Preface

1
SINUMERIK SINUMERIK 802D sl Surface grinding

Description

Software user interface 2

SINUMERIK Turning on, reference point
approach 3
SINUMERIK 802D sl
Surface grinding Setup 4

Manual mode 5
Programming and Operating Manual
Automatic mode 6

Part programming 7

System 8

Cycles 9

Programming 10

Network operation 11

Data Backup 12

PLC diagnostics 13

Appendix A
Valid for controller Software version
SINUMERIK 802D sl G/N 1.4

07/2009
6FC5398-5CP10-1BA0
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

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

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

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

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

NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, 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.
Proper use of Siemens products
Note the following:

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

Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG Ordernumber: 6FC5398-5CP10-1BA0 Copyright © Siemens AG 2009.

Industry Sector Ⓟ 08/2009 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Preface

Structure of the documentation

The SINUMERIK documentation is organized in 3 parts:
● General documentation
● User documentation
● Manufacturer/service documentation

Information on the following topics is available at

http://www.siemens.com/motioncontrol/docu:
● Ordering documentation
Here you can find an up-to-date overview of publications.
● Downloading documentation
Links to more information for downloading files from Service & Support.
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWEB.
● Compiling individual documentation on the basis of Siemens contents with the My
Documentation Manager (MDM), refer to http://www.siemens.com/mdm
My Documentation Manager provides you with a range of features for generating your
own machine documentation.
● Training and FAQs
Information on the range of training courses and FAQs (frequently asked questions) are
available via the page navigation.

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

Benefits
With the Programming and Operating Manual, the target group can develop, write, test and
debug programs and software user interfaces.
In addition, it enables the target group to operate the hardware and software of a machine.

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 3
Preface

Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
For the sake of simplicity, this documentation does not contain all detailed information about
all types of the product and cannot cover every conceivable case of installation, operation, or
maintenance.

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

Europe / Africa
Phone +49 180 5050 222
Fax +49 180 5050 223
€ 0.14/min. from German landlines, mobile phone prices may differ.
Internet http://www.siemens.com/automation/support-request

America
Phone +1 423 262 2522
Fax +1 423 262 2200
E-mail mailto:[email protected]

Asia/Pacific
Phone +86 1064 757575
Fax +86 1064 747474
E-mail mailto:[email protected]

Note
Country telephone numbers for technical support are provided under the following Internet
address:
http://www.automation.siemens.com/partner

Surface grinding
4 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Preface

Questions regarding documentation

If you have any queries (suggestions, corrections) in relation to this documentation, please
fax or e-mail us:

Fax +49 9131 98 2176

E-mail mailto:[email protected]
A fax form is available in the appendix of this document.

SINUMERIK Internet address

http://www.siemens.com/sinumerik

EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found/obtained
● on the internet:
http://support.automation.siemens.com
under the product/order No. 15263595
● at the relevant regional office of the I DT MC Business Unit of Siemens AG.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 5
Preface

Surface grinding
6 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Table of contents

Preface ...................................................................................................................................................... 3
1 Description............................................................................................................................................... 13
1.1 Control and display elements.......................................................................................................13
1.2 Error and status displays .............................................................................................................14
1.3 Key definition of the full CNC keyboard (vertical format).............................................................15
1.4 Key definition of the machine control panel .................................................................................17
1.5 Coordinate systems .....................................................................................................................19
2 Software user interface............................................................................................................................ 23
2.1 Screen layout ...............................................................................................................................23
2.2 Operating areas ...........................................................................................................................27
2.3 The help system...........................................................................................................................29
3 Turning on, reference point approach ...................................................................................................... 31
4 Setup ....................................................................................................................................................... 33
4.1 Entering tools and tool offsets......................................................................................................33
4.2 Create new tool ............................................................................................................................35
4.3 Register dresser...........................................................................................................................44
4.4 Sense workpiece..........................................................................................................................46
4.5 Shaping/dressing .........................................................................................................................48
4.6 Manual grinding ...........................................................................................................................50
4.7 Program setting data....................................................................................................................54
4.8 Arithmetic parameter R ................................................................................................................58
4.9 User data......................................................................................................................................59
5 Manual mode........................................................................................................................................... 61
5.1 Manual mode ...............................................................................................................................61
5.2 JOG mode - "Position" operating area.........................................................................................62
5.2.1 JOG mode....................................................................................................................................62
5.2.2 Assigning handwheels .................................................................................................................65
5.3 MDA mode (manual input) "Position" operating area .................................................................66
5.3.1 Teach In .......................................................................................................................................69
6 Automatic mode....................................................................................................................................... 73
6.1 Automatic mode ...........................................................................................................................73
6.2 Machining offset...........................................................................................................................78
6.3 Selection and start of a part program ..........................................................................................79

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Table of contents

6.4 Block search................................................................................................................................ 81

6.5 Simultaneous recording .............................................................................................................. 84
6.6 Stop / cancel a part program....................................................................................................... 87
6.7 Reapproach after cancellation .................................................................................................... 88
6.8 Repositioning after interruption ................................................................................................... 89
6.9 Execute from external ................................................................................................................. 90
7 Part programming .................................................................................................................................... 93
7.1 Part programming overview ........................................................................................................ 93
7.2 Enter new program...................................................................................................................... 97
7.3 Editing the part program.............................................................................................................. 98
8 System................................................................................................................................................... 101
8.1 "System" operating area ........................................................................................................... 101
8.2 SYSTEM - "Start-up" softkeys................................................................................................... 106
8.3 SYSTEM - "Machine data" softkeys.......................................................................................... 107
8.4 SYSTEM - "Service display" ..................................................................................................... 114
8.4.1 Action log................................................................................................................................... 116
8.4.2 Servo trace ................................................................................................................................ 117
8.4.3 Version/HMI details ................................................................................................................... 121
8.4.4 Service MSG ............................................................................................................................. 125
8.5 SYSTEM - "PLC" softkeys ........................................................................................................ 131
8.6 SYSTEM - "Start-up files" softkeys ........................................................................................... 139
8.7 Alarm display............................................................................................................................. 144
9 Cycles.................................................................................................................................................... 147
9.1 Overview of cycles .................................................................................................................... 147
9.2 Cycle requirements ................................................................................................................... 149
9.3 Programming cycles.................................................................................................................. 150
9.3.1 Call and return conditions ......................................................................................................... 150
9.3.2 Error messages and error handling .......................................................................................... 151
9.3.2.1 General information................................................................................................................... 151
9.3.2.2 Error handling within cycles ...................................................................................................... 151
9.3.3 Cycle call and parameter list ..................................................................................................... 152
9.4 Zyklenunterstützung im Programmeditor .................................................................................. 156
9.5 Z positioning with grinding wheel - CYCLE406......................................................................... 158
9.6 Safety position - CYCLE407 ..................................................................................................... 160
9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408 ................. 161
9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409 ......................... 165
9.9 Dressing and profiling - CYCLE416 .......................................................................................... 168
9.10 Oscillating plunge cutting - CYCLE426..................................................................................... 170
9.11 Surface grinding with continuous infeed - CYCLE427.............................................................. 173

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 Table of contents

9.12 Surface grinding with intermittent infeed - CYCLE428 ..............................................................176

9.13 Profile grinding - CYCLE429......................................................................................................179
9.14 Dressing with profile roller - CYCLE430 ....................................................................................182
9.15 Selection of the grinding wheel peripheral speed - CYCLE446.................................................184
10 Programming ......................................................................................................................................... 185
10.1 Fundamental principles of NC programming .............................................................................185
10.1.1 Program names .........................................................................................................................185
10.1.2 Program structure ......................................................................................................................185
10.1.3 Word structure and address.......................................................................................................186
10.1.4 Block format ...............................................................................................................................187
10.1.5 Fonts ..........................................................................................................................................189
10.1.6 List of instructions ......................................................................................................................190
10.2 Positional data ...........................................................................................................................201
10.2.1 Programming dimensions ..........................................................................................................201
10.2.2 Plane selection: G17 to G19 ......................................................................................................202
10.2.3 Absolute/incremental dimensioning: G90, G91, AC, IC.............................................................203
10.2.4 Dimensions in metric units and inches: G71, G70, G710, G700 ...............................................205
10.2.5 Polar coordinates, pole definition: G110, G111, G112 ..............................................................206
10.2.6 Programmable work offset: TRANS, ATRANS ..........................................................................208
10.2.7 Programmable rotation: ROT, AROT.........................................................................................209
10.2.8 Programmable scaling factor: SCALE, ASCALE .......................................................................211
10.2.9 Programmable mirroring: MIRROR, AMIRROR ........................................................................212
10.2.10 Workpiece clamping - settable work offset: G54 to G59, G500, G53, G153.............................214
10.2.11 Programmable working area limitation: G25, G26, WALIMON, WALIMOF ..............................216
10.3 Axis movements.........................................................................................................................218
10.3.1 Linear interpolation with rapid traverse: G0 ...............................................................................218
10.3.2 Linear interpolation with feedrate: G1........................................................................................220
10.3.3 Circular interpolation: G2, G3 ....................................................................................................222
10.3.4 Circular interpolation via intermediate point: CIP.......................................................................228
10.3.5 Circle with tangential transition: CT ...........................................................................................229
10.3.6 Fixed point approach: G75.........................................................................................................230
10.3.7 Reference point approach: G74.................................................................................................231
10.3.8 Measuring with touch-trigger probe: MEAS, MEAW..................................................................232
10.3.9 Feedrate F..................................................................................................................................234
10.3.10 Exact stop / continuous-path control mode: G9, G60, G64 .......................................................235
10.3.11 Acceleration pattern: BRISK, SOFT...........................................................................................238
10.3.12 Percentage acceleration override: ACC ....................................................................................239
10.3.13 Fourth axis .................................................................................................................................240
10.3.14 Dwell time: G4............................................................................................................................241
10.3.15 Travel to fixed stop.....................................................................................................................242
10.4 Spindle movement .....................................................................................................................245
10.4.1 Spindle speed S, directions of rotation ......................................................................................245
10.4.2 Spindle speed limitation: G25, G26 ...........................................................................................246
10.4.3 Spindle positioning: SPOS.........................................................................................................247
10.4.4 Gear stages................................................................................................................................248
10.4.5 2. Spindle ...................................................................................................................................248
10.5 Special functions........................................................................................................................250
10.5.1 Constant cutting rate: G96, G97 ................................................................................................250
10.5.2 Rounding, chamfer.....................................................................................................................252
10.5.3 Contour definition programming.................................................................................................255

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 9
Table of contents

10.6 Tool and tool offset.................................................................................................................... 257

10.6.1 General Information .................................................................................................................. 257
10.6.2 Tool T ........................................................................................................................................ 258
10.6.3 Tool offset number D................................................................................................................. 259
10.6.4 Selecting the tool radius compensation: G41, G42 .................................................................. 261
10.6.5 Corner behavior: G450, G451................................................................................................... 264
10.6.6 Tool radius compensation OFF: G40........................................................................................ 265
10.6.7 Special cases of the tool radius compensation......................................................................... 266
10.6.8 Example of tool radius compensation ....................................................................................... 267
10.7 Miscellaneous function M.......................................................................................................... 268
10.8 H function .................................................................................................................................. 270
10.9 Arithmetic parameters (R variables), LUD and PLC variables.................................................. 271
10.9.1 Arithmetic parameter R ............................................................................................................. 271
10.9.2 Local User Data (LUD).............................................................................................................. 274
10.9.3 Reading and writing PLC variables........................................................................................... 276
10.10 Program jumps.......................................................................................................................... 277
10.10.1 Jump destination for program jumps......................................................................................... 277
10.10.2 Unconditional program jumps ................................................................................................... 278
10.10.3 Conditional program jumps ....................................................................................................... 279
10.10.4 Program example for jumps ...................................................................................................... 281
10.11 Subroutine technique ................................................................................................................ 283
10.11.1 General information................................................................................................................... 283
10.11.2 Calling machining cycles........................................................................................................... 286
10.12 Timers and workpiece counters ................................................................................................ 287
10.12.1 Runtime timer............................................................................................................................ 287
10.12.2 Workpiece counter .................................................................................................................... 289
10.13 Multiple feedrate values in one block........................................................................................ 291
10.14 Oscillation.................................................................................................................................. 293
11 Network operation.................................................................................................................................. 297
11.1 Network operation prerequisites ............................................................................................... 297
11.2 RCS802 tool.............................................................................................................................. 298
11.3 Network operation ..................................................................................................................... 303
11.3.1 Configuring the network connection.......................................................................................... 304
11.3.2 User management..................................................................................................................... 306
11.3.3 User log in - RCS log in............................................................................................................. 307
11.3.4 Working on the basis of a network connection ......................................................................... 308
11.3.5 Sharing directories .................................................................................................................... 309
11.3.6 Connecting / disconnecting network drives............................................................................... 310
12 Data Backup .......................................................................................................................................... 313
12.1 Data transfer via RS232 interface............................................................................................. 313
12.2 Creating / reading in / reading out a start-up archive................................................................ 315
12.3 Reading in / reading out PLC projects ...................................................................................... 318
12.4 Copying and pasting files .......................................................................................................... 319
13 PLC diagnostics..................................................................................................................................... 321
13.1 Screen layout ............................................................................................................................ 322

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10 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Table of contents

13.2 Operating options.......................................................................................................................323

A Appendix................................................................................................................................................ 335
A.1 User data....................................................................................................................................335
A.2 Parameter tables of the tool data...............................................................................................338
A.3 Miscellaneous ............................................................................................................................343
A.3.1 Pocket calculator........................................................................................................................343
A.3.2 Editing Asian characters ............................................................................................................345
A.4 Feedback on the documentation................................................................................................349
A.5 Overview ....................................................................................................................................351
Glossary ................................................................................................................................................ 353
Index...................................................................................................................................................... 355

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 11
Table of contents

Surface grinding
12 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Description 1
1.1 Control and display elements

Operator control elements

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

9HUWLFDOVRIWNH\V

+RUL]RQWDOVRIWNH\V

Figure 1-1 CNC operator panel

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 13
Description
1.2 Error and status displays

1.2 Error and status displays

LED displays on the CNC operator panel (PCU)

The following LEDs are installed on the CNC operator panel.

(55 5'< 1& &)

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

Table 1- 1 Status and error displays

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

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

Surface grinding
14 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Description
1.3 Key definition of the full CNC keyboard (vertical format)

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

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Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 15
Description
1.3 Key definition of the full CNC keyboard (vertical format)

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

Keystroke combination Function

<CTRL> and <C> Copy selected text
<CTRL> and <B> Select text
<CTRL> and <X> Cut selected text
<CTRL> and <V> Paste copied text
<ALT> and <L> Changeover to small letters
<ALT> and <H> or <HELP> key Call help system
<ALT> and <S> Switch-in and switch-out the Editor for Asian
characters

Surface grinding
16 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Description
1.4 Key definition of the machine control panel

1.4 Key definition of the machine control panel

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Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 17
Description
1.4 Key definition of the machine control panel

Note
This documentation assumes an 802D standard machine control panel (MCP). Should you
use a different MCP, the operation may be other than described herein.

Surface grinding
18 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Description
1.5 Coordinate systems

1.5 Coordinate systems

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.

=
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Figure 1-2 Determination of the axis directions to one another; coordinate system for programming

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 19
Description
1.5 Coordinate systems

Machine coordinate system (MCS)

The orientation of the coordinate system relative to the machine depends on the respective
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 in front of the
machine, the middle finger of the right hand points in the opposite direction to the infeed of
the main spindle.

Figure 1-3 MCS for grinding (cylindrical grinding machine, surface grinding machine)

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= =

;

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Figure 1-4 Machine coordinate system

Surface grinding
20 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Description
1.5 Coordinate systems

The origin of this coordinate system is the machine zero.

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 machine axes can be in the negative range.

Workpiece coordinate system (WCS)

To describe the geometry of a workpiece in the workpiece program, a right-handed, right-
angled coordinate system is also used.
The workpiece zero can be freely selected by the programmer in the Y axis. In the Z axis, it
lies in the turning center.

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Figure 1-5 Workpiece Coordinate System

Relative coordinate system (REL)

In addition to the machine and workpiece coordinate systems, the control system provides a
relative coordinate system. This coordinate system is used for setting 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.

Note
The actual value in the associated coordinate system can be activated and displayed in the
"Position" operating area using the "MKS/WKS REL" vertical softkey.

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 21
Description
1.5 Coordinate systems

Clamping the workpiece

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 Y axis and entered in a data area intended for the settable work offset.
In the NC program, this offset is activated during program execution, e.g. using a
programmed G54.

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Figure 1-6 Workpiece on the machine

Current workpiece coordinate system

The programmed work offset TRANS can be used to generate an offset with reference to the
workpiece coordinate system. resulting in the current workpiece coordinate system (see
Section "Programmable work offset: TRANS").

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Surface grinding
22 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Software user interface 2
2.1 Screen layout

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Figure 2-1 Screen layout

The screen is divided into the following main areas:

● Status area
● Application area
● Note and softkey area

Status area

 



 

Figure 2-2 Status area

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 23
Software user interface
2.1 Screen layout

Table 2- 1 Explanation of the screen controls in the status area

Numbering Display Icon Significance

① Active operating area Position (operating area key <POSITION>)

System (operating area key <SYSTEM>)

Program (operating area key <PROGRAM>)

Program Manager (operating area key

<PROGRAM MANAGER>)

Parameter (operating area key <OFFSET

PARAM>)

Alarm (operating area key <ALARM>)

② Active mode Approaching a reference point

JOG

JOG INC; 1 INC, 10 INC, 100 INC, 1000 INC,

VAR INC
(incremental evaluation in the JOG mode)

MDA

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24 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Software user interface
2.1 Screen layout

Numbering Display Icon Significance

AUTOMATIC

③ Alarm and message line In addition, the following is displayed:

1. Alarm number with alarm text, or
2. Message text
④ Selected part program (main program)
⑤ Program state RESET Program canceled / default state
RUN Program is running
STOP Program stopped
⑥ Program control in automatic
mode

Note and softkey area

 



Figure 2-3 Note and softkey area

Table 2- 2 Explanation of the screen controls in the note and softkey area

Screen item Display Significance

① RECALL symbol
Pressing the <RECALL> key lets you return to the higher menu
level.

② Information line
Displays notes and information for the operator and fault states

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 25
Software user interface
2.1 Screen layout

Screen item Display Significance

③ HMI status information
ETC is possible (pressing this key displays the horizontal
softkey bar providing further functions.)

Mixed notation active (uppercase/lowercase letters)

ಯ/ಯ

RS232 connection active

Connection to commissioning and diagnostic tools (e.g.

Programming Tool 802) active

RCS network connection active

④ Softkey bar vertical and horizontal

Display of the softkeys in the document

To make the softkeys easier to locate, the horizontal and vertical softkeys are displayed in
different basic colors.

Horizontal softkey

Vertical softkey

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26 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Software user interface
2.2 Operating areas

2.2 Operating areas

The functions of the control system can be carried out in the following operating areas:

POSITION Machine operation

OFFSET PARAM Entering the compensation values and setting

2))6(7
3$5$0 data

PROGRAM Creation of part programs

PROGRAM Part program directory

MANAGER

6<67(0 SYSTEM Diagnostics, commissioning


$/$50

6<67(0 ALARM Alarm and message lists

$/$50

CUSTOM Users can call their own application

To change to another operating area, press the relevant key on the CNC full keyboard (hard
key).

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 27
Software user interface
2.2 Operating areas

Protection levels
The SINUMERIK 802D sl provides a concept of protection levels for enabling data areas.
The control system is delivered with default passwords for the protection levels 1 to 3.

Protection level 1 Experts password

Protection level 2 Manufacturer password
Protection level 3 User password
These control the various access rigths.
In the menus listed below the input and modification of data depends on the protection level
set:
● Tool offsets
● Work offsets
● Setting data
● RS232 settings
● Program creation / program correction

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28 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Software user interface
2.3 The help system

2.3 The help system

Comprehensive online help is stored in the control system. Some help topics are:
● Product brief of all important operating functions
● Overview and product brief of the NC commands
● Explanation of the drive parameters
● Explanation of the drive alarms

Operating sequence

You can call the help system from any operating area either by pressing the Info key or by
using the key combination <ALT+H>.

Figure 2-4 Help system: Table of contents

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 29
Software user interface
2.3 The help system

Softkeys

6KRZ This function opens the selected topic.

Figure 2-5 Help system: Description of the topic

*RWR
7RSLF
Use this function to select cross references. A cross reference is marked by the characters
">>....<<". This softkey is only displayed if a cross reference is displayed in the application
area.

%DFNWR
7RSLF
If you select a cross-reference, the "Back to topic" softkey will also be displayed. Select this
function to go back to the previous screen.

)LQG Use this function to search for a term in the table of contents. Type the term you are looking
for and start the search process.

Help in the "Program editor" area

The help system offers an explanation for each NC operation. To display the infotext directly,
position the cursor after the appropriate operation and press the Info key. The NC instruction
must be written using uppercase letters.

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30 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Turning on, reference point approach 3
Note
When you turn on the SINUMERIK 802D sl and the machine, please also observe the
machine documentation, since turning on and reference point approach are machine-
dependent functions.

Operating sequence
First, switch on the power supply for the CNC and the machine.
After the control system has booted, you are in the "Position" operating area, in the
"Reference point approach" mode.
The "Reference point" window is active.

Figure 3-1 Reference-point approach start screen

The "Reference point" window displays whether the axes are referenced.

$[LVPXVWEHUHIHUHQFHG

$[LVLVUHIHUHQFHGV\QFKURQL]HG

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 31
Turning on, reference point approach

Press the arrow keys.

;

<

= If you select the wrong approach direction, no motion is carried out.

One after the other, move each axis to the reference point.
You can exit the function by selecting another operating mode (MDA, AUTOMATIC or JOG).
To access the functions described below, you need to select "Jog" mode.

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32 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Setup 4
4.1 Entering tools and tool offsets

Functionality
The "OFFSET PARAM" operating area allows you to store the parameters required for
machine operation.

Operating sequences

2))6(7
3$5$0

7RROOLVW
This function opens the "Tool offset data" window which contains a list of the tools created.
Use the cursor keys and the <Page Up>/<Page Down> keys to navigate in this list.

Figure 4-1 Tool list

To input the offsets, position the cursor bar on the tool to be changed and press the <Tool
data> softkey.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 33
Setup
4.1 Entering tools and tool offsets

Softkeys

'HOHWH
GUDP Clearing the calculated dresser data.

7RRO
'HOHWH
Use this softkey to delete the tool.

7RRO
GDWD
Opens a lower-level menu bar offering all functions required to create and display further
tolol data.
1RPLQDO
GLPHQVLRQ
PRQLWRULQJ
This function is used to enter - guided by the menu - the nomiinal dimensions and monitoring
data of the grinding wheel.
*HRPHWU\
GDWD This function is used the enter the wheel geometry for the wheel type selected.
7HFKQR This function is used the enter the dressing technology for dressing the wheel type selected.
ORJ\GDWD
VW
GUHVVHU
This function is used to enter/verify the dresser data of the first dresser.
For dressers 2 and 3, it is selected through the respective softkeys.
([WHQGHG This function is used to enter/verify all tool data (D1 through D9).

7RRO
FRS\LQJ
Use this function to copy an already existing tool.

)LQG Use this function to search for a tool by its number.

/DWHVW
7RRO
Use this softkey to create tool compensation data for a new tool.

5SDUD
PHWHUV
This function is used to list and, if necessary, modify any R parameters that exist in the
control system.

6HWWLQJ
GDWD
Input of the setting data.

8VHUGDWD
This function is used to list and, if necessary, modify any user grinding data that exists in the
controller.

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34 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.2 Create new tool

4.2 Create new tool

Functionality
The tool offsets consist of various data describing the geometry, the wear and the tool type.
Each tool contains a defined number of parameters, depending on the tool type. Tools are
identified by a number (T number).

Operating sequences (general)

2))6(7
3$5$0
Press the <OFFSET PARAM> key.

7RRO
OLVW
This function opens the "Tool list" window which contains a list of the tools created. Use the
cursor keys and the <Page Up>/<Page Down> keys to navigate in this list.

Figure 4-2 Tool list

7RRO The offsets are entered by placing the cursor bar on the tool to be modified and pressing the
GDWD <Tool data> softkey.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 35
Setup
4.2 Create new tool

Operating sequences (new tool)

/DWHVW
7RRO
This function opens an input screen in which the tool number, tool type, and grinding wheel
shape are to be entered or selected.

Figure 4-3 New tool

2.
Confirm your input using <OK>.

Figure 4-4 New tool inserted

A data record loaded with zero will be included in the tool list. This data block consists of 9
cutting edges (D fields). The first 6 cutting edges have a cutting edge type and are used as
cutting edge geometry points.
The tool is assigned to a grinding spindle by an entry in the "S No" field. For values ≤0, an
externally controlled grinding spindle is used, for values >0, the grinding spindles of the
control system are known.

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36 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.2 Create new tool

Note:
Cylindrical grinding begins with S2.
Flat grinding begins with S1.
The conversion is done internally, for an entered value of 1.
For standard wheels (vertical and inclined), the D numbers are assigned a fixed meaning
(refer to the "Offset values" figure below). Based on the geometry data, this allocation is
always set by default for setting up and dressing.
For wheel having a free contour, the user is always responsible for the cutting edges. Only
when a wheel is newly created or for deleted wear values, the cutting edge values are set by
default once, depending on the dressing angle. The default setting is made for angle = 0, as
in the case of a simple vertical wheel, i.e. the odd cutting edges (D1, D3, D5) are on the left-
hand side and the even cutting edges (D2, D4, D6) on the right-hand side, taking into
account the entire wheel width.
The default setting for inclined wheels is arranged so that always all reference points are
identical. There is no distinction between left-hand and right-hand sides. The user has the
option of redefining the cutting edges in a dressing subroutine. For this, the NC syntax must
be followed. Any changes will be accepted only after the first complete dressing stroke and
not while shaping. Reference points are compensated as it is done for standard wheels.
Diameter and width monitoring will also be active only after both diameter and wear are
included in the particular D number. Thus the user can modify additional reference point in
the free contour. However, the left-hand and right-hand cutting edges regime must be
maintained since the compensations are always taken into account (left-hand side negative,
right-hand side positive) as they are for standard wheels.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 37
Setup
4.2 Create new tool

,QFOLQHGZKHHO
$QJOH $QJOH

: K
LGW
K LGW
:

/H
=



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' 
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WK

WK
5DGLXV 5DGLXV W
QJ

QJ


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/H

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QJ
WK

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5DGLXV

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Figure 4-5 Corrective values

Cutting edges 7-9 are the three available dressing tools have a fixed allocation to the
standard contour cutting edge.

Table 4- 1 Allocation of dressers

D field Dresser Assignment

D7 Dresser 1 Left-hand front cutting edge
D8 Dresser 2 Right-hand rear cutting edge
D9 Dresser 3 Optional for wheel diameter

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38 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.2 Create new tool

7RRO In the next step, the tool data are to be entered.

GDWD
● Nominal dimensions for monitoring
● Geometry data
● Technological data
● Data for the dressers

Nominal dimensions and monitoring

1RPLQDO
GLPHQVLRQ
PRQLWRULQJ
This function opens in input screen into which grinding wheel nominal dimensions and
monitoring data are entered.

Figure 4-6 Grinding wheel nominal dimensions and monitoring data

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 39
Setup
4.2 Create new tool

Geometry data

*HRPHWU\
GDWD
This function is used the enter the wheel geometry for the wheel type selected.

Figure 4-7 Geometry example data for a vertical wheel with back-slope

The following wheel types are available:

● Vertical wheel without back-slopes (type 1)
● Vertical wheel with back-slopes (type 2)
● Left-hand side inclined wheel (type 3)
● Right-hand side inclined wheel (type 4)
● Free contour (type 0)
The input screen is self-explaining.

Note
A red dot shown in the diagrammatic sketch indicates the geometry value just being entered.

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40 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.2 Create new tool

Technological data

7HFKQR By means of the technological data, the wheel type dependent dressing technology is
ORJ\GDWD
defined.

Figure 4-8 Technology example data for a vertical wheel with back-slope

Dresser

VW
GUHVVHU
Use the "1st dresser", "2nd dresser" or "3rd dresser" softkeys to access the dialog box for
entering or verifying the dresser data.

Figure 4-9 Fixed dresser

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 41
Setup
4.2 Create new tool

Use the "Type" toggle field to select the dresser type:

Fixed dresser: Tile/Diamond

Form roll 1 to 3
Diamond roll 1 to 3
Enter the parameters depending on the selection made.

Figure 4-10 Form roll

Figure 4-11 Diamond roll

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42 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.2 Create new tool

Parameter tables

([WHQGHG The function opens a summary of all cutting edge parameters.

Note: This function is available only with a password set (Customer).

Figure 4-12 The following table contains all cutting edge data.

Tool offset data

See Chapter "Parameter tables of tool offset data" in the annex.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 43
Setup
4.3 Register dresser

4.3 Register dresser

Functionality
This function is used to determine the dresser positions in the machine for dressers that are
used by means of the geometry axes. The axis values are determinded in machine
coordinates by the HMI and transmitted to the cycle.

Operation

The dresser is sensed in JOG mode.

6HQVH
GUHVVHU
The input screen is opened.

Figure 4-13 Register dresser

Use the "Dresser no.:" toggle field to select the dresser whose position you wish to register
(e.g. "1"). The order is irrelevant.
Each axis can be registered independently of the others.
The steps required are shown in a text line.
The axis line to be processed is indicated by an arrow.

Note
For swiveling wheels, the wheel must already be set to its dressing angle.

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44 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.3 Register dresser

&DOFXODWH Following scratching of the selected axis, select "Calculate position" to read the axis actual
SRVLWLRQ value and calculate it with the active tool.
The green check mark at the end of the line indicates this action.
For standard grinding wheels, the D number of the wheel is automatically selected in
accordance with the choice of dresser for dressers 1 and 2.
For the 3rd dresser, select the D number or approach the edge of the active wheel as it is
not automatically recognized.

%DFN Exit the "Register dresser" function.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 45
Setup
4.4 Sense workpiece

4.4 Sense workpiece

Functionality
This function is used to detect the workpiece position in the machine with respect to the
particular axis. The HMI transmits both axis name and setpoint to the cycle.

Operation

The workpiece is sensed in JOG mode by scratching the respective axes.

6HQVH
ZRUNSLHFH
The input screen is opened.

Figure 4-14 Sense workpiece

Use the "Axis name" toggle field to select the desired axis and enter the workpiece setpoint
measured in the input field.
&DOFXODWH
SRVLWLRQ Press the <Calculate position> softkey to calculate the setpoint.

Note
This procedure must be done for each axis separately.


%DFN Exit the "Register workpiece" function.

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46 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.4 Sense workpiece

Special features in connection with manual grinding

If you have interrupted manual grinding (Page 50) with the PLC key "Handwheel" during
manual grinding, then the last position of the infeed axis can be calculated following
"Measure workpiece" > "Calculate position".
Above the HMI, the following text appears:
"Accept setting value from manual grinding - continue with NC start".

Figure 4-15 Measure workpiece after manual grinding

Measuring is possible only for the infeed axis from manual grinding and only once directly
after manual grinding. If "Measure workpiece" is aborted or another axis is set as the last
infeed axis, then every axis with any axis positions must be calibrated again.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 47
Setup
4.5 Shaping/dressing

4.5 Shaping/dressing

Functionality
This function is used to shape a "raw" grinding wheel without generating an NC program.
The procedure always refers to the currently active tool.

Operation

Shaping is done in JOG mode.

6KDSLQJ The input screen is opened.

Figure 4-16 Shaping

The required shaper values that are machined in dressing strokes are entered using the
input fields
For a new wheel (no wear), the shaper allowance is suggested by the control system. The
number of dressing strokes can be freely selected.
6WDUW
SURI When you press the <Start prof.> softkey, the following prompt will appear:

Figure 4-17 Prompt

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48 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.5 Shaping/dressing

How profiling is executed

In the cycle, the shaper allowance is machined first and then all dressing strokes are
executed. The current state is shown in the fields.
The procedure can be aborted at any time.

6WDUW
SURI To restart it, press the <Start prof.> softkey. Values can be modified.


%DFN Exit the "Profiling" function.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 49
Setup
4.6 Manual grinding

4.6 Manual grinding

Functionality
This function is for grinding (precision grinding) with the handwheel. This function does not
require a workpiece program.

Operation

Manual grinding is done in "Jog" mode.

0DQXDO
JULQG
The input screen is opened.
Entry of parameters into the input screen for manual grinding (see figure below):
● T or D number
● Select oscillating motion via toggle field.
The following oscillating motions are possible:
– No function
– Infeed Y axis no oscillation
– Infeed Z axis no oscillation
– Infeed Y axis oscillation X axis
– Infeed Z axis oscillation X axis
– Infeed Y axis oscillation X/Z axis
● Peripheral speed of tool (m/s)
● Workpiece speed (rpm)

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50 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.6 Manual grinding

Manual grinding, no oscillation

The figure below shows an input screen with parameters for manual grinding without
oscillation:

Figure 4-18 Manual grinding without oscillation

6WDUW This function starts manual grinding with the handwheel. A prompt appears.
JULQG

Figure 4-19 Prompt

Execution of manual grinding with handwheel (without oscillation).


%DFN Exit manual grinding.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 51
Setup
4.6 Manual grinding

Manual grinding, oscillation

The figure below shows an input screen with parameters for manual grinding with oscillation:

Figure 4-20 Manual grinding with oscillation

2VFLOODWLRQ If you have selected oscillation, then you should use this function to enter the oscillation data
GDWD (see figure below):

Figure 4-21 Manual grinding with oscillation data in X and Z

The following oscillation data is possible:

● Position 1 (start)/2 (end):
– Use the numeric keypad to enter position 1/2 in the relevant input field.
– Use traversing key <X> or <Z> on the machine control panel to approach position 1/2
and use vertical softkey "Position 1"/"Position 2" to transfer the position to the input
field (teach in).
● Dwell time at reversal point position 1 (in seconds if there is a tool spindle present;
otherwise, in revolutions)
● Feedrate X (mm/min)

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52 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.6 Manual grinding

● Feedrate Z (mm/stroke)
● Dwell time at reversal point position 2 (in seconds if there is a tool spindle present;
otherwise, in revolutions)
This function starts manual grinding with the handwheel. The following prompt is displayed:
"The selected program starts a traversing motion of the axes! Do you wish to continue with
machining?"
Execution of manual grinding with handwheel (oscillation)

Exiting manual grinding

Exit manual grinding.

Special features in connection with "Measure workpiece"

In order to be able to intervene in the grinding process during manual grinding, the PLC keys
for "Interruption" and "Dressing" are active during manual grinding.
The PLC key "Handwheel" ends manual grinding on the starting position of the infeed axis.
By aborting manual grinding with PLC key "Handwheel", the last position of the infeed axis is
saved. This saved position of the infeed axis will be calculated with a following "Measure
workpiece (Page 46)".
Measuring is possible only for the infeed axis from manual grinding and only once directly
after manual grinding. If "Measure workpiece" is aborted or another axis is set as the last
infeed axis, then every axis with any axis positions can be calibrated again.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 53
Setup
4.7 Program setting data

4.7 Program setting data

Functionality
The setting data are used to define the settings for the operating states. These can be
changed as necessary.

Operating sequence

2))6(7
3$5$0
These can be found in the <OFFSET PARAM> operating area.

6HWWLQJ
GDWD
Press the "Setting data" softkey. The start screen "Setting data" is opened. Other softkey
functions are available here with which you can set various control system options.

Figure 4-22 Setting data start screen

● JOG feedrate
Feedrate value in JOG mode
If the feedrate value is zero, the control system will use the value stored in the machine
data.
● Spindle
Spindle speed
● Minimum / maximum
A limitation of the spindle speed in the "Max." (G26) / "Min." (G25) fields can only be
performed within the limit values defined in the machine data.
● Limitation using G96
Programmable upper speed limitation (LIMS) at constant cutting rate (G96).

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54 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.7 Program setting data

● Dry run feed (DRY)

The feedrate which can be entered here will be used instead of the programmed feedrate
in the AUTOMATIC mode if the "Dry run feed" function is selected.
● Starting angle for thread (SF)
For thread cutting, a start position for the spindle is displayed as the start angle. A
multiple thread can be cut by changing the angle when the thread cutting operation is
repeated.
Place the cursor bar on the input field to be modified and enter the value.

Either press the <Input> key or move the cursor to confirm.

Softkeys

/LPLW
ZRUNLQJDUHD The working area limitation is active with geometry and additional axes. If you want to use a
working area limitation, its values can be entered in this dialog box. Selecting the "Set active"
softkey enables/disables the values for the axis highlighted by the cursor.

Figure 4-23 Working area limitation

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 55
Setup
4.7 Program setting data

7LPHV Times Counters

0XOWLSOLHU

Figure 4-24 Times, Counters

Meaning:
● Total parts: Total number of workpieces produced (total actual)
● Parts requested: Number of workpieces required (workpiece setpoint)
● Number of parts: This counter registers the number of all workpieces produced since the
starting time.

Note
The counter functionality is set using the following channel-specific machine data:
• MD27880 $MC_PART_COUNTER, the workpiece counter is activated
• MD27882 $MC_PART_COUNTER_MCODE[0-2], workpiece counting with user
defined M command

● Total runtime: Total runtime of NC programs in AUTOMATIC mode

In the AUTOMATIC mode, the runtimes of all programs between NC START and end of
program / RESET are summed up. The timer is zeroed with each power-up of the control
system.
● Program runtime Active tool operating times
The runtime between NC Start and End of program / Reset is measured in the selected
NC program. The timer is reset with the start of a new NC program.
● Feedrate runtime
The runtime of the path axes is measured in all NC programs between NC START and
end of program / RESET without rapid traverse active and with the tool active. The
measurement is interrupted when a dwell time is active.
The timer is automatically reset to zero in the case of a "Control power-up with default
values".

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56 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.7 Program setting data

0LVF
Use this function to display all setting data for the control system in the form of a list. The
setting data are divided up into general, axis-specific and channel-specific data.
They can be selected using the following softkey functions:
● "General"
● "Axis-spec."
● "Channel-spec."

Figure 4-25 General setting data

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 57
Setup
4.8 Arithmetic parameter R

4.8 Arithmetic parameter R

Functionality
In the "R parameters" start screen, any R parameters that exist within the control system are
listed. These global parameters can be set or queried by the programmer of the part
program for any purpose in the program and can be changed as required.

Operating sequence

2))6(7
3$5$0
These can be found in the <OFFSET PARAM> operating area.

5SDUD
PHWHUV
Press the <R variable> softkey. The "R variables" start screen appears.

Figure 4-26 "R parameters" start screen

Place the cursor bar on the input field to be modified and enter the values.
Either press the <Input> key or move the cursor to confirm the entry.

)LQG Searching for R variables

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58 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Setup
4.9 User data

4.9 User data

Functionality
The user data is internally processed in the cycles. This data can be changed as necessary.

Operating sequences

2))6(7
3$5$0
These can be found in the <OFFSET PARAM> operating area.

8VHUGDWD
Press the <User data> softkey. This will open the "User data" start screen for the cycles.

Figure 4-27 User data

Place the cursor bar on the input field to be modified and enter the values.
Either press the <Input> key or move the cursor to confirm the entry.

)LQG

&RQWLQXH
ILQG
Use this function to search for the user data.

See also
User data (Page 335)

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 59
Setup
4.9 User data

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60 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Manual mode 5
5.1 Manual mode
Manual mode is supported by the JOG and MDA operating modes.

0DQXDO 5HJLVWHU 5HJLVWHU 3URI 6HWW

JULQG GUHVVHU ZRUNSLHFH LOLQJ LQJV
3UHSURI
ZKHHO

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=

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PP!LQFK
6WDUW &DOFXODWH &DOFXODWH 6WDUW
JULQGLQJ SRVLWLRQ SRVLWLRQ SURI

    
%DFN %DFN %DFN %DFN %DFN

Figure 5-1 JOG menu tree, "Position" operating area

7HDFK,Q 6HWW
LQJV
7HFKQROR
GDWD
5DSLG
WUDYHUVH

/LQHDU

&LUFXODU

(QG 6ZLWFK
EORFN PP!LQFK

([LW 
7HDFK,Q %DFN

Figure 5-2 MDA menu tree, "Position" operating area

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 61
Manual mode
5.2 JOG mode - "Position" operating area

5.2 JOG mode - "Position" operating area

5.2.1 JOG mode

Operating sequences

Use the <JOG> key on the machine control panel to select the Jog mode.

; To traverse the axes, press the appropriate key for the X, Y, or Z axis.

<

= The axes will traverse continuously at the velocity stored in the setting data until the key is
released. If the value of the setting data is zero, the value stored in the machine data is
used.
If necessary ,set the velocity using the override switch.

If you press the <Rapid traverse override> key at the same time, the selected axis will be
traversed at rapid traverse speed while both keys are being held down.

In the "Increment" mode, you can traverse by adjustable increments using the same
operating sequence. The set number of increments is displayed in the status area. To
deselect, press <JOG> again.

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 Manual mode
5.2 JOG mode - "Position" operating area

The JOG start screen displays the position, feedrate and spindle values, as well as the
current tool.

Figure 5-3 JOG mode start screen

Parameter

Table 5- 1 Description of the parameters in the JOG start screen

Parameter Explanation
MCS Displays the axes existing in the machine coordinate system (MCS) or in the workpiece
X coordinate system (WCS)
Y
Z
+X If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign
+Y will appear in the relevant field.
-Z If the axis is already in the required position, no sign is displayed.
Position These fields display the current position of the axes in the MCS or WCS.
mm
Repos. If the axes are traversed in the "Program interrupted" condition in the Jog mode, the
offset distance traversed by each axis is displayed referred to the interruption point.
G function Displays important G functions
Spindle S Displays the actual value and the setpoint of the spindle speed.
r.p.m.
Feed F Displays the path feedrate actual value and setpoint.
mm/min
Tool Displays the currently active tool with the current edge number

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Manual mode
5.2 JOG mode - "Position" operating area

Note
If a second spindle is integrated into the system, the workspindle will be displayed using a
smaller font. The window will always display the data of only one spindle.
The control system displays the spindle data according to the following aspects:
The master spindle (large display) is displayed:
- Idle,
- at spindle start
- with both spindles active
The workspindle (small display) is displayed:
- when starting the workspindle
The power bar applies to the spindle currently active. With both master spindle and
workspindle active, the master spindle performance bar is displayed.

Softkeys

Note
The vertical softkeys are explained in the the section titled MDA mode (Page 66).

0DQXDO
JULQG
This function is for grinding (precision grinding) with the handwheel. This function does not
require a workpiece program.

6HQVH
GUHVVHU
This function is used to determine the dresser positions in the machine for dressers that are
used by means of the geometry axes.

6HQVH
ZRUNSLHFH
This function is used to detect the workpiece position in the machine with respect to the
particular axis.

6KDSLQJ This function is used to shape a "raw" grinding wheel without generating an NC program.

6HWWLQJV

Note
The parameters within the "Settings" function do not affect grinding.

6ZLWFK
PP!LQFK Use this softkey to switch between the metric and the inch dimension systems

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 Manual mode
5.2 JOG mode - "Position" operating area

5.2.2 Assigning handwheels

Operating sequence

Select the "JOG" operating mode.

+DQGZKHHO Press the <Handwheel> softkey. The "Handwheel" window appears on the screen.
After the window has been opened, all axis identifiers are displayed in the "Axis" column,
which simultaneously appear in the softkey bar.
Select the desired handwheel using the cursor. Following this, assign or deselect as
appropriate by pressing the relevant axis softkey for the desired axis.
The ☑ symbol appears in the window.

Figure 5-4 Handwheel menu screen

0&6 Use the <MCS> softkey to select the axes from the machine or workpiece coordinate system
for hand wheel assignment.
The current setting is displayed in the window.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 65
Manual mode
5.3 MDA mode (manual input) "Position" operating area

5.3 MDA mode (manual input) "Position" operating area

Functionality
In the MDA mode, you can create or execute a part program.

CAUTION
The Manual mode is subject to the same safety interlocks as the fully automatic mode.
Furthermore, the same prerequisites are required as in the fully automatic mode.

Operating sequences
Use the machine control panel to select "MDA" mode.

Figure 5-5 MDA mode start screen

Enter one or several blocks using the keyboard.

By pressing <NC START> machining is started. During machining, editing of the blocks is no
longer possible.
After machining, the contents are preserved so that the machining can be repeated by
pressing <NC START> once more.

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 Manual mode
5.3 MDA mode (manual input) "Position" operating area

Parameter

Table 5- 2 Description of the parameters in the MDA working window

Parameter Explanation
MCS Displays the existing axes in the MCS or WCS
X
Z
+X If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign
-Z will appear in the relevant field.
If the axis is already in the required position, no sign is displayed.
Position These fields display the current position of the axes in the MCS or WCS.
mm
Distance-to- This field displays the distance to go of the axes in the MCS or WCS.
go
G function Displays important G functions
Spindle S Displays the actual value and the setpoint of the spindle speed.
r.p.m.
Feedrate F Displays the path feedrate actual value and setpoint in mm/min or mm/rev.
Tool Displays the currently active tool with the current edge number (T..., D...).
Editing In the "Stop" or "Reset" program state, an editing window serves to input a part
window program block.

Note
If a second spindle is integrated into the system, the workspindle will be displayed using a
smaller font. The window will always display the data of only one spindle.
The control system displays the spindle data according to the following aspects:
The master spindle is displayed:
- Idle,
- at spindle start
- with both spindles active
The workspindle is displayed:
- when starting the workspindle
The power bar applies to the spindle currently active.

Softkeys
The horizontal softkeys are explained in the section titled "JOG mode - 'Position' operating
area" (Page 62).

*
IXQFWLRQ
The G function window displays G functions whereby each G function is assigned to a group
and has a fixed position in the window.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 67
Manual mode
5.3 MDA mode (manual input) "Position" operating area

Use the <PageUp> or <PageDown> keys to display additional G functions. Selecting the
softkey repeatedly will close the window.

$X[LOLDU\
IXQFWLRQ
This window displays the auxiliary and M functions currently active. Selecting the softkey
repeatedly will close the window.

$OO*
IXQFWLRQV
All the G functions are displayed.

$[LV
IHHGUDWH
Use this softkey to display the "Axis feedrate" window.
Pressing the softkey repeatedly will close the window.

'HOHWH
0'$SURJU
Use this function to delete blocks from the program window.

6DYH
0'$SURJ
Enter a name in the input field for saving the MDA program in the program directory.
Alternatively, you may select an existing program from the list.
Use the Tab key to toggle between the input field and program list.

Figure 5-6 Saving an MDA program

0.6:.6
5(/
The actual values for the MDA mode are displayed depending on the selected coordinate
system. Use this softkey to switch between the two coordinate systems.

See also
JOG mode (Page 62)

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68 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Manual mode
5.3 MDA mode (manual input) "Position" operating area

5.3.1 Teach In

Functionality
You can use the "Teach In" function to create and change simple traversing blocks. You can
transfer axis position values directly into a newly generated or changed part program record.
The axis positions are reached by traversing with the axis direction keys and transferred into
the part program.

Operating sequence

In the <POSITION> operating area, use the machine control panel to select <MDA> mode.

7HDFK,Q Press the <Teach In> softkey.

In the "Teach In" submode, assume the following start screen:

Figure 5-7 Teach In start screen

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 69
Manual mode
5.3 MDA mode (manual input) "Position" operating area

General sequence
1. Use the arrow keys to select the program block that you want to edit or that is to have the
new traversing block inserted in front of it.
2. Select the appropriate softkey.

7HFKQRO
GDWD
– "Technological data"

Figure 5-8 Technological data

Enter the appropriate technological data (e.g. feedrate: 1000).

,QVHUW
WUDQVIHU Click "Insert transfer" to add a new part program block. The new part program block
will be added in front of the block selected with the cursor.
&KDQJH
WUDQVIHU
Click "Change transfer" to change the selected part program block.


%DFN Use "<<Back" to return to the "Teach In" start screen.

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 Manual mode
5.3 MDA mode (manual input) "Position" operating area

5DSLG – "Rapid feed"

WUDYHUVH

Figure 5-9 Rapid traverse

You traverse the axes and teach-in a rapid traverse block with the approached
positions.
/LQHDU – "Linear"

Figure 5-10 Linear

You traverse the axes and teach in a linear block with the approached positions.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 71
Manual mode
5.3 MDA mode (manual input) "Position" operating area

&LUFXODU
– "Circular"

Figure 5-11 Circular

You teach in an intermediate point and an end point for a circle.

Operation in the "Rapid traverse", "Linear", and "Circular" dialogs

;

< 1. Use the axis keys to traverse the axes to the required position that you want to
add/change in the part program.
,QVHUW 2. Click "Insert transfer" to add a new part program block. The new part program block will
WUDQVIHU be added in front of the block selected with the cursor.
&KDQJH 3. Click "Change transfer" to change the selected part program block.
WUDQVIHU
 Use "<<Back" to return to the "Teach In" start screen.
%DFN

([LW
7HDFK,Q Use "Exit Teach In" (see "Start screen") to leave the "Teach In" submode.

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Automatic mode 6
6.1 Automatic mode

Menu tree

0DFKLQLQJ 3URJUDP 6HW 6LPXOW 3URJUDP

RIIVHW &RQWURO 6HDUFK UHFRUGLQJ &RPSHQVDWLRQ

3URJUDP 8S =RRP
7HVW &RQWRXU $XWR
7ULDOUXQ 8S =RRP
)HHGUDWH (QGSRLQW 
&RQGLWLRQDO 1RQH =RRP
6WRS &DOF 
6NLS ,QWHU 6KRZ
SLQJ UXSW 
6LQJOH 'LVSOD\
6HDUFKLQJ
EORFNILQH DUHDV
529 5H 'HOHWLQJ
HIIHFWLYH JULQGLQJ DVFUHHQ

&XUVRU

    
%DFN %DFN %DFN %DFN %DFN

Figure 6-1 Automatic menu tree

Preconditions
The machine is set up for the AUTOMATIC mode according to the specifications of the
machine manufacturer.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 73
Automatic mode
6.1 Automatic mode

Operating sequence

Select Automatic mode by pressing the <Automatic> key on the machine control panel.
The Automatic start screen appears, displaying the position, feedrate, spindle, and tool
values, as well as the currently active block.

Figure 6-2 Automatic start screen

Parameter

Table 6- 1 Description of the parameters in the working window

Parameter Explanation
MCS Displays the existing axes in the MCS or WCS
X
Z
+X If you traverse an axis in the positive (+) or negative () direction, a plus or minus sign
-Z will appear in the relevant field.
If the axis is already in the required position, no sign is displayed.
Position These fields display the current position of the axes in the MCS or WCS.
mm
Distance-to- These fields display the current position of the axes in the MCS or WCS.
go
G function Displays important G functions
Spindle S Displays the actual value and the setpoint of the spindle speed.
r.p.m.
Feed F Displays the path feedrate actual value and setpoint.
mm/min or
mm/rev

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 Automatic mode
6.1 Automatic mode

Parameter Explanation
Tool Displays the currently active tool with the current edge number (T..., D...).
Current The block display displays seven subsequent blocks of the currently active part
block program. The display of one block is limited to the width of the window. If several
blocks are to be executed in quick succession, you are recommended to switch to the
"Program progress" window. To switch back to the seven-block display, use the
<Program sequence> softkey.

Note
If a second spindle is integrated into the system, the workspindle will be displayed using a
smaller font. The window will always display the data of only one spindle.
The control system displays the spindle data according to the following aspects:
The master spindle is displayed:
- Idle,
- at spindle start
- with both spindles active
The workspindle is displayed:
- when starting the workspindle
The power bar applies to the spindle currently active. With both master spindle and
workspindle active, the master spindle performance bar is displayed.

Softkeys

*
IXQFWLRQ
Opens the G functions window to display all G functions currently active.
The G functions window displays all the G functions that are currently active, with each G
function assigned to a group and having a fixed position in the window.

Figure 6-3 G Functions

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 75
Automatic mode
6.1 Automatic mode

Use the <PageUp> or <PageDown> keys to display additional G functions.

$X[LOLDU\
IXQFWLRQ
This window displays the auxiliary and M functions currently active.
Selecting the softkey repeatedly will close the window.

$OO*
IXQFWLRQV All the G functions are displayed.

$[LV
IHHGUDWH
Use this softkey to display the "Axis feedrate" window.
Pressing the softkey repeatedly will close the window.

3URJUDP
VHTXHQFH
Use this softkey to switch from the seven-block to the three-block display.

0.6:.6
5(/
Switches the axis value display between the machine, workpiece and relative coordinate
systems.

0DFKLQLQJ
RIIVHW
Use this softkey to display the "Machining offset" window.
Fine offsets can be entered in Y and Z, globally for each seat or individually for a specific
seat.
From then on, these offsets will always be used for the grinding work (seat).

%DFN Use this softkey to close the screen. Your offsets are saved.

3URJUDP
FRQWURO
The program control softkeys are displayed (e.g. "Skip block", "Program test").
● "Program test":
If "Program test" is selected, the output of setpoints to axes and spindles is disabled. The
set point display "simulates" the traverse movements.
● "Dry run feedrate":
If you select this softkey, all traversing motions will be performed with the feedrate
setpoint specified via the "Dry run feed" setting data. The dry run feedrate function
replaces the programmed travel commands.
● "Conditional stop":
When this function is active, processing of the program is stopped at every block in which
miscellaneous function M01 is programmed.
● "Skipping":
Program blocks, the block number of which is preceded by a slash, are skipped during
program execution (e.g. "/N100").

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 Automatic mode
6.1 Automatic mode

● "Single block, fine":

If this function is active, the part program blocks are executed as follows: Each block is
decoded separately, and a stop is performed at each block; an exception are only the
thread blocks without dry run feedrate. In such blocks, a stop is only performed at the end
of the current thread block. "Single block, fine" can only be selected in the RESET status.
● "ROV effective":
The feedrate override switch will also act on the rapid traverse override.

%DFN Use this softkey to close the screen.

%ORFN
VHDUFK
Use the block search function to go to the desired program location.

7R
FRQWRXU
Forward block search with calculation
During the block search, the same calculations are carried out as during normal program
operation, but the axes do not move.

7R
HQGSRLQW
Forward block search with calculation to the block end point
During the block search, the same calculations are carried out as during normal program
operation, but the axes do not move.

:LWKRXW
FDOFXODW
Block search without calculation
During the block search, no calculation is carried out.

,QWHUU
SRLQW
The cursor is placed on the main program block of the interrupt point.

)LQG The "Find" softkey provides the functions "Find line", "Find text" etc.

5H
JULQG Use this softkey to display the "Regrinding" window.
Enter the offset values for regrinding. When you select <OK>, the parameters will be
inserted in the program after the selected block.
6LPXOWDQHRXV
UHFRUGLQJ It is possible to simultaneously record when the part program is being executed (see Chapter
"Simultaneous recording (Page 84)").

&RUUHFW
SURJUDP
Use this softkey to correct a fault program passage. Any changes will be stored immediately.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 77
Automatic mode
6.2 Machining offset

6.2 Machining offset

Functionality
Fine offsets can be entered in Y and Z, globally for each seat or individually for a specific
seat.
From then on, these offsets will always be used for the grinding work (seat).

Operating sequence
0DFKLQLQJ
RIIVHW
The "Automatic" start screen will display a window for the machining offsets.

Figure 6-4 Machining offsets

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 Automatic mode
6.3 Selection and start of a part program

6.3 Selection and start of a part program

Functionality
Before starting the program, make sure that both the control system and the machine are set
up. Observe the relevant safety notes of the machine manufacturer.

Operating sequence

Select Automatic mode by pressing the <Automatic> key on the machine control panel.

The Program Manager is opened. Use the <NC directory> (default selection) or <Customer
CF card> softkeys to enter the appropriate directories.

Figure 6-5 "Program Manager" start screen

Place the cursor bar on the desired program.

([H
FXWH
Use the <Execute> softkey to select the program to be executed (see also "External
execution"). The name of the selected program will appear in the "Program name" screen
line.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 79
Automatic mode
6.3 Selection and start of a part program

3URJUDP If desired, here you can specify how you want the program to be executed.
FRQWURO

Figure 6-6 Program control

Press <NC START> to start executing the part program.

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 Automatic mode
6.4 Block search

6.4 Block search

Operating sequence
Prerequisite:The desired program has already been selected, and the control system is in
the RESET state.

%ORFN
VHDUFK The block search function provides advance of the program to the required block in the part
program. The search target is set by positioning the cursor bar directly on the required part
program block in the part program.

Figure 6-7 Block search

7R
FRQWRXU
Block search to block start

7R
HQGSRLQW
Block search to block end

:LWKRXW
FDOFXODW
Block search without calculation

,QWHUU
SRLQW
The interruption location is loaded.

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Automatic mode
6.4 Block search

Use this softkey to perform the block search by entering a term you are looking for.
)LQG

Figure 6-8 Entering the searched term

You can use the toggle field to define the starting position for the search.

Search result
The required part program block is displayed in the "Current block" window.

Note
For "Execute externally", no block search is possible.

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 Automatic mode
6.4 Block search

Regrinding
"Regrinding" enables you to remachine the "seat" of a workpiece that has already been
machined, either with or without an offset, but always with the same technological values.
5H
JULQG Use this softkey to display the "Regrinding" window.

Figure 6-9 Regrinding

Enter the offset values for regrinding.

Choose between the following options in the toggle field:
● Do not correct any axis
● Correct tool
● Machining offsets
When you select <OK>, the parameters will be inserted in the program after the selected
block.
The block search starts.

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Automatic mode
6.5 Simultaneous recording

6.5 Simultaneous recording

Operating sequence

You have selected a part program to be executed and have pressed <NC START>.

6LPXOWDQHRXV
UHFRUGLQJ Execution of the part program is simultaneously recorded on the HMI using the
"Simultaneous recording" function.

Figure 6-10 "Simultaneous recording" start screen

You can influence how the simultaneous recording function is displayed on the HMI using
the following vertical softkeys:
● "Zoom Auto"
● "Zoom +"
● "Zoom -"
● "Show ..."
– "All G17 blocks"
– "All G18 blocks"
– "All G19 blocks"
● "Display areas"
See the following page for a description.

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 Automatic mode
6.5 Simultaneous recording

● "Delete window"
● "Cursor"
– "Set cursor"
– "Cursor fine", "Cursor coarse", "Cursor very coarse"
When the cursor keys are pressed, the cross hair moves in small, average or large
steps.

%DFN Exit the "Simultaneous recording" function.

"Display areas"

'LVSOD\
DUHD Using the "Display areas" function, you have the possibility of saving a previously selected
area from the simulation display.
:LQGRZ
PLQPD[ The menu for the display area can be selected using the "Window min/max" function.

Figure 6-11 Display area "Window min"

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Automatic mode
6.5 Simultaneous recording

Figure 6-12 Display area "Window max"

Operating sequence to set and save the display area

1. You have selected an area in the simulation view.
'LVSOD\ 2. Press the "Display areas" function.
DUHD

:LQGRZ
PLQPD[ 3. Press the "Window min/max" so that a maximum display can be see according to the
screen "Display areas "Window max".
4. In the "Comment field", you can assign a name to the area.
5. Complete the entry with <Input>.

6DYHDUHD
6. Press "Save area".

Activating or deleting an area

'LVSOD\
DUHD You have selected a display area.

Using the cursor keys, select the area that you wish to either activate or delete.

$FWLYDWH
DUHD Press "Activate area" or "Delete area".

'HOHWH
DUHD

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 Automatic mode
6.6 Stop / cancel a part program

6.6 Stop / cancel a part program

Operating sequence

With <NC STOP> the execution of a part program is interrupted.

The interrupted machining can be continued with <NC START>.

Use <RESET> to abort the program currently running.

By pressing <NC START> once again, the aborted program is restarted and executed from
the beginning.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 87
Automatic mode
6.7 Reapproach after cancellation

6.7 Reapproach after cancellation

After a program cancellation (RESET), you can retract the tool from the contour in manual
mode (JOG).

Operating sequence

Select mode <AUTOMATIC> mode.

%ORFN
VHDUFK
Opening the "Block search" window for loading the interruption point.

,QWHUU
SRLQW
The interruption point is loaded.

7R
FRQWRXU
The block search to the interruption point will start. An adjustment to the start position of the
interrupted block will be carried out.

Press <NC START> to continue machining.

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 Automatic mode
6.8 Repositioning after interruption

6.8 Repositioning after interruption

After interrupting the program (<NC STOP>), you can retract the tool from the contour in
manual mode (JOG). The control saves the coordinates of the point of interruption. The
distances traversed are displayed.

Operating sequence

Select <AUTOMATIC> mode.

Press <NC START> to continue machining.

CAUTION
When reapproaching the interruption point, all axes will traverse at the same time. Make
sure that the traversing area is not obstructed.

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Automatic mode
6.9 Execute from external

6.9 Execute from external

Functionality

In <AUTOMATIC> mode > <PROGRAM MANAGER> operating area, the following

interfaces are available for external execution of programs:

&XVWRPHU
&)FDUG Customer CompactFlash card

5&6
FRQQHFW RCS connection for external execution via network (only for SINUMERIK 802D sl pro)

0DQXIDF
WXUHUGULYH Manufacturer's drive

86%
GULYH
USB FlashDrive

Start in the following start screen of the Program Manager:

Figure 6-13 The "Program Manager" start screen

Use vertical softkey "Ext. execution" to transmit the selected external program to the control
system; to execute this program, press <NC START>.
While the contents of the buffer memory are being processed, the blocks are reloaded
automatically.

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 Automatic mode
6.9 Execute from external

Operating sequence, execution from customer CompactFlash Card or USB FlashDrive

Requirement: The control system is in the "Reset" state.

Select the <AUTOMATIC> mode key .

Press the <PROGRAM MANAGER> key on the machine control panel.

&XVWRPHU
&)FDUG

86%
GULYH
Press the "Customer CF card" or "USB drive".
You can thus access the directories of the "Customer CF Card / USB FlashDrive".
Place the cursor bar on the desired program.
([W
H[HFXWLRQ
Press "Ext. execution".
The program is transferred into the buffer memory and selected and displayed in the
program selection automatically.
Press the <NC START> key.
Machining starts. The program is reloaded continuously.
At the end of the program or in case of <RESET>, the program is automatically removed
from the control system.

Note
For "Execute externally", no block search is possible.

Requirements for external execution via network

● The control system and the external programming device/PC are connected via Ethernet.
● The RCS tool is installed on the programming device/PC.
The following conditions are required on the the devices:
1. Control: (see "User Management")
– Create an authorization for using the network using the following dialog:
Operating area <SYSTEM> > "Service Display" > "Service Control" > "Service
Network" > "Authorization" > "Create"
2. Control: (see "User log in - RCS log in")
– Log in for the RCS connection using the following dialog:
Operating area <SYSTEM> > vertical softkey "RCS log in" > "Log in"
3. Programming device/PC:
– Start the RCS tool.

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Automatic mode
6.9 Execute from external

4. Programming device/PC:
– Activate the drive/directory for network operation.
5. Programming device/PC:
– Establish an Ethernet connection to the control.
6. Control: (see "Connecting / disconnecting a network drive")
– Connect to the directory activated on the programming device/PC using the following
dialog:
Operating area <SYSTEM> > "Service Display" > "Service Control" > "Service
Network" > > "Connect" > "RCS Network" (Select a free drive of the control > Enter
the server name and and activated directory of the programming device/PC, for
example: "\\123.456.789.0\External Program")

Operating sequences for external execution via network

Select the <AUTOMATIC> mode key .

Press the <PROGRAM MANAGER> key on the machine control panel.

5&6
FRQQHFW Press "RCS connect."".
You go to the directories of the PG/PC.
Place the cursor bar on the desired program.
([W
H[HFXWLRQ
Press "Ext. execution".
The program is transferred into the buffer memory and selected and displayed in the
program selection automatically.
Press the <NC START> key.
Machining starts. The program is reloaded continuously.
At the end of the program or in case of <RESET>, the program is automatically removed
from the control system.

Note
The program can only be executed. Program correction is not possible at the control.

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Part programming 7
7.1 Part programming overview

Menu tree

2QO\6,180(
5,.'VOSUR

1& &XVWRPHU 5&6 0DQX 86%GULYH

56
GLUHFWRU\ &)FDUG FRQQHFWLRQ GULYH
([HFXWLRQ ([HFXWLRQ ([HFXWLRQ ([HFXWLRQ
([HFXWH IURPH[WHUQDO IURPH[WHUQDO IURPH[WHUQDO IURPH[WHUQDO

1HZ 1HZ 1HZ 1HZ

1HZ GLUHFWRU\ GLUHFWRU\ GLUHFWRU\ GLUHFWRU\

2SHQ 2SHQ 2SHQ 6HQG 2SHQ 2SHQ

6HOHFWDOO 6HOHFWDOO 6HOHFWDOO 6HOHFWDOO 6HOHFWDOO

5HFHLYH

&RS\ &RS\ &RS\ &RS\ &RS\

3DVWH 3DVWH 3DVWH 3DVWH 3DVWH

(UURU
'HOHWH 'HOHWH 'HOHWH 'HOHWH 'HOHWH
ORJ

1H[W 1H[W 1H[W 1H[W 1H[W 1H[W

    

Figure 7-1 "Program Manager" menu tree

Functionality
The PROGRAM MANAGER operating area is the management area for workpiece programs
in the control system. In this area, programs can be created, opened for modification,
selected for execution, copied, and inserted.

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Part programming
7.1 Part programming overview

Operating sequence

Press the <PROGRAM MANAGER> key to open the program directory.

Figure 7-2 The "Program Manager" start screen

Use the cursor keys to navigate in the program directory. To find program names quickly,
simply type the initial letter of the program name. The control system will automatically
position the cursor on a program with matching characters.

Softkeys

1&
GLUHFWRULHV Use this softkey to display the directories of the NC.

([H
FXWH
Use this softkey to select the program on which the cursor is placed for execution. The
control system will switch to the position display. Use <NC START> to start this program.

1HZ Use the "New" softkey to create a new program.

2SHQ Use the "Open" softkey to open the file highlighted by the cursor for processing.

0DUN
DOO
Use this softkey to select all files for the subsequent operations. The selection can be
canceled by pressing the softkey once more.

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 Part programming
7.1 Part programming overview

Note
Selecting individual files:
Position the cursor on the corresponding file and press the <Select> key. The selected line
will change its color. If you press the <Select> key once more, the selection is canceled.

&RS\ This function will enter one or several files in a list of files (called 'clipboard') to be copied.

3DVWH This function will paste files or directories from the clipboard to the current directory.

'HOHWH When selecting the "Delete" softkey, the file selected by the cursor is deleted after a
confirmation warning. If several files have been selected, all these files will be deleted after a
confirmation warning.
Use the "OK" softkey to execute the deletion request and "Abort" to discard.

0RUH

Use this softkey to branch to further functions.

5HQDPLQJ A window opens where you can rename the program you have selected beforehand using
the cursor.
After you have entered the new name, either press "OK" to confirm or "Abort" to cancel.

3UHYLHZ
ZLQGRZ
This function opens a window displaying the first seven lines of a file if the cursor has been
positioned on the program name for a certain time.
)LQG A window opens up where you can enter a file name you are looking for.
After you have entered the name, either press "OK" to confirm or "Abort" to cancel.
(QDEOHV A selected directory can be released for network operation.

6SOLW
ZLQGRZ
The function splits the window on the HMI. You can use the <Tab> key to switch over
between windows.
3URSHU
WLHV
The function gives information on the properties of the memory of the selected directory and
of the selected file.
(UURU
ORJ
The function gives information in a logfile on the executed functions (e.g. copying a file) as
well as on wrongly executed functions of the PROGRAM MANAGER. The logfile will be
deleted after cold restart of the control.
&XVWRPHU
&)FDUG Selecting this softkey provides the functions required to read out / read in files via the
customer CompactFlash card and the function "Program execution from external". When the
function is selected, the directories of the customer CompactFlash card are displayed.

([W
H[HFXWLRQ
Use this softkey to select the program on which the cursor is placed for execution. If the CF
card is selected, the program is executed by the NC as an external program. This program

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Part programming
7.1 Part programming overview

must not contain any program calls of part programs which are not stored in the directory of
the NC.

5&6
FRQQHFW This softkey is needed in connection with the work in the network. Additional information is
provided in Chapter, network operation (only for SINUMERIK 802D sl pro).

56 The functions required for reading out/reading in files are provided via the RS232 interface.

6HQG Use this function to transmit files from the clipboard to a PC connected to the RS232.

5HFHLYH Load files via the RS232 interface.

For the settings of the interface, please refer to the "System" operating area. The part
programs must be transmitted using the text format.

(UURU
ORJ
Error log

0DQXIDF
WXUHUGULYH Selecting this softkey provides the functions required to read out / read in files via the
manufacturer drive and the function "Program execution from external". When the function is
selected, the directories of the manufacturer's drive are displayed.
86%
GULYH Selecting this softkey provides the functions required to read out / read in files via USB
FlashDrive and the function "Program execution from external". When the function is
selected, the directories of the USB FlashDrive are displayed.

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 Part programming
7.2 Enter new program

7.2 Enter new program

Operating sequences

You have selected the PROGRAM MANAGER operating area.

1&
GLUHFWRULHV Use the "NC directory" softkeys to select the storage location for the new program.
1HZ Press "New". You have the choice of the following options:

Figure 7-3 New program

1HZ After presssing the softkey "New directory" a dialog window will open up for setting up a new
GLUHFWRU\ file.
Enter a name and confirm with "OK."
1HZ
ILOH
After presssing the softkey "New file" a dialog window will open up for setting up a new
program file. in which you can enter the names of the new main programs and subprograms.
The .MPF extension for main programs is entered automatically. The .SPF extension for
subprograms must be entered along with the program name.
Conclude your entry with "OK". The new part program file will be created, and the editor
window is opened automatically.

;
$ERUW Use "Cancel" to cancel the creation of the program. the window is closed.

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Part programming
7.3 Editing the part program

7.3 Editing the part program

Functionality
A part program can only be edited if it is currently not being executed.
Any modifications to the part program are stored immediately.

Figure 7-4 Program editor start screen

Menu tree

*ULQGLQJ 5HFRP
0DFKLQLQJ
F\FOHV SLOH

([H *:36WRRO
FXWH

0DUNEORFN 6DIHW\
KHLJKW

&RS\ =SRV
EORFN ZLWKZKHHO

3DVWH 'UHVVLQJ
EORFN

'HOHWH
EORFN *ULQGLQJ

)LQG

5HQXPEHU

6HHVHFWLRQWLWOHG&\FOHV

Figure 7-5 "Program" menu tree

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 Part programming
7.3 Editing the part program

Operating sequence
In the PROGRAM MANAGER operating area, select the program to be edited.

2SHQ Press the <Open> softkey. The selected program will open.

Softkeys

0DFKLQLQJ
Use this softkey to edit a file.

([W
H[HFXWLRQ
Use this softkey to execute the selected file.

0DUN
EORFN
Use this softkey to select a text segment up to the current cursor position (alternatively:
<CTRL+B>)

&RS\
EORFN
Use this softkey to copy a selected block to the clipboard (alternatively: <CTRL+C>)

,QVHUW
EORFN
Use this softkey to paste a text from the clipboard at the current cursor position (alternatively:
<CTRL+V>)

'HOHWH
EORFN
Use this softkey to delete a selected text (alternatively: <XTRL+X>)

)LQG Use the <Find> softkey to search for a string in the program file displayed.
Type the term you are looking for in the input line and use the <OK> softkey to start the
search. Use <Abort> to close the dialog box without starting the search process.

5HQXPEHU Use this softkey to replace the block numbers from the current cursor position up to the
program end.

*ULQGLQJ
F\FOHV
See section titled "Cycles" (Page 156)

5HFRPS
For recompilation, position the cursor on the cycle calling line in the program. This function
decodes the cycle name and prepares the screenform with the relevant parameters. If there
are any parameters beyond the range of validity, the function will automatically use the
default values. After closing the screenform, the original parameter block is replaced by the
corrected block.

Note
Only automatically generated blocks can be recompiled.

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Part programming
7.3 Editing the part program

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System 8
8.1 "System" operating area

Functionality
The SYSTEM operating area includes functions required for parameterizing and analyzing
the NCK, the PLC and the drive.
Depending on the functions selected, the horizontal and the vertical softkey bars change.
The menu tree shown below only includes the horizontal softkeys.

Menu tree

0DFKLQH 6HUYLFH 6WDUWXS

6WDUWXS 3/&
GDWD 'LVSOD\ )LOHV
1& *HQHUDO 6HUYLFH 67(3 '
0' $[HV FRQQHFW 'DWD
$[LV 6HUYLFH 3/& &XVWRPHUV
3/&
0' 'ULYHV 6WDWH &)FDUG
&KDQQHO 6HUYLFH 6WDWH 5&6
+0,
0' H[WEXV /LVW FRQQHFW
'ULYHV 6HUYLFH 3/& 56
0' &RQWURO 3URJUDP
6HUYLFH 3URJUDP 0DQXIDFWXU
RYHUYLHZ /LVW HU
VGULYH
'LVSOD\ 86%
0' 'ULYH
6HUYR 6HUYR 0DQX
WUDFH WUDFH DUFKLYH
(GLW3/&
9HUVLRQ
DODUPW[W

Figure 8-1 System menu tree

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System
8.1 "System" operating area

Operating sequence

6<67(0

 The full CNC keyboard is used to change to the <SHIFT> and <SYSTEM> operating areas
$/$50 and the start screen is displayed.

Figure 8-2 "System" operating area start screen

Softkeys
The start screen vertical softkeys are described below.

6HW
SDVVZRUG
"Set password"
Three password levels are distinguished in the control system, which provide different
access rights:
● System password
● Manufacturer password
● User password
It is possible to change certain data corresponding to the access levels. If you do not know
the password, access will be denied.

Note
Also see SINUMERIK 802D sl "Lists".

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 System
8.1 "System" operating area

Figure 8-3 Entering the password

After selecting the "Accept" softkey, the password is set.

Use "Abort" to return without any action to the "System" start screen.

&KDQJH
SDVVZRUG "Change Password"

Figure 8-4 Change password

Depending on the access right, various possibilities are offered in the softkey bar to change
the password.
Select the password level using the appropriate softkeys. Enter the new password and press
"Accept" to complete your input. You will be prompted to enter the new password once more
for confirmation.
Press "Accept" to complete the password change.
Use "Abort" to return without any action to the start screen.

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System
8.1 "System" operating area

'HOHWH Resetting the credential

SDVVZRUG

5&6
ORJLQ
User network log-in

&KDQJH
ODQJXDJH
Use "Change language" to select the user interface language.

Figure 8-5 User interface language

Use the cursor keys to select the language and confirm it by pressing "OK".

Note
The HMI is automatically restarted when a new language is selected.

6HUYLFH
ODQJXDJH
Use "Service language" to always select "English" as the user interface language.
Press the "Service language" softkey again to restore the previously active language (e. g.
"Simpl. Chinese").

Note
An asterisk "*" marks the languages you have used.

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 System
8.1 "System" operating area

6DYH "Save data"

GDWD
This function will save the contents of the volatile memory into a nonvolatile memory area.
Requirement: There is no program currently executed.
Do not carry out any operator actions while the data backup is running!
The NC and PLC data are backed up. The drive data are not backed up.

Note
Saved data can be called via the following operator action:
• Press the <SELECT> key while the control system is booting.
• In the setup menu, select "Reload saved user data".
• Press the <Input> key

Note
Data that have been backed up can be called again from the operating area <SYSTEM> >
"Start-up" > "Power up with backed up data"!

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System
8.2 SYSTEM - "Start-up" softkeys

8.2 SYSTEM - "Start-up" softkeys

6WDUWXS Commissioning

1& Use this softkey to select the NC power-up mode.

Select the desired mode using the cursor.
● Normal power-up
The system is restarted
● Power-up with default data
The display machine data are reset to their standard values (restores the initial state
when originally supplied)
● Power-up with backed up data
The system restarts with the data that were last backed up (see Backup data)

3/&
The PLC can be started in the following modes:
● Restart
● Memory reset
Furthermore, it is possible to link the start with a subsequent debugging mode.

+0, Selects the power-up mode of the HMI.

Select the desired mode using the cursor.
● Normal power-up
The system is restarted
● Power-up with default data
The system restarts with default values (restores the initial state when originally supplied)
Use "OK" to RESET the control system and to carry out a restart in the mode selected.
2.
Use the <RECALL> key to return to the system start screen without performing any action.

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 System
8.3 SYSTEM - "Machine data" softkeys

8.3 SYSTEM - "Machine data" softkeys

References
You will find a description of the machine data in the following manufacturers´ documents:
SINUMERIK 802D sl List Manual
SINUMERIK 802D sl Function Manual for turning, milling, nibbling

Machine data

0DFKLQH
GDWD
Any changes in the machine data have a substantial influence on the machine.

Figure 8-6 Structure of a machine data line

Table 8- 1 Legend

No. Significance
1 MD number
2 Name
3 Value
4 Unit
5 Effective so immediately effective
cf with confirmation
re Reset
po Power on

CAUTION
Incorrect parameterization may result in destruction of the machine!

The machine data are divided into the groups described in the following.

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System
8.3 SYSTEM - "Machine data" softkeys

General machine data

*HQHUDO
0'
Open the "General machine data" window. Use the Page Up / Page Down keys to browse
forward / backward.

Figure 8-7 General machine data

1&.UHVHW Executes a warm restart at the control.

SR

)LQG "Find"
Type the number or the name (or a part of the name) of the machine data you are looking for
and press "OK".
The cursor will jump to the data searched.
&RQWLQXH
ILQG
Use this softkey to continue searching for the next match.

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 System
8.3 SYSTEM - "Machine data" softkeys

6HOHFW This function provides various display filters for the active machine data group. Further
JURXS softkeys are provided:
● "Expert": Use this softkey to select all data groups of the expert mode for display.
● "Filter active": Use this softkey to activate all data groups selected. After you have quit the
window, you will only see the selected data on the machine data display.
● "Select all": Use this softkey to select all data groups of the Expert mode for display.
● "Deselect all": Selecting this softkey deselects all data groups.

Figure 8-8 Display filter

Axis-specific machine data

D[LV
0'
Open the "Axis-specific machine data" window. The softkey bar will be supplemented by the
softkeys "Axis +" and "Axis ".

Figure 8-9 Axis-specific machine data

The data of axis 1 are displayed.

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System
8.3 SYSTEM - "Machine data" softkeys

Use "Axis +" or "Axis " to switch to the machine area of the next or previous axis.
$[LV
8SGDWH
The contents of the machine data are updated.

Channel-specific machine data

FKDQ
0'
Open the "Channel-specific machine data" window. Use the PageUp / PageDown keys to
browse forward / backward.

Figure 8-10 Channel-specific machine data

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 System
8.3 SYSTEM - "Machine data" softkeys

SINAMICS drive machine data

'ULYH
0'
Open the "Drive machine data" dialog box.
The first dialog box displays the current configuration, as well as the states of the control,
power supply and drive units.

Figure 8-11 Drive machine data

'LVSOD\ To display the parameters, position the cursor on the appropriate unit and press the
SDUDPHWHU "Parameter display" softkey. For a description of the parameters, please refer to the
documentation of SINAMICS drives.

Figure 8-12 Parameter list

'ULYH
REMHFW
Switch to the respective drive objects.
'ULYH
REMHFW

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System
8.3 SYSTEM - "Machine data" softkeys

9DOXHLQ
KH[ELQ In the note line, the selected value is displayed in hexadecimal and binary values.

)LQG Use these functions to search in the parameter list for the term you are looking for.

&RQWLQXH
ILQG

Display of machine data

'LVSOD\
0'
Open the "Display machine data" window. Use the PageUp / PageDown keys to browse
forward / backward.

Figure 8-13 Display of machine data

&RORU Use the "Softkey color" and "Window color" softkeys to specify user-defined color settings.
FKDQJLQJ The displayed color consists of the components red, green and blue.
The "Change color" window displays the values currently set in the input fields. The desired
color can be produced by changing these values. In addition, the brightness can be
changed.
The next mixing ratio is displayed temporarily upon completion of an input. Use the cursor
keys to switch between the input fields.
With "OK", the settings are accepted and the dialog box is closed. Selecting the "Abort"
softkey will close the dialog box without accepting your changes.

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 System
8.3 SYSTEM - "Machine data" softkeys

&RORU Use this function to change the colors of the tip and softkey area.
6RIWNH\

Figure 8-14 Edit softkey color.

&RORU Use this softkey to change the color of the border of dialog boxes.
:LQGRZ The "Active window" softkey function will assign your settings to the focus window, and the
"Inactive window" function to the non-active window.

Figure 8-15 Edit frame color.

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System
8.4 SYSTEM - "Service display"

8.4 SYSTEM - "Service display"

6HUYLFH The "Service display" window appears on the screen.
GLVSOD\
The start screen for the "Service control" function is shown in the following diagram.

Figure 8-16 The "Service control" start screen

6HUYLFH This window displays information on the axis drive.

D[HV
The "Axis +" or "Axis -" softkeys are additionally displayed. These can be used to display the
values for the next or previous axis.

6HUYLFH
GULYHV
This window displays information in respect of the digital drive.

6HUYLFH
H[W%XV
The window displays information on external bus settings.

6HUYLFH
FRQWURO
Use this softkey function to activate the window for the following functions:
● "Service network" (see chapter "Network operation")
● "Action log" (see chapter "Action log")
● "Service Firewall" (see chapter "Network operation")
● "Direct connect." (see chapter "Network operation")
● "Service MSG" (see chapter "Service MSG")
6HUYLFH This window contains information about
2YHUYLHZ
● Assignment, Machine axis <=> Channel axis <=> Drive number
● The enable status of the NC and drive
● Drive state regarding ready, faults and alarms
6HUYR An oscilloscope function is available in this window to optimize the drives (see chapter
WUDFH "Servo trace").

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 System
8.4 SYSTEM - "Service display"

9HUVLRQ
This window displays the version numbers and the date of creation of the individual CNC
components.
The following functions can be selected from this window (also see chapter "Versions"):
● "HMI details"
● "License key"
● "Options"
● "Save as"
The displayed versions can be saved in a text file

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System
8.4 SYSTEM - "Service display"

8.4.1 Action log

$FWLRQ The function "Action log" is provided for service events. The contents of the action log file
ORJ can only be accessed through a system password on the HMI.

Figure 8-17 Action log

6DYH Irrespective of the system password, it is possible to output the file using softkey "Save
XQGHU under..." on a CF card or on the USB FlashDrive.
In case of difficulties, please contact the hotline (see the "Technical Support" Section in the
preface for contacting the hotline).

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 System
8.4 SYSTEM - "Service display"

8.4.2 Servo trace

6HUYR An oscilloscope function is provided for the purpose of optimizing the drives. This enables
WUDFH graphical representation:
● of the velocity setpoint
● of the contour violation
● of the following error
● of the actual position value
● of the position setpoint
● of exact stop coarse / fine
The start of tracing can be linked to various criteria allowing a synchronous tracing of internal
control states. This setting must be made using the "Select signal" function.
To analyze the result, the following functions are provided:
● Changing and scaling of abscissa and ordinate;
● Measuring of a value using the horizontal or vertical marker;
● Measuring of abscissa and ordinate values as a difference between two marker positions;
● Storing of the result as a file in the part program directory. Thereafter, it is possible to
export the file using either RCS802 or the CF card and to process the data in MS Excel.

Figure 8-18 Servo trace start screen

The header of the diagram contains the current scaling of the abscissa and the difference
value of the markers.
The diagram shown above can be moved within the visible screen area using the cursor
keys.

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System
8.4 SYSTEM - "Service display"

1 Time Base
2 Marker position time
3 Difference in time between marker 1 and current marker position.
Figure 8-19 Meaning of the fields

6HOHFW
VLJQDO Use this menu to parameterize the measuring channel.

Figure 8-20 Select signal

● Selecting the axis: To select the axis, use the "Axis" toggle field.
● "Signal type":
Following error
Controller difference
Contour deviation
Position actual value
Speed actual value
Speed setpoint
Compensation value
Parameter block
Position setpoint controller input
Speed setpoint controller input
Acceleration setpoint controller input
Speed feedforward control value
Exact stop fine signal
Exact stop coarse signal
● "Status":
On: Tracing is performed in this channel
Off: Channel inactive

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 System
8.4 SYSTEM - "Service display"

The parameters for the measuring time and for the trigger type for channel 1 can be set in
the lower screen half. The remaining channels will accept this setting.
● Determining the measuring period: The measuring period in ms is entered directly into
the "Measuring period" input field (6,133 ms max.).
● Selecting the trigger condition: Position the cursor on the "Trigger condition" field and
select the relevant condition using the toggle key.
– No trigger, i.e. the measurement starts directly after selecting the "Start" softkey;
– Positive edge;
– Negative edge
– Exact stop fine reached;
– Exact stop coarse reached
9PDUNRII The "V mark ON" / "V mark OFF"softkeys are used to hide/show the vertical gridlines. Using
the "Select signal" function you can determine the signal to be displayed in the vertical axis.
7PDUNRII
The "T mark ON" / "T mark OFF"softkeys are used to hide/show the horizontal gridlines of
the time axis.

)L[9PDUN
Use the markers to determine the differences in the horizontal or vertical directions. To do
this, place the marker on the start point and press "Fix V mark" or "Fix T mark". The
difference between the starting point and the current marker position is now displayed in the
status bar. The softkey labels will change to "Free V mark" or "Free T mark".

7UDFH
GLVSOD\ This function opens another menu level offering softkeys for hiding / displaying the diagrams.
If a softkey is displayed on a black background, the diagrams are displayed for the selected
trace channel.

7LPH
VFDOH Use this function to zoom in / zoom out the time basis.

9HUWLFDO
VFDOH
Use this function to increase / reduce the resolution (amplitude).

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8.4 SYSTEM - "Service display"

0DUNHU Use these softkeys to define the step sizes of the markers.
VWHSV

Figure 8-21 Marker steps

The markers are moved using the cursor keys at a step size of one increment. larger step
sizes can be set using the input fields. The value specifies how many grid units the marker
must be moved per "SHIFT" + cursor movement. When a marker reaches the margin of the
diagram, the grid automatically appears in the horizontal or vertical direction.

)LOH
VHUYLFH
Use this softkey to save or load trace data.

Figure 8-22 Trace data

Type the desired file name without extension in the "File name" field.
Use the "Save" softkey to save the data with the specified name in the part program
directory. Thereafter, the file can be exported, and the data can be processed in MS Excel.
"Load" loads the specified file and graphically displays the data.

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8.4 SYSTEM - "Service display"

8.4.3 Version/HMI details

9HUVLRQ
This window displays the version numbers and the date of creation of the individual CNC
components.

Figure 8-23 Version

Note
The version releases shown in the version screen shot are for example only.

6DYH
XQGHU Saves the contents of the "Version" window in a text file. The target (e.g. "customer CF
card") can be selected.

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8.4 SYSTEM - "Service display"

+0, The "HMI details" menu is intended for servicing and can only be accessed via the user
'HWDLOV password level. All programs provided by the operator unit are displayed with their version
numbers. By reloading software components, the version numbers can be differ from each
other.

Figure 8-24 The "HMI version" menu area

5HJLVWU\
'HWDLOV This "Registry details" function displays the assignment of the hard keys (operating area
keys POSITION (machine), OFFSET PARAM (parameter), PROGRAM (program),
PROGRAM MANAGER (progman), ...) for the programs to be started in the form of a list. For
the meanings of the individual columns, please refer to the table below.

Figure 8-25 Registry details

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8.4 SYSTEM - "Service display"

Note
After the system has booted, the control system automatically starts the <POSITION>
operating area. If a start behavior is required, the "Change ready to start" function allows
defining another starting program.
The starting operating area is then displayed above the table in the "Registry Details"
window.

)RQW
'HWDLOV
The "Font details" function displays the data of the loaded character sets in the form of a list.

Figure 8-26 Font details

OLFHQVH Entering the license key.

NH\

Figure 8-27 License key

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System
8.4 SYSTEM - "Service display"

References
SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Licensing
in SINUMERIK 802D sl
2SWLRQV Setting the licensed options.

Figure 8-28 Options

References
SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Licensing
in SINUMERIK 802D sl
1&.UHVHW
SR
Executes a warm restart at the control.

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8.4 SYSTEM - "Service display"

8.4.4 Service MSG

6HUYLFH The "Service MSG" function allows message texts/messages to be output via the following
06* interfaces:
● Output via the RS232 interface (V24) as data stream without protocol
● Output in a file
Message texts/messages include:
● Alarms
● Texts of MSG commands
The message texts/messages are programmed in the part program using a specified syntax.
The particular syntax is described in the following table:

Table 8- 2 Syntax of the message texts/messages

Output Syntax ("<interface>: Message text")

via RS232 interface (V24) MSG ("V24: Message text")
in a file MSG ("File: Message text")
Alarm line at the HMI MSG ("Alarm text")
The MSG text output is defined using the MSG command as well as by appropriately
parameterizing the output interface. For the alarm output, only the output interface has to be
taken into consideration.
If the information line "Processing error MSG command occurred" is output, then the error
protocol can be evaluated under the operating area <SYSTEM> > "Service display" >
"Service control" > "Service MSG" > "Error protocol".

Figure 8-29 Dialog box, Service MSG

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8.4 SYSTEM - "Service display"

Settings for output via the RS232 interface

6HWWLQJ
56
Settings of the RS232 output interface.

Figure 8-30 Dialog box, RS232 interface settings

"Sending messages via this interface can be activated or deactivated using the "Send via
RS232" checkbox. Incoming messages are ignored when the interface is deactivated!

Note
When transferring a file via a serial interface (RS232), please note the end of transmission
character for RS232 communication (analog to the communication setting, RS232 on HMI).

Further, when sending via RS232, it can be defined as to which messages are sent for which
events:
● Programmed messages from the part program
● An alarm has occurred
The settings are saved and the dialog box exited by pressing the "OK" softkey.
The dialog box is exited without saving by pressing "Cancel".

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8.4 SYSTEM - "Service display"

To transfer messages via the RS232 interface, the communication settings from the
operating area <SYSTEM> > "Start-up files" > "RS232" > "Settings" are used.

Figure 8-31 Parameters of the RS232 interface

Note
When using the MSG service via RS232, the RS232 interface must not be active for another
application.
The means, e.g. the RS232 interface must not be active from the operating area <SYSTEM>
"PLC" > "Step7 connect."

Settings to output in a file

6HWWLQJ
)LOH
Settings for the file storage location.

Figure 8-32 Dialog box, file settings

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System
8.4 SYSTEM - "Service display"

Sending messages to the selected file is activated or deactivated using the "Send to file"
checkbox. When the interface is deactivated, messages are not output and the information
line "Processing error MSG command occurred".
A path, the file name and the max. size of the file can be selected.
Drive D (customer CF card), F: (USB drive) and the drive connected per RCS connection
can be selected in the "Path" input field.
10kByte, 100kByte and 1MByte can be selected as max. file size. When the max. size is
reached, the file is written as ring buffer, i.e. at the beginning, as many lines are deleted line-
by-line as is required by the new message at the end of the file.
Here, when sending to a file, it can be defined as to which messages are sent for which
events:
● Programmed messages from the part program
● An alarm has occurred
The settings are saved and the dialog box exited by pressing the "OK" softkey.
The dialog box is exited without saving by pressing "Cancel".

Error log

(UURU
ORJ
Error log display.

Figure 8-33 Dialog box, error log

All messages with the associated error information, where an error occurred when
processing them, are saved in the error log.
The error log can be deleted using the "reset" softkey.

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8.4 SYSTEM - "Service display"

The dialog box is closed by pressing "Back".

Note
The error log can be used for analysis when the information line "Processing error MSG
command occurred" is output.

Example of programming using the "MSG" command

For SINUMERIK 802D sl, messages programmed in the NC program are displayed in the
alarm display as standard.

Table 8- 3 Activating/deleting messages

N10 MSG ("Roughing the contour") ; The text "Roughing the contour"
is displayed in the alarm display
N20 X… Y… N …
N…
N90 MSG () ; Delete message from the alarm
display

Table 8- 4 Message text contains a variable

N10 R12=$AA_IW[X] ; Actual position of the X axis in

R12
N20 MSG ("Check position of X axis"<<R12<<) ; Activate message
N20 X… Y… N …
N…
N90 MSG () ; Delete message from the alarm
display

To output messages to other interfaces, an additional command is located in front of the

actual message text that defines the output interface of this message.

Table 8- 5 Messages to the RS232 output interface

N20 MSG ("V24: Roughing the contour") ; The text "Roughing the contour" is
sent in the ASCII format via the
RS232 interface

Table 8- 6 Messages to the output interface file

N20 MSG ("FILE: Roughing the contour") ; The text "Roughing the contour" is
sent to the selected file

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8.4 SYSTEM - "Service display"

Note
If, in the part program, the text for the messages is repeated unchanged, then after each
output, a command for an empty text must be entered.
e.g.
...
MSG("<interface>: Sample text")
MSG("<interface>:")
...
...
MSG("<interface>: Sample text")
MSG("<interface>:")
...
...
MSG("<interface>: Sample text")
MSG("<interface>:")

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8.5 SYSTEM - "PLC" softkeys

8.5 SYSTEM - "PLC" softkeys

3/& This softkey provides further functions for diagnostics and commissioning of the PLC.

&RQQHFWWR
67(3 This softkey opens the configuration dialog for the interface parameters of the STEP 7
connection using the RS232 interface of the control system.
If the RS232 interface is already occupied by the data transfer, you can connect the control
system to the PLC802 programming tool on the programming device/PC only if the
transmission is completed.
The RS232 interface is initialized with activation of the connection.

Figure 8-34 Communication settings

The baud rate is set using the toggle field. The following values are possible: 9600 / 19200 /
38400 / 57600 / 115200.

Note
The appropriate connection symbol is displayed at the bottom right after the connection has
been established. The communication setting can then no longer be changed.

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8.5 SYSTEM - "PLC" softkeys

Modem
If the data transfer is performed on the RS232 interface via modem, start with the following
initialization option:

Figure 8-35 Initialize the modem

The following initializations are possible via toggle fields:

● Baud rate
9600 / 19200 / 38400 / 57600 / 115200.
● Parity:
"without" for 10 bit
"odd" for 11 bit
Using the "Modem settings" softkey you can make the following additional settings for a
connection that does not yet exist:

Figure 8-36 Modem settings

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8.5 SYSTEM - "PLC" softkeys

You can select the following modem types via toggle field:
● Analog modem
● ISDN box
● Mobile phone

Note
The types of both communication partners must match with each other.

When you want to enter several AT command sets, you have to start with AT only once and
simply have to add all other commands, e.g. AT&FS0=1E1X0&W.
Refer to the manufacturers' manuals to look up the commands and their parameters, as they
sometimes differ even between the devices of one manufacturer. The default values of the
control system are therefore only a real minimum and should be verified in any case before
they are used for the first time.
&RQQHFW
RQ
Use this softkey to activate the connection between the control system and the programming
device/PC. The program waits for the call of Programming Tool PLC802. No modifications to
the settings are possible in this state.
The softkey label changes to "Connection inactive".
By pressing "Connection inactive", the transfer from the control system can be terminated at
any point. Now it is possible again to make changes in the settings.
The active or inactive state is kept even after Power On (except power-up with the default
data). An active connection is displayed by a symbol in the status bar.
Press "RECALL" to exit the menu.

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System
8.5 SYSTEM - "PLC" softkeys

Additional functions

3/&
VWDWXV
Use this function to display and change the current states of the memory areas listed in the
following table.
It is possible to display 16 operands at the same time.

Table 8- 7 Memory areas

Inputs I Input byte (IBx), input word (Iwx), input double-word (IDx)
Outputs Q Output byte (Qbx), output word (Qwx), output double-word (QDx)
Flags M Flag byte (Mx), flag word (Mw), flag double-word (MDx)
Times T Time (Tx)
Meters C Counter (Cx)
data V Data byte (Vbx), data word (Vwx), data double-word (VDx)
Format B Binary
H Hexadecimal
D Decimal
The binary representation is not possible with double words. Counters and timers
are represented decimally.

Figure 8-37 PLC status display

2SHUDQG

The operand address displays the value incremented by 1.

2SHUDQG

The operand address displays the value respectively decremented by 1.

'HOHWH Use this softkey to delete all operands.

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8.5 SYSTEM - "PLC" softkeys

Cyclic updating of the values is interrupted. Then you can change the values of the
&KDQJH
operands.

6WDWXV
OLVW
Use the "Status list" function to display and modify PLC signals.
There are 3 lists to choose from:
● Inputs (default setting) left-hand list
● Flags (default setting) center list
● Outputs (default setting) right-hand list
● Variable

Figure 8-38 PLC status list

&KDQJH Use this softkey to change the value of the highlighted variable. Press the "Accept" softkey
to confirm your changes.

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System
8.5 SYSTEM - "PLC" softkeys

(GLW Use this softkey to assign the active column a new area. To this end, the interactive
SDG screenform offers four areas to choose from. For each column, a start address can be
assigned which must be entered in the relevant input field. When you quit the interactive
screenform, the control system will save your settings.

Figure 8-39 The "Data type" selection screen

Use the cursor keys and the "Page Up" / "Page Down" keys to navigate in and between the
columns.

3/&
SURJUDP PLC diagnosis using a ladder diagram (see chapter "PLC diagnosis using a ladder
diagram").

3URJUDP
OLVW Using the PLC, you may select part programs and run them via the PLC. To this end, the
PLC user program writes a program number to the PLC interface, which is then converted to
a program name using a reference list. It is possible to manage max. 255 programs.

Figure 8-40 PLC program list

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8.5 SYSTEM - "PLC" softkeys

This dialog displays all files of the MPF directory and their assignment in the reference list
(PLCPROG.LST) in the form of a list. You can use the TAB key to switch between the two
columns. The Copy, Insert and Delete softkey functions are displayed with reference to a
specific context. If the cursor is placed on the left-hand side, only the Copy function is
available. On the right-hand side, the Insert and Delete functions are provided to modify the
reference list.

List of references for interface signals

SINUMERIK 802D sl Function Manual; Various Interface Signals (A2)
SINUMERIK 802D sl List Manual

&RS\ Writes the selected file name to the clipboard.

3DVWH Pastes the file name at the current cursor position.

'HOHWH Deletes the selected file name from the assignment list.
Structure of the reference list (file PLCPROG.LST)
It is divided into 3 areas:

Number range Protection level

1 to 100 User area User
101 to 200 Machine manufacturer Machine manufacturer
201 to 255 Siemens Siemens
The notation is carried out for each program by lines. Two columns are intended per line,
which must be separated from each other by TAB, space or the "|" character. In the first
column, the PLC reference number must be specified, and in the second column, the file
name.
Example:
1 | shaft.mpf
2 | taper.mpf

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System
8.5 SYSTEM - "PLC" softkeys

(GLW3/& This function can be used to insert or modify PLC user alarm texts. Select the desired alarm
DODUPW[W number using the cursor. At the same time, the text currently valid is displayed in the input
line.

Figure 8-41 Editing the PLC alarm text

Enter the new text in the input line. Press the "Input" key to complete your input and select
"Save" to save it.
For the notation of the texts, please refer to the operating instructions.

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 System
8.6 SYSTEM - "Start-up files" softkeys

8.6 SYSTEM - "Start-up files" softkeys

6WDUWXS
ILOHV The menu allows general files, commissioning archives and PLC projects to be created,
read-out or read-in, copied, deleted etc.
This window displays the contents of the selected drive in a tree structure. The horizontal
softkeys display the available drives for selection in the form of a list. The vertical softkeys
provide the control functions possible for the drive in question.
There are the following permanently set drive assignments:
● 802D data: Commissioning data
● Customer CF card: Customer data on the CF card
● RCS connection: Data of a drive released on PC/PG via the the RCS tool (only for
SINUMERIK 802D sl pro)
● RS232: Serial Interface
● Manufacturer drive: Data that the manufacturer specifically stored
● USB drive: Customer data on a USB FlashDrive
● Manufacturer archive: Commissioning data archived on the system CompactFlash Card
All data is handled using the "Copy & Paste" principle.

Figure 8-42 Start-up files

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System
8.6 SYSTEM - "Start-up files" softkeys

'GDWD The individual data groups in the "802D data" area have the following significance:

Note
The sag compensation is ONLY listed if the associated function was activated.

● Data (in text format)

These data are special initialization data and are transferred in an ASCII file.
– Machine data
– Setting data
– Tool data
– R parameters
– Work offset
– Leadscrew error compensation
– Sag compensation
– Global user data
● Commissioning archive (drive/NC/PLC/HMI)
These data constitute a commissioning file for HMI data and are transferred in the binary
format using the HMI archive format.
– Drive machine data
– NC data
– NC directories
– Display machine data
– Leadscrew error compensation
– Sag compensation
– PLC project
– HMI data and applications
● PLC project (*.PTE)
A direct exchange between the control system and programming tool is possible without
conversion with the support of PLC project handling in the programming tool export
format.
● File for license key
&XVWRPHU Reading-in and reading-out data on a CompactFlash Card (CF card).
&)FDUG

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8.6 SYSTEM - "Start-up files" softkeys

5&6 Reading-in and reading-out data to a PG/PC via a network. The RCS tool must be installed
FRQQHFW on the PG/PC (only for SINUMERIK 802D sl pro).

Note
The RCS tool provides a detailed online help function. Refer to this help menu for further
details e.g. establishing a connection, project management etc.

56 Reading-in and reading-out data via the RS232 interface.

0RUH


(UURU
ORJ
Note
Using the softkey function "Continue...", you may also inspect the transmission log. The
"Error log" function is available for that.

6HW
WLQJ
Use this function to display and change the RS232 interface parameters. Any changes in the
settings come into effect immediately.
Selecting the "Save" softkey will save the selected settings even beyond switching off.
The "Default settings" softkey will reset all settings to their default settings.

Figure 8-43 Parameters of the RS232 interface

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System
8.6 SYSTEM - "Start-up files" softkeys

Interface parameters

Table 8- 8 Interface parameters

Parameter Description
Device type RTS CTS
The signal RTS (Request to Send) controls the send mode of the data transfer
device.
The CTS signal indicates the readiness to transmit data as the acknowledgment
signal for RTS.
Baud rate ... used to set the interface transmission rate.
300 baud
600 baud
1200 baud
2400 baud
4800 baud
9600 baud
19200 baud
38400 baud
57600 baud
115200 baud
Stop bits Number of stop bits with asynchronous transmission
Input:
1 stop bit (default setting)
2 stop bits
Parity Parity bits are used for error detection. These are added to the coded character to
convert the number of digits set to "1" into an odd or even number.
Input:
No parity (default setting)
Even parity
Odd parity
Data bits Number of data bits with asynchronous transmission
Input:
7 data bits
8 data bits (default)
Overwriting Y: When reading in, it is checked whether the file already exists in the NC.
with N: The files are overwritten without confirmation warning.
confirmation

0DQXIDF
WXUHUGULYH Reading-in and reading-out data of the manufacturer's directory "F".

86%
GULYH Reading-in and reading-out data of a USB FlashDrive.

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8.6 SYSTEM - "Start-up files" softkeys

PDQX Use this function to create/restore a commissioning archive on/from the system
DUFKLYH CompactFlash Card.
No archive file has been created in the following display. The symbol for the zip archive
sends a signal with an exclamation mark.

Figure 8-44 Manufacturers` archive, archive file not yet created

Vertical softkeys
The following vertical softkeys are available upon activating the file functions:
● "Rename": Use this function to rename a file selected beforehand using the cursor.
● "New directory": Creates a new directory
● "Copy": Use this softkey to copy one or more files to the clipboard.
● "Paste": Use this softkey to paste files or directories from the clipboard to the current
directory.
● "Delete": Deletes the selected file name from the assignment list.
● "Select all": Use this softkey to select all files for subsequent operations.
● "Properties": Display memory capacity.
● "Job list": Displays a list with active file jobs and provides the option to terminate or
display a file job.
0RUH Use this function to switch to the respective vertical softkeys.


Note
If individual functions are grayed out, then these functions are not available for the displayed
drive/directory.

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System
8.7 Alarm display

8.7 Alarm display

Operating sequence

6<67(0
The alarm window is opened. You can sort the NC alarms using softkeys; PLC alarms will
$/$50 not be sorted.

Figure 8-45 Alarm display window

Softkeys

+LJKHVW
SULRULW\
Use this softkey to display all alarms sorted by their priorities. The highest priority alarm is at
the beginning of the list.

0RVWUHF
DODUP
Use this softkey to display the alarms sorted by the time of their occurrence. The most recent
alarm stands at the beginning of the list.

2OGHVW
DODUP
Use this softkey to display the alarms sorted by the time of their occurrence. The oldest
alarm stands at the beginning of the list.

6WRS
XSGDWLQJ
Updating of pending alarms is stopped / started.

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 System
8.7 Alarm display

$ODUPORJ All alarms are logged.

Figure 8-46 Alarm log

The log is deleted using softkey "Delete log".

6DYH
XQGHU The file is output using softkey "Save under..." on a CF card or on the USB FlashDrive.

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System
8.7 Alarm display

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Cycles 9
9.1 Overview of cycles
Cycles consist of technology subroutines.
You can use cycles for general implementation of a certain machining process, such as
plunge-cut grinding, dressing, or longitudinal grinding.
These cycles are adapted to individual tasks by parameter assignment.
In principle, grinding involves two different types of technological sequence:
● Dressing the grinding wheel
● Grinding the workpiece
The dressing and grinding machining operations are achieved by means of NC cycles.
Grinding tools need to be dressed after a certain time in service to compensate for worn
wheels and to restore their original profile.
Dressing of a wheel pursues two objectives:
● Profiling is aimed at achieving the required wheel shape.
● Sharpening is aimed at restoring the wheel's ability to cut.
The workpiece grinding cycles enable surface grinding with the Y/Z infeed axes (right-
angled).

Grinding cycles
The SINUMERIK 802D sl controller supports the following cycles for surface grinding:

CYCLE406 Z positioning with grinding wheel

CYCLE407 Safety position approaching
CYCLE408 3-stage plunge-cut oscillation (roughing, finishing and fine-finishing)
CYCLE409 3-stage surface grinding (roughing, finishing and fine-finishing)
CYCLE416 Dressing and profiling
CYCLE426 Oscillating plunge cutting
CYCLE427 Surface grinding with continuous infeed
CYCLE428 Surface grinding with intermittent infeed
CYCLE429 Profile grinding
CYCLE430 Dressing with profile roller
CYCLE446 Selection of grinding wheel peripheral speed
The cycles are supplied with the tool box. They are loaded via the RS232 interface into the
part program memory during the start-up of the control system.

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Cycles
9.1 Overview of cycles

Operation while a machining cycle is underway

All cycles are compatible with both automatic infeed and handwheel infeed. You have the
option of interrupting the machining process while it is underway and forcing intermediate
dressing.

Note
The possible operations (e.g. intermediate dressing) are assigned to the keys of the CNC
machine control panel by the machine manufacturer.

Further processing then takes place on the basis of a preliminary dimensional value.
If a cycle is parameterized, then the icons above the parameter sketch will indicate the
corresponding possible operations that are available (see figure below).

Figure 9-1 Parameter sketch for a cycle

What the icons mean:

Interrupt cycle with adoption of retraction position and off-loading

Intermediate dressing with off-loading

Handwheel infeed possible in Y direction

Handwheel infeed possible in Z direction

Note
The functions associated with the icons (e.g. "interrupt cycle") remain effective all the time
that there is an infeed amount available.
The "interrupt cycle" function also applies during air grinding.

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 Cycles
9.2 Cycle requirements

9.2 Cycle requirements

Prerequisites
The following requirements must be met in respect of the individual grinding cycles:
1. The machining plane must be active.
In principle, all planes are possible with surface grinding.
However, G19 is selected by default, as it is the option required for dressing (Y/Z).
This plane is also activated for the purpose of selecting the geometry axes.
However, other planes (G17, G18) can be active within the context of the process.
The relationship between the planes depends on the infeed axis and the relevant
oscillating axis/axes.
2. A tool number and the associated tool offset must be programmed before the cycle is
called.
3. The grinding wheel peripheral speed is calculated from the parameters that contain the
peripheral speeds in CYCLE446.
4. The file called SGUD_MA.DEF contains default values for all the machine-specific M
commands, such as those that relate to the direction of spindle rotation, coolant and
measuring device switching.
These values can be changed by the machine manufacturer.
5. In addition to assigning values for the grinding wheel and dresser offset data, the tool-
specific grinding data must also be defined.
6. For example, in order to determine the initial infeed value, the computational resolution
must be at least 10 times higher than the input resolution in the display machine data so
that the start position can be calculated for surface grinding.
The following machine data is used for the computational resolution:
– Computational resolution
MD10200 INT_INCR_PER_MM (computational resolution for linear positions) or
MD10210 INT_INCR_PER_DEG (computational angular resolution)
– Input resolution
MD203 DISPLAY_RESOLUTION (display resolution) or
MD204 DISPLAY_RESOLUTION_INCH (display resolution for inch measuring
system)

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Cycles
9.3 Programming cycles

9.3 Programming cycles

A cycle is defined as a subroutine with a name and parameter list assigned.

9.3.1 Call and return conditions

The G functions effective prior to the cycle call and the programmable offsets remain active
beyond the cycle.
The machining level (G17, G18, G19) must be defined before calling the cycle. A cycle
operates in the current plane with the following axes:
● 1st axis of the plane (abscissa)
● 2nd axis of the plane (ordinate)
● Tool axis/infeed axis, 3rd axis, standing vertically to the plane (applicate).

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Command Plane Vertical infeed axis

G17 X/Y Z
G18 Z/X Y
G19 Y/Z X

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 Cycles
9.3 Programming cycles

9.3.2 Error messages and error handling

9.3.2.1 General information

If error conditions are detected in the cycles, an alarm is generated and the execution of the
cycle is aborted.
The cycles continue to output messages in the dialog line of the control. These message will
not interrupt the program execution.

Reference
For more information on errors and required responses, as well as messages output in the
controller's dialog line, please refer to the SINUMERIK 802D sl Diagnostics Manual.

9.3.2.2 Error handling within cycles

Alarms with numbers between 61000 and 62999 generated in the cycles. This range of
numbers, in turn, is divided again with regard to alarm responses and cancel criteria. The
error text that is displayed together with the alarm number gives you more detailed
information on the error cause.

Alarm number Clearing Alarm Response

criterion
61000 ... 61999 NC_RESET Block preparation in the NC is aborted
62000 ... 62999 Clear key Program execution is not interrupted; display only

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Cycles
9.3 Programming cycles

9.3.3 Cycle call and parameter list

The cycles use user-defined variables. The defining parameters for the cycles can be
transferred via the parameter list when the cycle is called.

Note
Cycle calls must always be programmed in a separate block.

Basic information on assigning parameters to cycles

The Programming Guide describes the parameter list of every cycle with the
● order and the
● type.
It is imperative to observe the order of the defining parameters.
Each defining parameter of a cycle has a certain data type. The parameter being used must
be specified when the cycle is called. In this parameter list, the following can be transferred:
● R parameters
● Constants
If R parameters are used in the parameter list, they must first be assigned values in the
calling program. Proceed as follows to call the cycles:
● With an incomplete parameter list or
● By leaving out parameters
If you want to exclude the last transfer parameters that have to be written in a call, you can
prematurely terminate the parameter list with ")". If any parameters are to be omitted within
the list, a comma "..., ,..." must be written as a placeholder.

Note
No plausibility checks are made of parameter values with a discrete or limited value range
unless an error response has been specifically described for a cycle.
If a cycle is called the parameter list of which contains more entries than parameters defined
in the cycle, the general NC alarm 12340 "Too many parameters" is displayed and the cycle
is not executed.

Cycle call
The individual methods for writing a cycle are shown in the programming examples provided
for the individual cycles.

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 Cycles
9.3 Programming cycles

Hardware prerequisites
The grinding machine must meet additional hardware requirements before any grinding
cycles can be used.
One or two handwheels are required for motion overlay during setup.
There must be connection options for the following external equipment:
● Acoustic emission sensor
● Measurement control
● Touch trigger probe
● 7 rapid inputs via MCPA for:
– Measurement control (5 inputs)
– Acoustic emission sensor (2 inputs)

Call and return conditions

The grinding cycles are programmed independently of the actual axis names. The collions-
free approach to the grinding position is to be done in the higher-level program before the
cycle is called.
The required values for spindle speed and direction of spindle rotation must be programmed
in the part program if there are no defining parameters in the grinding cycle.
The G functions active prior to the cycle call remain active beyond the cycle.

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Cycles
9.3 Programming cycles

Coordinate systems for grinding

In general, CNC grinding machines have separate coordinate systems for grinding and
dressing. The zero points of both coordinate systems must be defined once when setting up
the machine.
The workpiece zero is defined by the operator when setting up the machine, by scratching
the workpiece in all necessary axes. All additional geometric specifications for creating the
automatic program refer to this zero point.
The dresser zero is defined during setup by scratching the wheel with the dressing
diamonds. It serves as a reference point for the dressing program.

* ;

' B*&B'180
=

' B*&B'180 ' B*&B'180

Figure 9-2 Coordinate systems for grinding

Plane definition
Before using the grinding cycles, G507 must be activated. Typically, the infeed axis is the
first geometry axis.
A tool length compensation must be selected before the cycle is called. Tool length
compensation is always effective in the selected plane and remains active even after the end
of the cycle.

Types of grinding wheels

The cycles support two types of grinding wheels: vertical and inclined wheels.
During machining, the wheel feeds only in the Y or Z direction.

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 Cycles
9.3 Programming cycles

The use of measuring devices and sensors

When grinding, the following measuring devices/sensors can be used:
● Measuring probe
● Measurement control
● Acoustic emission sensor
Using a swiveling measuring probe, a longitudinal position in Z is detected. This axis position
is stored on a parameter and aids in calculating the errors that occur in the compensation for
each workpiece.
Measurement control is performed at the same time as the grinding machining on the
workpiece diameter. The measurement control switches over the feedrate or defines the end
position at the allowance coordinates in Y for roughing, finishing and fine finishing.
The acoustic emission sensor implements the feedrate stop when the workpiece diameter
sparkles. Time-optimized approach conditions are created.

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Cycles
9.4 Zyklenunterstützung im Programmeditor

9.4 Zyklenunterstützung im Programmeditor

The program editor provides programming support for adding cycle calls to the program and
for entering parameters.

Function
The cycle support offers the following functions:
● Cycle selection via soft keys
● Input screen forms for parameter assignment with help displays
Decompilable program code is generated from the individual screens.

Summary of required files

The following files constitute the basis for cycle support:
● sc.com
● cov.com

Note
These files are loaded during the start-up of the control system and must always remain
loaded.

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 Cycles
9.4 Zyklenunterstützung im Programmeditor

Operating the cycle support

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Figure 9-3 Menu tree for cycle support

To add a cycle call to the program, carry out the following steps one after the other:
● From the horizontal softkey bar, selection bars for the individual cycles can be selected
using the <Grinding cycles> softkey.
● To select a cycle, keep using the vertical softkey bar until the appropriate input screen
plus help display appears on the screen.
● Number values can be directly entered. Entered values are verified for proper range.
● Some parameters that may have only a few values are selected using the toggle key.
● Press <OK> to complete your input (or <Abort> in case of error).

Recompiling
Recompiling of program codes serves to make modifications to an existing program using
the cycle support.
Position the cursor on the line to be modified and select the <Recompile> softkey. This will
reopen the corresponding input screen from which the program piece has been created, and
you can modify and accept the values.

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Cycles
9.5 Z positioning with grinding wheel - CYCLE406

9.5 Z positioning with grinding wheel - CYCLE406

Programming
CYCLE406( N_SITZ, CLEAR, CAL, Z_LPOS, MODE, Y_POS, Z_POS, ZSTW, A_Z, F_LU,
F_SR, N_FR, FX, XSTART, XENDE)

Parameters

Table 9- 1 Parameter CYCLE406

Parameters Data type Meaning

N_SITZ INT Seat number
CLEAR INT Deletes the old offset prior to the approach
CAL INT Sets axis to Z position at end
Z_LPOS INT Retraction direction
MODE INT Type of approach:
0 = Sensor+Handwheel
1 = Sensor+ measurement
2 = Handwheel only
3 = Handwheel+measurement
Y_POS REAL Height
Z_POS REAL Z position for setting value
ZSTW REAL Z offset
A_Z REAL Z allowance after contact
F_LU REAL Feedrate for sparking, per stroke
F_SR REAL Grinding feedrate, per stroke
N_FR REAL Sparking-out strokes with oscillation
FX REAL X axis feedrate
XSTART REAL X axis starting position
XENDE REAL X axis end position

Function
This cycle is used for approaching and setting a Z position with the grinding wheel.

Sequence
The cycle moves to the Z preliminary position and commences the approach either with an
optional acoustic emission sensor or just with the handwheel.
Once contact has been detected, grinding is performed, either in accordance with a
handwheel value or in relation to the contact point.
Once the end point is reached, if the CAL parameter is set to "1", the Z axis will be set to the
Z position.

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 Cycles
9.5 Z positioning with grinding wheel - CYCLE406

If no acoustic emission sensor input has been configured, the cycle will immediately switch
to the handwheel at the start of the operation, provided that an air grinding feedrate exists.

Sketch of the geometry parameters

Figure 9-4 Z positioning with grinding wheel - CYCLE406

Programming example
Machining sequence:
● Inching at position -100.0000 mm to Y position -20.0000 mm, old offset is deleted first
and axis value is set at the end point.
● The handwheel is used exclusively for the infeed.
● If an automatic infeed is selected, it will be implemented on a per-stroke basis.
● The start position is at -110.000 mm.
● The table feedrate is 30,000 mm/min between points -350 and 100 (450 oscillating path).
● Sparking-out strokes are performed when infeed is aborted.
● In the example below, which illustrates the next step, the sequence continues with a 3-
stage oscillating plunge cutting cycle. This will always grind away 50 micrometers,
because the axis has been calibrated to -100 mm in advance.

N10 T2D2
N20 CYCLE446( 20)
N30 CYCLE406( 0, 1, 1, -1, 2, -20, -100, 10, 0.1, 3, 0.1, 1, 30000, -350, 100)
N40 CYCLE408( 0, 100, -350, -20, -99.95, 0, 0, 0, 0, 0, -0.05, 0.02, 0.005, 0, 0.01,
0.002, 0.001, 1, 1, 5, 0, 1, 0, 0, 0.01, 30000, 30000, 30000, 30000)
N50 M30

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Cycles
9.6 Safety position - CYCLE407

9.6 Safety position - CYCLE407

Programming
CYCLE407(YS, STORE, KOORD)

Parameters

Table 9- 2 Parameters of CYCLE407

Parameter Data type Meaning

YS REAL Retraction position mm
STORE INT Stores position globally 0/1
KOORD INT Position in WCS=1 and in MCS=0

Function
This cycle is used for approaching a safety position during the grinding process or during
interruptions such as intermediate dressing.

Sequence
The cycle checks the current position and approaches it if the infeed axis is smaller than the
value entered.
The position is approached in accordance with the KOORD parameter in the workpiece or
machine coordinate systems (basic coordinates).

Sketch of the geometry parameters

Figure 9-5 Safety position - CYCLE407

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 Cycles
9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408

9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) -

CYCLE408

Programming
CYCLE408( N_SITZ, XSTART, XEND, YEND ZEND, KS, Y_A_LU, Y_A_SR, Y_A_SL,
Y_A_FS, Z_A_LU, Z_A_SR, Z_A_SL, Z_A_FS, LUZ, SRZ, SLZ, FSZ, N_SR, N_SL, N_FS,
D_SR, D_SL, D_FS, ESL, EFS, FX_SR, FX_SL, FX_FS, FR)

Parameters

Table 9- 3 Parameters of CYCLE408

Parameter Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
XEND REAL X axis end position (abs)
YEND REAL Y position of wheel, finished dimension (abs)
ZEND REAL Z position of wheel (abs), finished dimension
KS INT Acoustic emission sensor
Y_A_LU REAL Air grinding allowance (incr.)
Y_A_SR REAL Roughing allowance (incr.)
Y_A_SL REAL Finishing allowance (incr.)
Y_A_FS REAL Fine-finishing allowance (incr.)
Z_A_LU REAL Air grinding allowance (incr.)
Z_A_SR REAL Roughing allowance (incr.)
Z_A_SL REAL Finishing allowance (incr.)
Z_A_FS REAL Fine-finishing allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Roughing feedrate, per stroke
SLZ REAL Finishing feedrate, per stroke
FSZ REAL Fine-finishing feedrate, per stroke
N_SR INT Sparking-out strokes following roughing
N_SL INT Sparking-out strokes following finishing
N_FS INT Sparking-out strokes following fine-finishing
D_SR INT Dressing strokes prior to roughing
D_SL INT Dressing strokes prior to finishing
D_FS INT Dressing strokes prior to fine-finishing
ESL INT Off-loading prior to finishing
EFS INT Off-loading prior to fine-finishing
FX_SR REAL X feedrate, roughing
FX_SL REAL X feedrate, finishing
FX_FS REAL X feedrate, fine-finishing
FR REAL Y feedrate/Z feedrate

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Cycles
9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408

Function
The 3-stage plunge-cut cycle is called for the purpose of machining a slot or surface that is
smaller than the wheel width.
It can also be used for grinding front faces. The surface concerned is ground using the
oscillation method.
Infeed takes place at the reversal points. Intermediate dressing, interruption and use of the
handwheel are all supported.
The keys will only ever respond at the end point.
At the end, the tool retracts to the allowance position.
Infeed is possible in the Y or Z directions and the Z value can be either negative or positive.
A higher infeed amount can be used at the start of machining. Once contact has been
detected using an acoustic emission sensor, the tool will retract by the acoustic emission
sensor infeed amount minus the grinding infeed amount. If no acoustic emission sensor input
has been configured, the cycle will immediately switch to the handwheel at the start of the
operation.
The cycle automatically divides cutting into roughing, finishing and fine-finishing. Sparking-
out strokes can be programmed for the end of each stage.
Off-loading is also possible at the end of the roughing and finishing stages.
Dressing strokes can be programmed to take place prior to each technology step.

Sequence
Traverse to allowance position.
Approach X starting position and Z position.
Start oscillating motion, infeed at reversal points.
The first infeed once oscillating motion has commenced is adjusted to ensure that all
additional infeed operations correspond to the infeed amount. This process is also performed
following interruptions, intermediate dressing and deselection of the handwheel override
function.
Following interruption/dressing, an off-loading value is applied as the tool approaches the
machining start point.
At the end, the tool retracts to the allowance position.

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 Cycles
9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408

Sketch of the geometry parameters

Figure 9-6 3-stage plunge cut workshop cycle (roughing, finishing and fine-finishing) - CYCLE408

Programming example - 1
Machining sequence:
● Plunge cut in Y direction at a peripheral speed of 20 m/s.
● In part program block N30: allowance of 0.1 mm, acoustic emission sensor, and 0.1 mm
standard infeed, finishing reversing point 0.05 mm, fine-finishing reversing point 0.01 mm.
● Infeed of 0.03 mm per stroke with acoustic emission sensor and 0.02 mm infeed for
roughing, 0.01 mm infeed for finishing, and 0.002 mm infeed for fine-finishing.
● 1 sparking-out stroke following roughing, 2 strokes following finishing, and 3 strokes
following fine-finishing.
● Single-stroke dressing for finishing and fine-finishing respectively.
● Off-loading value of 0.03 mm following roughing and 0.015 mm following finishing.

N10 T1D1
N20 CYCLE446( 20)
N30 CYCLE408( 0, 100, -100, 0, 0, 0, 0.1, 0.1, 0.05, 0.01, 0.1, 0, 0.05, 0.01, 0.03,
0.02, 0.01, 0.002, 1, 2, 3, 0, 1, 1, 0.03, 0.015, 30000, 29000, 28000, 3000)
N40 M30

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Cycles
9.7 3-stage plunge cut oscillation (roughing, finishing and fine-finishing) - CYCLE408

Programming example - 2
Machining sequence:
● Plunge cut in Z direction at a peripheral speed of 20 m/s.
● In part program block N30: allowance of 0.1 mm, acoustic emission sensor, and 0.1 mm
standard infeed, finishing reversing point 0.05 mm, fine-finishing reversing point 0.01 mm.
● Infeed of 0.03 mm per stroke with acoustic emission sensor and 0.02 mm infeed for
roughing, 0.01 mm infeed for finishing, and 0.002 mm infeed for fine-finishing.
● 1 sparking-out stroke following roughing, 2 strokes following finishing, and 3 strokes
following fine-finishing.
● Single-stroke dressing for finishing and fine-finishing respectively.
● Off-loading value of 0.03 mm following roughing and 0.015 mm following finishing.

N10 T1D1
N20 CYCLE446( 20)
N30 CYCLE408( 0, 100, -100, 0, 0, 0, 0.1, 0, 0.05, 0.01, 0.1, -0.1, 0.05, 0.01,
0.03, 0.02, 0.01, 0.002, 1, 2, 3, 0, 1, 1, 0.03, 0.015, 30000, 29000, 28000, 3000)
N40 M30

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 Cycles
9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409

9.8 3-stage surface grinding (roughing, finishing and fine-finishing) -

CYCLE409

Programming
CYCLE409( N_SITZ, XSTART, XENDE, ZSTART, ZEND, YEND, B_SR, B_SL, B_FS, KS,
Y_A_LU, Y_A_SR, Y_A_SL, Y_A_FS, LUZ, SRZ, SLZ, FSZ, N_SR, N_SL, N_FS, D_SR,
D_SL, D_FS, ESL, EFS, FX_SR, FX_SL, FX_FS, FZ_SR, FZ_SL, FZ_FS, FY)

Parameters

Table 9- 4 Parameters of CYCLE409

Parameter Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
XEND REAL X axis end position (abs)
ZSTART REAL Z axis starting position (abs)
ZEND REAL Z axis end position (abs)
YEND REAL Finished dimension (abs.)
B_SR INT Roughing machining type:
0 - Continuous
1 - Intermittent
B_SL INT Finishing machining type:
0 - Continuous
1 - Intermittent
B_FS INT Fine-finishing machining type:
0 - Continuous
1 - Intermittent
KS INT Acoustic emission sensor
Y_A_LU REAL Air grinding allowance (incr.)
Y_A_SR REAL Roughing allowance (incr.)
Y_A_SL REAL Finishing allowance (incr.)
Y_A_FS REAL Fine-finishing allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Roughing feedrate, per stroke
SLZ REAL Finishing feedrate, per stroke
FSZ REAL Fine-finishing feedrate, per stroke
N_SR INT Sparking-out strokes following roughing
N_SL INT Sparking-out strokes following finishing
N_FS INT Sparking-out strokes following fine-finishing
D_SR INT Dressing strokes prior to roughing
D_SL INT Dressing strokes prior to finishing
D_FS INT Dressing strokes prior to fine-finishing

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Cycles
9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409

Parameter Data type Meaning

FX_SR REAL X feedrate, roughing
FX_SL REAL X feedrate, finishing
FX_FS REAL X feedrate, fine-finishing
FZ_SR REAL Z feedrate, roughing
FZ_SL REAL Z feedrate, finishing
FZ_S REAL Z feedrate, fine-finishing
FY REAL Y feedrate

Function
The 3-stage surface grinding cycle allows you to machine a surface that is wider than the
wheel itself. The surface concerned is ground using the oscillation method/intermittently.
Y infeed takes place at the X and Z reversal points (left/rear, right/rear, left/front or
right/front).
Intermediate dressing, interruption and use of the handwheel are all supported.
The keys will only ever respond at the end point.
At the end, the tool retracts to the starting position.
A higher infeed amount can be used at the start of machining.
Once contact has been detected using an acoustic emission sensor, the tool will retract by
the acoustic emission sensor infeed amount minus the grinding infeed amount.
If no acoustic emission sensor input has been configured, the cycle will immediately switch
to the handwheel at the start of the operation.
The cycle automatically divides cutting into roughing, finishing and fine-finishing.
Sparking-out strokes can be programmed for the end of each stage.
Off-loading is also possible at the end of the roughing and finishing stages.
Dressing strokes can be programmed to take place prior to each technology step.

Sequence
Approach allowance position, approach X starting position and Z starting position.
Start oscillating motion, infeed at reversal points.
The first infeed once oscillating motion has commenced is adjusted to ensure that all
additional infeed operations correspond to the infeed amount. This process is also performed
following interruptions, intermediate dressing and deselection of the handwheel override
function.
The oscillating motion is not performed with the oscillation function, as this would cause
problems in terms of residual path deletion, and would overload the PLC.
Following interruption/dressing, an off-loading value is applied as the tool approaches the
machining start point.
At the end, the tool retracts to the starting position.

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 Cycles
9.8 3-stage surface grinding (roughing, finishing and fine-finishing) - CYCLE409

Sketch of the geometry parameters

Figure 9-7 3-stage surface grinding workshop cycle (roughing, finishing and fine-finishing) -
CYCLE409

Programming example
Machining sequence:
● Grind surface at a grinding wheel peripheral speed of 20 m/s.
● In part program block N30: air allowance of 0.05 mm and roughing allowance of 0.05 mm,
finishing allowance of 0.025 mm, and fine-finishing allowance of 0.005 mm.
● Infeed of 0.03 mm per stroke with acoustic emission sensor and 0.02 mm infeed for
roughing, 0.01 mm infeed for finishing, and 0.001 mm infeed for fine-finishing.
● 1 sparking-out stroke following roughing, 2 strokes following finishing, and 3 strokes
following fine-finishing.
● Single-stroke dressing for finishing and fine-finishing respectively.
● 2 strokes prior to finishing, 1 stroke prior to fine-finishing.
● Off-loading value of 0.03 mm following roughing and 0.015 mm following finishing.
● With roughing, infeed is performed continuously in Z.
● With finishing and fine-finishing, infeed is performed intermittently.

N10 T2D1
N20 CYCLE446( 20)
N30 CYCLE409( 0, 100, -350, 0, -150, 10, 0, 1, 1, 0, 0.05, 0.05, 0.025, 0.005, 0.03,
0.02, 0.01, 0.001, 1, 2, 3, 0, 2, 1, 0.03, 0.015, 30000, 29000, 28000, 40, 35, 30,
3000)
N40 M30

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Cycles
9.9 Dressing and profiling - CYCLE416

9.9 Dressing and profiling - CYCLE416

Programming
CYCLE416(Y_AB, Z_AB_L, Z_AB_R, F_DL_AB, F_BL_AB, F_DR_AB, F_BR_AB, F_Z_AB,
N_ABR, USCH, N_AWST)

Parameters

Table 9- 5 Parameters of CYCLE416

Parameter Data type Meaning

Y_AB REAL Dressing amount in Y (incr.)
Z_AB_L REAL Dressing amount in Z, left (incr.)
Z_AB_R REAL Dressing amount in Z, right (incr.)
F_DL_AB REAL Dressing feedrate in Y, left
F_BL_AB REAL Dressing feedrate in the path, left
F_DR_AB REAL Dressing feedrate in Y, right
F_BR_AB REAL Dressing feedrate in the path, right
F_Z_AB REAL Dressing feedrate in Z
N_ABR INT Number of dressing strokes
USCH REAL Grinding wheel peripheral speed
N_AWST INT Number of workpieces between two dressing
operations

Function
This cycle is used for dressing wheels with a path dresser.
Following each dressing stroke, the dressed amount is taken into account in the wear
parameters of the current tool offset.
Dressing is performed in accordance with workpiece counter _GC_WKS.

Sequence
Dressing involving setup cycles for the path dresser dressing method (CYCLE432).

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 Cycles
9.9 Dressing and profiling - CYCLE416

Sketch of the geometry parameters

Figure 9-8 Dressing and profiling - CYCLE416

Programming example
Machining sequence:
● Single-stroke dressing with dressing amounts of 0.02 mm (left) and 0.01 mm (right) after
every 5 workpieces.
● The number of idle strokes is stored in the tool data, along with the peripheral speed
ratios of the spindles in the case of a rotating dresser.

N10 T1D1
N20 CYCLE416(0.02,0.01,0.01,0.2,0.2,0.2,0.2,0.2,1,35,5)
N30 M30

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Cycles
9.10 Oscillating plunge cutting - CYCLE426

9.10 Oscillating plunge cutting - CYCLE426

Programming
CYCLE426( N_SITZ, XSTART, XEND, YEND, ZEND, ZU_ART, KS, Y_A_LU, Y_A_SR,
Z_A_LU, Z_A_SR, LUZ, SRZ, N_FR, A_HEB, FR, FX)

Parameters

Table 9- 6 Parameters of CYCLE426

Parameter Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
XEND REAL X axis end position (abs)
YEND REAL Y position of wheel, finished dimension (abs)
ZEND REAL Z position of wheel (abs), finished dimension
ZU_ART INT Infeed left/right/both sides
KS INT Acoustic emission sensor
Y_A_LU REAL Air grinding allowance (incr.)
Y_A_SR REAL Allowance (incr.)
Z_A_LU REAL Air grinding allowance (incr.)
Z_A_SR REAL Allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Infeed per stroke
N_FR INT Sparking-out strokes
A_HEB REAL Retraction amount (incr.)
FR REAL Feedrate at reversal point
FX REAL Table feedrate

Function
The oscillating plunge cutting cycle is called for the purpose of machining a slot or surface
that is smaller than the wheel width. It can also be used for grinding front faces. The surface
concerned is ground using the oscillation method.
Infeed takes place at the reversal points. Intermediate dressing, interruption and use of the
handwheel are all supported.
The keys will only ever respond at the end point.
At the end, the tool retracts or grinding continues with a different technology.
Infeed is possible in the Y or Z directions and the Z value can be either negative or positive.
Machining will take place in the Z direction if no roughing allowance has been programmed
for Y.

Surface grinding
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 Cycles
9.10 Oscillating plunge cutting - CYCLE426

A higher infeed amount can be used at the start of machining. Once contact has been
detected using an acoustic emission sensor, the tool will retract by the acoustic emission
sensor infeed amount minus the grinding infeed amount.
If no acoustic emission sensor input has been configured, the cycle will immediately switch
to the handwheel at the start of the operation.

Sequence
Approach allowance position, approach X starting position and Z position.
Start oscillating motion, infeed at reversal points.
The first infeed once oscillating motion has commenced is adjusted to ensure that all
additional infeed operations correspond to the infeed amount. This process is also performed
following interruptions, intermediate dressing and deselection of the handwheel override
function.
Following interruption/dressing, an off-loading value is applied as the tool approaches the
machining start point.
At the end, the tool retracts by the retraction amount or machining continues using a new
technology, assuming that the end point of the first machining operation is the same as the
starting point for the new machining operation. In other words, if the oscillating axis is at the
X axis end or start point and the allowance is correct, machining will continue from this point.
As a result, it is possible to combine any number of technology seats.

Sketch of the geometry parameters

Figure 9-9 Oscillating plunge cutting - CYCLE426

Surface grinding
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Cycles
9.10 Oscillating plunge cutting - CYCLE426

Programming example - 1
Machining sequence:
● Plunge cut in Y direction at a grinding wheel peripheral speed of 20 m/s with two infeed
blocks.
● In part program block N30: allowance of 0.1 mm and infeed of 0.005 mm per stroke, no
retraction at the end and, therefore, grinding immediately continues in part program block
N40 with an allowance of 0.02 mm and infeed of 0.002 mm per stroke.
● Both operations involve 2 sparking-out strokes. These are performed with the same
geometry positions and feedrates.
● The fact that the start point of the second machining operation is precisely matched to an
end point of the first machining operation means that infeed can take place straight away.
In order for this to happen, grinding with an acoustic emission sensor must be
deactivated.

N10 T1D1
N20 CYCLE446( 20)
N30 CYCLE426( 0, -350, 100, 10.500000, -95, 0, 0, 0, 0.100000, 0, 0, 0.005000,
0.005000, 2, 0, 1000, 30000)
N40 CYCLE426( 0, -350, 100, 10.480000, -95, 0, 0, 0, 0.020000, 0, 0, 0.005000,
0.002000, 2, 1, 1000, 30000)
M30

Programming example - 2
Machining sequence:
● Plunge cut in Z direction at a grinding wheel peripheral speed of 20 m/s with two infeed
blocks.
● In part program block N30: allowance of 0.01 mm, acoustic emission sensor, and
standard infeed of 0.01 mm and infeed of 0.005 mm per stroke with acoustic emission
sensor at end point, plus infeed of 0.002 mm with grinding at end point, no retraction at
the end and, therefore, grinding immediately continues in part program block N40 with an
allowance of 0.02 mm and infeed of 0.002 mm per stroke.
● Both operations involve 2 sparking-out strokes. These are performed with the same
geometry positions and feedrates.
● The fact that the start point of the second machining operation is precisely matched to an
end point of the first machining operation means that infeed can take place straight away.
In order for this to happen, grinding with an acoustic emission sensor must be
deactivated.

N10 T2D1
N20 CYCLE446( 20)
N30 CYCLE426( 0, 100, -350, 10.5, -95, 1, 0, 0, 0.01, 0.01, 0.005, 0.002, 2, 0,
1000, 30000)
N40 CYCLE426( 0, -350, 100, 10.5, -95.02, 1, 0, 0, 0.01, 0.01, 0, 0.002, 2, 1,
1000, 30000)
M30

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 Cycles
9.11 Surface grinding with continuous infeed - CYCLE427

9.11 Surface grinding with continuous infeed - CYCLE427

Programming
CYCLE427( N_SITZ, XSTART, XEND, ZSTART, ZEND, YEND, ZU_ART, KS, A_LU, A_SR,
LUZ, SRZ, N_FR, A_HEB, FY, FX, FZ)

Parameters

Table 9- 7 Parameter CYCLE427

Parameters Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
XEND REAL X axis end position (abs)
ZSTART REAL Z axis starting position (abs)
ZEND REAL Z axis end position (abs)
YEND REAL Finished dimension (abs.)
ZU_ART INT Infeed left/right/both sides
KS INT Acoustic emission sensor
A_LU REAL Air grinding allowance (incr.)
A_SR REAL Allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Infeed per stroke
N_FR INT Sparking-out strokes
A_HEB REAL Retraction amount (incr.)
FY REAL Feedrate at reversal point
FX REAL Table feedrate
FZ REAL Z axis infeed in X, per stroke

Function
The surface grinding cycle with continuous infeed is called for the purpose of machining a
surface that is wider than the wheel itself. The surface concerned is ground using the
oscillation method. Stroke infeed in X is performed continuously.
Y infeed takes place at the X and Z reversal points (left/rear, right/rear, left/front or
right/front).
Intermediate dressing, interruption and use of the handwheel are all supported.
The keys will only ever respond at the end point.
At the end, the tool retracts or grinding continues with a different technology.
A higher infeed amount can be used at the start of machining.
Once contact has been detected using an acoustic emission sensor, the tool will retract by
the acoustic emission sensor infeed amount minus the grinding infeed amount.

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Cycles
9.11 Surface grinding with continuous infeed - CYCLE427

If no acoustic emission sensor input has been configured, the cycle will immediately switch
to the handwheel at the start of the operation.

Sequence
Approach allowance position, approach X starting position and Z starting position.
Start oscillating motion, infeed at reversal points.
The first infeed once oscillating motion has commenced is adjusted to ensure that all
additional infeed operations correspond to the infeed amount. This process is also performed
following interruptions, intermediate dressing and deselection of the handwheel override
function. The oscillating motion is not performed with the oscillation function, as this would
cause problems in terms of residual path deletion, and would overload the PLC.
Following interruption/dressing, an off-loading value is applied as the tool approaches the
machining start point.
At the end, the tool retracts by the retraction amount or machining continues at the end point
using a new technology. In other words, if the oscillating axis is at the X axis end or start
point and the allowance is correct, machining will continue from this point. As a result, it is
possible to combine any number of technology seats.

Sketch of the geometry parameters

Figure 9-10 Surface grinding with continuous infeed - CYCLE427

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 Cycles
9.11 Surface grinding with continuous infeed - CYCLE427

Programming example
Machining sequence
● Oscillation with continuous infeed in Z direction at a grinding wheel peripheral speed of
20 m/s with two infeed blocks.
● In part program block N30: allowance of 0.1 mm and infeed of 0.005 mm per stroke, no
retraction at the end and, therefore, grinding immediately continues in part program block
N40 with an allowance of 0.02 mm and infeed of 0.002 mm per stroke.
● Both operations involve 2 sparking-out strokes. These are performed with the same
geometry positions.
● The per-stroke feedrate in X is 40 mm for the 1st operation and 10 mm for the 2nd.
● The fact that the start point of the second machining operation is precisely matched to an
end point of the first machining operation means that infeed can take place straight away.
In order for this to happen, grinding with an acoustic emission sensor must be
deactivated.

N10 T2D1
N20 CYCLE446( 20)
N30 CYCLE427( 0, 100, -350, -95, 0, 10.5, 0, 0, 0, 0.1, 0, 0.005, 2, 0, 3000, 30000,
40)
N40 CYCLE427( 0, 100, -350, -95, 0, 10.48, 0, 0, 0, 0.02, 0, 0.002, 2, 1, 3000,
30000, 10)
N50 M30

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Cycles
9.12 Surface grinding with intermittent infeed - CYCLE428

9.12 Surface grinding with intermittent infeed - CYCLE428

Programming
CYCLE428( N_SITZ, XSTART, XEND ZSTART, ZEND, YEND, ZU_ART, ZZU_ART, KS,
A_LU, A_SR, LUZ, SRZ, N_FR, A_HEB, FY, FX, FZ)

Parameters

Table 9- 8 Parameter CYCLE428

Parameters Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
XEND REAL X axis end position (abs)
ZSTART REAL Z axis starting position (abs)
ZEND REAL Z axis end position (abs)
YEND REAL Finished dimension (abs.)
ZU_ART INT Infeed:
- left
- right
- both sides
ZZU_ART INT Intermittent infeed:
- left
- right
- both sides
KS INT Acoustic emission sensor
A_LU REAL Air grinding allowance (incr.)
A_SR REAL Allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Infeed per stroke
N_FR INT Sparking-out strokes
A_HEB REAL Retraction amount (incr.)
FY REAL Feedrate at reversal point
FX REAL Table feedrate
FZ REAL Z axis infeed in X, per stroke

Function
The surface grinding cycle with intermittent infeed is called for the purpose of machining a
surface that is wider than the wheel itself. The surface concerned is ground using the
oscillation method. Infeed is performed at the end of the strokes in X.
This infeed is circular so that sudden acceleration can be avoided.
With this method, it is also possible to select the infeed side in the Z direction.

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 Cycles
9.12 Surface grinding with intermittent infeed - CYCLE428

Y infeed takes place at the X and Z reversal points (left/rear, right/rear, left/front or
right/front).
Intermediate dressing, interruption and use of the handwheel are all supported.
The keys will only ever respond at the end point.
At the end, the tool retracts or grinding continues with a different technology.
A higher infeed amount can be used at the start of machining. Once contact has been
detected using an acoustic emission sensor, the tool will retract by the acoustic emission
sensor infeed amount minus the grinding infeed amount. If no acoustic emission sensor input
has been configured, the cycle will immediately switch to the handwheel at the start of the
operation.
The value of the FZ parameter (infeed per stroke) can be used to determine whether the X
values should be used for the start or the end of the circular motion. If the values used are
negative, then the X positions will not be overtraveled, even with circular interpolation.

Sequence
Traverse to allowance position. Approach X starting position and Z starting position.
Start oscillating motion, infeed at reversal points.
The first infeed once oscillating motion has commenced is adjusted to ensure that all
additional infeed operations correspond to the infeed amount. This process is also performed
following interruptions, intermediate dressing and deselection of the handwheel override
function.
The oscillating motion is not performed with the oscillation function, as this would cause
problems in terms of residual path deletion, and would overload the PLC.
Following interruption/dressing, an off-loading value is applied as the tool approaches the
machining start point.
At the end, the tool retracts by the retraction amount or machining continues at the end point
using a new technology. In other words, if the oscillating axis is at the X axis end or start
point and the allowance is correct, machining will continue from this point. As a result, it is
possible to combine any number of technology seats.

Sketch of the geometry parameters

Figure 9-11 Surface grinding with intermittent infeed - CYCLE428

Surface grinding
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Cycles
9.12 Surface grinding with intermittent infeed - CYCLE428

Programming example
Machining sequence:
● Oscillation with continuous infeed in Z direction at a grinding wheel peripheral speed of
20 m/s with two infeed blocks.
● In part program block N30: allowance of 0.1 mm and infeed of 0.005 mm per stroke, no
retraction at the end and, therefore, grinding immediately continues in part program block
N40 with an allowance of 0.02 mm and infeed of 0.002 mm per stroke.
● Both operations involve 2 sparking-out strokes. These are performed with the same
geometry positions.
● The per-stroke feedrate in X is 40 mm for the 1st operation and 10 mm for the 2nd.
● The fact that the start point of the second machining operation is precisely matched to an
end point of the first machining operation means that infeed can take place straight away.
In order for this to happen, grinding with an acoustic emission sensor must be
deactivated.

N10 T2D1
N20 CYCLE446( 20)
N30 CYCLE428( 0, 100, -350, -95, 0, 10.500000, 0, 0, 0, 0, 0.1, 0, 0.005000, 2, 0,
3000, 30000, 40)
N40 CYCLE428( 0, 100, -350, -95, 0, 10.48, 0, 0, 0, 0, 0.02, 0, 0.002, 2, 1, 3000,
30000, 10)
N50 M30

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 Cycles
9.13 Profile grinding - CYCLE429

9.13 Profile grinding - CYCLE429

Programming
CYCLE429( N_SITZ, XSTART, ZSTART, YEND, KS, A_LU, A_SR, LUZ, SRZ, N_FR,
A_HEB, FX, KONTUR)

Parameters

Table 9- 9 Parameters of CYCLE429

Parameter Data type Meaning

N_SITZ INT Seat number
XSTART REAL X axis starting position (abs)
ZSTART REAL Z axis starting position (abs)
YEND REAL Y position at starting position of Z axis (abs) and X
axis (abs)
KS INT Acoustic emission sensor
A_LU REAL Air grinding allowance (incr.)
A_SR REAL Allowance (incr.)
LUZ REAL Air grinding feedrate, per stroke
SRZ REAL Infeed per stroke
N_FR INT Sparking-out strokes
A_HEB REAL Retraction amount (incr.)
FX REAL Table feedrate
KONTUR String Contour name

Function
The profile grinding cycle is called for the purpose of machining a surface with a free
contour.
The entire contour is contained within the contour subroutine.
The cycle merely handles the infeed process and the interrupt keys, which do not have any
effect until the end of the contour is reached.
Both intermediate dressing and interruption are supported.
At the end of each stroke, retraction is performed followed by a return to the starting point.
Machining must be performed using active tool nose radius compensation (G41/G42).
The tool offset is modified by the cycle.
The user has the option of programming both an outward and a return motion in the free
contour. In this case, no retraction amount is required.
The user must select the correct G group (G41/G42) in the contour program, because this
program also happens to contain the machining direction.

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Cycles
9.13 Profile grinding - CYCLE429

Sequence
Enter allowance in work offset.
Traverse to retraction amount.
Traverse to X starting position and Z starting position.
Call contour program.
Retract and reset work offset.
Approach the start point again until the allowance has been machined.
At the end, the tool retracts by the retraction amount.
Machining continues at the end point using a new technology.

Sketch of the geometry parameters

Figure 9-12 Profile grinding - CYCLE429

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 Cycles
9.13 Profile grinding - CYCLE429

Programming example
Machining sequence:
● Profile grinding with an allowance of 0.02 mm and an infeed of 0.005 mm per stroke.
● The surface offset is used for the infeed. The contour is always programmed to the
finished dimension.
● 2 sparking-out strokes are then performed at the end.
● Retraction should be programmed as follows:
– It should be possible to perform a return journey in absolute safety.
– The return motion is contained within the contour.
● In the example below, subsequent machining is carried out with a different infeed but the
same contour.
● The contour must be stored as an individual subroutine. The direction of tool nose radius
compensation is also activated in the contour.

N10 T1D1
N20 CYCLE446( 20)
CYCLE429( 0, 100, 0, 0, 0, 0, 0.02, 0, 0.005, 2, 20, 10000, "K123")
N30 Y0
N40 CYCLE429( 1, 100, 0, 0, 0, 0.02, 0, 0.005, 2, 20, 10000, "K123")
N50 M30

Example contour program

%_N_K123_SPF
G17
G42
G64 G90 X100 Y0
G64 X0 Y0
G64 X-100 Y10
G64 X-210 Y0
G64 X-260
RET

Surface grinding
Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 181
Cycles
9.14 Dressing with profile roller - CYCLE430

9.14 Dressing with profile roller - CYCLE430

Programming
CYCLE430( Y_AB, F_TVOR, F_VOR, N_AUS, N_ABR, USCH, N_AWST)

Parameters

Table 9- 10 Parameters of CYCLE430

Parameter Data type Meaning

Y_AB REAL Dressing amount in Y (incr.)
F_TVOR REAL Insertion stroke in mm/rev
F_VOR REAL Dressing feedrate in mm/rev
N_AUS REAL Coasting revolutions
N_ABR INT Number of dressing strokes
USCH REAL Grinding wheel peripheral speed
N_AWST INT Number of workpieces between two dressing
operations

Function
This cycle is used for dressing wheels using a profile roller.
Following dressing (each stroke), the dressed amount is taken into account in the wear
parameters of the current tool offset.
Dressing is performed in accordance with workpiece counter GC_WKS.

Sequence
If a profiling allowance is specified, this is processed first. This value can also be used to
search for a dresser if no sensor system is installed.
When processing the profiling allowance, no dresser wear compensation is currently applied.
The profiling allowance is taken into account in the base dimension of the dresser when
selecting the valid coordinate system. This does away with the requirement for a
programmable work offset for grinding operations. The coasting revolutions are the number
of revolutions taken for the roller to come to a stop against the wheel.

Surface grinding
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 Cycles
9.14 Dressing with profile roller - CYCLE430

Sketch of the geometry parameters

Figure 9-13 Dressing with profile roller - CYCLE430

Programming example
Machining sequence:
● 2-stroke dressing with a dressing amount of 0.02 mm and 2 sparking-out revolutions
every 5 workpieces.
● The number of idle strokes is stored in the tool data, along with the peripheral speed
ratios of the spindles.

N10 T1D1
N20 CYCLE430(0.02,20,0.2,2,2,35,5)
N30 M30

Surface grinding
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Cycles
9.15 Selection of the grinding wheel peripheral speed - CYCLE446

9.15 Selection of the grinding wheel peripheral speed - CYCLE446

Programming
CYCLE446(SUG)

Parameter

Table 9- 11 Parameters of CYCLE446

Parameter Data Type Meaning

GWPS REAL Value of the grinding wheel peripheral speed

Function
This function is used to switch on the grinding wheel at a desired peripheral wheel speed,
including the testing of the max. peripheral wheel speed and RPM. If the speed is exceeded,
a message is issued (no alarm). The value is limited to the respective maximum value. This
is checked for all wheels that are mounted on the spindle (wheels of a set). A setup menu is
also required in order to obtain an overview of the wheels used.
Checking and calculation is performed on the currently largest diameter of the wheels. This
is a purely calculated monitoring function. Internally, no limitations are set that implement
reliable monitoring. This must be ensured by the user.
For machines without NC spindles, it is possible to use a computation of the necessary
speed with a spindle number ≤ 0 if the cycle CYCLE425 is available. In this case, the
CYCLE425 receives the computed and limited speed. At this point, the user can give this
speed to groups or directly to an external actuator (M functions, etc.). The user must then
assign the speed set, which may deviate from the required speed, to parameter
_GC_PARR[5]. In this way, the dressing cycle can compute, for example, the necessary
dressing feedrate in mm/rev using the correct speed.

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Programming 10
10.1 Fundamental principles of NC programming

10.1.1 Program names

Each program has its own program name. The name can be freely chosen during program
creation, taking the following conventions into account:
● The first two characters must be letters.
● Use only letters, digits or underscore.
● Do not use delimiters (see Section "Character set").
● The decimal point must only be used for separation of the file extension.
● Do not use more than 27 characters.
Example: WORKPIECE

10.1.2 Program structure

Structure and content

The NC program consists of a sequence of blocks (see Table below).
Each block represents a machining step.
Instructions are written in the blocks in the form of words.
The last block in the execution sequence contains a special word for the end of program:
e.g. M2.

Table 10- 1 NC program structure

Set Word Word Word ... ; Comment

Set N10 G0 X20 ... ; 1. Set
Set N20 G2 Z37 ... ; 2. Set
Set N30 G91 ... ... ; ...
Set N40 ... ... ...
Set N50 M2 ; End of program

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Programming
10.1 Fundamental principles of NC programming

10.1.3 Word structure and address

Functionality/structure
A word is a block element and mainly constitutes a control command. The word consists of:
● Address characters: generally a letter and a
● Numerical value: a sequence of digits which with certain addresses can be added by a
sign put in front of the address, and a decimal point.
A positive sign (+) can be omitted.

:RUG :RUG :RUG

$GGUHVV 9DOXH $GGUHVV 9DOXH $GGUHVV 9DOXH

([DPSOH * ; )

7UDYHUVHZLWK 'LVWDQFHWREH
WUDYHUVHGRUHQG )HHGUDWH
([SODQDWLRQ OLQHDU
SRVLWLRQIRUWKH; PPPLQ
LQWHUSRODWLRQ
D[LVPP

Figure 10-1 Word structure (example)

Several address characters

A word can also contain several address letters. In this case, however, the numerical value
must be assigned via the intermediate character "=".
Example: CR=5.23
Additionally, it is also possible to call G functions using a symbolic name (see also Section
"List of instructions").
Example: SCALE ; Enable scaling factor

Extended address
For the following addresses, the address is extended by 1 to 4 digits to obtain a higher
number of addresses.
R: Arithmetic parameters
H: H function
I, J, K: Interpolation parameters/intermediate point
In this case, the value must be assigned using an equality sign "=" (see also Section "List of
instructions").
Example: R10=6.234 H5=12.1 I1=32.67

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 Programming
10.1 Fundamental principles of NC programming

10.1.4 Block format

Functionality
A block should contain all data required to execute a machining step.
Generally, a block consists of several words and is always completed with the
end-of-block character " LF " (Linefeed). This character is automatically generated when
pressing the linefeed or <Input>key when writing.

1 :RUG :RUG  :RUGQ &RPPHQW /)

6SDFH 6SDFH 6SDFH 6SDFH

(QGRIEORFNFKDUDFWHU
%/$1.   

%ORFNLQVWUXFWLRQV
%ORFNQXPEHUVWDQGVLQIURQWRILQVWUXFWLRQV
RQO\LIUHTXLUHG
2QO\DVQHHGHGLQVWHDGRI1PDLQEORFNVKDYH
LVZULWWHQDWWKHHQGGHOLPLWHGIURP
WKHV\PEROಯಯ&RORQ
WKHUHPDLQLQJSDUWRIWKHEORFNE\
%ORFNVNLS
RQO\LIQHFHVVDU\VWDQGVDWWKHEHJLQQLQJ
7RWDOQXPEHURIFKDUDFWHUVLQDEORFNFKDUDFWHUV

Figure 10-2 Block structure diagram

Word order
If there are several instructions in a block, the following order is recommended:
N... G... X... Z... F... S... T... D... M... H...

Note regarding block numbers

First select the block numbers in steps of 5 or 10. Thus, you can later insert blocks and
nevertheless observe the ascending order of block numbers.

Block skip
Blocks of a program, which are to be executed not with each program run, can be marked by
a slash / in front of the block number.
The block skip itself is activated via Operation (program control: "SKP") or by the
programmable controller (signal). A section can be skipped by several blocks in succession
using " / ".
If a block must be skipped during program execution, all program blocks marked with " / " are
not executed. All instructions contained in the blocks concerned will not be considered. The
program is continued with the next block without marking.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 187
Programming
10.1 Fundamental principles of NC programming

Comment, remark
The instructions in the blocks of a program can be explained using comments (remarks). A
comment always starts with a semicolon " ; " and ends with end-of-block.
Comments are displayed together with the contents of the remaining block in the current
block display.

Messages
Messages are programmed in a separate block. A message is displayed in a special field
and remains active until a block with a new message is executed or until the end of the
program is reached. Max. 65 characters can be displayed in message texts.
A message without message text cancels a previous message.
MSG("THIS IS THE MESSAGE TEXT")
See also chapter "Service MSG".

Programming example

N10 ; G&S company, order no. 12A71

N20 ; Pump part 17, drawing no.: 123 677
N30 ; Program created by H. Adam, Dept. TV 4
N40 MSG("DRAWING NO.: 123677")
:50 G54 F4.7 S220 D2 M3 ;Main block
N60 G0 G90 X100 Z200
N70 G1 Z185.6
N80 X112
/N90 X118 Z180 ; Block can be suppressed
N100 X118 Z120
N110 G0 G90 X200
N120 M2 ; End of program

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 Programming
10.1 Fundamental principles of NC programming

10.1.5 Fonts
The following characters are used for programming; they are interpreted in accordance with
the relevant definitions.

Letters, digits
A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W X, Y, Z
0, 1, 2, 3, 4, 5, 6, 7, 8, 9
No distinction is made between upper and lower case letters.

Printable special characters

( Open parenthesis " Inverted commas

) Close parenthesis _ Underscore (belongs to letters)
[ Open square bracket . Decimal point
] Close square bracket , Comma, separator
< less than ; Comment start
> greater than % Reserved; do not use
: Main block, end of label & Reserved; do not use
= Assignment, part of equation ' Reserved; do not use
/ Division, block suppression $ System variable identifiers
* Multiplication ? Reserved; do not use
+ Addition and positive sign ! Reserved; do not use
- Subtraction, minus sign

Non-printable special characters

LF: End-of-block character
Blank: Separator between words; blank
Tabulator: Reserved; do not use

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10.1.6 List of instructions

Functions available with SINUMERIK 802D sl plus and pro

Address Meaning Value assignments Information Programming

D Tool offset number 0 ... 9only integer, Contains offset data for a D...
no sign certain tool T... ; D0 à offset
values= 0,
max. 9 D numbers per tool
F Feed 0.001 ... 99 Path velocity of a F...
999.999 tool/workpiece;
unit: mm/min or mm/revolution
depending on G94 or G95
F Dwell time (block 0.001 ... 99 Dwell time in seconds G4 F...; separate block
with G4) 999.999
G G function Only integer, The G functions are divided into G...
(preparatory function) specified values G groups. Only one G function or symbolic name, e.g.:
of a group can be programmed CIP
in a block.
A G function can be either
modal (until it is canceled by
another function of the same
group) or only effective for the
block in which it is programmed
(non-modal).
G group:
G0 Linear interpolation at rapid traverse rate 1: Motion commands G0 X... Z...
G1 * Linear interpolation at feedrate (type of interpolation) G1 X...Z... F...
G2 Circular interpolation clockwise G2 X... Z... I... K... F... ;
Center and end point
G2 X... Z... CR=... F... ;
Radius and end point
G2 AR=... I... K... F... ;
Aperture angle and center
point
G2 AR=... X... Z... F... ;
Aperture angle and end point
G3 Circular interpolation counter-clockwise G3 ... ; otherwise as for G2
CIP Circular interpolation through intermediate CIP X... Z... I1=... K1=... F...
point ;I1, K1 is intermediate point
CT Circular interpolation; tangential transition N10 ...
N20 CT Z... X... F... ; circle;
tangential transition
to the previous path
segment N10
G4 Dwell time 2: Special motions, dwell time G4 F...;separate block, F:
non-modal Time in seconds
or
G4 S.... ;separate block, S: in
spindle revolutions

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G74 Reference point approach G74 X1=0 Z1=0 ;separate
block,
(machine axis identifier!)
G75 Fixed point approach G75 X1=0 Z1=0 ;separate
block,
(machine axis identifier!)
TRANS translation, programmable 3: Write memory TRANS X... Z... ;separate
block
SCALE Programmable scaling factor non-modal SCALE X... Z... ; scaling
factor in the direction
of the specified axis,
separate block
ROT rotation, programmable ROT RPL=... ;rotation in the
current plane
G17 to G19, separate block
MIRROR Programmable mirroring MIRROR X0 ; coordinate
axis whose
direction is changed,
separate block
ATRANS additive translation, programming ATRANS X... Z... ; separate
block
ASCALE Additive programmable scaling factor ASCALE X... Z... ; scaling
factor in the direction
of the specified axis,
separate block
AROT additive programmable rotation AROT RPL=... ; rotation in
the current plane
G17 to G19,
separate block
AMIRROR additive programmable mirroring AMIRROR X0 ; coordinate
axis whose
direction is changed,
separate block
G25 Lower spindle speed limitation G25 S... ;separate block
or
lower working area limitation G25 X... Z... ;separate block
G26 Upper spindle speed limitation G26 S... ; separate block
or
upper working area limitation G26 X... Z... ; separate block
G17 X/Y plane 6: Plane selection
G18 * Z/X plane
G19 Y/Z plane
G40 * Tool radius compensation OFF 7: Tool radius compensation
G41 Tool radius compensation left of contour modally effective
G42 Tool radius compensation right of contour
G500 Settable work offset OFF 8: Settable zero offset
G54 1st Settable zero offset modally effective
G55 2nd Settable zero offset
G56 3rd Settable zero offset

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G57 4th Settable zero offset
G58 5th Settable zero offset
G59 6th Settable zero offset
G53 Non-modal skipping of the settable work 9: Skipping of the settable work
offset offset
non-modal
G153 Non-modal skipping of the settable work
offset including base frame
G60 * Exact stop 10: Approach behavior
G64 Continuous-path mode modally effective
G9 Non-modal exact stop 11: Non-modal exact stop
non-modal
G601 * Exact stop window, fine, with G60, G9 12: Exact stop window
G602 Exact stop window, coarse, with G60, G9 modally effective
G70 Inch dimension input 13: Inch / metr.dimension input
G71 * Metric dimension data input modally effective
G700 Inch dimension data input; also for
feedrate F
G710 Metric dimension data input; also for
feedrate F
G90 * Absolute dimension data input 14: Absolute / incremental
G91 Incremental dimension dimension
modally effective
G94 * Feed F in mm/min 15: Feedrate / spindle
G95 Feedrate F in mm/spindle revolutions modally effective
G96 Constant cutting rate ON G96 S... LIMS=... F...
(F in mm/rev., S in m/min)
G97 Constant cutting speed OFF
G450 * Transition circle 18: Behavior at corners when
G451 Point of intersection working with tool radius
compensation
modally effective
BRISK * Jerking path acceleration 21: Acceleration profile
SOFT Jerk-limited path acceleration modally effective
FFWOF * Feedforward control OFF 24: Precontrol
FFWON Feedforward control ON modally effective
WALIMON * Working area limitation ON 28: Working area limitation ; applies to all axes activated
modally effective via setting data;
values set via G25, G26
WALIMOF Working area limitation OFF
G290 * SIEMENS mode 47: External NC languages
The functions marked with an asterisk (*) act when starting the program (in the default condition of the control system,
unless otherwise programmed and if the machine manufacturer has preserved the default settings for the grinding
technology).

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H H function ± 0.0000001 ... Value transfer to the PLC; H0=... H9999=...
9999 9999 meaning defined by the
H0= (8 decimal places) machine manufacturer e.g.: H7=23.456
to or with specification
H9999= of an exponent:
± (10-300 ...
10+300 )
I Interpolation ±0.001 ... 99 Belongs to the X axis; meaning See G2, G3 and G33, G34,
parameters 999.999 dependent on G2,G3 ->circle G35
Thread: center or
0.001 ... 2000.000 G33, G34, G35 G331, G332 à
thread pitch
K Interpolation ±0.001 ... 99 Belongs to the Z axis; See G2, G3 and G33, G34,
parameters 999.999 otherwise, as with I G35
Thread:
0.001 ... 2000.000
I1= Intermediate point for ±0.001 ... 99 Belongs to the X axis; See CIP
circular interpolation 999.999 specification for circular
interpolation with CIP
K1= Intermediate point for ±0.001 ... 99 Belongs to the Z axis; See CIP
circular interpolation 999.999 specification for circular
interpolation with CIP
L Subroutine; name 7 decimals; Instead of a free name, it is also L.... ;separate block
and call integer only, no possible to select L1
sign ...L9999999;
this also calls the subroutine
(UP) in a separate block,
Please note: L0001 is not
always equal to L1.
The name "LL6" is reserved for
the tool change subroutine.
M Additional function 0 ... 99 For example, for initiating M...
only integer, no switching actions,
sign such as "Coolant ON";
max. 5 M functions per block
M0 Programmed stop The machining is stopped at the
end of a block containing M0; to
continue, press NC START.
M1 Optional stop As with M0, but the stop is only
performed if a special signal
(Program control: "M01") is
present.
M2 End of program Can be found in the last block
of the processing sequence
M30 - Reserved; do not use
M17 - Reserved; do not use
M3 CW rotation of spindle (for master spindle)
M4 CCW rotation of spindle (for master
spindle)
M5 Spindle stop (for master spindle)

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Mn=3 CW rotation of spindle (for spindle n) n = 1 or = 2 M2=3 ; CW rotation stop for
spindle 2
Mn=4 CCW rotation of spindle (for spindle n) n = 1 or = 2 M2=4 ; CCW rotation stop for
spindle 2
Mn=5 Spindle stop (for spindle n) n = 1 or = 2 M2=5 ; Spindle stop for
spindle 2
M6 Tool change Only if activated with M6 via the
machine control panel;
otherwise, change directly using
the T command
M40 Automatic gear stage switching
(for master spindle)
Mn=40 Automatic gear stage switching n = 1 or = 2 M1=40 ; automatic gear
(for spindle n) stage
; for spindle 1
M41 to M45 Gear stage 1 to
gear stage 5 (for master spindle)
Mn=41 to Gear stage 1 to n = 1 or = 2 M2=41; 1st gear stage for
Mn=45 gear stage 5 (for spindle n) spindle 2
M70, M19 - Reserved; do not use
M... Remaining M functions Functionality is not defined by
the control system and can
therefore be used freely by the
machine manufacturer
N Block number - 0 ... 9999 9999 Can be used to identify blocks N20
subblock only integer, no with a number;
sign is written in the beginning of a
block
: Block number of a 0 ... 9999 9999 Special block identification, :20
main block only integer, no used instead of N... ; such a
sign block should contain all
instructions for a complete
subsequent machining step.
P Number of 1 ... 9999 Is used if the subroutine is run L781 P... ;separate block
subroutine passes only integer, no several times and is contained
sign in the same block as the call N10 L871 P3 ; three cycles
R0 Arithmetic ± 0.0000001 ... R1=7.9431 R2=4
to parameters 9999 9999
R299 (8 decimal places)
or with specification with specification of an
of an exponent: exponent:
± (10-300 ... R1=-1.9876EX9; R1=-1 987
10+300 ) 600 000
Arithmetic functions In addition to the 4 basic
arithmetic functions using the
operands + - * /, there are the
following arithmetic functions:
SIN( ) sinusoidal Degrees R1=SIN(17.35)
COS() Cosine Degrees R2=COS(R3)
TAN() Tangent Degrees R4=TAN(R5)

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ASIN() Arc sine R10=ASIN(0.35) ; R10:
20.487 degrees
ACOS() Arc cosine R20=ACOS(R2) ; R20: ...
Degrees
ATAN2( , ) Arctangent2 The angle of the sum vector is R40=ATAN2(30.5,80.1) ;
calculated from 2 vectors R40: 20.8455 degrees
standing vertically one on
another. The 2nd vector
specified is always used for
angle reference.
Result in the range: -180 to
+180 degrees
SQRT() Square root R6=SQRT(R7)
POT() Square R12=POT(R13)
ABS() Absolute value R8=ABS(R9)
TRUNC() Truncate to integer R10=TRUNC(R2)
LN() Natural logarithm R12=LN(R9)
EXP() Exponential function R13=EXP(R1)
RET Subroutine end Used instead of M2 - to RET ;separate block
maintain the continuous-path
control mode
S... Spindle speed 0.001 ... 99 Unit of measurement of the S...
(master spindle) 999.999 spindle r.p.m.
S1=... Spindle speed 0.001 ... 99 Unit of measurement of the S1=725 ; speed 725 r.p.m.
for spindle 1 999.999 spindle r.p.m. for spindle 1
S2=... Spindle speed 0.001 ... 99 Unit of measurement of the S2=730 ; speed 730 r.p.m.
for spindle 2 999.999 spindle r.p.m. for spindle 2
S Cutting rate 0.001 ... 99 Cutting rate unit m/min with G96
with G96 active 999.999 G96; S...
for master spindle only
S Dwell time 0.001 ... 99 Dwell time in spindle revolutions G4 S... ;separate block
in block with G4 999.999
T Tool number 1 ... 32 000 The tool change can be T...
only integer, no performed either directly using
sign the T command or only with M6.
This can be set in the machine
data.
X Axis ±0.001 ... 99 Positional data X...
999.999
Z Axis ±0.001 ... 99 Positional data Z...
999.999
AC Absolute coordinate - The dimension can be specified N10 G91 X10 Z=AC(20) ;X -
for the end or center point of a incremental dimension,
certain axis, irrespective of Z - absolute dimension
G91.
ACC[axis] Percentage 1 ... 200, integer Acceleration override for an N10 ACC[X]=80 ;for the X
acceleration override axis or spindle; specified as a axis 80%
percentage N20 ACC[S]=50;for the
spindle: 50%

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ACP Absolute coordinate; - It is also possible to specify the N10 A=ACP(45.3) ;
approach position in dimensions for the end point of Approach absolute position
the positive direction a rotary axis with ACP(...) of the A axis in
(for rotary axis, irrespective of G90/G91; also the positive direction
spindle) applies to spindle positioning N20 SPOS=ACP(33.1);
Position spindle
ACN Absolute coordinate; - It is also possible to specify the N10 A=ACN(45.3) ;
approach position in dimensions for the end point of Approach absolute position
the negative direction a rotary axis with ACN(...) of the A axis in
(for rotary axis, irrespective of G90/G91; also the negative direction
spindle) applies to spindle positioning N20 SPOS=ACN(33.1);
Position spindle
ANG Angle for the ±0.00001 ... Specified in degrees; N10 G1 X... Z....
specification of a 359.99999 one possibility of specifying a N11 X... ANG=...
straight line for the straight line when using G0 or or contour over several
contour definition G1 if only one end-point blocks:
coordinate of the plane is N10 G1 X... Z...
known N11 ANG=...
or N12 X... Z... ANG=...
if the complete end point is
known with contour ranging
over several blocks
AR Aperture angle for 0.00001 ... Specified in degrees; one See G2, G3
circular interpolation 359.99999 possibility of defining the circle
when using G2/G3
CALL Indirect cycle call - Special form of the cycle call; N10 CALL VARNAME ;
no parameter transfer; the variable name
name of the cycle is stored in a
variable;
only intended for cycle-internal
use
CHF Chamfer; 0.001 ... 99 Inserts a chamfer of the N10 X... Z.... CHF=...
general use 999.999 specified chamfer length N11 X... Z...
between two contour blocks
CHR Chamfer; 0.001 ... 99 Inserts a chamfer of the N10 X... Z.... CHR=...
in the contour 999.999 specified leg length between N11 X... Z...
definition two contour blocks
CR Radius for circular 0.010 ... 99 One possibility of defining a See G2, G3
interpolation 999.999 circle when using G2/G3
Negative sign - for
selecting the circle:
greater than
semicircle
CYCLE... Machining cycle Only specified The call of the machining cycles
values requires a separate block; the
appropriate transfer parameters
must be loaded with values.
Special cycle calls are also
possible with an additional
MCALL or CALL.
CYCLE406 Z positioning with grinding wheel N10 CYCLE406(...) ;
separate block

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CYCLE407 Safety position N10 CYCLE407(...) ;
separate block
CYCLE408 3-stage plunge cut workshop cycle N10 CYCLE408(...) ;
(roughing, finishing and fine-finishing) separate block
CYCLE409 3-stage surface grinding workshop cycle N10 CYCLE409(...) ;
(roughing, finishing and fine-finishing) separate block
CYCLE426 Oscillating plunge cutting N10 CYCLE426(...) ;
separate block
CYCLE427 Surface grinding with continuous infeed N10 CYCLE427(...) ;
separate block
CYCLE428 Surface grinding with intermittent infeed N10 CYCLE428(...) ;
separate block
CYCLE429 Profile grinding N10 CYCLE429(...) ;
separate block
CYCLE430 Dressing with profile roller N10 CYCLE430(...) ;
separate block
DC Absolute coordinate; - It is also possible to specify the N10 A=DC(45.3) ;Approach
approach position dimensions for the end point of absolute position of the A
directly(for rotary a rotary axis with DC(...) axis directly
axis, spindle) irrespective of G90/G91; also N20 SPOS=DC(33.1);
applies to spindle positioning Position spindle
DEF Definition instruction Defining a local user variable of DEF INT VARI1=24, VARI2 ;
the type 2 variables of the type INT
BOOL, CHAR, INT, REAL, ; name defined by user
directly at the beginning of the
program
FRC Non-modal feedrate 0, >0 In case FRC=0: Feedrate Fwill For the unit, see F and G94,
for chamfer/rounding act G95;
for chamfer/rounding, see
CHF, CHR, RND
FRCM Modal feedrate for 0, >0 In case FRCM=0: Feedrate For the unit, see F and G94,
chamfer/rounding Fwill act G95;
for rounding/modal rounding,
see RND, RNDM
FXS Travel to fixed stop =1: select Axis: Use the machine identifier N20 G1 X10 Z25 FXS[Z1]=1
[axis] =0: Deselection FXST[Z1]=12.3 FXSW[Z1]=2
F...
FXST [axis] Clamping torque, > 0.0 ... 100.0 in %, max. 100% from the max. N30 FXST[Z1]=12.3
travel to fixed stop torque of the drive,
axis: Use the machine identifier
FXSW [axis] Monitoring window, > 0.0 Unit of measurement mm or N40 FXSW[Z1]=2.4
travel to fixed stop degrees, axis-specific,
axis: Use the machine identifier
GOTOB GoBack instruction - A GoTo operation is performed N10 LABEL1: ...
to a block marked by a label; ...
the jump destination is in the N100 GOTOB LABEL1
direction of the program start.

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GOTOF GoForward - A GoTo operation is performed N10 GOTOF LABEL2
instruction to a block marked by a label; ...
the jump destination is in the N130 LABEL2: ...
direction of the end of the
program.
IC Coordinate specified - The dimension can be specified N10 G90 X10 Z=IC(20) ;Z -
using incremental for the end or center point of a incremental dimension,
dimensions certain axis irrespective of G90. X - absolute dimension
IF Jump condition - If the jump condition is fulfilled, N10 IF R1>5 GOTOF
the GoTo operation to the block LABEL3
with the following label is ...
performed; , otherwise, the next N80 LABEL3: ...
instruction/block will follow.In
one block,
several IF instructions are
possible.
Relational operators:
= = equal, <> not equal
> greater than, < less than
>= greater than or equal to
<= less than or equal to
LIMS Upper limit speed of 0.001 ... 99 Limits the spindle speed with See G96
the spindle with G96, 999.999 the G96 function enabled -
G97 constant cutting rate and G97
MEAS Measurement with +1 =+1: Measuring input 1, rising N10 MEAS=-1 G1 X... Z...
deletion of distance- -1 edge F...
to-go =-1: Measuring input1, falling
edge
MEAW Measurement without +1 =+1: Measuring input 1, rising N10 MEAW=1 G1 X... Z...
deletion of distance- -1 edge F...
to-go =-1: Measuring input1, falling
edge
$A_DBB[n] Data byte Reading and writing PLC N10 $A_DBR[5]=16.3 ; Write
$A_DBW[n] Data word variables Real variables
$A_DBD[n] Data double-word ; with offset position 5
$A_DBR[n] Real data ; (position, type and meaning
are agreed between NC and
PLC
)
$AA_FXS Status, - Values: 0 ... 5 N10 IF $AA_FXS[X1]==1
[axis] travel to fixed stop Axis: Machine axis identifier GOTOF ....
$AA_MM Measurement result - Axis: Identifier of an axis (X, Z) N10 R1=$AA_MM[X]
[axis] for an axis in the traversing when measuring
machine coordinate
system
$AA_MW Measurement result - Axis: Identifier of an axis (X, Z) N10 R2=$AA_MW[X]
[axis] for an axis in the traversing when measuring
workpiece coordinate
system

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$AC_MEA Measuring job status - Default condition: N10 IF $AC_MEAS[1]==1
[1] 0: Default condition, probe did GOTOF .... ; Continue
not switch program when probe has
1: Probe switched switched ...
$A..._..._ Timer for run time: 0.0 ... 10+300 System variable:
TIME $AN_SETUP_TIME Time since the control system
min (read only has last booted
$AN_POWERON_TI
value) Time since the control system
ME
has last booted normally N10 IF
$AC_OPERATING_T min (read only Total runtime of all NC $AC_CYCLE_TIME==50.5
IME value)
programs ....
$AC_CYCLE_TIME s Runtime of the NC program
$AC_CUTTING_TIM (only of the selected program)
E s Tool action time

s
$AC_..._ Workpiece counter: 0 ... 999 999 999, System variable:
PARTS $AC_TOTAL_PARTS integer Total actual count
$AC_REQUIRED Set number of workpiece
_PARTS
$AC_ACTUAL_PART Current actual count N10 IF
S Count of workpieces - specified $AC_ACTUAL_PARTS==15
$AC_SPECIAL_PAR by the user ....
TS
$AC_ Number of the active read-only
MSNUM master spindle
$P_ Number of Read-only
MSNUM programmed master
spindle
$P_NUM_ Number of Read-only
SPINDLES configured spindles
$AA_S[n] Actual speed of Spindle number n =1 or =2,
spindle n read-only
$P_S[n] Last programmed Spindle number n =1 or =2,
speed of spindle n read-only
$AC_ Current direction of Spindle number n =1 or =2,
SDIR[n] rotation of spindle n read-only
$P_ Last programmed Spindle number n =1 or =2,
SDIR[n] direction of rotation read-only
of
spindle n
$P_ Number of the active - read-only N10 IF $P_TOOLNO==12
TOOLNO tool T GOTOF ....
$P_TOOL Active D number of - read-only N10 IF $P_TOOL==1
the active tool GOTOF ....
MSG () Message max. 65 characters Message text in inverted MSG("MESSAGE TEXT") ;
commas separate block
...
N150 MSG() ; Clear previous
message

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RND Rounding 0.010 ... 99 Inserts a rounding with the N10 X... Z.... RND=...
999.999 specified radius value N11 X... Z...
tangentially between two
contour blocks
RNDM Modal rounding 0.010 ... 99 - Inserts roundings with the N10 X... Y.... RNDM=.7.3
999.999 specified radius value ;modal rounding ON
tangentially at the following N11 X... Y...
contour corners; special ....
0 feedrate possible:FRCM= ... N100 RNDM=.0 ;modal
- Modal rounding OFF rounding OFF
RPL Angle of rotation with ±0.00001 ... Specification in degrees; angle see ROT, AROT
ROT, AROT 359.9999 for a programmable rotation in
the current plane G17 to G19
SET( , , , ) Set values for the SET: Various values, from the
variable fields specified element up to: DEF REAL
REP() according to the number of VAR2[12]=REP(4.5) ; all
values elements value 4.5
REP: the same value, from the N10 R10=SET(1.1,2.3,4.4) ;
specified element up to the end R10=1.1, R11=2.3, R4=4.4
of the field
SETMS(n) Define spindle as n= 1 or n= 2 n: Number of the spindle, N10 SETMS(2) ; separate
SETMS master spindle if only SETMS is set, the default block, 2nd spindle = master
master spindle comes into
effect
SF Thread starting point 0.001 ... 359.999 Specified in degrees; the thread See G33
when using G33 starting point with G33 will be
offset by the specified value
SPI(n) converts the spindle n =1 or =2,
number n into the axis identifier: e.g. "SP1" or "C"
axis identifier
SPOS spindle position 0.0000 ... 359.9999 specified in degrees; the N10 SPOS=....
spindle stops at the specified N10 SPOS=ACP(...)
position (to achieve this, the N10 SPOS=ACN(...)
spindle must provide the N10 SPOS=IC(...)
SPOS(n) appropriate technical N10 SPOS=DC(...)
prerequisites: position control)
Spindle number n: 1 or 2
STOPFIFO Stops the fast Special function; STOPFIFO; separate block,
machining step filling of the buffer memory until start of filling
STARTFIFO, "Buffer memory N10 X...
full" or "End of program" is N20 X...
detected.
STARTFIFO Start of fast Special function; N30 X...
machining step the buffer memory is filled at the STARTFIFO ;separate block,
same time. end of filling
STOPRE Preprocessing stop Special function; the next block STOPRE ; separate block
is only decoded if the block
before STOPRE is completed.
G05 Activates oblique Can only be set with inclined G05 X...
plunge-cutting axis (TRAANG)
G07 Approach starting Can only be set with inclined G07 X... Z...
position axis (TRAANG)

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10.2 Positional data

10.2.1 Programming dimensions

In this section you will find descriptions of the commands, with which you can directly
program dimensions taken from a drawing. This has the advantage that no extensive
calculations have to be made for NC programming.

Note
The commands described in this section stand in most cases at the start of a NC program.
The way, in which these functions are combined, is not intended to be a patent remedy. For
example, the choice of working plane may be made at another point in the NC program. The
real purpose of this and the following sections is to illustrate the conventional structure of an
NC program.

Overview of typical dimensions

The basis of most NC programs is a drawing with concrete dimensions.
When implementing in a NC program, it is helpful to take over exactly the dimensions of a
workpiece drawing into the machining program. These can be:
● Absolute dimension, G90 modally effective applies for all axes in the block, up to
revocation by G91 in a following block.
● Absolute dimension, X=AC(value) only this value applies only for the stated axis and is
not influenced by G90/G91. This is possible for all axes and also for SPOS, SPOSA
spindle positionings, and interpolation parameters I, J, K.
● Absolute dimension, X=CC(value) directly approaching the position by the shortest route,
only this value applies only for the stated rotary axis and is not influenced by G90/G91. Is
also possible for SPOS, SPOSA spindle positionings.
● Absolute dimension, X=ACP(value) approaching the position in positive direction, only
this value is set only for the rotary axis, the range of which is set to 0... < 360 degrees in
the machine data.
● Absolute dimension, X=ACN(value) approaching the position in negative direction, only
this value is set only for the rotary axis, the range of which is set to 0... < 360 degrees in
the machine data.
● Incremental dimension, G91 modally effective applies for all axes in the block, until it is
revoked by G90 in a following block.
● Incremental dimension, X=IC(value) only this value applies exclusively for the stated axis
and is not influenced by G90/G91. This is possible for all axes and also for SPOS,
SPOSA spindle positionings, and interpolation parameters I, J, K.
● Inch dimension, G70 applies for all linear axes in the block, until revoked by G71 in a
following block.
● Metric dimension, G71 applies for all linear axes in the block, until revoked by G70 in a
following block.

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10.2 Positional data

● Inch dimension as for G70, but applies also for feedrate and length-related setting data.
● Metric dimension as for G71, but applies also for feedrate and length-related setting data.

10.2.2 Plane selection: G17 to G19

Functionality
To assign, for example, tool radius and tool length compensations, a plane with two axes is
selected from the three axes X, Y and Z. In this plane, you can activate a tool radius
compensation.
For drill and cutter, the length compensation (length1) is assigned to the axis standing
vertically on the selected plane (see Section "Tool and tool offsets"). It is also possible to use
a 3-dimensional length compensation for special cases.
Another influence of plane selection is described with the appropriate functions (e.g. Section
"Support for the contour definition programming").
The individual planes are also used to define the direction of rotation of the circle for the
circular interpolation CW or CCW. In the plane in which the circle is traversed, the abscissa
and the ordinate are designed and thus also the direction of rotation of the circle. Circles can
also be traversed in a plane other than that of the currently active G17 to G19 plane (see
Section "Axis Movements").
The following plane and axis assignments are possible:

Table 10- 2 Plane and axis assignments

G function Plane Vertical axis on plane

(abscissa/ordinate) (length compensation axis when drilling/milling)
G17 X/Y Z
G18 Z/X Y
G19 Y/Z X

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Figure 10-3 Planes and axis assignment

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10.2 Positional data

Programming example

N10 G17 T... D... M... ; X/Y plane selected

N20 ... X... Y... Z... ; tool length compensation (length1) in Z axis

10.2.3 Absolute/incremental dimensioning: G90, G91, AC, IC

Functionality
With the instructions G90/G91, the written positional data X, Y, Z, ... are evaluated as a
coordinate point (G90) or as an axis position to traverse to (G91). G90/G91 applies to all
axes.
Irrespective of G90/G91, certain positional data can be specified for certain blocks in
absolute/incremental dimensions using AC/IC.
These instructions do not determine the path by which the end points are reached; this is
provided by a G group (G0, G1, G2 and G3... see Chapter "Axis Movements").

Programming

G90 ; Absolute dimension data

G91 ; Incremental dimension data
X=AC(...) ; Absolute dimensioning for a certain axis (here: X axis), non-modal
X=IC(...) ; Absolute dimensioning for a certain axis (here: X axis), non-modal

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Figure 10-4 Different dimensioning types in the drawing

Absolute dimensioning G90

With absolute dimensioning, the dimensioning data refers to the zero of the coordinate
system currently active (workpiece or current workpiece coordinate system or machine
coordinate system). This is dependent on which offsets are currently active: programmable,
settable, or no offsets.

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10.2 Positional data

Upon program start, G90 is active for all axes and remains active until it is deselected in a
subsequent block by G91 (incremental dimensioning data) (modally active).

Incremental dimensioning G91

With incremental dimensioning, the numerical value of the path information corresponds to
the axis path to be traversed. The leading sign indicates the traversing direction.
G91 applies to all axes and can be deselected in a subsequent block by G90 (absolute
dimensioning).

Specification with =AC(...), =IC(...)

After the end point coordinate, write an equality sign. The value must be specified in round
brackets.
Absolute dimensions are also possible for circle center points using =AC(...). Otherwise, the
reference point for the circle center is the circle starting point.

Programming example

N10 G90 X20 Z90 ; Absolute dimensions

N20 X75 Z=IC(-32) ; X-dimensions remain absolute, incremental Z dimension
...
N180 G91 X40 Z20 ; Switch-over to incremental dimensioning
N190 X-12 Z=AC(17) ; X-remains incremental dimensioning, Z-absolute

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10.2 Positional data

10.2.4 Dimensions in metric units and inches: G71, G70, G710, G700

Functionality
If workpiece dimensions that deviate from the base system settings of the control are present
(inch or mm), the dimensions can be entered directly in the program. The required
conversion into the base system is performed by the control system.

Programming

G70 ; Inch dimensions

G71 ' Metric dimensions
G700 ; Inch dimensions, also for feedrate F
G710 ; Metric dimensions, also for feedrate F

Programming example

N10 G70 X10 Z30 ; Inch dimensions

N20 X40 Z50 ;G70 continues to act
...
N80 G71 X19 Z17.3 ; metric dimensioning from this point on

Information
Depending on the default setting you have chosen, the control system interprets all
geometric values as either metric or inch dimensions. Tool offsets and settable work offsets
including their display are also to be understood as geometrical values; this also applies to
the feedrate F in mm/min or inch/min. The default setting can be set via machine data.
All examples listed in this manual are based on a metric default setting.
G70 or G71 evaluates all geometric parameters that directly refer to the workpiece, either as
inches or metric units, for example:
● Positional data X, Y, Z, ... for G0,G1,G2,G3,G33, CIP, CT
● Interpolation parameters I, J, K (also thread pitch)
● Circle radius CR
● Programmable work offset (TRANS, ATRANS)
● Polar radius RP
All remaining geometric parameters that are not direct workpiece parameters, such as
feedrates, tool offsets, and settable work offsets, are not affected by G70/G71.
G700/G710 however, also affects the feedrate F (inch/min, inch/rev. or mm/min, mm/rev.).

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10.2 Positional data

10.2.5 Polar coordinates, pole definition: G110, G111, G112

Functionality
In addition to the common specification in Cartesian coordinates (X, Y, Z), the points of a
workpiece can also be specified using polar coordinates.
Polar coordinates are also helpful if a workpiece or a part of it is dimensioned from a central
point (pole) with specification of the radius and the angle.

Plane
The polar coordinates refer to the plane activated with G17 to G19. In addition, the third axis
standing vertically on this plane can be specified. When doing so, spatial specifications can
be programmed as cylinder coordinates.

Polar radius RP=...

The polar radius specifies the distance of the point to the pole. It is stored and must only be
written in blocks in which it changes, after changing the pole or when switching the plane.

Polar angle AP=...

The angle is always referred to the horizontal axis (abscissa) of the plane (for example, with
G17: X axis). Positive or negative angle specifications are possible.
The polar angle remains stored and must only be written in blocks in which it changes, after
changing the pole or when switching the plane.

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Figure 10-5 Polar radius and polar angle with definition of the positive direction in different planes

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10.2 Positional data

Pole definition, programming

G110 Pole specification relative to the setpoint position last programmed (in the
plane, e.g. with G17: X/Y)
G111 ; Pole specification relative to the origin of the current workpiece coordinate
system (in the plane, e.g. with G17: X/Y)
G112 ; Pole specification, relative to the last valid pole; preserve plane

Note
Pole specifications
• Pole definitions can also be performed using polar coordinates. This makes sense if a
pole already exists.
• If no pole is defined, the origin of the current workpiece coordinate system will act as the
pole.

Programming example

N10 G17 ; X/Y plane

N20 G111 X17 Y36 ; Pole coordinates in the current workpiece
coordinate system
...
N80 G112 AP=45 RP=27.8 ; New pole, relative to the last pole as a polar
coordinate
N90 ... AP=12.5 RP=47.679 ; Polar coordinate
N100 ... AP=26.3 RP=7.344 Z4 ; Polar coordinate and Z axis (= cylinder
coordinate)

Traversing with polar coordinates

The positions programmed using polar coordinates can also be traversed as positions
specified with Cartesian coordinates as follows:
● G0 - linear interpolation with rapid traverse
● G1 - linear interpolation with feedrate
● G2 - circular interpolation CW
● G3 - circular interpolation CCW
(see also Section "Axis movements").

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10.2 Positional data

10.2.6 Programmable work offset: TRANS, ATRANS

Functionality
The programmable work offset can be used:
● for recurring shapes/arrangements in various positions on the workpiece
● when selecting a new reference point for the dimensioning
● as a stock allowance when roughing
This results in the current workpiece coordinate system. The rewritten dimensions use this
as a reference.
The offset is possible in all axes.

Programming

TRANS X... Y... Z... ; programmable offset, deletes old instructions for offsetting,
rotation, scaling factor, mirroring
ATRANS X... Y... Z... ; programmable offset, additive to existing instructions
TRANS ; without values: clears old instructions for offset, rotation,
scaling factor, mirroring
The instructions that contain TRANS or ATRANS each require a separate block.

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Figure 10-6 Programmable offset (example)

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10.2 Positional data

Programming example

N20 TRANS X20 Y15 ; Programmable translation

N30 L10 ; Subroutine call; contains the geometry to be offset
...
N70 TRANS ; Offset cleared

Subroutine call - see Section "Subroutine technique "

10.2.7 Programmable rotation: ROT, AROT

Functionality
The rotation is performed in the current plane G17 or G18 or G19 using the value of RPL=...
specified in degrees.

Programming

ROT RPL=... ; Programmable rotation, deletes old instructions for offsetting, rotation,
scaling factor, mirroring
AROT RPL=... ; Programmable rotation, additive to existing instructions
ROT ; without values: Clears old instructions for offset, rotation, scaling
factor, mirroring
The instructions that contain ROT or AROT each require a separate block.

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Figure 10-7 Definition of the positive direction of the angle of rotation in the individual planes

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10.2 Positional data



Figure 10-8 Programming example for programmable offset and rotation

Programming example

N10 G17 ... ; X/Y plane

N20 TRANS X20 Y10 ; Programmable translation
N30 L10 ; Subroutine call; contains the geometry to be offset
N40 TRANS X30 Y26 ; New offset
N50 AROT RPL=45 ; Additive 45 degree rotation
N60 L10 ; Subroutine call
N70 TRANS ; Offset and rotation cleared
...

Subroutine call - see Section "Subroutine technique "

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10.2 Positional data

10.2.8 Programmable scaling factor: SCALE, ASCALE

Functionality
A scale factor can be programmed for all axes with SCALE, ASCALE. The path is enlarged
or reduced by this factor in the axis specified. The currently set coordinate system is used as
the reference for the scale change.

Programming

SCALE X... Y... Z... ; Programmable scaling factor, clears old instructions for offset,
rotation, scaling factor, mirroring
ASCALE X... Y... Z... ; Programmable scaling factor, additive to existing instructions
SCALE ; without values: clears old instructions for offset, rotation, scaling
factor, mirroring
The instructions that contain SCALE or ASCALE each require a separate block.

Note
For circles, the same factor should be used in both axes.
If ATRANS is programmed with SCALE/ASCALE active, these offset values are also scaled.

Programming example

N10 G17 ; X/Y plane

N20 L10 ; Programmed contour original
N30 SCALE X2 Y2 ; Contour in X and Z enlarged two times
N40 L10
N50 ATRANS X2.5 Y18 ; Values are also scaled!
N60 L10 ; Contour enlarged and offset

Subroutine call - see Section "Subroutine technique "

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10.2 Positional data

10.2.9 Programmable mirroring: MIRROR, AMIRROR

Functionality
MIRROR and AMIRROR can be used to mirror workpiece shapes on coordinate axes. All
traversing motions of axes for which mirroring is programmed are reversed in their direction.

Programming

MIRROR X0 Y0 Z0 ; Programmable mirroring, clears old instructions for offset,

rotation, scaling factor, mirroring
AMIRROR X0 Y0 Z0 ; Programmable mirroring, additive to existing instructions
MIRROR ; Without values: clears old instructions for offset, rotation,
scaling factor, mirroring
The instructions that contain MIRROR or AMIRROR each require a separate block. The axis
value has no influence. A value, however, must be specified.

Note
Any active tool radius compensation (G41/G42) is reversed automatically when mirroring.
The direction of rotation of the circle G2/G3 is also reversed automatically when mirroring.

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Figure 10-9 Example for mirroring with the tool position shown

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10.2 Positional data

Programming example
Mirroring in different coordinate axes with influence on an active tool radius compensation
and G2/G3:

...
N10 G17 ; X/Y plane, Z standing vertically on it
N20 L10 ; Programmed contour with G41
N30 MIRROR X0 ; Direction changed in X
N40 L10 ; Mirrored contour
N50 MIRROR Y0 ; Direction changed in Y
N60 L10
N70 AMIRROR X0 ; Mirroring once more, but now in X
N80 L10 ; Twice-mirrored contour
N90 MIRROR ; Mirroring off
...

Subroutine call - see Section "Subroutine technique "

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10.2 Positional data

10.2.10 Workpiece clamping - settable work offset: G54 to G59, G500, G53, G153

Functionality
The settable work offset specifies the position of the workpiece zero on the machine (offset
of the workpiece zero with respect to the machine zero). This offset is determined upon
clamping of the workpiece into the machine and must be entered in the corresponding data
field by the operator. The value is activated by the program by selection from six possible
groupings: G54 to G59.

Note
Workpiece clamping at an angle is possible by entering the angles of rotation around the
machine axes. These rotation portions are activated with the offset G54 to G59.

For information on operation, see Section "Setting/changing the work offset"

Programming

G54 ; 1st Settable zero offset

G55 ; 2nd Settable zero offset
G56 ; 3rd Settable zero offset
G57 ; 4th Settable zero offset
G58 ; 5th Settable zero offset
G59 ; 6th Settable zero offset
G500 ; Settable zero offset OFF - modal
G53 ; settable zero offset OFF non-modal, also suppresses programmable offset
G153 ; As with G53; additionally suppresses base frame

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Figure 10-10 Settable zero offset

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10.2 Positional data

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Figure 10-11 Various workpiece clamping positions when drilling/milling

Programming example

N10 G54 ... ; Call first settable zero offset

N20 L47 ; Machining of workpiece 1, here using L47
N30 G55 ... ; Call second settable zero offset
N40 L47 ; Machining of workpiece 2, here using L47
N50 G56 ... ; Call third settable zero offset
N60 L47 ; Machining of workpiece 3, here using L47
N70 G57 ... ; Call fourth settable zero offset
N80 L47 ; Machining of workpiece 4, here using L47
N90 G500 G0 X... ; Deactivate settable zero offset

Subroutine call - see Section "Subroutine technique "

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10.2 Positional data

10.2.11 Programmable working area limitation: G25, G26, WALIMON, WALIMOF

Functionality
With G25, G26, a working area can be defined for all axes in which it is possible to traverse,
with no traversing allowed outside this area. With the tool length compensation active, the
tool tip is decisive; The coordinate parameters are machine-based.
In order to be able to use the working area limitation, it must be activated for the respective
axis. This is done via the input screen under "Offset param" > "Setting data" > "Working area
limit".
There are two options for defining the working area:
● Entering values via the input screen of the control system under "Offset param" > "Setting
data" > "Working area limit".
This makes the working area limitation effective in JOG mode as well.
● Programing with G25/G26
The values for the individual axes can be changed in the part program. The values that
were input in the input screen ("Offset param" > "Setting data" > "Working area limit") are
overwritten.
The working area limitation is enabled/disabled in the program by WALIMON/WALIMOF.

Programming

G25 X... Y... Z... ; Lower working area limitation

G26 X... Y... Z... ; Upper working area limitation
WALIMON ; Working area limitation ON
WALIMOF ; Working area limitation OFF

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Figure 10-12 Programmable working area limitation (example: 2-dimensional)

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10.2 Positional data

Note
• The channel axis designation from MD20080 AXCONF_CHANAX_NAME_TAB should be
used for G25, G26.
With SINUMERIK 802D sl, kinematic transformations (TRANSMIT, TRACYL) are
possible. It is possible that different axis designations for MD20080 and the MD20060
AXCONF_GEOAX_NAME_TAB geometry axis designation are specified here.
• G25, G26 is also used in connection with the address S for the spindle speed limitation
(see also Section "Spindle speed limitation").
• A working area limitation can only be activated if the reference point for the relevant axes
has been approached.

Programming example

N10 G25 X10 Y-20 Z30 ; Values of the lower working area limitation
N20 G26 X100 Y110 Z300 ; Values of the upper working area limitation
N30 T1 M6
N40 G0 X90 Y100 Z180
N50 WALIMON ; Working area limitation ON
... ; Work only within working range limits
N90 WALIMOF ; Working area limitation OFF

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Programming
10.3 Axis movements

10.3 Axis movements

10.3.1 Linear interpolation with rapid traverse: G0

Functionality
The rapid traverse movement G0 is used for rapid positioning of the tool, but not for direct
workpiece machining.
All the axes can be traversed simultaneously - on a straight path.
For each axis, the maximum speed (rapid traverse) is defined in machine data. If only one
axis traverses, it uses its rapid traverse. If two or three axes are traversed simultaneously,
the path velocity (e.g. the resulting velocity at the tool tip) must be selected such that the
maximum possible path velocity with consideration of all axes involved results.
A programmed feedrate (F word) has no meaning for G0. G0 remains active until canceled
by another instruction from this G group (G1, G2, G3, ...).

Programming

G0 X... Y... Z... ; Cartesian coordinates

G0 AP=... RP=... ; Polar coordinates
G0 AP=... RP=... Z... ; Cylindrical coordinates (3dimensional)

Note
Another option for linear programming is available with the angle specification ANG=... (see
Section "Blueprint programming").

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Figure 10-13 Linear interpolation with rapid traverse from point P1 to P2

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10.3 Axis movements

Programming example

N10 G0 X100 Y150 Z65 ; Cartesian coordinate

...
N50 G0 RP=16.78 AP=45 ; Polar coordinate

Information
Another group of G functions exists for movement to the position (see Section "Exact stop /
continuous-path control mode: G9, G60, G64").
For G60 exact stop, a window with various precision values can be selected with another G
group. For exact stop, an alternative instruction with non-modal effectiveness exists: G9.
You should consider these options for adaptation to your positioning tasks.

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Programming
10.3 Axis movements

10.3.2 Linear interpolation with feedrate: G1

Functionality
The tool moves from the starting point to the end point along a straight path. The path
velocity is determined by the programmed F word.
All axes can be traversed simultaneously.
G1 remains active until canceled by another instruction from this G group (G0, G2, G3, ...).

Programming

G1 X... Y... Z... F... ; Cartesian coordinates

G1 AP=... RP=... F... ; Polar coordinates
G1 AP=... RP=... Z... F... ; cylindrical coordinates (3dimensional)

Note
Another option for linear programming is available with the angle specification ANG=... (see
Section "Blueprint programming").

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 Programming
10.3 Axis movements

Programming example

N05 G0 G90 X40 Y48 Z2 S500 M3 ; The tool traverses in rapid traverse on
P1, three axes concurrently, spindle
speed = 500 rpm, clockwise
N10 G1 Z-12 F100 ; Infeed on Z-12, feed 100 mm/min
N15 X20 Y18 Z-10 ; Tool travels on a straight line in
space on P2
N20 G0 Z100 ; Retraction in rapid traverse
N25 X-20 Y80
N30 M2 ; End of program

To machine a workpiece, spindle speed S ... and direction M3/M4 are required (see Section
"Spindle movement").

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Programming
10.3 Axis movements

10.3.3 Circular interpolation: G2, G3

Functionality
The tool moves from the starting point to the end point along a circular path. The direction is
determined by the G function:
G2: clockwise
G3: counter-clockwise

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The description of the desired circle can be given in various ways:

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G2

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 Programming
10.3 Axis movements

G2/G3 remains active until canceled by another instruction from this G group (G0, G1, ...).
The path velocity is determined by the programmed F word.

Programming

G2/G3 X... Y... I... J... ; Center and end point

G2/G3 CR=... X... Y... ; Circle radius and end point
G2/G3 AR=... I... J... ; Opening angle and center point
G2/G3 AR=... X... Y... ; Opening angle and end point
G2/G3 AP=... RP=... ; Polar coordinates, circle around the pole

Note
Further possibilities for circle programming result from:
CT - circle with tangential connection and
CIP - circle via intermediate point (see next sections).

Input tolerances for the circle

Circles are only accepted by the control system with a certain dimensional tolerance. The
circle radius at the starting and end points are compared here. If the difference is within the
tolerance, the center point is exactly set internally. Otherwise, an alarm message is issued.
The tolerance value can be set via machine data (see "Operating Instructions" 802Dsl).

Information
Full circles in a block are only possible if the center point and the end point are specified.
For circles with radius specification, the arithmetic sign of CR=... is used to select the correct
circle. It is possible to program two circles with the same starting and end points, as well as
with the same radius and the same direction. The negative sign in front of CR=-...
determines the circle whose circle segment is greater than a semi-circle; otherwise, the circle
with the circle segment is less than or equal to the semi-circle and determined as follows:

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Programming
10.3 Axis movements

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Figure 10-17 Selection of the circle from two possible circles with radius specification using the sign of
CR=

Programming example: Definition of center point and end point

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Figure 10-18 Example for center point and end point specification

N5 G90 X30 Y40 ; Starting point circle for N10

N10 G2 X50 Y40 I10 J-7 ; End point and center point

Note
Center point values refer to the circle starting point!

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10.3 Axis movements

Programming example: End point and radius specification

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Figure 10-19 Example for end point and radius specification

N5 G90 X30 Y40 ; Starting point circle for N10

N10 G2 X50 Y40 CR=12.207 ; End point and radius

Note
With a negative leading sign for the value with CR=-..., a circular segment larger than a
semi-circle is selected.

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10.3 Axis movements

Programming example: Definition of end point and aperture angle

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N5 G90 X30 Y40 ; Starting point circle for N10

N10 G2 X50 Y40 AR=105 ; End point and aperture angle

Programming example: Definition of center point and aperture angle

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Figure 10-21 Example for center point and aperture angle specification

N5 G90 X30 Y40 ; Starting point circle for N10

N10 G2 I10 J-7 AR=105 ; Center point and aperture angle

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10.3 Axis movements

Note
Center point values refer to the circle starting point!

Programming example: Polar coordinates

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Figure 10-22 Example for circle with polar coordinates

N1 G17 ; X/Y plane

N5 G90 G0 X30 Y40 ; Starting point circle for N10
N10 G111 X40 Y33 ; Pole = circle center
N20 G2 RP=12.207 AP=21 ; Polar specifications

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10.3 Axis movements

10.3.4 Circular interpolation via intermediate point: CIP

Functionality
If you know three contour points of the circle, instead of center point or radius or aperture
angle, then it is advantageous to use the CIP function.
The direction of the circle results here from the position of the intermediate point (between
starting and end points). The intermediate point is written according to the following axis
assignment:
I1=... for the X axis,
J1=... for the Y axis,
K1=... for the Z axis.
CIP remains active until canceled by another instruction from this G group (G0, G1, G2, ...).

Note
The configured dimensional data G90 or G91 applies to the end point and the intermediate
point.

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Programming example

N5 G90 X30 Y40 ;Starting point circle for N10

N10 CIP X50 Y40 I1=40 J1=45 ; End point and intermediate point

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10.3 Axis movements

10.3.5 Circle with tangential transition: CT

Functionality
With CT and the programmed end point in the current plane G17 through G19, a circle is
generated which is connected tangentially to the previous path segment (circle or straight
line) in this plane.
This defines the radius and center point of the circle from the geometric relationships of the
previous path section and the programmed circle end point.

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Programming example

N10 G1 X20 F300 ; Straight line

N20 CT X... Y... ; Circle with tangential connection

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10.3 Axis movements

10.3.6 Fixed point approach: G75

Functionality
By using G75, a fixed point on the machine, e.g. tool change point, can be approached. The
position is stored permanently in the machine data for all axes. A maximum of four fixed
points can be defined for each axis.
No offset is effective. The speed of each axis is its rapid traverse.
G75 requires a separate block and is non-modal. The machine axis identifier must be
programmed!
In the block after G75, the previous G command of the "Interpolation type" group (G0,
G1,G2, ...) is active again.

Programming

G75 FP=<n> X1=0 Y1=0 Z1=0

Note
FPn references with axis machine date MD30600 $MA_FIX_POINT_POS[n-1]. If no FP has
been programmed, then the first fixed point will be selected.

Table 10- 3 Explanation

Command Significance
G75 Fixed point approach
FP=<n> Fixed point that is to be approached. The fixed point number is specified: <n>
Value range of <n>: 1, 2, 3, 4
If no fixed point is specified, fixed point 1 is approached automatically.
X1=0 Y1=0 Z1=0 Machine axes to be traversed to the fixed point.
Here, specify the axes with value "0" with which the fixed point is to be
approached simultaneously.
Each axis is traversed with the maximum axial velocity.

Programming example

N05 G75 FP=1 Z1=0 ; Approach fixed point 1 in Z

N10 G75 FP=2 X1=0 Y1=0 ; Approach fixed point 2 in X and Y,
e. g. to change a tool
N30 M30 ; End of program

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10.3 Axis movements

Note
The programmed position values for X1, Y1, Z1 (any value, here = 0) are ignored, but must
still be written.

10.3.7 Reference point approach: G74

Functionality
The reference point can be approached in the NC program with G74. The direction and
speed of each axis are stored in machine data.
G74 requires a separate block and is non-modal. The machine axis identifier must be
programmed!
In the block after G74, the previous G command of the "Interpolation type" group (G0,
G1,G2, ...) is active again.

Programming example

N10 G74 X1=0 Y1=0 Z1=0

Note
The programmed position values for X1, Y1, Z1 (any value, here = 0) are ignored, but must
still be written.

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10.3 Axis movements

10.3.8 Measuring with touch-trigger probe: MEAS, MEAW

Functionality
The function is available for SINUMERIK 802D sl plus and pro.
If the instruction MEAS=... or MEAW=... is in a block with traversing movements of axes, the
positions of the traversed axes for the switching edge of a connected measuring probe are
registered and stored. The measurement result can be read for each axis in the program.
For MEAS, the movement of the axes is halted when the selected switching edge of the
probe appears and the remaining distance to go is deleted.

Programming

MEAS=1 G1 X... Y... Z... F... ; Measuring with rising edge of the probe, clearing the
distance to go
MEAS=-1 G1 X... Y... Z... F... ; Measuring with falling edge of the probe, clearing the
distance to go
MEAW=1 G1 X... Y... Z... F... ; Measuring with rising edge of the probe, without
clearing the distance to go
MEAW=-1 G1 X... Y... Z... F... ; Measuring with falling edge of the probe, without
clearing the distance to go

CAUTION
For MEAW: Measuring probe travels to the programmed position even after is has
triggered. Risk of destruction!

Measuring job status

If the probe has switched, the variable $AC_MEA[1] after the measuring block has the value
=1; otherwise, value = 0.
At the start of a measuring block, the variable is set to the value=0.

Measuring result
When the probe is successfully activated, the result of the measurement is available for the
axes traversed in the measuring block with the following variables after the measuring block:
in the machine coordinate system: $AA_MM[axis]
in the workpiece coordinate system: $AA_MW[axis]

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Programming example

N10 MEAS=1 G1 X300 Z-40 F4000 ; Measurement with deletion of distance-

to-go,
; Probe with rising edge
N20 IF $AC_MEA[1]==0 GOTOF MEASERR ; Measuring error?
N30 R5=$AA_MW[X] R6=$AA_MW[Z] ; Processing of the measured values
..
N100 MEASERR: M0 ; Measuring error

Note
IF instruction - see Section "Conditional program jumps"

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10.3 Axis movements

10.3.9 Feedrate F

Functionality
The feed F is the path velocity and represents the value of the geometric sum of the velocity
components of all axes involved. The individual axis velocities therefore result from the
portion of the axis path in the overall distance to be traversed.
The feedrate F is effective for the interpolation types G1, G2, G3, CIP, and CT and is
retained until a new F word is written.

Programming

F...

Note
For integer values, the decimal point is not required, e.g. F300.

Unit of measure for F with G94, G95

The dimension unit for the F word is determined by G functions:
● G94: F as the feedrate in mm/min
● G95: Feedrate F in mm/spindle revolutions
(only meaningful when the spindle is running)

Note
This unit of measure applies to metric dimensions. According to Section "Metric and inch
dimensioning", settings with inch dimensioning are also possible.

Programming example

N10 G94 F310 ; Feedrate in mm/min

...
N110 S200 M3 ; Spindle rotation
N120 G95 F15.5 ; Feedrate in mm/revolution

Note
Write a new F word if you change G94 - G95.

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10.3.10 Exact stop / continuous-path control mode: G9, G60, G64

Functionality
G functions are provided for optimum adaptation to different requirements to set the
traversing behavior at the block boundaries and for block advancing. Example: For example,
you would like to quickly position with the axes or you would like to machine path contours
over multiple blocks.

Programming

G60 ; Exact stop, modal

G64 ; Continuous-path mode
G9 ; Exact stop, non-modal
G601 ; Exact stop window fine
G602 ; Exact stop window coarse

Exact stop G60, G9

If the exact stop function (G60 or G9) is active, the velocity for reaching the exact end
position at the end of a block is decelerated to zero.
Another modal G group can be used here to set when the traversing movement of this block
is considered ended and the next block is started.
● G601; Exact stop window fine
Block advance takes place when all axes have reached the "Exact stop window fine"
(value in the machine data).
● G602: Exact stop window coarse
Block advance takes place when all axes have reached the "Exact stop window coarse"
(value in the machine data).
The selection of the exact stop window has a significant influence on the total time if many
positioning operations are executed. Fine adjustments require more time.

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Programming
10.3 Axis movements

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Programming example

N5 G602 ; Exact stop window coarse

N10 G0 G60 Z... ; Exact stop modal
N20 Y... Z... ; G60 continues to act
...
N50 G1 G601 ... ; Exact stop window fine
N80 G64 Z... ; Switching over to continuous-path mode
...
N100 G0 G9 Z... ; Exact stop acts only in this block
N111 ... ; Again continuous-path mode

Note
The G9 command only generates exact stop for the block in which it is programmed; G60,
however, is effective until it is canceled by G64.

Continuous-path control mode G64

The objective of the continuous-path control mode is to avoid deceleration at the block
boundaries and to switch to the next block with a path velocity as constant as possible (in
the case of tangential transitions). The function works with look-ahead velocity control over
several blocks.
For non-tangential transitions (corners), the velocity can be reduced rapidly enough so that
the axes are subject to a relatively high velocity change over a short period of time. This may
lead to a significant jerk (acceleration change). The size of the jerk can be limited by
activating the SOFT function.

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Programming example

N10 G64 G1 Z... F... ; Continuous-path mode

N20 Y.. ; Continuous-path control mode continues to be active
...
N180 G60 ... ; Switching over to exact stop

Look-ahead velocity control:

In the continuous-path control mode with G64, the control system automatically determines
the velocity control for several NC blocks in advance. This enables acceleration and
deceleration across multiple blocks with approximately tangential transitions. For paths that
consist of short travels in the NC blocks, higher velocities can be achieved than without look
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10.3 Axis movements

10.3.11 Acceleration pattern: BRISK, SOFT

BRISK
The axes of the machine change their velocities using the maximum permissible acceleration
value until reaching the final velocity. BRISK allows time-optimized working. The set velocity
is reached in a short time. However, jumps are present in the acceleration pattern.

SOFT
The axes of the machine accelerate along a non-linear, constant characteristic until reaching
the final velocity. With this jerk-free acceleration, SOFT allows for reduced machine load.
The same behavior can also be applied to braking procedures.

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Programming

BRISK ; Jerking path acceleration

SOFT ; Jerk-limited path acceleration

Programming example

N10 SOFT G1 X30 Z84 F650 ; Jerk-limited path acceleration

...
N90 BRISK X87 Z104 ; Continuing with jerking path acceleration
...

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10.3 Axis movements

10.3.12 Percentage acceleration override: ACC

Functionality
Certain program sections can require the axis and spindle acceleration set via the machine
data to be changed using the program. This programmable acceleration is a percentage
acceleration override.
For each axis (e.g. X) or spindle (S), a percentage value >0% and ≤200% can be
programmed. The axis interpolation is then carried out with this proportional acceleration.
The reference value (100%) is the valid machine data value for the acceleration (depending
on whether it is the axis or spindle; for the spindle it depends further on the gear stage and
whether it is in positioning mode or speed mode).

Programming

ACC[axis name] = percentage ; for axis

ACC[S] = percentage ; for spindle

Programming example

N10 ACC[X]=80 ; 80% acceleration for the x axis

N20 ACC[S]=50 ; 50% acceleration for the spindle
...
N100 ACC[X]=100 ; Deactivate the override for the X-axis

Effectivity
The limitation is effective in all interpolation types of the AUTOMATIC and MDA modes. The
limitation is not active in JOG mode and during reference point approach.
The value assignment ACC[...] = 100 deactivates the override; likewise, as do RESET and
End of program.
The programmed override value is also active with dry run feedrate.

CAUTION
A value greater than 100% may only be programmed if this load is permissible for the
machine mechanics and the drives have the corresponding reserves. Failure to adhere to
the limits can lead to damage to the mechanical parts and/or error messages.

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10.3 Axis movements

10.3.13 Fourth axis

Functionality
Depending on the machine variant, a fourth axis may be necessary, e.g. dividing unit,
swiveling dresser, head dresser, etc. This axis can take the form of either a linear or a rotary
axis. The designation of this axis must be configured accordingly, e.g. U, C, or A etc. For
rotary axes, the traversing range can be configured between 0 ...360 degrees (modulo-
behavior).
With an appropriate machine design, the fourth axis can be traversed linear simultaneously
with the remaining axes. If the axis is traversed together with the remaining axes (X, Z) in a
block that contains G1 or G2/G3, no component of the feedrate F is assigned to this axis; its
velocity will depend on the time for traveling along the X and Z axes, and its motion starts
and ends with the remaining path axes. The velocity, however, must not be greater than the
defined limit value.
If in one block only this fourth axis is programmed, the axis will traverse using the active
feedrate F if G1 is active. If the axis is a rotary axis, the unit for F is degrees/min with G94 or
degrees/rev. of the spindle with G95.
For this axis, it is also possible to specify (G54 ... G59) and program (TRANS, ATRANS)
offsets.

Programming example
The fourth axis is a swivel table (rotary axis) and has the axis identifier A:

N5 G94 ; Feedrate F in mm/min or degrees/min

N10 G0 X10 Y20 Z30 A45 ; Traverse X-Y-Z path with rapid traverse, A at the
same time
N20 G1 X12 Y21 Z33 A60 F400 ; Traverse X-Y-Z path at 400 mm/min, A at the same
time
N30 G1 A90 F3000 ; Axis A traverses alone to position 90 degrees at a
speed of 3000 degrees/min

Special instructions for rotary axes: DC, ACP, ACN

For example, for rotary axis A:

A=DC(...) ; Absolute dimensions, approach position directly (on the

shortest path)
A=ACP(...) ; Absolute dimensions, approach position in positive direction
A=ACN(...) ; Absolute dimensions, approach position in negative direction

Example:

N10 A=ACP(55.7) ; Approach absolute position 55.7 degrees in positive direction

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10.3.14 Dwell time: G4

Functionality
Between two NC blocks, you can interrupt the machining for a defined time by inserting a
separate block with G4; e.g. for relief cutting.
The words with F... or S... are only used in this block for the specified time. Any previously
programmed feedrate F or a spindle speed S remain valid.

Programming

G4 F... ; Dwell time in seconds

G4 S... ; Dwell time in spindle revolutions

Programming example

N5 G1 F200 Z-50 S300 M3 ; Feed F; spindle speed S

N10 G4 F2.5 ; Dwell time 2.5 seconds
N20 Z70
N30 G4 S30 ; Dwelling 30 revolutions of the spindle, corresponds
at S=300 rpm and 100% speed override to: t=0.1 min
N40 X... ; Feed and spindle speed remain effective

Note
G4 S.. is only possible if a controlled spindle is available (if the speed specifications are also
programmed via S...).

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10.3 Axis movements

10.3.15 Travel to fixed stop

Functionality
This function is available for 802D sl plus and 802D sl pro.
The travel to fixed stop (FXS = Fixed Stop) function can be used to establish defined forces
for clamping workpieces, such as those required for sleeves and grippers. The function can
also be used for the approach of mechanical reference points. With sufficiently reduced
torque, it is also possible to perform simple measurement operations without connecting a
probe.

Programming

FXS[axis]=1 ; Select travel to fixed stop

FXS[axis]=0 ; Deselect travel to fixed stop
FXST[axis]=... ; Clamping torque, specified in % of the max. torque of the drive
FXSW[axis]=… ; Width of the window for fixed-stop monitoring in mm/degrees

Note
The machine axis identifier should be used as the axis identifier, e.g. X1. The channel axis
identifier (e.g. X) is permitted only if e.g. no coordinate rotation is active and this axis is
directly assigned to a machine axis.
The commands are modal. The traversing path and the selection of the function FXS[axis]=1
must be programmed in one block.

Programming example - selection

N10 G1 G94 ...

N100 X250 Z100 F100 FXS[Z1]=1 FXST[Z1]=12.3 FXSW[Z1]=2
; for Z1 machine axis FXS function selected,
; clamping torque 12.3%,
; window width 2 mm

Note
When selected, the fixed stop must be located between the start and end positions.
The parameters for torque FXST[ ]= and window width FXSW[ ]= are optional. If these are
not written, the values from existing setting data (SD) are in effect. Programmed values are
imported to the setting data. At the start, the setting data are loaded with values from
machine data. FXST[ ]=... or FXSW[ ]=... can be changed in the program at any time. The
changes are applied before traversing movements in the block.

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10.3 Axis movements

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Other programming examples

N10 G1 G94 ...

N20 X250 Z100 F100 FXS[X1]=1 ; Selected for machine axis X1 FXS,
clamping torque and window width from SDs
N20 X250 Z100 F100 FXS[X1]=1 ; Selected for machine axis X1 FXS, 12.3%
FXST[X1]=12.3 clamping torque and window width from SDs
N20 X250 Z100 F100 FXS[X1]=1 ; Selected for machine axis X1 FXS, 12.3%
FXST[X1]=12.3 FXSW[X1]=2 clamping torque and window width 2 mm
N20 X250 Z100 F100 FXS[X1]=1 FXSW[X1]=2 ; Selected for machine axis X1 FXS,
clamping torque from SD, window width 2
mm

Fixed stop reached

When the fixed stop has been reached:
● The distance-to-go is deleted and the position setpoint is manipulated.
● The drive torque increases to the programmed limit value FXST[ ]=... or the value from
SD and then remains constant.
● The monitoring of the fixed stop is active within the specified window width (FXSW[ ]=...
or value from SD).

Deselecting the function

Deselection of the function triggers a preprocessing stop. The block with FXS[X1]=0 must
contain traversing movements.
Example:

N200 G1 G94 X200 Y400 F200 FXS[X1] = 0 ; Axis X1 is retracted from the fixed
stop to position X= 200 mm.

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10.3 Axis movements

Note
The traversing movement to the retraction position must lead away from the fixed stop;
otherwise, damage to the fixed stop or to the machine may result.

The block change takes place when the retraction position has been reached. If no retraction
position is specified, the block change takes place immediately once the torque limit has
been deactivated.

Note
"Measuring with deletion of distance-to-go" ("MEAS" command) and "Travel to fixed stop"
cannot be programmed in the same block.
Contour monitoring is not performed while "Travel to fixed stop" is active.
If the torque limit is reduced too far, the axis will not be able to follow the specified setpoint;
the position controller then goes to the limit and the contour deviation increases. In this
operating state, an increase in the torque limit may result in sudden, jerky movements.
Ensure that the axis can still follow. For this reason, it must be verified that the contour
deviation is not larger than that with unlimited torque.
A rate of rise ramp for the new torque limit can be defined in MD to prevent any abrupt
changes to the torque limit setting (e.g. insertion of a spindle sleeve or quill).

System variable for status: $AA_FXS[axis]

This system variable provides the "Travel to fixed stop" status for the axis specified:
● Value =
– 0: Axis not at fixed stop
– 1: Fixed stop successfully approached
(axis is in fixed-stop monitoring window)
– 2: Approach to fixed stop has failed (axis is not at fixed stop)
– 3: Travel to fixed stop activated
– 4: Fixed stop detected
– 5: Travel to fixed stop is deselected. The deselection is not yet completed.
Query of the system variable in the part program initiates a preprocessing stop.
For SINUMERIK 802D sl, only the static states can be detected before and after
selection/deselection.

Alarm suppression
The issuing of the following alarms can be suppressed with machine data:
● 20091 "Fixed stop not reached"
● 20094 "Fixed stop aborted"
References: "Description of Functions", Section "Travel to fixed stop"

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10.4 Spindle movement

10.4 Spindle movement

10.4.1 Spindle speed S, directions of rotation

Functionality
The spindle speed is programmed in revolutions per minute under the address S provided
that the machine possesses a controlled spindle.
The direction of rotation and the start or end of the movement are specified via M commands
(also see Section "Miscellaneous function M").
M3: Spindle clockwise
M4: Spindle counter-clockwise
M5: Spindle stop

Note
For integer S values, the decimal point can be omitted, e.g. S270.

Information
If you write M3 or M4 in a block with axis movements, the M commands become active
before the axis movements.
Default setting: The axis movements will only start once the spindle has accelerated to
speed (M3, M4). M5 is also issued before the axis movement. However, there is no waiting
for spindle standstill. The axis movements begin before spindle standstill.
The spindle is stopped at program end or with RESET.
At program start, spindle speed zero (S0) is in effect.

Note
Other settings can be configured via machine data.

Programming example

N10 G1 X70 Z20 F300 S270 M3 ; Before the axis traversing X, Z the spindle
accelerates to 270 rpm, clockwise
...
N80 S450 ... ; Speed change
...
N170 G0 Z180 M5 ; Z movement, spindle comes to a stop

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10.4 Spindle movement

10.4.2 Spindle speed limitation: G25, G26

Functionality
In the program, you can limit the limit values that would otherwise apply for a controlled
spindle by writing G25 or G26 and the spindle address S with the speed limit value. This
overwrites the values entered in the setting data at the same time.
G25 and G26 each require a separate block. A previously programmed speed S is
maintained.

Programming

G25 S... ; Lower spindle speed limitation

G26 S... ; Upper spindle speed limitation

Information
The outmost limits of the spindle speed are set in machine data. Appropriate inputs via the
operator panel can activate various setting data for further limiting.

Programming example

N10 G25 S12 ; Lower spindle speed limitation : 12 rpm

N20 G26 S700 ; Upper spindle speed limitation : 700 rpm

Note
G25/G26 are used in conjunction with axis addresses for a working area limitation (see
Section "Working area limitation").

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10.4 Spindle movement

10.4.3 Spindle positioning: SPOS

Functionality
Requirement: The spindle must be technically designed for position control.
With the function SPOS= you can position the spindle in a specific angular position. The
spindle is held in the position by position control.
The speed of the positioning procedure is defined in machine data.
With SPOS=value from the M3/M4 movement, the respective direction of rotation is
maintained until the end of the positioning. When positioning from standstill, the position is
approached via the shortest path. The direction results from the respective start and end
position.
Exception: First movement of the spindle, i.e. if the measuring system is not yet
synchronized. In this case, the direction is specified in machine data.
Other movement specifications for the spindle are possible with SPOS=ACP(...),
SPOS=ACN(...), ... as for rotary axes (see Section "4. Axis").
The spindle movement takes place parallel to any other axis movements in the same block.
This block is ended when both movements are finished.

Programming

SPOS=... ; Absolute position: 0 ... <360 degrees

SPOS=ACP(...) ; Absolute dimensions, approach position in positive direction
SPOS=ACN(...) ; Absolute dimensions, approach position in negative direction
SPOS=IC(...) ; Incremental dimensions, leading sign determines the traversal
direction
SPOS=DC(...) ; Absolute dimensions, approach position directly (on the shortest
path)

Programming example

N10 SPOS=14.3 ; Spindle position 14.3 degrees

...
N80 G0 X89 Z300 SPOS=25.6 ; Positioning spindle with axis movements
; This block is ended when all movements have
finished
N81 X200 Z300 ; The N81 block only begins once the spindle position
from N80 is reached

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Programming
10.4 Spindle movement

10.4.4 Gear stages

Function
Up to 5 gear stages can be configured for a spindle for speed / torque adaptation. The
selection of a gear stage takes place in the program via M commands (see Section
"Miscellaneous function M"):
● M40: Automatic gear stage selection
● M41 to M45: Gear stage 1 to 5

10.4.5 2. Spindle

Function
With SINUMERIK 802D sl plus and 802D sl pro, a 2nd spindle is provided.
For these control systems, the kinematic transformation functions for grinding are possible.
These functions require a second spindle for the driven workpiece.
The main spindle is operated as a rotary axis in these functions.

Master spindle
A series of functions is associated with the master spindle that can only be used with this
spindle:

• G95 ; Rev. feedrate

• G96, G97 ; Constant cutting rate
• LIMS ; upper speed limit for G96, G97
• M3, M4, M5, S... ; simple specifications for direction of rotation, stop and speed
The master spindle is defined via configuration (machine data). Generally it is the main
spindle (spindle 1). A different spindle can be defined as master spindle in the program:

• SETMS(n) ; spindle n (= 1 or 2) is the master spindle as of now.

Switching back can also be performed via:

• SETMS ; configured master spindle is now master spindle again

• SETMS (1) ; Spindle 1 is now master spindle again.
The definition of the master spindle changed in the program is only valid until End of
program/program abort. Thereafter, the configured master spindle is again active.

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 Programming
10.4 Spindle movement

Programming via spindle number

Some spindle functions can also be selected via the spindle number:

S1=..., S2=... ; Spindle speed for spindle 1 or 2

M1=3, M1=4, M1=5 ; Specifications for direction of rotation, stop for
spindle 1
M2=3, M2=4, M2=5 ; Specifications for direction of rotation, stop for
spindle 2
M1=40, ..., M1=45 ; gear stages for spindle 1 (if available)
M2=40, ..., M2=45 ; gear stages for spindle 2 (if available)
SPOS [n] ; Position spindle n
SPI(n) ; Converts spindle number n to axis identifier,
; e.g. "SP1" or "CC"
; n must be a valid spindle number (1 or 2)
; The functions of spindle identifiers SPI(n) and Sn are
identical.
$P_S[n] ; Last programmed speed of spindle n
$AA_S[n] ; Actual speed of spindle n
$P_SDIR[ n ] ; Last programmed direction of rotation of spindle n
$AC_SDIR[ n ] ; Current direction of rotation of spindle n

2 spindles installed
The following can be interrogated in the program via the system variable:

$P_NUM_SPINDLES ; Number of configured spindles (in the channel)

$P_MSNUM ; Number of programmed master spindle
$AC_MSNUM ; Number of the active master spindle

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Programming
10.5 Special functions

10.5 Special functions

10.5.1 Constant cutting rate: G96, G97

Requirement
A controlled spindle must be present.

Functionality
With activated G96 function, the spindle speed is adapted to the currently machined
workpiece diameter (transverse axis) such that a programmed cutting rate S remains
constant on the tool edge:
Spindle speed times diameter = constant.
The S word is evaluated as the cutting rate as of the block with G96. G96 is modally effective
until cancellation by another G function of the group (G94, G95, G97).

Programming

G96 S... LIMS=... F... ; Constant cutting speed ON

G97 ; Constant cutting speed OFF

S ; Cutting rate in m/min.

LIMS= ; Upper limit speed of the spindle with G96, G97
effective
F ; feedrate in mm/revolution –as for G95

Remark:
If G94 instead of G95 was active before, a new appropriate F value must be written!

Rapid traverse
With rapid traverse G0, there is no change in speed.
Exception: If the contour is approached at rapid traverse and the next block contains an
interpolation type G1 or G2, G3, CIP, CT (contour block), then the speed for the contour
block is applied already in the approach block with G0.

Upper speed limit LIMS=

During machining from large to small diameters, the spindle speed can increase significantly.
In this case, it is recommended the upper spindle speed limitation LIMS=... . LIMS is only
effective with G96 and G97.
By programming LIMS=..., the value entered into the setting data (SD 43230:
SPIND_MAX_VELO_LIMS) is overwritten. This SD takes effect when LIMS is not written.
The upper limit speed programmed with G26 or defined via machine data cannot be
overwritten with LIMS=.

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 Programming
10.5 Special functions

Deactivate constant cutting rate: G97

The function "Constant cutting rate" is deactivated with G97. If G97 is active, a programmed
S word is given in RPM as the spindle speed .
If no new S word is programmed, the spindle turns at the last defined speed with G96
function active.

Programming example

N10 ... M3 ; Spindle's direction of rotation

N20 G96 S120 LIMS=2500 ; Activate constant cutting speed, 120 m/min, speed
limit 2,500 r.p.m.
N30 G0 X150 ; no change in speed, because block N31 with G0
N31 X50 Z... ; no change in speed, because block N32 with G0
N32 X40 ; Approach on contour, new speed is automatically set as
is required for the beginning of block N40
N40 G1 F0.2 X32 Z... ; Feedrate 0.2 mm/revolution
...
N180 G97 X... Z... ; Deactivating constant cutting rate
N190 S... ; new spindle speed, r.p.m.

Information
The G96 function can also be deactivated with G94 or G95 (same G group). In this case, the
last programmed spindle speed S is active for the remaining machining sequence if no new
S word is programmed.
The programmable offset TRANS or ATRANS (see section of that name) should not be used
on the transverse axis X or used only with low values. The workpiece zero point should be
located at the turning center. Only then is the exact function of G96 guaranteed.

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Programming
10.5 Special functions

10.5.2 Rounding, chamfer

Functionality
You can insert the chamfer (CHF or CHR) or rounding (RND) elements into a contour corner.
If you wish to round several contour corners sequentially in the same manner, use the
"Modal rounding" (RNDM) command.
You can program the feedrate for the chamfer/rounding with FRC=... (blockwise) or FRCM=
... (modal). If FRC/FRCM is not programmed, the normal feedrate F is applied.

Programming

CHF=… ; Insert chamfer, value: Length of chamfer

CHR=... ; Insert chamfer, value: Side length of the chamfer
RND=... ; Insert rounding, value: Radius of chamfer
RNDM=... ; Modal rounding:
; Value >0: Radius of rounding, modal rounding ON
: This rounding is inserted in all contour corners.
: Value = 0: Modal rounding OFF...
FRC=… ; Non-modal feedrate for chamfer/rounding
,
Value = 0, feedrate in mm/min (G94) or mm/rev (G95)
FRCM=… ; Modal feedrate for chamfer/rounding:
; value >0: Feedrate in mm/min (G94) or mm/rev. (G95),
; modal feedrate for chamfer/rounding ON
; value =0: Modal feedrate for chamfer/rounding OFF
; The feedrate F applies for the chamfer/rounding.

Information
The appropriate instruction CHF= ... or CHR=... or RND=... or RNDM=... is written in the
block with axis movements leading to the corner.
The programmed value for chamfer and rounding is automatically reduced if the contour
length of an involved block is insufficient.
No chamfer/rounding is inserted if
● more than three blocks in the connection are programmed that do not contain any
information for traversing in the plane,
● or a plane change is carried out.
F, FRC, FRCM are not active when a chamfer is traversed with G0.
If the feedrate F is active for chamfer/rounding, it is by default the value from the block which
leads away from the corner. Other settings can be configured via machine data.

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 Programming
10.5 Special functions

Chamfer CHF or CHR

A linear contour element is inserted between linear and circle contours in any combination.
The edge is broken.

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Figure 10-30 Inserting a chamfer with CHR using the example "Between two straight lines"

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Programming
10.5 Special functions

Programming examples of chamfer

N5 F...
N10 G1 X... CHF=5 ; Insert chamfer with chamfer length of 5 mm
N20 X... Z...
...
N100 G1 X... CHR=2 ; Insert chamfer with leg length of 2 mm
N110 X... Z...
...
N200 G1 FRC=200 X... CHR=4 ; Insert chamfer with feedrate FRC
N210 X... Z...

Rounding RND or RNDM

A circle contour element can be inserted with tangential connection between the linear and
circle contours in any combination.

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Programming examples for rounding

N5 F...
N10 G1 X... RND=4 ; Insert 1 rounding with radius 4 mm, feedrate F
N20 X... Z...
...
N50 G1 X... FRCM= ... RNDM=2.5 ; Modal rounding, radius 2.5 mm with
; special feedrate FRCM (modal)
N60 G3 X... Z... ; continue inserting this rounding - to N70
N70 G1 X... Z... RNDM=0 ; Modal rounding OFF
...

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 Programming
10.5 Special functions

10.5.3 Contour definition programming

Functionality
If the end points for the contour are not directly specified in the machining drawing, it is also
possible to use an angle specification ANG=... to determine the straight line. In a contour
corner, you can insert the elements chamfer or rounding. The respective instruction CHR= ...
or RND=... is written in the block, which leads to the corner.
The blueprint programming can be used in blocks with G0 or G1 (linear contours).
Theoretically, any number of straight line blocks can be connected and a rounding or a
chamfer can be inserted between them. Every straight line must be clearly identified by point
values and/or angle values.

Programming

ANG=... ; Angle specification for defining a straight line

RND=... ; Insert rounding, value: Radius of chamfer
CHR=... ; Insert chamfer, value: Side length of the chamfer

Information
The blueprint programming function is executed in the current plane G17 to G19. It is not
possible to change the plane during blueprint programming.
If radius and chamfer are programmed in one block, only the radius is inserted regardless of
the programming sequence.

Angle ANG
If only one end point coordinate of the plane is known for a straight line or for contours
across multiple blocks the cumulative end point, an angle parameter can be used for
uniquely definiting the straight line path. The angle is always referred to the abscissa of the
current plane G17 to G19, e.g. for G17 on the X axis. Positive angles are aligned counter-
clockwise.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 255
Programming
10.5 Special functions

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256 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Programming
10.6 Tool and tool offset

10.6 Tool and tool offset

10.6.1 General Information

Functionality
During program creation for the workpiece machining, you do not have to take tool lengths or
cutting radius into consideration. You program the workpiece dimensions directly, for
example following the drawing.
The tool data must be entered separately in a special data area.
In the program, you will merely call the required tool with its offset data. The control system
performs the required path compensations based on this data to create the described
workpiece. In doing this, automatic compensation of the swivel angle of the grinding wheel
takes place via the basic dimension of the tool such that the geometry of the wheel is always
entered at under 0 degrees. This also applies to fixed, inclined wheels. The maximum
diameter and the wheel width are input into the wheel data image here.

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Programming
10.6 Tool and tool offset

10.6.2 Tool T

Functionality
The tool selection takes place when the T word is programmed. Whether this is a tool
change or only a preselection, is defined in the machine data. For grinding, the tool change
(tool call) takes place directly with the T word.
Note:
If a specific tool has been activated, it remains stored as an active tool beyond the end of the
program and switching off/on of the control.
If you change a tool manually, enter the change also in the control to make sure the control
knows the correct tools. For example, you can start a block with the new T word in MDA
mode.

Programming

T... ; Tool number: 1 ... 32 000

Note
In the control system, you can simultaneously store the following maximum values:
● SINUMERIK 802D sl plus: 7 tools with 9 cutting edges each
● SINUMERIK 802D sl pro: 14 tools with 9 cutting edges each.

Programming example

N10 T1 D1 ; Tool 1 cutting edge 1

...
N70 T588 ; Tool 588

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 Programming
10.6 Tool and tool offset

10.6.3 Tool offset number D

Functionality
It is possible to assign 1 to 9 data fields with different tool offset blocks (for multiple cutting
edges) to a specific tool. If a special cutting tool is required, it can be programmed with D
and the corresponding number.
If no D word is written, D1 is automatically effective.
If D0 is programmed, the offsets for the tool are ineffective.
The tool radius offset numbers are automatically generated when a tool is created (all 9
cutting edges). The cutting edges of the tool have a fixed meaning (geometric position on the
grinding wheel). Cutting edges 1, 3 and 5 describe the left wheel edge, cutting edges 2, 4
and 6 describe the right wheel edge for standard contours.
The same applies for all contours (including free contours) when compensating the dressing
amount, which means that the odd numbers are left (negative wear value) and the even
numbers are right (positive wear value). The wear in direction X (diameter) is the same for all
points (negative for grinding direction in negative direction). Cutting edges 7 to 9 are the
three possible dressers of a wheel. They are permanently assigned to the sections of the
wheel.

Dresser 1 (D7) Left wheel edge

Dresser 2 (D8) Right wheel edge
Dresser 3 (D9) Optional for the diameter and if dresser 1 or 2 is not used.
Option: If the dresser is a diamond roller dresser, which only performs immersion dressing,
dresser 1 is always significant here. The other dressers are not used.

Programming

D... ; Tool offset number: 1 ... 9, D0: No compensations active!

Information
The tool offsets of the T/D fields have permanent meanings that are entered in the tool
management. A list of the parameters appears later in this Section.
Tool length compensations become effective immediately when the tool is active; when no D
number was programmed with the values of D1.
The compensation is retracted with the first programmed traversing of the associated length
compensation axis.
A tool radius compensation must also be activated by G41/G42.

Programming example

Table 10- 4 Tool change:

N10 T1 ; Tool 1 is activated with the associated D1

N11 G0 X... Z... ; the length offset compensation is overlaid here

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Programming
10.6 Tool and tool offset

N50 T4 D2 ; Load tool 4, D2 from T4 is active

…
N70 G0 Z... D1 ; D1 for tool 4 active, only cutting edge changed

Contents of an compensation memory

● Geometrical dimensions: Length, radius
These consist of several components (geometry, wear). The control systems computes
the components to a certain dimension (e.g. overall length 1, total radius). The respective
overall dimension becomes active when the offset memory is activated.
The way in which these values are computed in the axes is determined by the tool type
and the current plane G17, G18, G19.
● The tool type
The tool type determines which geometry data are required and how they will be
computed (wheel types).
● Cutting edge position
For dressers, you must also enter the cutting edge position.
The following figures provide information on the required tool parameters for the respective
tool type.

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 Programming
10.6 Tool and tool offset

10.6.4 Selecting the tool radius compensation: G41, G42

Functionality
A tool with a corresponding D number must be active. The tool radius offset (cutting edge
radius offset) is activated by G41/G42. The controller automatically calculates the required
equidistant tool paths for the programmed contour for the respective current tool radius.
G18 must be active.

Figure 10-35 Tool radius compensation (cutter radius compensation)

Programming

G41 Y... Z... ; Tool radius compensation left of contour

G42 Y... Z... ; Tool radius compensation right of contour

Remark: The selection can only be made for linear interpolation (G0, G1).
Program both axes. If you only specify one axis, the second axis is automatically completed
with the last programmed value.

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Programming
10.6 Tool and tool offset

* *

Figure 10-36 Compensation to the right/left of the contour

Starting the compensation

The tool approaches the contour on a straight line and positions itself vertically to the path
tangent in the starting point of the contour.
Select the start point so as to ensure collision-free traversing.

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Information
As a rule, the block with G41/G42 is followed by the block with the workpiece contour.
However, the contour description may be interrupted by an intervening block that does not
contain information for the contour path, e.g. only M command.

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 Programming
10.6 Tool and tool offset

Programming example

N10 T... F...

N15 Y... Z... ; P0 - starting point
N20 G1 G42 Y... Z... ; Selection right of contour, P1
N30 Y... Z... ; ; Starting contour, circle or straight line

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Programming
10.6 Tool and tool offset

10.6.5 Corner behavior: G450, G451

Functionality
Using the functions G450 and G451, you can set the behavior for non-continuous transition
from one contour element to another contour element (corner behavior) when G41/G42 is
active.
Internal and external corners are detected by the control system automatically. For internal
corners, the intersection of the equidistant paths is always approached.

Programming

G450 ;Transition circle

G451 ;Point of intersection

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Transition circle G450

The tool center point travels around the workpiece external corner in an arc with the tool
radius. In view of the data, for example, as far as the feedrate value is concerned, the
transition circle belongs to the next block containing traversing movements.

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 Programming
10.6 Tool and tool offset

Point of intersection G451

For a G451 intersection of the equidistant paths, the point (intersection) that results from the
center point paths of the tool (circle or straight line) is approached.

10.6.6 Tool radius compensation OFF: G40

Functionality
The compensation mode (G41/G42) is deselected with G40. G40 is also the switch-on
position at the beginning of the program.
The tool ends the block before G40 in the normal end position (compensation vector vertical
to the tangent in the end point); independently of the start angle.
If G40 is active, the reference point is the tool tip. The tool tip then travels to the programmed
point upon deselection.
Always select the end point of the G40 block such that collision-free traversing is
guaranteed!

Programming

G40 Y... Z... ; Tool radius compensation OFF

Remark: The compensation mode can only be deselected with linear interpolation (G0, G1).
Program both axes. If you only specify one axis, the second axis is automatically completed
with the last programmed value.

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Programming example

...
N100 Y... Z... ;Last block on the contour, circle or straight line, P1
N110 G40 G1 Y... Z... ;Switch off tool radius compensation,P2

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Programming
10.6 Tool and tool offset

10.6.7 Special cases of the tool radius compensation

Change of the compensation direction

The G41 ⇄ G42 compensation direction can be changed without writing G40 in between.
The last block that uses the old compensation direction will end at the normal end position of
the compensation vector in the end point. The new compensation direction is executed as a
compensation start (default setting at starting point).

Repetition of G41, G41 or G42, G42

The same compensation can again be programmed without writing G40 in between.
The last block before the new compensation call will end at the normal positon of the
compensation vector in the end point. The new compensation is carried out as a
compensation start (behavior as described for change in compensation direction).

Changing the offset number D

The offset number D can be changed in the compensation mode. A modified tool radius is
active with effect from the block in which the new D number is programmed. Its complete
modification is only achieved at the end of the block. In other words: The modification is
traversed continuously over the entire block, also for circular interpolation.

Cancellation of compensation by M2
If the offset mode is canceled with M2 (program end) without writing the command G40, the
last block with coordinates ends in the normal offset vector setting. No compensating
movement is executed. The program ends with this tool position.

Critical machining cases

When programming, pay special attention to cases where the contour path for inner corners
is smaller than the tool radius; and smaller than the diameter for two successive inner
corners.
Such cases should be avoided.
Also check over multiple blocks that the contour contains no "bottlenecks".
When carrying out a test/dry run, use the largest tool radius you are offered.

Acute contour angles

If very sharp outside corners occur in the contour with active G451 intersection, the control
system automatically switches to transition circle. This avoids long idle motions.

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 Programming
10.6 Tool and tool offset

10.6.8 Example of tool radius compensation

The wheel should have the contour shown in the figure. Dressing takes place from left to
right using MIRROR and G41
Caution: The workpiece zero (XWP) in wheel data must be -110 to be able to program the
contour in workpiece coordinates.

     


 
 
 
   


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N1 ; Contour cut
N10 F... S... M... ; Radius dimension, technological values
N15 G500 ; Work offset "OFF"
N20 MIRROR X0 Z0 ; Begin compensation mode
N30 G90 G0 X-90
N40 Z-10
N50 Y110 ; Approach R55
N60 G41 G64 G1 Z20 F500 ; Dressing contour section ①
N70 Y100
N80 Z60 RND=20 ; Dressing contour section ①
N90 Y60
N100 Z68 ; Dressing contour section ①
N110 Y40 Z98 ; Dressing contour section ①
N120 Z118 ; Dressing contour section ①
N130 Y30 Z123 ; Dressing contour section ①
N140 Z123 ; Dressing contour section ①
N150 G0 Y-90 ;Move clear
N160 MIRROR ; End compensation mode
M17

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Programming
10.7 Miscellaneous function M

10.7 Miscellaneous function M

Functionality
The miscellaneous function M initiates switching operations, such as "Coolant ON/OFF" and
other functionalities.
Various M functions have already been assigned a fixed functionality by the CNC
manufacturer. The functions not yet assigned fixed functions are reserved for free use of the
machine manufacturer.

Note
An overview of the M miscellaneous functions used and reserved in the control system can
be found in section "Overview of instructions".

Programming

M... ;Max. 5 M functions per block

Effect
Activation in blocks with axis movements:
If the functions M0, M1, M2 are contained in a block with traversing movements of the axes,
these M functions become effective after the traversing movements.
The functions M3, M4, M5 are output to the internal interface (PLC) before the traversing
movements. The axis movements only begin once the controlled spindle has ramped up for
M3, M4. For M5, however, the spindle standstill is not waited for. The axis movements
already begin before the spindle stops (default setting).
The remaining M functions are output to the PLC with the traversing movements.
If you would like to program an M function directly before or after an axis movement, insert a
separate block with this M function. Please note: This block interrupts the G64 continuous
path mode and generates exact stop.

Programming example

N10 S...
N20 X... M3 ;M function in the block with axis movement, spindle
accelerates before the X axis movement
N180 M78 M67 M10 M12 M37 ;Max. 5 M functions in the block

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10.7 Miscellaneous function M

Note
In addition to M and H functions, T, D, and S functions can also be transferred to the PLC
(programmable logic controller). In all, a maximum of 10 such function outputs are possible
in a block.

Information
With the SINUMERIK 802D sl plus and 802D sl pro, two spindles are possible. This results in
an expanded programming capability for the M commands - only for the spindles:

M1=3, M1=4, M1=5, M1=40, ... ; M3, M4, M5, M40, ... for spindle 1
M2=3, M2=4, M2=5, M2=40, ... ; M3, M4, M5, M40, ... for spindle 2

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Programming
10.8 H function

10.8 H function

Functionality
With H functions, floating point data (REAL data type - as with arithmetic parameters, see
Section "Arithmetic Parameters R") can be transferred from the program to the PLC.
The meaning of the values for a given H function is defined by the machine manufacturer.

Programming

H0=... to H9999=... ;Max. 3 H functions per block

Programming example

N10 H1=1.987 H2=978.123 H3=4 ;3 H functions in block

N20 G0 X71.3 H99=-8978.234 ;With axis movements in block
N30 H5 ;Corresponds to H0=5.0

Note
In addition to M and H functions, T, D, and S functions can also be transferred to the PLC
(programmable logic controller). In all, a maximum of 10 function outputs of this type are
possible in a part program block.

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 Programming
10.9 Arithmetic parameters (R variables), LUD and PLC variables

10.9 Arithmetic parameters (R variables), LUD and PLC variables

10.9.1 Arithmetic parameter R

Functionality
The arithmetic parameters are used if an NC program is not only to be valid for values
assigned once, or if you must calculate values. The required values can be set or calculated
by the control system during program execution.
Another possibility consists of setting the arithmetic parameter values by operator inputs. If
values have been assigned to the arithmetic parameters, they can be assigned to other
variable-setting NC addresses in the program.

Programming

R0=... to R299=... ;Assign values to the arithmetic parameters

R[R0]=... ;Indirect programming: Assign a value to the arithmetic parameter R,
whose number can be found, e.g. in R0
X=R0 ;Assign arithmetic parameters to the NC addresses, e.g. for the X axis

Value assignments
You can assign values in the following range to the R parameters:
±(0.000 0001 ... 9999 9999)
(8 decimal places, arithmetic sign, and decimal point)
The decimal point can be omitted for integer values. A plus sign can always be omitted.
Example:
R0=3.5678 R1=-37.3 R2=2 R3=-7 R4=-45678.123
Use the exponential notation to assign an extended range of numbers:
± (10-300 ... 10+300)
The value of the exponent is written after the EX characters; maximum total number of
characters: 10 (including leading signs and decimal point)
Range of values for EX: -300 to +300
Example:

R0=-0.1EX-5 ;Meaning: R0 = -0.000 001

R1=1.874EX8 ;Meaning: R1 = 187 400 000

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Programming
10.9 Arithmetic parameters (R variables), LUD and PLC variables

Note
There can be several assignments in one block incl. assignments of arithmetic expressions.

Assignments to other addresses

The flexibility of an NC program lies in assigning these arithmetic parameters or expressions
with arithmetic parameters to other NC addresses. Values, arithmetic expressions and
arithmetic parameters can be assigned to all addresses; Exception: addresses N, G, and L.
When assigning, write the " = " sign after the address character. It is also possible to have an
assignment with a minus sign.
A separate block is required for assignments to axis addresses (traversing instructions).
Example:

N10 G0 X=R2 ;Assignment to X axis

Arithmetic operations/arithmetic functions

When operators/arithmetic functions are used, it is imperative to use conventional
mathematical notation. Machining priorities are set using round brackets. Otherwise,
multiplication and division take precedence over addition and subtraction.
Degrees are used for the trigonometrical functions.
Permitted arithmetic functions: see Section "List of instructions"

Programming example: Calculating with R parameters

N10 R1= R1+1 ;The new R1 is calculated from the old R1

plus 1
N20 R1=R2+R3 R4=R5-R6 R7=R8*R9 R10=R11/R12
N30 R13=SIN(25.3) ;R13 equals sine of 25.3 degrees
N40 R14=R1*R2+R3 ; Multiplication and division take precedence
over addition or subtraction R14=(R1*R2)+R3
N50 R14=R3+R2*R1 ;Result, the same as block N40
N60 R15=SQRT(R1*R1+R2*R2) ;Meaning:
N70 R1= -R1 ;The new R1 is the negative old R1

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10.9 Arithmetic parameters (R variables), LUD and PLC variables

Programming example: Assign R parameters to the axes

N10 G1 G91 X=R1 Z=R2 F300 ;Separate blocks (traversing blocks)

N20 Z=R3
N30 X=-R4
N40 Z= SIN(25.3)-R5 ;With arithmetic operations
...

Programming example: Indirect programming

N10 R1=5 ;Assigning R1 directly value 5 (integer)

...
N100 R[R1]=27.123 ;Indirectly assign R5 the value 27.123

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Programming
10.9 Arithmetic parameters (R variables), LUD and PLC variables

10.9.2 Local User Data (LUD)

Functionality
The operator/programmer (user) can define his/her own variable in the program from various
data types (LUD = Local User Data). These variables are only available in the program in
which they were defined. The definition takes place immediately at the start of the program
and can also be associated with a value assignment at the same time. Otherwise the starting
value is zero.
The name of a variable can be defined by the programmer. The naming is subject to the
following rules:
● A maximum of 32 characters can be used.
● It is imperative to use letters for the first two characters; the remaining characters can be
either letters, underscore or digits.
● Do not use a name already used in the control system (NC addresses, keywords, names
of programs, subroutines, etc.).

Programming / data types

DEF BOOL varname1 ;Boolean typ, values: TRUE (=1), FALSE (=0)
DEF CHAR varname2 ;Char type, 1 ASCII code character: "a", "b", ...
;Numerical code value: 0 ... 255
DEF INT varname3 ;Integer type, integer values, 32 bit value range:
;-2 147 483 648 through +2 147 483 647 (decimal)
DEF REAL varname4 ;Real type, natural number (like arithmetic parameter
R),
;Value range: ±(0.000 0001 ... 9999 9999)
;(8 decimal places, arithmetic sign and decimal point)
or
;Exponential notation: ± (10 to power of -300 ... 10 to
power of +300)
DEF STRING[string length] ; STRING type, [string length]: Maximum number of
varname41 characters
Each data type requires its own program line. However, several variables of the same type
can be defined in one line.
Example:

DEF INT PVAR1, PVAR2, PVAR3=12, PVAR4 ;4 type INT variables

Example for STRING type with assignment:

DEF STRING[12] PVAR="Hello" ; Define variable PVAR with a maximum of

12 characters and assign string "Hello"

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10.9 Arithmetic parameters (R variables), LUD and PLC variables

Fields
In addition to the individual variables, one or two-dimensional fields of variables of these data
types can also be defined:

DEF INT PVAR5[n] ;One-dimensional field, type INT, n: integer

DEF INT PVAR6[n,m] ;Two-dimensional field, type INT, n, m: integer

Example:

DEF INT PVAR7[3] ;Field with 3 elements of the type INT

Within the program, the individual field elements can be reached via the field index and can
be treated like individual variables. The field index runs from 0 to a small number of the
elements.
Example:

N10 PVAR7[2]=24 ;The third field element (with index 2) is assigned

the value 24.

Value assignment for field with SET instruction:

N20 PVAR5[2]=SET(1,2,3) ;After the 3rd field element, different values are
assigned.

Value assignment for field with REP instruction:

N20 PVAR7[4]=REP(2) ;After field element [4] - all are assigned the same
value, here 2.

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Programming
10.9 Arithmetic parameters (R variables), LUD and PLC variables

10.9.3 Reading and writing PLC variables

Functionality
To allow rapid data exchange between NC and PLC, a special data area exists in the PLC
user interface with a length of 512 bytes. In this area, PLC data are compatible in data type
and position offset. In the NC program, these compatible PLC variables can be read or
written.
To this end, special system variables are provided:

$A_DBB[n] ;Data byte (8-bit value)

$A_DBW[n] ;Data word (16-bit value)
$A_DBD[n] ;Data double-word (32-bit value)
$A_DBR[n] ;REAL data (32-bit value)
"n" stands here for the position offset (start of data area to start of variable) in bytes

Programming example

R1=$A_DBR[5] ;Reading a REAL value, offset 5 (starts at byte 5 of range)

Note
The reading of variables generates a preprocessing stop (internal STOPRE).

NOTICE
Writing of PLC tags is generally limited to a maximum of three tags (elements).
Where PLC tags are to be written in rapid succession, one element will be required per
write operation.
If more write operations are to be executed than there are elements available, then block
transfer will be required (a preprocessing stop may need to be triggered).
Example:
$A_DBB[1]=1 $A_DBB[2]=2 $A_DBB[3]=3
STOPRE
$A_DBB[4]=4

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 Programming
10.10 Program jumps

10.10 Program jumps

10.10.1 Jump destination for program jumps

Functionality
A label or a block number serve to mark blocks as jump destinations for program jumps.
Program jumps can be used to branch to the program sequence.
Labels can be freely selected, but must contain a minimum of 2 and a maximum of 8 letters
or numbers of which the first two characters must be letters or underscore characters.
Labels that are in the block that serves as the jump destination are ended by a colon. They
are always at the start of a block. If a block number is also present, the label is located after
the block number.
Labels must be unique within a program.

Programming example

N10 LABEL1: G1 X20 ;LABEL1 is the label, jump destination

...
TR789: G0 X10 Z20 ;TR789 is the label, jump destination
- No block number existing
N100 ... ;Block number can be jump target
...

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Programming
10.10 Program jumps

10.10.2 Unconditional program jumps

Functionality
NC programs process their blocks in the sequence in which they were arranged when they
were written.
The processing sequence can be changed by introducing program jumps.
The jump destination can be a block with a label or with a block number. This block must be
located within the program.
The unconditional jump instruction requires a separate block.

Programming

GOTOF label ;Jump forward (in the direction of the last block of the program)
GOTOB label ;Jump backwards (in the direction of the first block of the
program)
Label ;Selected string for the label (jump label) or block number

3URJUDPH[HFXWLRQ 1*;=


1*272)/$%(/MXPSVWRODEHO/$%(/





1/$%(/5 55
1*272)/$%(/MXPSVWRODEHO/$%(/


/$%(/;=
10(QGRISURJUDP
/$%(/;=

1*272%/$%(/MXPSVWRODEHO/$%(/

Figure 10-42 Unconditional jumps using an example

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 Programming
10.10 Program jumps

10.10.3 Conditional program jumps

Functionality
Jump conditions are formulated after the IF instruction. If the jump condition (value not zero)
is satisfied, the jump takes place.
The jump destination can be a block with a label or with a block number. This block must be
located within the program.
Conditional jump instructions require a separate block. Several conditional jump instructions
can be located in the same block.
By using conditional program jumps, you can also considerably shorten the program, if
necessary.

Programming

IF condition GOTOF label ;Jump forward

IF condition GOTOB label ;Jump backwards
GOTOF ;Jump direction forward (in the direction of the last block
of the program)
GOTOB ;Jump direction backwards (in the direction of the first
block of the program)
Label ;Selected string for the label (jump label) or block number
IF ;Introduction of the jump condition
Condition ;Arithmetic parameter, arithmetic expression for
formulating the condition

Comparison operations

Operators Meaning
== Equal to
<> Not equal to
> greater than
< less than
>= greater than or equal to
<= less than or equal to
The comparison operations support formulating of a jump condition. Arithmetic expressions
can also be compared.
The result of comparison operations is "satisfied" or "not satisfied." "Not satisfied" sets the
value to zero.

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Programming
10.10 Program jumps

Programming example for comparison operators

R1>1 ;R1 greater than 1

1 < R1 ;1 less than R1
R1<R2+R3 ;R1 less than R2 plus R3
R6>=SIN( R7*R7) ; R6 greater than or equal to SIN (R7) squared

Programming example

N10 IF R1 GOTOF LABEL1 ;If R1 is not null then go to the block

having LABEL1
...
N90 LABEL1: ...
N100 IF R1>1 GOTOF LABEL2 ;If R1 is greater than 1 then go to the
block having LABEL2
...
N150 LABEL2: ...
...
N800 LABEL3: ...
...
N1000 IF R45==R7+1 GOTOB LABEL3 ;If R45 is equal to R7 plus 1 then go to the
block having LABEL3
...
Several conditional jumps in the
block:
N10 MA1: ...
...
N20 IF R1==1 GOTOB MA1 IF R1==2 GOTOF MA2 ...
...
N50 MA2: ...

Note
The jump is executed for the first fulfilled condition.

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 Programming
10.10 Program jumps

10.10.4 Program example for jumps

Task
Approaching points on a circle segment:
Existing conditions:
Start angle: 30° in R1
Circle radius: 32 mm in R2
Position spacing: 10° in R3
Number of points: 11 in R4
Position of circle center in Z: 50 mm in R5
Position of circle center in X: 20 mm in R6

5 QXPEHURISRLQWV

;

3RLQW
3RLQW

3RLQW
3RLQW 5
5 5
3RLQW
5


5

5 =


Figure 10-43 Linear approach of points on a circle segment

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Programming
10.10 Program jumps

Programming example

N10 R1=30 R2=32 R3=10 R4=11 R5=50 R6=20 ;Assignment of initial values
N20 MA1: G0 Z=R2*COS (R1)+R5 ;Calculation and assignment to axis
X=R2*SIN(R1)+R6 addresses
N30 R1=R1+R3 R4= R4-1
N40 IF R4 > 0 GOTOB MA1
N50 M2

Explanation
In block N10, the starting conditions are assigned to the corresponding arithmetic
parameters. The calculation of the coordinates in X and Z and the processing takes place in
N20.
In block N30, R1 is incremented by the clearance angle R3, and R4 is decremented by 1.
If R4 > 0, N20 is executed again; otherwise, N50 with End of program.

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 Programming
10.11 Subroutine technique

10.11 Subroutine technique

10.11.1 General information

Usage
Basically, there is no difference between a main program and a subroutine.
Frequently recurring machining sequences are stored in subroutines, e.g certain contour
shapes. These subroutines are called at the appropriate locations in the main program and
then executed.
One form of a subroutine is the machining cycle. Machining cycles contain universally valid
machining scenarios. By assigning values via included transfer parameters, you can adapt
the subroutine to your specific application.

Layout
The structure of a subroutine is identical to that of a main program (see Section "Program
structure"). Like main programs, subroutines contain M2 - end of program in the last block of
the program sequence. This means a return to the program level where the subroutine was
called from.

End of program
The end instruction RET can also be used instead of the M2 program end in the subroutine.
RET must be programmed in a separate block.
The RET instruction is used when G64 continuous-path mode is not to be interrupted by a
return. With M2, G64 is interrupted and exact stop is initiated.

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Programming
10.11 Subroutine technique

0DLQSURJUDP 6HTXHQFH
0$,1


6XESURJUDP
1/&DOO &DOO
1 /
5HWXUQ
 15 

 OO
&D 1;=




1/&DOO
 0
5HWXUQ



0

Figure 10-44 Example of a sequence when a subroutine is called in a two-channel manner.

Subroutine name
The subprogram is given a unique name allowing it to be selected from several subroutines.
When you create the program, the program name may be freely selected provided the
following conventions are observed:
The same rules apply as for the names of main programs.
Example: BUCHSE7
It is also possible to use the address word L... in subroutines. The value can have 7 decimal
places (integers only).
Please observe: With address L, leading zeros are meaningful for differentiation.
Example: L128 ist nicht L0128 oder L00128 !
Dies sind 3 verschiedene Unterprogramme.
Note: The subroutine name LL6 is reserved for tool change.

Subroutine call
Subroutines are called in a program (main or subprogram) with their names. To do this, a
separate block is required.
Example:

N10 L785 ; Subprogram call L785

N20 SHAFT7 ; Subprogram call SHAFT7

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10.11 Subroutine technique

Program repetition P...

If a subroutine is to be executed several times in succession, write the number of times it is
to be executed in the block of the call after the subroutine name under the address P. A
maximum of 9,999 cycles are possible (P1 ... P9999).
Example:

N10 L785 P3 ; Subprogram call L785, 3 cycles

Nesting depth
Subroutines can also be called from a subroutine, not only from a main program. In total, up
to 8 program levels are available for this type of nested call, including the main program
level.

VWOHYHO QGOHYHO UGOHYHO  WKOHYHO

0DLQSURJUDP
6XESURJUDP
6XESURJUDP

6XESURJUDP

Figure 10-45 Execution with 8 program levels

Information
Modal G functions can be changed in the subroutine, e.g. G90 -> G91. When returning to the
calling program, ensure that all modal functions are set the way you need them to be.
Please make sure that the values of your arithmetic parameters used in upper program
levels are not inadvertently changed in lower program levels.
When working with SIEMENS cycles, up to 7 program levels are needed.

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Programming
10.11 Subroutine technique

10.11.2 Calling machining cycles

Functionality
Cycles are technology subroutines that implement a certain machining process in a
universally valid way. Adaptation to the particular problem is performaed directly via supply
parameters/values when calling the respective cycle.

Programming example

N10 CYCLE83(110, 90, ...) ; Call of cycle 83, transfer values directly,
; separate block
…
N40 RTP=100 RFP= 95.5 ... ; Set transfer parameters for cycle 82
N50 CYCLE82(RTP, RFP, ...) ; Call of cycle 82, separate block

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 Programming
10.12 Timers and workpiece counters

10.12 Timers and workpiece counters

10.12.1 Runtime timer

Functionality
The timers are prepared as system variables ($A...) that can be used for monitoring the
technological processes in the program or only in the display.
These timers are read-only. There are timers that are always active. Others can be
deactivated via machine data.

Timers - always active

● $AN_SETUP_TIME
Time since the last control powerup with default values (in minutes)
It is automatically reset in the case of a "Control power-up with default values".
● $AN_POWERON_TIME
Time since the last control powerup (in minutes)
It is reset to zero automatically with each power-up of the control system.

Timers that can be deactivated

The following timers are activated via machine data (default setting).
The start is timer-specific. Each active run-time measurement is automatically interrupted in
the stopped program state or for feedrate-override-zero.
The behavior of the activated timers for active dry run feedrate and program testing can be
specified using machine data.

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Programming
10.12 Timers and workpiece counters

● $AC_OPERATING_TIME
Total execution time in seconds of NC programs in the automatic mode
In the AUTOMATIC mode, the runtimes of all programs between NC START and end of
program / RESET are summed up. The timer is zeroed with each power-up of the control
system.
● $AC_CYCLE_TIME
Runtime of the selected NC program (in seconds)
The runtime between NC Start and End of program / Reset is measured in the selected
NC program. The timer is reset with the start of a new NC program.
● $AC_CUTTING_TIME
Tool action time (in seconds)
The runtime of the path axes is measured in all NC programs between NC START and
end of program / RESET without rapid traverse active and with the tool active (default
setting).
The measurement is interrupted when a dwell time is active.
The timer is automatically set to zero with each power-up of the control system.

Programming example

N10 IF $AC_CUTTING_TIME>=R10 GOTOF WZZEIT ; Tool operation time limit

value?
...
N80 WZZEIT:
N90 MSG("Tool action time: Limit value reached")
N100 M0

Display
The contents of the active system variables are visible on the screen under
<OFFSET PARAM> -> "Setting data" ">" "Times/counters":
Total run time = $AC_OPERATING_TIME
Program run time = $AC_CYCLE_TIME
Feedrate run time = $AC_CUTTING_TIME
Time since cold restart = $AN_SETUP_TIME
Time since warm restart= $AN_POWERON_TIME
"Program run time" is also visible in the AUTOMATIC mode in the "Position" operating area
in the information line.

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10.12 Timers and workpiece counters

10.12.2 Workpiece counter

Functionality
The "Workpiece counter" function provides counters for counting workpieces.
These counters exist as system variables with write and read access from the program or via
operator input (observe the protection level for writing!).
Machine data can be used to control counter activation, counter reset timing and the
counting algorithm.

Counters
● $AC_REQUIRED_PARTS
Number of workpieces required (workpiece setpoint)
In this counter you can define the number of workpieces at which the actual workpiece
counter $AC_ACTUAL_PARTS is reset to zero.
The generation of the display alarm 21800 "Workpiece setpoint reached" can be activated
via machine data.
● $AC_TOTAL_PARTS
Total number of workpieces produced (total actual)
The counter specifies the total number of all workpieces produced since the start time.
The counter is automatically set to zero upon every booting of the control system.
● $AC_ACTUAL_PARTS
Number of actual workpieces (actual)
This counter registers the number of all workpieces produced since the starting time.
When the workpiece setpoint is reached ( $AC_REQUIRED_PARTS, value greater than
zero), the counter is automatically zeroed.
● $AC_SPECIAL_PARTS
Number of workpieces specified by the user
This counter allows users to make a workpiece counting in accordance with their own
definition. Alarm output can be defined for the case of identity with
$AC_REQUIRED_PARTS (workpiece target). Users must reset the counter themselves.

Programming example

N10 IF $AC_TOTAL_PARTS==R15 GOTOF SIST ; Count reached?

...
N80 SIST:
N90 MSG("Workpiece setpoint reached")
N100 M0

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Programming
10.12 Timers and workpiece counters

Display
The contents of the active system variables are visible on the screen under
<OFFSET PARAM> -> "Setting data" ">" "Times/counters":
Total parts= $AC_TOTAL_PARTS
Required parts= $AC_REQUIRED_PARTS
Number of parts =$AC_ACTUAL_PARTS, $AC_SPECIAL_PARTS not available for display
"Number of parts" is also visible in the AUTOMATIC mode in the "Position" operating area in
the information line.

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 Programming
10.13 Multiple feedrate values in one block

10.13 Multiple feedrate values in one block

Function
The "Several feedrates in one block" function can be used independent of external analog
and/or digital inputs to activate
● Different feedrates of an NC block,
● dwell time, and
● Retraction
in synchronism with the movement.
The hardware input signals are combined in one input byte.

Programming

F2=... F3=... In addition to the path feed, you can program up to 2

further feedrates in the block; non-modal
ST=... Dwell time (for grinding technology: sparking-out time);
non-modal
SR=... Return path; non modal. The unit for the retraction path
refers to the current valid unit of measurement (mm or
inch).
FMA [2,x] =... In addition to the path feed, you can program up to 2
FMA[3,x]=... further feedrates per axis in the block; non modal
STA=... Axial dwell time (for grinding technology: sparking-out
time); non-modal
SRA=... Axial return path; non-modal

FMA and F value

The axial feedrate (FMA value) or path feedrate (F value) corresponds to 100% feedrate.
You can use this function to realize feedrates that are smaller than or equal to the axial
feedrate or the path feedrate.

Note
If feedrates, dwell time or return path are programmed for an axis on account of an external
input, this axis must in this block must not be programmed as POSA axis (positioning axis
over multiple blocks).
Look Ahead is also active for multiple feedrates in one block. In this way, the current
feedrate is restricted by the Look Ahead value.

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Programming
10.13 Multiple feedrate values in one block

Example of programming path motion

The path feed is programmed under the address F and remains valid until an input signal is
present. The numerical expansion indicates the bit number of the input that activates the
feedrate when changed:

F3=20 ;3 corresponds to input bit 3

F2=5 ;2 corresponds to input bit 2
ST=1 ;Dwell time (s) input bit 1
SR=0.5 ;Return path (mm) input bit 0

Example of programming axial motion

The axial path feed is programmed under the address FA and remains valid until an input
signal is present.
FMA[3,x]= to FMA[2,x]= can be used to program up to 2 further feeds per axis in the block.
The first expression in the square brackets indicates the bit number of the input; the second
the axis for which the feedrate is to apply

FMA[3, x]=1000 ;Axial feedrate with the value 1000 for X axis, 3
;corresponds to input bit 3

Example of axial dwell time and return path

Dwell time and return path are programmed under the following additional addresses:

STA[x]=... ;Axial dwell time (s) input bit 1

SRA[x]=... ;Axial return path (mm) input bit 0

If input bit 1 is activated for the dwell time or bit 0 for the return path, the distance to go for
the path axes or the relevant single axes is deleted and the dwell time or return started.

Example of several operations in one block

N20 T1 D1 F500 G0 X100 ;Initial setting

N25 G1 X105 F=20 F3=5 ; Roughing with F, finishing withF3,
F2=0.5 ST=1.5 ; smooth-finishing with F2, dwell time 1.5 s
SR= 0.5 ;return path 0.5 mm
N30 ...
…

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 Programming
10.14 Oscillation

10.14 Oscillation

Function
An oscillating axis travels back and forth between two reversal points 1 and 2 at a defined
feedrate, until the oscillating motion is deactivated.
Other axes can be interpolated as desired during the oscillating motion. A continuous infeed
can be achieved via a path movement or with a positioning axis, however, there is no
relationship between the oscillating movement and the infeed movement.
Properties of asynchronized oscillation
● Asynchronous oscillation is active on an axis-specific basis beyond block limits.
● Block-oriented activation of the oscillation movement is ensured by the parts program.
● Combined interpolation of several axes and superimposing of oscillation paths are not
possible.

Programming
The following addresses allow asynchronized oscillation to be activated and controlled from
the part program.
The programmed values are entered in the corresponding setting data with block
synchronization during the main run and remain active until changed again.
Activate, deactivate oscillation: OS
OS[axis] = 1: resistor
OS[axis] = 0: switch off

Parameter

OSP1 [axis]= Position of reversal point 1 (oscillating: left reversal

OSP2 [axis]= point)
Position of reversal point 2 (oscillating: right reversal
point)
OST1 [axis]= Stopping time at reversal points in seconds
OST2 [axis]=
FA[axis]= Feed for oscillating axis
OSCTRL [axis]= (Set, reset options)
OSNSC [axis]= Number of sparking-out strokes
OSE [axis]= End position
OS [axis]= 1 = activate oscillation; 0 = deactivate oscillation

Stopping times at reversal points: OST1, OST2

Hold time Movement in exact stop area at reversal point

-2 Interpolation continues without wait for exact stop
-1 Wait for exact stop coarse

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Programming
10.14 Oscillation

Hold time Movement in exact stop area at reversal point

0 Wait for exact stop fine
>0 Wait for exact stop fine and then wait for stopping time
The unit for the stopping time is identical to the stopping time programmed with G4.

Example of an oscillating axis that should oscillate between two reversal points
The oscillation axis Z must oscillate between 10 and 100. Approach reversal point 1 with
exact stop fine, reversal point 2 with exact stop coarse. Machining is performed with feedrate
250 for the oscillating axis. Three sparking-out strokes must be executed at the end of the
machining operation followed by approach by oscillation axis to end position 200. The
feedrate for the infeed axis is 1, end of the infeed in X direction is at 15.

N20 WAITP(X,Y,Z) ;Initial setting

N30 G0 X100 Y100 Z100 ;Switch over in positioning axis
operation
N40 WAITP(X,Z)
N50 OSP1[Z]=10 OSP2[Z]=100 -> ;Reversal point 1, reversal point 2
-> OSE[Z]=200 -> ;End position
-> OST1[Z]=0 OST2[Z]=–1 -> ;Stopping time at U1: Exact stop fine;
; stopping time at U2: Exact stop coarse
-> FA[Z]=250 FA[X]=1 -> ;Feed for oscillating axis, infeed axis
-> OSCTRL[Z]=(4,0) -> ;Setting options
-> OSNSC[Z]=3 ;Three spark-out strokes
N60 OS[Z]=1 ;Start oscillation
N70 POS[X]=15 ;Starting position X axis
N80 POS[X]=50
N90 OS[Z]=0 ;Stop oscillation
N100 M30

-> can be programmed in a single block.

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 Programming
10.14 Oscillation

Description
The following apply to the oscillating axis:
● Every axis may be used as an oscillation axis.
● Several oscillation axes can be active at the same time (maximum: the number of the
positioning axes).
● Linear interpolation G1is always active for the oscillating axis – irrespective of the G
command currently valid in the program.
The oscillating axis can
● act as an input axis for a dynamic transformation
● act as a guide axis for gantry and combined-motion axes
● be traversed
– without jerk limitation (BRISK) or
– with jerk limitation (SOFT) or
– with acceleration curve with a knee (as positioning axes).

Oscillation reversal points

The current offsets must be taken into account when oscillation positions are defined:
● Absolute specification
OSP1[Z]=value 1
Position of reversal point = sum of offsets + programmed value
● Relative specification
OSP1[Z]=IC(value)
Position of reversal point = reversal point 1 + programmed value
Example:
N10 OSP1[Z]=100 OSP2[Z]=110
.
.
N40 OSP1[Z]=IC(3)

Note
WAITP (axis):
• If oscillation is to be performed with a geometry axis, you must enable this axis for
oscillation with WAITP.
• When oscillation has finished, this command is used to enter the oscillating axis as a
positioning axis again for normal use.

Setting feed, FA
The feedrate is the defined feedrate of the positioning axis. If no feedrate is defined, the
value stored in the machine data applies.

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Programming
10.14 Oscillation

Defining the sequence of motions, OSCTRL

The control settings for the movement are set with enable and reset options.
OSCTRL[oscillating axis] = (set-option, reset-option)
The set options are defined as follows (the reset options deselect the settings):

Reset options
These options are deactivated (only if they have previously been activated as setting
options).

Setting options
These options are switched over. When OSE (end position) is programmed, option 4 is
implicitly activated.

Option value Meaning

0 When the oscillation is deactivated, stop at the next reversal point (default)
only possible by resetting values 1 and 2
1 When the oscillation is deactivated, stop at reversal point 1
2 When the oscillation is deactivated, stop at reversal point 2
3 When the oscillation is deactivated, do not approach reversal point if no
spark-out strokes are programmed
4 Approach end position after spark-out
8 If the oscillation movement is canceled by deletion of the distance-to-go:
then execute spark-out strokes and approach end position if appropriate
16 If the oscillation movement is canceled by deletion of the distance-to-go:
reversal position is approached as with deactivation
32 New feed is only active after the next reversal point
64 FA equal to 0, FA = 0: Path overlay is active
FA not equal to 0, FA <> 0: Speed overlay is active
128 For rotary axis DC (shortest path)
256 0=The sparking out stroke is a dual stroke (default). 1=Single stroke.
Several options are appended with plus characters.
Example:
The oscillating motion for the Z axis should stop at the reversal point 1 when switched off.
Where
● an end position is approached,
● a changed feed acts immediately and should immediately stop the axis after the deletion
of distance-to-go.
OSCTRL[Z] = (1+4,16+32+64)

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Network operation 11
11.1 Network operation prerequisites

Introduction
A network function is available for communicating between the control system and a PG/PC.

Prerequisites
The RCS802 tool is required on the PG/PC for communication.
For connecting the control system via the network, various options are available.
These options are described in the chapters "RCS tool" and "Network operation".
The connections are enabled via the following control system interfaces:
● RS232 interface
● Ethernet peer-to-peer interface
● Interface Ethernet network (available only for SINUMERIK 802D sl)

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Network operation
11.2 RCS802 tool

11.2 RCS802 tool

With the RCS802 tool (Remote Control System), you have a tool for your PG/PC that will
support you in your daily work with SINUMERIK 802D sl.
The RCS802 tool is part of the SINUMERIK802Dsl and is supplied as CD with each control.
You can connect the control system and the PG/PC using the following interfaces:

Table 11- 1 Interfaces

Interfaces SINUMERIK 802D sl RCS802 on PG/PC

RS232 Is available for value, plus and Are available.
pro.
Peer-to-peer Ethernet Is available for value, plus and Are available.
pro.
Ethernet network Only available for SINUMERIK Function that requires a license
802D sl pro.

Functions of the RCS802 tool with license key

NOTICE
You will only obtain the full functionality of the RCS802 tool after importing the license key
RCS802.

Table 11- 2 Functions of the RCS802 tool that require a license

Function RCS802 tool without license key RCS802 tool with license key
Managing projects Yes Yes
Data exchange with Yes Yes
SINUMERIK 802D sl
Commissioning Yes Yes
SINUMERIK 802D sl
Setting-up a share drive No Yes
Remote control No Yes
Screen shot No Yes

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 Network operation
11.2 RCS802 tool

RCS802 tool

Figure 11-1 Explorer window of the RCS802 tool

After starting the RCS802 tool, you will be in OFFLINE mode. In this mode you only manage
files on your PC.
In the ONLINE mode, the directory Control 802 is also available. This directory makes data
exchange with the control system possible. In addition, a remote control function is provided
for process monitoring.
The ONLINE connections from the PG/PC to the control are parameterized/activated via the
"Setting" > "Connection" menu items in the "Connection Settings" dialog box.

Figure 11-2 Connection Settings

Note
The RCS802 tool includes a detailed online help function. Refer to this help menu for further
details e.g. establishing a connection, project management etc.

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Network operation
11.2 RCS802 tool

Operating sequence to make an RS232 connection to the control

6<67(0

 ● You are now in the <SYSTEM> operating area.

$/$50

3/& ● Press the "PLC” softkey.

Figure 11-3 Communication settings RS232

&RQQHFWWR ● Set the parameters for communication in the "STEP 7 Connect" dialog.
67(3

&RQQHFW
RQ ● Activate the RS232 connection with the "Connect. ON" softkey.

Figure 11-4 RS232 connection active

No modifications to the settings are possible in this state.

The softkey label changes to "Connect. OFF".

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 Network operation
11.2 RCS802 tool

In the lower right corner of the screen, the icon shows that the connection to PG/PC via the
RS232 interface is active.

Operating sequence to make an Ethernet peer-to-peer connection to the control

6<67(0

 ● You are now in the <SYSTEM> operating area.

$/$50

6HUYLFH
GLVSOD\
● Press the softkeys "Service display" >"Service control".

6HUYLFH
FRQWURO

Figure 11-5 "Service control"

'LUHFW ● Press the "Direct connect." softkey.

FRQQHFWLRQ
The following message is shown on the HMI:
"Connection is set up"
– IP Address: 169.254.11.22
– Subnet mask: 255.255.0.0
The IP address and subnet mask shown are fixed values.
These values cannot be changed.
'LUHFW ● You can cancel the Ethernet peer-to-peer connection once more using the "Direct
FRQQHFWLRQ connect." softkey.

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Network operation
11.2 RCS802 tool

Operating sequence to make an Ethernet network connection to the control

6<67(0

 ● You are now in the <SYSTEM> operating area.

$/$50

6HUYLFH
GLVSOD\
● Press the softkeys "Service display" >"Service control".
6HUYLFH
FRQWURO

Figure 11-6 "Service control"

6HUYLFH
QHWZRUN ● Press the softkey "Service network" (only available for SINUMERIK 802D sl pro).

Reference
SINUMERIK 802D sl Programming and Operating Manual; Network Operation

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 Network operation
11.3 Network operation

11.3 Network operation

Note
The network function is only available for SINUMERIK 802D sl.

Thanks to the integrated network adapter, the control system is network-capable. The
following connections are possible:
● Ethernet peer-to-peer: Direct connection between control system and PC using a cross-
over cable
● Ethernet network: Integrating the control system into an existing Ethernet network using a
patch cable.
Screened network operation with encrypted data transfer is possible using an 802D specific
transmission protocol. This protocol is used, e.g. for transmitting and executing part
programs in conjunction with the RCS tool.

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Network operation
11.3 Network operation

11.3.1 Configuring the network connection

Prerequisite
The control system is connected to the PC or the local network via the X5 interface.

Entering network parameters

6<67(0

 Switch to the the <SYSTEM> operating area.

$/$50

6HUYLFH
GLVSOD\

6HUYLFH
FRQWURO
Press the "Service display" "Service control system" softkeys.

6HUYLFH
QHWZRUN
Select the "Service network" softkey to display the network configuration window.

Figure 11-7 "Network configuration" start screen

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 Network operation
11.3 Network operation

Table 11- 3 Network configuration required

Parameter Explanation
DHCP DHCP log: A DHCP server is needed in the network which dynamically
distributes the IP addresses.
When No is selected fixed network addresses will be assigned.
When Yes is selected the network addresses are assigned dynamically. Input
fields that are no longer needed will be hidden.
If you selected "yes", the following steps are necessary to activate the fields for
the computer name, IP address and Subnet mask:
1. Press the vertical softkey "Save".
2. Switch the control system off and on again.
Computer name Name of the control system in the network
IP address Network address of the control system (e.g. 192.168.1.1)
Subnet mask Network identification (e.g. 255.255.252.0)

Enabling the communication ports

6HUYLFH
)LUHZDOO
Use the "Service Firewall" softkey to enable or disable communication ports.
To ensure maximum possible safety, all ports not needed should be closed.

Figure 11-8 Firewall configuration

The RCS network requires the ports 80 and 1597 for communication.
To change the port status, select the relevant port using the cursor. Pressing the <Input> key
changes the port status.
Open ports are shown with the checkbox enabled.

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Network operation
11.3 Network operation

11.3.2 User management

6<67(0

 Press the "Service display" "Service control system" softkeys in the <SYSTEM> operating
$/$50 area.

6HUYLFH
GLVSOD\

6HUYLFH
FRQWURO

6HUYLFH
QHWZRUN

$XWKRU
L]DWLRQ Select the "Service network" "Authorization" softkey to display the user account input screen.

Figure 11-9 User accounts

The user accounts serve for saving personal settings of the users. To create a new account,
type the user name and the log-in password in the input fields.
A user account is required for communication between HMI and the RCS tool on the
programming device/PC.
For this purpose the user has to enter this password on the HMI during RCS log-in via
network.
This password is required also, if the user want to communicate with the control system from
the RCS tool.
Use the "Create" softkey to insert a new user into the user management.
Use the "Delete" softkey to delete the selected user from the user management.

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 Network operation
11.3 Network operation

11.3.3 User log in - RCS log in

6<67(0


$/$50

5&6
ORJLQ
In the <SYSTEM> operating area, select the "RCS Connect" softkey. The user log-in input
screen will appear.

Figure 11-10 User log-in

Logon
Type user name and password into the appropriate input fields and select the "Log in"
softkey to confirm your input.
After successful log-in, the user name is displayed in the Current user line.
Select the "Back" softkey to close the dialog box.

Note
This log-in simultaneously serves for user identification for remote connections.

Logoff
Press the "Log off" softkey. This will log out the current user, all user-specific settings are
saved, and any enables already granted are canceled.

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Network operation
11.3 Network operation

11.3.4 Working on the basis of a network connection

The remote access (access to the control system from a PC or from a network) to the control
system is disabled by default.
After log-in of a local user, the following functions are offered to the RCS tool:
● Commissioning functions
● Data transfer (transfer of part programs)
● Remote control for the control system
To grant access to a part of the file system, first share the relevant directories with other
users.

Note
If you share directories with other users, the authorized network nodes are granted access to
the shared files in the control system. Depending on the sharting option, the user can modify
or delete files.

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 Network operation
11.3 Network operation

11.3.5 Sharing directories

This function defines the rights for access of remote users to the file system of the control
system.

Use the Program manager to select the directory you want to share.
Use the "Next..." > "Share" softkeys to open the input screen for sharing the selected
directory.

Figure 11-11 Sharing status

● Select the sharing status for the selected directory:

– Do not share this directory Directory will not be shared
– Share this directory The directory will be shared and a share name must be entered.
● Type an identifier into the Share name field through which authorized users can access
the files in the directory.
● By pressing the "Add" softkey, you arrive at the user list. Select the user. With "Add" you
can make any entries in the "Shared" field.
● Define the user rights (Authorizations).
– Full access User has full access
– Change User may modify files.
– Read User may read files.
– Delete User may delete files.
By pressing the "OK" softkey the set properties are confirmed. As in Windows, shared
directories are marked with a "hand".

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Network operation
11.3 Network operation

11.3.6 Connecting / disconnecting network drives

6<67(0

 Press the "Service display" "Service control system" "Service network" softkeys in the
$/$50 <SYSTEM> operating area.

6HUYLFH
GLVSOD\

6HUYLFH
FRQWURO

6HUYLFH
QHWZRUN

&RQQHFW
'LVFRQQ Use "Connect/Disconnect" to enter the network drive configuration area.

Figure 11-12 Network connections

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 Network operation
11.3 Network operation

Connecting network drives

&RQQHFW The "Connect" function is used to assign a local drive to a network drive.

Note
You have shared a directory for a network connection with a certain user on a programming
device/PC.
The RCS802 tool includes a detailed online help function. The procedure for using this help
function is described in Chapter "RCS802 share drive".

Figure 11-13 Connecting network drives

Sequences of operation for connecting network drives

1. Place the cursor on a free drive.
2. Change to the "Path" input field using the TAB key.
Specify the IP address of the server and the sharing name.
Example: \\157.163.240.241\
&RQQHFW Press "Connect".
The server connection is connected with the drive of the control system.

Note
For example, for executing an external subprogram, please see Chapter "Automatic Mode" -
> "Execution from external".

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Network operation
11.3 Network operation

Disconnecting network drives

'LV
FRQQHFW
By selecting the ">>Back" softkey and the "Disconnect" function you can disconnect an
existing network connection.
1. Place the cursor on the relevant drive.
2. Press the "Disconnect" softkey.
The selected network drive is disconnected from the control.

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Data Backup 12
12.1 Data transfer via RS232 interface

Functionality
The RS232 interface of the control system can be used to output data (e.g. part programs) to
an external data backup device or to read in data from there. The RS232 interface and your
data backup device must be matched with each other.

Operating sequence

You have selected the <PROGRAM MANAGER> operating area and you are in the overview
of the NC programs already created.
Select the data to be transmitted using either the cursor or the "Select all" softkey,

&RS\ and copy the data to the clipboard.

56 Press the "RS232" softkey and select the desired transfer mode.

Figure 12-1 Reading out a program

6HQG Press "Send" to start the data transfer. All data copied to the clipboard will be transmitted.

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Data Backup
12.1 Data transfer via RS232 interface

Further softkeys

5HFHLYH Load files via the RS232 interface.

0RUH

The following function is provided at this level:

(UURU
ORJ
Transmission protocol
This log contains all transmitted files including status information:
● For files to be output
: name of file
error log
● For files to be input
: name of file and path
error log

Table 12- 1 Transmission messages

OK Transmission completed successfully

ERR EOF End-of-text character received, but archive file incomplete
Time Out The time monitoring is reporting an interruption of the data transfer
User Abort Data transfer aborted by the <Stop> softkey
Error Com Error at the COM 1 port
NC / PLC Error Error message from the NC
Error Data Data error
1. Files read in with / without header
or
2. Files transmitted without file names in the punched-tape format
Error File Name The file name does not correspond to the name convention of the
NC.

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 Data Backup
12.2 Creating / reading in / reading out a start-up archive

12.2 Creating / reading in / reading out a start-up archive

References
SINUMERIK 802D sl Operating Instructions for Turning, Milling, Grinding, Nibbling; Data
Backup and Series Start-Up

Operating sequence

6<67(0


$/$50

6WDUWXS
ILOHV Press the "Start-up files" softkey in the <SYSTEM> operating area.

Creating a start-up archive

A start-up archive can be created either with all components or with some selected
components.
To create an archive with selected components, the following operator actions are required:
'GDWD
Press "802D data". Please select the line "Start-up archive (drive/NC/PLC/HMI)" using the
direction keys.

Press the "Input" key to open the directory and select the desired lines using the "Select"
key.

&RS\ Press the "Copy" softkey. The files are copied to the clipboard.

Figure 12-2 Copy entire start-up archive

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Data Backup
12.2 Creating / reading in / reading out a start-up archive

Figure 12-3 Contents of the start-up archive

By pressing the <Select> key, the respective files can be individually selected/deselected in
the start-up archive.

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 Data Backup
12.2 Creating / reading in / reading out a start-up archive

Writing the start-up archive to a customer CompactFlash card/USB FlashDrive

Requirement: The CompactFlash Card/USB FlashDrive is inserted, and the start-up archive
has been copied to the clipboard.
Operating sequence:

&XVWRPHU
&)FDUG or

86%
GULYH Press the "Customer CF card" or "USB drive" softkey. In the directory, select the saving
location (directory).

3DVWH Use the "Insert" softkey to start writing of the start-up archive.
In the dialog that follows, confirm the name that is specified or enter a new name. Close the
dialog box by pressing "OK".

Figure 12-4 Insert files

Reading in start-up archive from customer CompactFlash card/USB FlashDrive

To import a start-up archive, perform the following operator actions:
1. CompactFlash card/USB FlashDrive are inserted
2. Press the "Customer CF card"/"USB drive" softkey and select the line with the desired
archive file.
3. Press "Copy" to copy the file to the clipboard.
4. Press the "802D data" softkey and position the cursor on the start-up archive
(drive/NC/PLC/HMI) line.
5. Press the "Paste" softkey; commissioning starts.
6. Acknowledge the start dialog on the control system.

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Data Backup
12.3 Reading in / reading out PLC projects

12.3 Reading in / reading out PLC projects

When reading in a project, this will be transferred to the file system of the PLC and then
activated. To complete the activation, the control system is restarted (warm start).

Reading in project from CompactFlash card/USB FlashDrive

To read in a PLC project, perform the following operator actions:
1. CompactFlash card/USB FlashDrive are inserted
2. Press the "Customer CF card"/"USB drive" softkey and select the line with the desired
project file in PTE format.
3. Press "Copy" to copy the file to the clipboard.
4. Press the "802D data" softkey and position the cursor on the PLC Project (PT802D
*.PTE) line.
5. Press the "Paste" softkey; reading in and activation starts.

Writing project to CompactFlash card/USB FlashDrive

Perform the following operator actions:
1. CompactFlash card/USB FlashDrive are inserted
2. Select the "802D data" softkey and position the direction keys on the PLC project
(PT802D *.PTE) line.
3. Press "Copy" to copy the file to the clipboard.
4. Press the "Customer CF card"/"USB drive" softkey and select the saving location for the
file.
5. Press the "Paste" softkey; the writing process starts.

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 Data Backup
12.4 Copying and pasting files

12.4 Copying and pasting files

In the <PROGRAM MANAGER> operating area and in the "Start-up files" function, files or
directories can be copied into another directory or onto a different drive using the softkey
functions "Copy" and "Paste". When doing so, the "Copy" function enters the references to
the files or directories in a list which is subsequently executed by the "Paste" function. This
function will perform the actual copying process.
The list is kept until a new copying process overwrites this list.
Special situation:
If the RS232 interface has been selected as the data target, "Paste" will be replaced by the
"Send" softkey function.. When reading in files ("Receive" softkey), it is not necessary to
specify a target, since the name of the target directory is not contained in the data flow.

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Data Backup
12.4 Copying and pasting files

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PLC diagnostics 13
Functionality
A PLC user program consists to a large degree of logical operations to realize safety
functions and to support process sequences. These logical operations include the linking of
various contacts and relays. As a rule, the failure of a single contact or relay results in a
failure of the whole system/installation.
To locate causes of faults/failures or of a program error, various diagnostic functions are
offered in the "System" operating area.

Operating sequence

6<67(0


$/$50

3/& Press the "PLC" softkey in the <SYSTEM> operating area.

3/&
SURJUDP Press "PLC program".
The project stored in the residual memory is opened.

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PLC diagnostics
13.1 Screen layout

13.1 Screen layout

The screen layout with its division into the main areas corresponds to the layout already
described in section "Software Interface".
Any deviations and supplements pertaining to the PLC diagnostics are shown in the
following screen.

   

Figure 13-1 Screen layout

Table 13- 1 Key to screen layout

Screen item Display Meaning

① Application area
② Supported PLC program language
③ Name of the active program block
Representation: Symbolic name (absolute name)
④ Program status
RUN Program is running
STOP Program stopped
Status of the application area
Sym Symbolic representation
abs Absolute representation
⑤ Display of the active keys
⑥ Focus
Performs the tasks of the cursor
⑦ Tip line
contains notes for searching

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 PLC diagnostics
13.2 Operating options

13.2 Operating options

In addition to the softkeys and the navigation keys, this area provides still further key
combinations.

Hotkeys
The cursor keys move the focus over the PLC user program. When reaching the window
borders, it is scrolled automatically.

Table 13- 2 Hotkeys

Keystroke combination Action

To the first line of the row

or

To the last line of the row

or

Up a screen

Down a screen

One field to the left

One field to the right

Up a field

Down a field

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PLC diagnostics
13.2 Operating options

Keystroke combination Action

To the first field of the first network

or

To the last field of the first network

or

Opens the next program block in the same window

Opens the previous program block in the same window

and

The function of the Select key depends on the position of the input
focus.
• Table line: Displays the complete text line
• Network title: Displays the network comment
• Command: Displays the complete operands
If the input focus is positioned on a command, all operands
including the comments are displayed.

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 PLC diagnostics
13.2 Operating options

Softkeys

3/&
LQIR
The following PLC properties are shown with this softkey:
● Mode
● Name of the PLC project
● PLC system version
● Cycle time
● Machining time of the PLC user program

Figure 13-2 PLC info

By pressing the "Reset machining time" softkey, machining time data is reset.

3/&
VWDWXV
The values of the operands can be monitored and changed during program execution using
the "PLC status display" window.

Figure 13-3 PLC status display

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PLC diagnostics
13.2 Operating options

6WDWXV
OLVW
Use the "Status list" softkey to display and modify PLC signals.

Figure 13-4 Status list

:LQGRZ
2% Using the "Window 1 ..." and "Window 2 ..." softkeys you can display any logical and
graphical information of a program block. The program block is one of the components of the
PLC user program.
The program block can be selected in the "Program list" using the "Open" softkey. The name
of the program block will be displayed on the softkey (for "..." e.g. "Window 1 SBR16").
The logics in the ladder diagram (LAD) display the following:
● Networks with program parts and current paths
● Electrical current flow through a number of logical operations

Figure 13-5 Window 1, OB1

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 PLC diagnostics
13.2 Operating options

3URJUDP This softkey can be used to select the list of the PLC program blocks.
EORFN

Figure 13-6 Select the PLC program block

3URSHU
WLHV
Using this softkey will display the following properties of the selected program block:
● Symbolic name
● Author
● Comments

Figure 13-7 Properties of the selected PLC program block

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PLC diagnostics
13.2 Operating options

/RFDO Selecting this softkey displays the table of local variables of the selected program block.
YDULDEOHV
There are two types of program blocks.
● OB1 only temporary local variable
● SBRxx temporary local variable

Figure 13-8 Table of local variables for the selected PLC program block

The text of the current cursor position is additionally displayed in a text field above the table.
With longer texts, it is possible to display the whole text by pressing the SELECT key.

&RYHU When a program block is protected by a password, this softkey can be used to enable the
display of the ladder diagram.
A password is required for this. The password can be allocated during creation of a program
block in Programming Tool PLC802.
2SHQ The selected program block is opened.
The name (absolute) of the program block will then be displayed on "Window 1..." softkey
(for "..." e.g. "Window 1 OB1").

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 PLC diagnostics
13.2 Operating options

3URJUDP Selecting this softkey activates or deactivates the program status display.
VWDW2))
You can monitor the current status of the networks from the PLC cycle end.
The states of all operands are displayed in the "Program status" ladder diagram (top right in
the window). This LAD acquires the values for the status display in several PLC cycles and
then refreshes the status display.

Figure 13-9 "Program status" ON – symbolic representation

Figure 13-10 "Program status" ON – absolute representation

6\PEROLF
DGGUHVV
Use this softkey to switch between the absolute and symbolic representation of the
operands. The softkey labelling changes accordingly.
Depending on the selected type of representation, the operands are displayed either with
absolute or symbolic identifiers.
If no symbol exists for a variable, this is automatically displayed absolutely.

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PLC diagnostics
13.2 Operating options

=RRP

The representation in the application area can be zoomed in or zoomed out step by step.
The following zoom stages are provided:
=RRP

20% (default), 60%, 100% and 300%

)LQG Can be used to search for operands in the symbolic or absolute representation (see
following screen).
A dialog box is displayed from which various search criteria can be selected. Use the
"Absolute/symbol. address" softkey to search for a certain operand matching this criterion in
both PLC windows (see the following screen). When searching, uppercase and lowercase
letters are ignored.
Selection in the upper toggle field:
● Search for absolute and symbolic operands
● Go to network number
● Find SBR command
Further search criteria:
● Search direction down (from the current cursor position)
● Whole program block (from the beginning)
● In one program block
● Over all program blocks
You can search for the operands and constants as whole words (identifiers).
Depending on the display settings, you can search for symbolic or absolute operands.
"OK" starts the search. The found search element is highlighted by the focus. If nothing is
found, an appropriate error message will appear in the notes line.
Use the "Abort" softkey to exit the dialog box. no search is carried out.

Figure 13-11 Search for symbolic operands

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 PLC diagnostics
13.2 Operating options

Figure 13-12 Search for absolute operands

If the search object is found, use the "Continue search" softkey to continue the search.

6\PERO
LQIR
Selecting this softkey displays all symbolic identifiers used in the highlighted network.

Figure 13-13 Network symbol information table

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PLC diagnostics
13.2 Operating options

&URVV Use this softkey to display the list of cross references. All operands used in the PLC project
UHIV are displayed.
This list indicates in which networks an input, output, flag etc. is used.

Figure 13-14 Cross references main menu (absolute)

Figure 13-15 Cross references main menu (symbolic))

2SHQLQ
ZLQGRZ
You can open the appropriate program segment directly in the 1/2 window using the "Open
in Window 1" or "Open in Window 2" function.

6\PEROLF
DGGUHVV
Use this softkey to switch between the absolute and symbolic representation of the
components. The softkey labelling changes accordingly.
Depending on the selected type of representation, the components are displayed either with
absolute or symbolic identifiers.

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 PLC diagnostics
13.2 Operating options

If no symbol exists for an identifier, the description is automatically absolute.

The type of representation is displayed in the status line at the top right of the window (e.g.
"Abs"). The absolute representation is set by default.
Example:
You want to view the logic interrelation of the absolute operand M251.0 in network 2 in
program block OB1.
After the operand has been selected from the cross-reference list and the "Open in Window
1" softkey has been pressed, the corresponding program section is displayed in window 1.
&URVV
UHIV

Figure 13-16 Cursor M251.0 in OB1 network 2

2SHQLQ
ZLQGRZ

Figure 13-17 M251.0 in OB1 network 2 in window 1

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PLC diagnostics
13.2 Operating options

Searching operands in the cross-reference list (see following screen).

)LQG
You can search for the operands as whole words (identifiers). When searching, uppercase
and lowercase letters are ignored.
Search options:
● Search for absolute and symbolic operands
● Go to line
Search criteria:
● Down (from the current cursor position)
● Whole program block (from the beginning)

Figure 13-18 Searching for operands in cross references

The text you are looking for is displayed in the notes line. If the text is not found, a
corresponding error message is displayed which must be confirmed with "OK".

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Appendix A
A.1 User data
The user data is internally processed in the grinding cycles. They are stored in the program
manager of the control system (in the directory \DEF) as a definition file and remain stored
even when the control is switched off and on.

Description of the user data

The parameters included in the definition files are described as follows:

Name Type Default Description

Value
_GC_LERF REAL Detected longitudinal position when setting up
_GC_LVER REAL Offset during longitudinal position sensing
_GC_LNPVZ REAL Initial Z zero shift during calibration
_GC_LXPOS REAL X position while longiitudinal position is sensed
_GC_PARR[20] REAL REAL type parameters for inter cycle as well as cycle HMI
communication
_GC_PAR[0] INT 0/1 Selection of the type of plunging feedrate in mm/min / specific cutting
volumes
_GC_PAR[1] INT 0/1 Selection of the longitudinal grinding feedrate in mm/min or mm/rev
_GC_PARI[20] INT INTEGER type parameters for inter cycle as well as cycle HMI
communication
_GC_SYNC INT 0 HMI synchronisation parameters
_GC_SYNC INIRE INT 0 Delete synchronisation parameters on reset
_GC_WPC INT 0 Workpiece counter for dressing interval
_GC_BAXIS STRING[10] Name of the swivel axis
_GC_DNUM INT 7 D number for the 1st data block of dressing data in the tool
compensation
_GC_KNVX INT 0 There it is defined how the detected offset will be taken into account
in X:
0 ... Through work offset (NV)
1 ... as wheel diameter offset
_GC_KORR INT 0 Selection of measurement control compensation computation
0 ... Compensation of the setpoint-actual value difference in the wear
of the wheel / dresser
1 ... Compensation of the setpoint-actual value difference in WO in X
2 ... No compensation of the setpoint-actual value difference
_GC_MF[20] INT M command number

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Appendix
A.1 User data

Name Type Default Description

Value
_GC_MF[0] INT 3 Grinding spindle direction of rotation (M3)
_GC_MF[1] 21 Swing in measurement control (M21)
_GC_MF[2] 22 Swing out measurement control (M22)
_GC_MF[3] 33 Structure-borne noise ON (M33)
_GC_MF[4] 34 Structure-borne noise OFF (M34)
_GC_MF[5] 41 Advance dresser (M41)
_GC_MF[6] 42 Retract dresser (M42)
_GC_MF[7] 65 Swing out caliper (M65)
_GC_MF[8] 66 Swing in caliper (M66)
_GC_MF[9] 80 Enable handwheel (M80)
_GC_MF[10] 81 Disable handwheel (M81)
_GC_MF[11] 4 Workpiece spindle direction of rotation (M4)
_GC_MF[12] . 7 Coolant ON (M7)
_GC_MF[13] 9 Coolant OFF (M9)
_GC_MF[14] Swing in measurement control, program control (M23)
_GC_MF[15] Swing out measurement control, program control (M24)
_GC_MF[16] Disable stroke reversal if no longitudinal stroke (M27)
_GC_MF[17] Enable stroke reversal if longitudinal stroke (M28)
Number of inputs IN:
_GC_IN_KS INT 16 Acoustic emission sensor
_GC_IN_MZ0 INT 9 Retract measurement control
_GC_IN_MZ1 INT 10 Time measurement control
_GC_IN_MZ2 INT 11 Switch-over fine finishing measurement control
_GC_IN_MZ3 INT 12 Switch-over finishing measurement control
_GC_IN_MZ4 INT 13 Reserved for inputs/outputs
_GC_IN_ABR INT 14 Intermediate dressing upon key
_GC_IN_HAND INT 15 Handwheel key
_GC_IN_BREAK INT 13 Program interrupt key
_GC_IN_HUB INT 12 Stroke reversal key
_GC_IN_FEEDSTOP INT 11 Infeed stop key
_GC_WEARTYP INT 0 Selection of wear compensation, comparison or nominal dimensions
_GC_SSTAT INT Selection ... with/without grinding spindle monitoring
_GC_FEIN[2] REAL Global fine compensation
_GC_FEIN[0] REAL Incremental X fine compensation
_GC_FEIN[1] Incremental Z fine compensation
_GC_SFEIN[10,2] REAL Fine compensation seat-specific
1st index … seat number
2nd index ... axis
_GC_RLZTYP INT 0 Do not approach the return position of the Z-axis in -1-, MCS=0
WCS=1
_GC_RLXTYP INT 0 Type of return position in
_GC_RLX REAL X return position; dresser or workpiece can be collision-free
approached using a machine specific return position
_GC_RLZ REAL Z return position; dresser or workpiece can be approached without
collision using a machine-specific return position.
_GC_BT REAL Measurement control tolerance in which a measurement control
signal is expected

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 Appendix
A.1 User data

Name Type Default Description

Value
_GC_FWEG REAL Free wheel travel path (measurement control)
_GC_SEARCHS Tag for seat regrinding is evaluated by the cycles so that the
individual seat can be identified via a block search.
_GC_SEARCH Tag for seat regrinding is evaluated by the cycles so that the
individual seat can be identified via a block search.
_GC_SEARCHSET Tag for seat regrinding is evaluated by the cycles so that the axes
can be recalibrated.
_GC_SEACRHVALUE[ Regrinding calibration values
0..2]
_GC_SUGFEED Independent of basic system
0 = GWPS in m/s
1 = GWPS in feed/min
_GC_MF[18] Enable program level abort of CYCLE448
_GC_MF[19] Blocking and resetting of last program level abort

NOTICE
The values stored as the default must be checked by the machine manufacturer and
adapted to the realities of the machine.

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Appendix
A.2 Parameter tables of the tool data

A.2 Parameter tables of the tool data

The following parameters, operated from the HMI, are available for the tool offsets.

Table A- 1 Grinding wheel data, x=[1...n] y=[1...6]

Tx TPG1 INT Spindle number

Tx TPG2 INT Concatenation rule = 0
Tx TPG3 REAL Min. wheel diameter
Tx TPG4 REAL Min. wheel width
Tx TPG5 REAL Current grinding wheel width
Tx TPG6 REAL Maximum speed
Tx TPG7 REAL Maximum GWPS
Tx TPG8 REAL Angle of inclined wheel
Tx TPG9 INT Parameter no. for radius calculation

Tx TPC1 REAL Wheel type (vertical, inclined, free)

Tx TPC2 REAL Amount of crown
Tx TPC3 REAL Dressing amount
Tx TPC4 REAL Cylindric compensation
Tx TPC5 REAL GWPS
Tx TPC6 REAL GWPS ratio
Tx TPC7 REAL Bypassing strategy (obstacle diameter)
Tx TPC8 REAL Basic cutting edge for dressing contour
Tx TPC9 REAL X shift
Tx TPC10 REAL Z shift

Table A- 2 1. Cutting edge 2. Cutting edge for left/right wheel edge for grinding wheel

Tx Dy DP1 INT Tool type=403

Tx Dy DP2 INT Cutting edge position (1...9)
Tx Dy DP3 REAL D - Diameter of the new wheel
Tx Dy DP4 REAL L - Distance of the wheel reference point
Tx Dy DP5 REAL (reserved, length 3)
Tx Dy DP6 REAL R - Tool nose radius
Tx Dy DP7 REAL Dressing amount (µm) left/right
Tx Dy DP8 REAL Dresser wear X (µm) left/right
Tx Dy DP9 REAL Dresser wear Z (µm) left/right
Tx Dy DP10 REAL Path feedrate (mm/rev), left/right
Tx Dy DP11 REAL Path feedrate X (mm/rev), left/right
Tx Dy DP12 REAL dD - Change in diameter (dressing amount X)
Tx Dy DP13 REAL dL - Change in distance (dressing amount Z)
Tx Dy DP14 REAL (Length 3)
Tx Dy DP15 REAL dR - Change in tool nose radius (radius wear)

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A.2 Parameter tables of the tool data

Tx Dy DP16 REAL Diameter dressing amount (µm)

Tx Dy DP17 REAL Dresser wear X (µm) diameter
Tx Dy DP18 REAL Dresser wear Z (µm) diameter
Tx Dy DP19 REAL Dressing direction (drawing/plunging) diameter
Tx Dy DP20 REAL Path feedrate (mm/rev) diameter
Tx Dy DP21 REAL Additional compens. in X, diameter, basic dimension
Tx Dy DP22 REAL Additional compens. in Z, length in Z, basic dimension
Tx Dy DP23 REAL (reserved, length 3)
Tx Dy DP24 REAL Diameter compensation of measurement control or cutting edge 1-6
initial dimension
Tx Dy DP25 REAL Z compensation of measurement control or initial dimension of each
cutting edge

Tx Dy DPC1 REAL Left/right overrun

Tx Dy DPC2 REAL Left/right radius
Tx Dy DPC3 REAL Left/right X chamfer
Tx Dy DPC4 REAL Left/right Z chamfer
Tx Dy DPC5 REAL Left/right shoulder height
Tx Dy DPC6 REAL Left/right back-slope angle
Tx Dy DPC7 REAL Left/right back-slope height
Tx Dy DPC8 REAL X overrun
Tx Dy DPC9 REAL Usable wheel width
Tx Dy DPC10 REAL No. of contour program

Table A- 3 3. Cutting edge for grinding wheel

Tx Dy DP1 INT Tool type=403

Tx Dy DP2 INT Cutting edge position (1...9)
Tx Dy DP3 REAL D - Diameter of the new wheel
Tx Dy DP4 REAL L - Distance of the wheel reference point
Tx Dy DP5 REAL (reserved, length 3)
Tx Dy DP6 REAL R - Tool nose radius
Tx Dy DP7 REAL Coasting revolutions
Tx Dy DP8 REAL Profile roller plunge feed (wheel types 5 and 6)
Tx Dy DP9 REAL Profile roller dressing feed (wheel types 5 and 6)
Tx Dy DP10 REAL GWPS profile roller (wheel types 5 and 6)
Tx Dy DP11 REAL Profile roller GWPS ratio (wheel types 5 and 6)
Tx Dy DP12 REAL dD - Change in diameter (dressing amount X)
Tx Dy DP13 REAL dL - Change in distance (dressing amount Z)
Tx Dy DP14 REAL (Length 3)
Tx Dy DP15 REAL dR - Change in tool nose radius (radius wear)
Tx Dy DP16 REAL Profile roller dressing number (wheel types 5 and 6)
Tx Dy DP17 REAL Reserved

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Appendix
A.2 Parameter tables of the tool data

Tx Dy DP18 REAL Reserved

Tx Dy DP19 REAL Reserved
Tx Dy DP20 REAL Reserved
Tx Dy DP21 REAL Additional compens. in X, diameter, basic dimension
Tx Dy DP22 REAL Additional compens. in Z, length in Z, basic dimension
Tx Dy DP23 REAL (reserved, length 3)
Tx Dy DP24 REAL Reserved
Tx Dy DP25 REAL Reserved

Tx Dy DPC1 REAL Idle strokes when dressing a path

Tx Dy DPC2 REAL Reserved
Tx Dy DPC3 REAL Reserved
Tx Dy DPC4 REAL Reserved
Tx Dy DPC5 REAL Reserved
Tx Dy DPC6 REAL Reserved
Tx Dy DPC7 REAL Reserved
Tx Dy DPC8 REAL Reserved
Tx Dy DPC9 REAL Reserved
Tx Dy DPC10 REAL Reserved

Table A- 4 4. to 6th cutting edge for grinding wheels

Tx Dy DP1 INT Tool type=403

Tx Dy DP2 INT Cutting edge position (1...9)
Tx Dy DP3 REAL D - Diameter of the new wheel
Tx Dy DP4 REAL L - Distance to the wheel reference point
Tx Dy DP5 REAL (reserved, length 3)
Tx Dy DP6 REAL R - Tool nose radius
Tx Dy DP7 REAL Reserved
Tx Dy DP8 REAL Reserved
Tx Dy DP9 REAL Reserved
Tx Dy DP10 REAL Reserved
Tx Dy DP11 REAL Reserved
Tx Dy DP12 REAL dD - Change in diameter (dressing amount X)
Tx Dy DP13 REAL dL - Change in distance (dressing amount Z)
Tx Dy DP14 REAL (Length 3)
Tx Dy DP15 REAL dR - Change in tool nose radius (radius wear)
Tx Dy DP16 REAL Reserved
Tx Dy DP17 REAL Reserved
Tx Dy DP18 REAL Reserved
Tx Dy DP19 REAL Reserved
Tx Dy DP20 REAL Reserved
Tx Dy DP21 REAL Additional compens. in X, diameter, basic dimension

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 Appendix
A.2 Parameter tables of the tool data

Tx Dy DP22 REAL Additional compens. in Z, length in Z, basic dimension

Tx Dy DP23 REAL (reserved, length 3)
Tx Dy DP24 REAL Reserved
Tx Dy DP25 REAL Reserved

Tx Dy DPC1 REAL Reserved

Tx Dy DPC2 REAL Reserved
Tx Dy DPC3 REAL Reserved
Tx Dy DPC4 REAL Reserved
Tx Dy DPC5 REAL Reserved
Tx Dy DPC6 REAL Reserved
Tx Dy DPC7 REAL Reserved
Tx Dy DPC8 REAL Reserved
Tx Dy DPC9 REAL Reserved
Tx Dy DPC10 REAL Reserved

Table A- 5 7. to 9th cutting edge for dressers

Tx Dy DP1 INT Tool type=403

Tx Dy DP2 INT Cutting edge position (1...9)
Tx Dy DP3 REAL Position
Tx Dy DP4 REAL Position
Tx Dy DP5 REAL Position
Tx Dy DP6 REAL R - Tool nose radius
Tx Dy DP7 REAL Diameter
Tx Dy DP8 REAL Width
Tx Dy DP9 REAL Maximum peripheral speed
Tx Dy DP10 REAL Maximum speed
Tx Dy DP11 REAL Probing data block
Tx Dy DP12 REAL dD - Change in diameter (dressing amount X)
Tx Dy DP13 REAL dL - Change in distance (dressing amount Z)
Tx Dy DP14 REAL (Length 3)
Tx Dy DP15 REAL dR - Change in tool nose radius (radius wear)
Tx Dy DP16 REAL Roller circumference speed
Tx Dy DP17 REAL Maximum length 1 wear
Tx Dy DP18 REAL Maximum length 2 wear
Tx Dy DP19 REAL Maximum length 3 wear
Tx Dy DP20 REAL Roller direction of rotation optional
Tx Dy DP21 REAL Additional compens. in X, diameter, basic dimension
Tx Dy DP22 REAL Additional compens. in Z, length in Z, basic dimension
Tx Dy DP23 REAL (reserved, length 3)
Tx Dy DP24 REAL Z oscillating path
Tx Dy DP25 REAL Infeed amount per stroke

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Appendix
A.2 Parameter tables of the tool data

Tx Dy DPC1 REAL Reciprocation speed

Tx Dy DPC2 REAL Dressing amount
Tx Dy DPC3 REAL Approaching distance
Tx Dy DPC4 REAL X start
Tx Dy DPC5 REAL Z start
Tx Dy DPC6 REAL Dresser type (0 – X/Z, >0 rear, rotating,...)
Tx Dy DPC7 REAL Profile depth
Tx Dy DPC8 REAL Safety speed
Tx Dy DPC9 REAL X oscillating path
Tx Dy DPC10 REAL Reserved

In addition to the default coding of the tool data (tool type, cutting edge position, etc.), the
following coded parameters are used.

Encoding Wheel type $TC_TPC1[T]

0 free contour
1 Standard contour straight without rear definitions
2 Standard contour straight with rear definitions
3 Standard contour inclined left
4 Standard contour inclined right
5 Standard contour straight profile roller with geo axes

Encoding Dressing mode at the diameter $TC_DP19[T,1]

0 neither drawing nor plunging (3rd dresser)
1 drawing (last active dresser)
2 plunging (last active dresser)
11 drawing (1st dresser)
12 plunging (1st dresser)
21 drawing (2nd dresser)
22 plunging (2nd dresser)

Encoding Dresser type $TC_DPC6[T,_GC_DNUM+dresser-1]

0 Dresser geometry axes (diamond) non-rotating
1 Dresser geometry axes (diamond) non-rotating
...
11 Dresser, geometry axes (form roll) rotating
12 Dresser, geometry axes (form roll) rotating
21 Dresser, geometry axes (diamond) rotating

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 Appendix
A.3 Miscellaneous

A.3 Miscellaneous

A.3.1 Pocket calculator

The calculator function can be activated from any operating area using <SHIFT> and <=> or
<CTRL> and <A>.
For calculating, the four basic arithmetic operations are available, as well as the functions
"sine", "cosine", "squaring" and "square root". A bracket function is provided to calculate
nested terms. The bracket depth is unlimited.
If the input field is already occupied by a value, the function will accept this value into the
input line of the pocket calculator.
<Input> starts the calculation. The result is displayed in the pocket calculator.
Selecting the "Accept" softkey enters the result in the input field at the current cursor position
of the part program editor and closes the pocket calculator automatically.

Note
If an input field is in the editing mode, it is possible to restore the original status using the
"Toggle" key.

Figure A-1 Pocket calculator

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Appendix
A.3 Miscellaneous

Characters that may be entered

+, -, *, / Basic arithmetic operations

S Sine function
The X value (in degrees) in front of the input cursor is replaced by the sin(X)
value.
O Cosine function
The X value (in degrees) in front of the input cursor is replaced by the cos(X)
value.
Q Square root function
The X value in front of the input cursor is replaced by the X2 value.
R Square root function
The X value in front of the input cursor is replaced by the √X value.
() Bracket function (X+Y)*Z

Calculation examples

Task Input -> Result

100 + (67*3) 100+67*3 -> 301
sin(45_) 45 S -> 0.707107
cos(45_) 45 O -> 0.707107
42 4 Q -> 16
√4 4 R -> 2
(34+3*2)*10 (34+3*2)*10 -> 400
To calculate auxiliary points on a contour, the pocket calculator offers the following functions:
● Calculating the tangential transition between a circle sector and a straight line
● Moving a point in the plane
● Converting polar coordinates to Cartesian coordinates
● Adding the second end point of a straight line/straight line contour section given from an
angular relation

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344 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Appendix
A.3 Miscellaneous

A.3.2 Editing Asian characters

The program editor and PLC alarm text editor both allow you to edit Asian characters.
This function is available in the following Asian language versions:
● Simplified Chinese
● Traditional Chinese (as used in Taiwan)
● Korean
Press <Alt+S> to switch the editor on or off.

Simplified/Traditional Chinese
Characters can be selected according to the pinyin input method, which involves combining
letters of the Roman alphabet in order to reproduce the sound of the character.
The editor will then show a list of characters that correspond to that particular sound.
You can then select the character you need.

Figure A-2 Example of editing Simplified Chinese

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)XQFWLRQVHOHFWLRQ
2WKHUFKDUDFWHUVFDQEHVHOHFWHG

Figure A-3 Structure of editor

The "Function selection" toggle field enables switching between the PinYin-entry method and
entering Latin graphic characters as well as activating the function for editing the dictionary.
When a character is selected, the editor records the frequency with which it is selected for a
specific phonetic notation and when the editor is again opened, it offers the most frequently
used characters.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 345
Appendix
A.3 Miscellaneous

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Figure A-4 Structure of editor when learning function is active

● Editing the dictionary

When this function is activated, another line showing the combined characters and
sounds will appear.
The editor will then offer various characters for this sound, from which you can choose
the desired one by entering either of the digits (1 to 9).
You can toggle the input cursor between the compound phonetic notations field and the
phonetic input field by pressing the <TAB> key.
When the cursor is positioned in the upper field, you can undo the combination by
pressing the <backspace> key.
Press <select> to save the characters currently being displayed.
Press the <delete> key if you want to delete the currently displayed group of characters
from the dictionary.

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 Appendix
A.3 Miscellaneous

Korean
To enter Korean characters, you will need a keyboard with the keyboard assignment shown
below.
In terms of key layout, this keyboard is the equivalent of an English QWERTY keyboard and
individual characters must be grouped together to form syllabic blocks.

Figure A-5 Korean keyboard assignment

The Korean alphabet (Hangeul) consists of 24 letters: 14 consonants and 10 vowels. The
syllable blocks are created by combining consonants and vowels.

Figure A-6 Korean editor with standard keyboard assignment

6HOHF &KDUDFWHU
WLRQ ,QSXWVHOHFWLRQ
NH\ERDUGPDWUL[ .RUHDQ5RPDQ

Figure A-7 Structure of Korean editor

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Appendix
A.3 Miscellaneous

● Input via matrix

If you only have access to a control keyboard, then you can use a matrix input method as
an alternative to the keyboard assignment shown above. All you will need for this is the
numeric keypad.

Figure A-8 Korean editor with selection matrix

To select characters, proceed as follows:

● Select a row (the row will be color-highlighted)
● Select a column (the character will briefly be color-highlighted and then transferred to the
"Character" field).
● Press the <input> key to transfer the character into the edit field.

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348 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Appendix
A.4 Feedback on the documentation

A.4 Feedback on the documentation

This document will be continuously improved with regard to its quality and ease of use.
Please help us with this task by sending your comments and suggestions for improvement
via e-mail or fax to:

E-mail: mailto:[email protected]

Fax: +49 9131 - 98 2176

Please use the fax form on the back of this page.

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 349
Appendix
A.4 Feedback on the documentation

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350 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
 Appendix
A.5 Overview

A.5 Overview
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Appendix
A.5 Overview

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352 Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0
Glossary

Effective wheel width

Wheel width of the inclined grinding wheel which is used to machine the diameter. It is
dependent upon:
● the physical width
● the evading height
● the angle of the wheel

Evasion/evasion angle
Tapering of the left or right side of the grinding wheel for face-grinding operations in which a
so-called cross-grinding is produced.

GAP/structure-borne noise/air grinding

Bridging the air gap between the workpiece and grinding wheel with a structure-borne noise
microphone, which is built into the machine.

GWPS
Grinding wheel peripheral speed in m/s

MCPA
Input card for rapid I/O to the control system

MD
Machine data; machine data are predefined variables (system variables), with which the
NCK, as per the requirements of the machine manufacturer, is adapted to the machine-tool.

SD
Setting data are system variables that indicate the current machine properties to the NCK.
Unlike machine data, changes to setting data always become effective immediately.

Seat
Machining operation

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Glossary

Shoulder
Left or right side of the grinding wheel or of the tool

TPS
Workpiece peripheral speed in m/min

XWP/ZWP when dressing a free contour

Workpiece offset for offsetting the programmed contour to the current cutting edge of the
grinding wheel; which is necessary so that workpiece coordinates can be programmed in the
free contour.

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Index

" F
"Display areas", 85 FA, 295
Feedrate values in one block, 291
Files
A Copy, 319
Paste, 319
Access right, 28
Fonts, 189
Address, 186
Fundamental Principles of NC Programming, 185
Arithmetic parameters, 58
Asynchronous oscillation, 293
Axis assignment, 150
G
Axis-specific machine data, 109
G1, 295
G4, 294
B General machine data, 108
Block format, 187
Block search, 81
H
Handwheel, 65
C Help system, 29
Hold time, 293
Call conditions, 150
Hot keys, 16
Change language, 104
Channel-specific machine data, 110
Connecting network drives, 310
I
Coordinate systems, 19
Machine coordinate system (MCS), 20 Interface parameters, 142
Relative coordinate system, 21
Workpiece coordinate system (WCS), 21
Cycle call, 152 J
Cycle support in the program editor, 156
JOG, 62
JOG mode, 62
D
Data transfer, 313 L
Disconnecting network drives, 310
LED displays on the CNC operator panel (PCU), 14
Display of machine data, 112
Drive machine data, 111
M
E Machine data, 107
Axis-specific machine data, 109
Enabling the communication ports, 305
Channel-specific machine data, 110
Enter tools, 35
Display of machine data, 112
Error displays, 14
Drive machine data, 111
Execution from external, 90
General machine data, 108

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Programming and Operating Manual, 07/2009, 6FC5398-5CP10-1BA0 355
Index

Machine operating area, 62 R

Machining offset, 76
RCS log in, 307
Machining plane, 150
RCS tool, 298
Manual input, 66
Reapproach after cancellation, 88
Manufacturer archive, 139
Reapproaching after interruption, 89
MDA mode, 66
Reference point approach, 31
Modem, 132
Regrinding, 77, 83
Multiple feedrate values in one block, 291
Return conditions, 150
RS232 interface, 313
N
Network connection, 304 S
Network operation, 303
Saving data, 105
Network parameters, 304
Screen layout, 23
Non-printable special characters, 189
Setting data, 54
Sharing directories, 309
Sparking-out stroke, 294
O
Spindle speed limitation, 291
Offset Parameters operating area, 33, 35 Start, 150
Online help, 29 Status displays, 14
Operating areas, 27
Operator control and display elements, 13
OS, 293 T
Oscillating axis, 295
Transmission messages, 314
Oscillation
Transmission protocol, 314
Activate, deactivate oscillation, 293
Asynchronous oscillation, 293
Defining the sequence of motions, 296
U
Oscillation reversal points, 295
OSCTRL, 293, 296 User log-in, 307
OSE, 293, 296 User management, 306
OSNSC, 293
OSP, 295
OSP1, 293 W
OSP2, 293
Word structure, 186
OST, 293
OST1, 293
OST2, 293
Overview of cycles, 147

P
Parameter list, 152
Part program
selection and start, 79
Stopping / canceling, 87
Plane definition, 150
Printable special characters, 189
Program list, 137
Program Manager, 93
Protection levels, 28

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SINUMERIK SINUMERIK 802D sl Surface grinding
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