for MCP to periphery. See hand book module C11 for MCPA diagnostic See hand book module C32 for periphery testing SINUMERIK 802D sl Operating and Service Training Manual Page 6...
  • Page 207 Due to the update time of the HMI software you should press the key for a longer duration for the test. The signals can be then tested using the PLC status display “see hand book module C32” SINUMERIK 802D sl Operating and Service Training Manual Page 7...
  • Page 208 SINUMERIK 802D sl Operating and Service Training Manual Page 8...
  • Page 209 Section 3 ule LED's Status of Active Line Section 3 Module LED's Status of Smart Line Section 4 Module LED's Status of Smart Line Section 3 Module ≥ 16kW LED's SINUMERIK 802D sl Operating and Service Training Manual Page 1...
  • Page 210 In the case where a fault diagnosis is not possible a status of the LED´s should be given to the OEM or to Siemens service personnel. (only when module is ready) SINUMERIK 802D sl Operating and Service Training Manual...
  • Page 211 In the case where a fault diagnosis is not possible a status of the LED´s should be given to the OEM or to Siemens service personnel. SINUMERIK 802D sl Operating and Service Training Manual Page 3...
  • Page 212 SINUMERIK 802D sl Operating and Service Training Manual Page 4...

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