Seimens 840D

Milling ___________________
Preface
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Introduction 1
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Setting up the machine 2
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Execution in manual mode 3
SINUMERIK
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Machining the workpiece 4
SINUMERIK 840D sl/828D ___________________
Simulating machining 5
Milling
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Creating G code program 6
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Creating a ShopMill program 7
Operating Manual Programming technological
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functions (cycles) 8
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Multi-channel view 9
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User variables 10
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Teaching in a program 11
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Tool management 12
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Program management 13
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Setting up drives 14
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HT 8 15
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Ctrl Energy 16
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Easy Message (828D only) 17
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Easy Extend (828D only) 18
Valid for:
Controller
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Service Planner (828D only) 19
SINUMERIK 840D sl / 840DE sl / 828D Ladder Viewer and Ladder
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add-on (828D only) 20
Software Version Alarms, error messages, and
CNC software for 840D sl / 840DE sl 4.4 ___________________
system alarms 21
SINUMERIK Operate for PCU/PC 4.4
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Appendix A
09/2011
6FC5398-7CP40-2BA0
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 order number: 6FC5398-7CP40-2BA0 Copyright Siemens AG 2011.

Industry Sector 04/2011 Technical data subject to change
Postfach 48 48
90026 NRNBERG
GERMANY
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
General documentation
User documentation
Manufacturer/service documentation
Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
Ordering documentation/overview of documentation
Additional links to download documents
Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
docu.motioncontrol@siemens.com
My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer under:
www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com
Milling
Operating Manual, 09/2011, 6FC5398-7CP40-2BA0 3
Preface
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
Target group
This documentation is intended for users of milling machines running the SINUMERIK
Operate software.
Benefits
The operating manual helps users familiarize themselves with the control elements and
commands. Guided by the manual, users are capable of responding to problems and taking
corrective action.
Standard scope
This documentation describes the functionality of the standard scope. Extensions or changes
made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
Furthermore, for the sake of clarity, 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.
Terms
The meanings of some basic terms used in this documentation are given below.
Program
A program is a sequence of instructions to the CNC which combine to produce a specific
workpiece on the machine.
Contour
The term contour refers generally to the outline of a workpiece. More specifically, it refers to
the section of the program that defines the outline of a workpiece comprising individual
elements.
Cycle
A cycle, e.g. milling a rectangular pocket, is a subprogram defined in SINUMERIK Operate
for executing a frequently repeated machining operation.
Milling
4 Operating Manual, 09/2011, 6FC5398-7CP40-2BA0
Preface
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support
Milling
Preface
Milling
Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction.............................................................................................................................................. 19
1.1 Product overview .........................................................................................................................19
1.2 Operator panel fronts ...................................................................................................................20
1.2.1 Overview ......................................................................................................................................20
1.2.2 Keys of the operator panel...........................................................................................................22
1.3 Machine control panels ................................................................................................................31
1.3.1 Overview ......................................................................................................................................31
1.3.2 Controls on the machine control panel ........................................................................................31
1.4 User interface...............................................................................................................................34
1.4.1 Screen layout ...............................................................................................................................34
1.4.2 Status display...............................................................................................................................35
1.4.3 Actual value window ....................................................................................................................38
1.4.4 T,F,S window ...............................................................................................................................39
1.4.5 Current block display ...................................................................................................................41
1.4.6 Operation via softkeys and buttons .............................................................................................41
1.4.7 Entering or selecting parameters .................................................................................................43
1.4.8 Pocket calculator..........................................................................................................................45
1.4.9 Context menu...............................................................................................................................47
1.4.10 Touch operation ...........................................................................................................................47
1.4.11 Changing the user interface language.........................................................................................48
1.4.12 Entering Asian characters............................................................................................................49
1.4.13 Protection levels...........................................................................................................................51
1.4.14 Online help in HMI sl....................................................................................................................53
2 Setting up the machine ............................................................................................................................ 57
2.1 Switching on and switching off.....................................................................................................57
2.2 Approaching a reference point.....................................................................................................58
2.2.1 Referencing axes .........................................................................................................................58
2.2.2 User agreement ...........................................................................................................................59
2.3 Operating modes .........................................................................................................................61
2.3.1 General ........................................................................................................................................61
2.3.2 Modes groups and channels........................................................................................................63
2.3.3 Channel switchover......................................................................................................................63
2.4 Settings for the machine ..............................................................................................................65
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................65
2.4.2 Switching the unit of measurement..............................................................................................66
2.4.3 Setting the work offset .................................................................................................................67
2.5 Measuring the tool .......................................................................................................................69
2.5.1 Measuring a tool manually ...........................................................................................................69
2.5.2 Measuring the tool length with the workpiece as reference point................................................70
2.5.3 Measuring radius or diameter ......................................................................................................71
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2.5.4 Fixed point calibration ................................................................................................................. 72

2.5.5 Measuring a tool with an electrical tool probe............................................................................. 73
2.5.6 Calibrating the electrical tool probe............................................................................................. 75
2.6 Measuring the workpiece zero .................................................................................................... 76
2.6.1 Overview ..................................................................................................................................... 76
2.6.2 Sequence of operations .............................................................................................................. 80
2.6.3 Examples with manual swivel ..................................................................................................... 81
2.6.4 Calibrating the electronic workpiece probe ................................................................................. 82
2.6.5 Setting the edge .......................................................................................................................... 84
2.6.6 Edge measurement..................................................................................................................... 86
2.6.7 Measuring a corner ..................................................................................................................... 89
2.6.8 Measuring a pocket and hole ...................................................................................................... 92
2.6.9 Measuring a spigot...................................................................................................................... 98
2.6.10 Aligning the plane...................................................................................................................... 104
2.6.11 Defining the measurement function selection ........................................................................... 106
2.6.12 Corrections after measurement of the zero point ..................................................................... 107
2.7 Work offsets .............................................................................................................................. 109
2.7.1 Display active zero offset .......................................................................................................... 110
2.7.2 Displaying the work offset "overview" ....................................................................................... 111
2.7.3 Displaying and editing base zero offset .................................................................................... 112
2.7.4 Displaying and editing settable zero offset ............................................................................... 113
2.7.5 Displaying the zero offset details. ............................................................................................. 114
2.7.6 Deleting a work offset................................................................................................................ 115
2.7.7 Measuring the workpiece zero .................................................................................................. 116
2.8 Monitoring axis and spindle data .............................................................................................. 117
2.8.1 Specify working area limitations................................................................................................ 117
2.8.2 Editing spindle data................................................................................................................... 118
2.9 Displaying setting data lists....................................................................................................... 119
2.10 Handwheel assignment............................................................................................................. 119
2.11 MDA .......................................................................................................................................... 122
2.11.1 Loading an MDA program from the Program Manager ............................................................ 122
2.11.2 Saving an MDA program........................................................................................................... 123
2.11.3 Executing an MDA program ...................................................................................................... 124
2.11.4 Deleting an MDA program......................................................................................................... 124
3 Execution in manual mode..................................................................................................................... 125
3.1 General...................................................................................................................................... 125
3.2 Selecting a tool and spindle ...................................................................................................... 125
3.2.1 T, S, M windows........................................................................................................................ 125
3.2.2 Selecting a tool.......................................................................................................................... 127
3.2.3 Starting and stopping a spindle manually ................................................................................. 127
3.2.4 Position spindle ......................................................................................................................... 128
3.3 Traversing axes......................................................................................................................... 130
3.3.1 Traverse axes by a defined increment...................................................................................... 130
3.3.2 Traversing axes by a variable increment .................................................................................. 131
3.4 Positioning axes ........................................................................................................................ 132
3.5 Swiveling ................................................................................................................................... 133
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3.6 Simple face milling of workpiece................................................................................................137

3.7 Default settings for manual mode ..............................................................................................140
4 Machining the workpiece ....................................................................................................................... 141
4.1 Starting and stopping machining................................................................................................141
4.2 Selecting a program...................................................................................................................142
4.3 Testing a program......................................................................................................................143
4.4 Displaying the current program block ........................................................................................145
4.4.1 Current block display .................................................................................................................145
4.4.2 Displaying a basic block.............................................................................................................145
4.4.3 Display program level ................................................................................................................146
4.5 Correcting a program .................................................................................................................148
4.6 Repositioning axes.....................................................................................................................149
4.7 Starting machining at a specific point ........................................................................................150
4.7.1 Use block search .......................................................................................................................150
4.7.2 Continuing program from search target .....................................................................................152
4.7.3 Simple search target definition...................................................................................................153
4.7.4 Defining an interruption point as search target ..........................................................................153
4.7.5 Entering the search target via search pointer ............................................................................154
4.7.6 Parameters for block search in the search pointer ....................................................................155
4.7.7 Block search mode ....................................................................................................................156
4.8 Intervening in the program sequence ........................................................................................158
4.8.1 Program control..........................................................................................................................158
4.8.2 Skip blocks .................................................................................................................................159
4.9 Overstore ...................................................................................................................................161
4.10 Editing a program.......................................................................................................................162
4.10.1 Searching in programs...............................................................................................................163
4.10.2 Replacing program text..............................................................................................................164
4.10.3 Copying/pasting/deleting a program block.................................................................................165
4.10.4 Renumber program....................................................................................................................166
4.10.5 Creating a program block...........................................................................................................167
4.10.6 Opening additional programs.....................................................................................................168
4.10.7 Editor settings ............................................................................................................................169
4.11 Mold making view ......................................................................................................................171
4.11.1 Starting the mold making view ...................................................................................................173
4.11.2 Specifically jump to the program block ......................................................................................174
4.11.3 Searching for program blocks ....................................................................................................174
4.11.4 Changing the view .....................................................................................................................175
4.11.4.1 Enlarging or reducing the graphical representation ...................................................................175
4.11.4.2 Modifying the viewport ...............................................................................................................176
4.12 Displaying G Functions and Auxiliary Functions........................................................................177
4.12.1 Selected G functions..................................................................................................................177
4.12.2 All G functions ............................................................................................................................179
4.12.3 Auxiliary functions ......................................................................................................................180
4.13 Displaying the program runtime and counting workpieces ........................................................183
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4.14 Setting for automatic mode ....................................................................................................... 185

5 Simulating machining............................................................................................................................. 187
5.1 Overview ................................................................................................................................... 187
5.2 Simulation before machining of the workpiece ......................................................................... 194
5.3 Simultaneous recording before machining of the workpiece .................................................... 195
5.4 Simultaneous recording during machining of the workpiece .................................................... 196
5.5 Different views of a workpiece .................................................................................................. 197
5.5.1 Plan view ................................................................................................................................... 197
5.5.2 3D view...................................................................................................................................... 197
5.5.3 Side view ................................................................................................................................... 198
5.6 Editing the simulation display.................................................................................................... 199
5.6.1 Blank display ............................................................................................................................. 199
5.6.2 Showing and hiding the tool path.............................................................................................. 199
5.7 Program control during the simulation ...................................................................................... 200
5.7.1 Changing the feedrate............................................................................................................... 200
5.7.2 Simulating the program block by block ..................................................................................... 201
5.8 Changing and adapting a simulation graphic............................................................................ 202
5.8.1 Enlarging or reducing the graphical representation .................................................................. 202
5.8.2 Panning a graphical representation .......................................................................................... 203
5.8.3 Rotating the graphical representation ....................................................................................... 203
5.8.4 Modifying the viewport .............................................................................................................. 204
5.8.5 Defining cutting planes.............................................................................................................. 205
5.9 Displaying simulation alarms..................................................................................................... 206
6 Creating G code program ...................................................................................................................... 207
6.1 Graphical programming............................................................................................................. 207
6.2 Program views .......................................................................................................................... 208
6.3 Program structure ..................................................................................................................... 211
6.4 Basics........................................................................................................................................ 211
6.4.1 Machining planes ...................................................................................................................... 211
6.4.2 Current planes in cycles and input screens .............................................................................. 212
6.4.3 Programming a tool (T) ............................................................................................................. 213
6.5 Generating a G code program .................................................................................................. 214
6.6 Blank input ................................................................................................................................ 215
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F) ........................................................................................................................................ 217
6.8 Selection of the cycles via softkey ............................................................................................ 218
6.9 Calling technology functions ..................................................................................................... 222
6.9.1 Hiding cycle parameters............................................................................................................ 222
6.9.2 Setting data for cycles............................................................................................................... 222
6.9.3 Checking cycle parameters....................................................................................................... 223
6.9.4 Changing a cycle call ................................................................................................................ 223
6.9.5 Compatibility for cycle support .................................................................................................. 224
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Table of contents
6.9.6 Additional functions in the input screens ...................................................................................224

6.10 Measuring cycle support ............................................................................................................225
7 Creating a ShopMill program ................................................................................................................. 227
7.1 Program views ...........................................................................................................................228
7.2 Program structure ......................................................................................................................232
7.3 Basic information .......................................................................................................................233
7.3.1 Machining planes .......................................................................................................................233
7.3.2 Polar coordinates .......................................................................................................................233
7.3.3 Absolute and incremental dimensions .......................................................................................234
7.4 Creating a ShopMill program .....................................................................................................236
7.5 Program header .........................................................................................................................237
7.6 Generating program blocks........................................................................................................239
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V).........................................................240
7.8 Defining machine functions........................................................................................................242
7.9 Call work offsets.........................................................................................................................244
7.10 Repeating program blocks .........................................................................................................245
7.11 Specifying the number of workpieces ........................................................................................247
7.12 Changing program blocks ..........................................................................................................248
7.13 Changing program settings........................................................................................................249
7.14 Selection of the cycles via softkey .............................................................................................250
7.15 Calling technology functions ......................................................................................................254
7.15.1 Additional functions in the input screens ...................................................................................254
7.15.2 Checking input parameters ........................................................................................................254
7.15.3 Setting data for technological functions .....................................................................................255
7.15.4 Changing a cycle call .................................................................................................................255
7.15.5 Compatibility for cycle support ...................................................................................................256
7.16 Measuring cycle support ............................................................................................................256
7.17 Example, standard machining....................................................................................................257
7.17.1 Workpiece drawing ....................................................................................................................258
7.17.2 Programming..............................................................................................................................258
7.17.3 Results/simulation test ...............................................................................................................270
7.17.4 G code machining program........................................................................................................272
8 Programming technological functions (cycles) ....................................................................................... 275
8.1 Drilling ........................................................................................................................................275
8.1.1 General ......................................................................................................................................275
8.1.2 Centering (CYCLE81) ................................................................................................................276
8.1.2.1 Function .....................................................................................................................................276
8.1.3 Drilling (CYCLE82).....................................................................................................................278
8.1.3.1 Function .....................................................................................................................................278
8.1.4 Reaming (CYCLE85) .................................................................................................................279
8.1.4.1 Function .....................................................................................................................................279
8.1.5 Deep-hole drilling (CYCLE83)....................................................................................................281
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8.1.5.1 Function..................................................................................................................................... 281

8.1.6 Boring (CYCLE86) .................................................................................................................... 284
8.1.6.1 Function..................................................................................................................................... 284
8.1.7 Tapping (CYCLE84, 840).......................................................................................................... 286
8.1.7.1 Function..................................................................................................................................... 286
8.1.8 Drill and thread milling (CYCLE78) ........................................................................................... 291
8.1.8.1 Function..................................................................................................................................... 291
8.1.9 Positioning and position patterns .............................................................................................. 295
8.1.10 Arbitrary positions (CYCLE802)................................................................................................ 297
8.1.11 Position pattern Line (HOLES1), Grid or Frame (CYCLE801).................................................. 300
8.1.12 Circle position pattern (HOLES2).............................................................................................. 302
8.1.13 Displaying and hiding positions................................................................................................. 304
8.1.14 Repeating positions................................................................................................................... 305
8.2 Milling ........................................................................................................................................ 307
8.2.1 Face milling (CYCLE61)............................................................................................................ 307
8.2.1.1 Function..................................................................................................................................... 307
8.2.2 Rectangular pocket (POCKET3)............................................................................................... 310
8.2.3 Circular pocket (POCKET4) ...................................................................................................... 313
8.2.4 Rectangular spigot (CYCLE76)................................................................................................. 318
8.2.5 Circular spigot (CYCLE77)........................................................................................................ 321
8.2.5.1 Function..................................................................................................................................... 321
8.2.6 Multi-edge (CYCLE79) .............................................................................................................. 323
8.2.6.1 Function..................................................................................................................................... 323
8.2.7 Longitudinal groove (SLOT1) .................................................................................................... 326
8.2.8 Circumferential groove (SLOT2) ............................................................................................... 329
8.2.9 Open groove (CYCLE899) ........................................................................................................ 332
8.2.10 Long hole (LONGHOLE) - only for G code programs............................................................... 339
8.2.11 Thread milling (CYCLE70) ........................................................................................................ 341
8.2.12 Engraving (CYCLE60)............................................................................................................... 344
8.3 Contour milling .......................................................................................................................... 351
8.3.1 General...................................................................................................................................... 351
8.3.2 Representation of the contour................................................................................................... 351
8.3.3 Creating a new contour ............................................................................................................. 353
8.3.4 Creating contour elements ........................................................................................................ 355
8.3.5 Changing the contour................................................................................................................ 360
8.3.6 Contour call (CYCLE62) - only for G code program ................................................................. 361
8.3.7 Path milling (CYCLE72) ............................................................................................................ 362
8.3.8 Contour pocket/contour spigot (CYCLE63/64).......................................................................... 366
8.3.9 Predrilling contour pocket (CYCLE64) ...................................................................................... 368
8.3.10 Milling contour pocket (CYCLE63)............................................................................................ 371
8.3.11 Residual material contour pocket (CYCLE63) .......................................................................... 373
8.3.12 Milling contour spigot (CYCLE63)............................................................................................. 375
8.3.13 Residual material contour spigot (CYCLE63) ........................................................................... 377
8.4 Turning - only for G code programs .......................................................................................... 380
8.4.1 General...................................................................................................................................... 380
8.4.2 Stock removal (CYCLE951) ...................................................................................................... 380
8.4.3 Groove (CYCLE930) ................................................................................................................. 383
8.4.4 Undercut form E and F (CYCLE940) ........................................................................................ 386
8.4.5 Thread undercut (CYCLE940) .................................................................................................. 388
8.4.6 Thread turning (CYCLE99) ....................................................................................................... 391
8.4.7 Thread chain (CYCLE98).......................................................................................................... 400
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Table of contents
8.4.8 Cut-off (CYCLE92).....................................................................................................................403

8.5 Contour turning - only for G code programs ..............................................................................406
8.5.1 General information ...................................................................................................................406
8.5.2 Representation of the contour....................................................................................................407
8.5.3 Creating a new contour..............................................................................................................408
8.5.4 Creating contour elements.........................................................................................................411
8.5.5 Changing the contour.................................................................................................................417
8.5.6 Contour call (CYCLE62) ............................................................................................................418
8.5.7 Stock removal (CYCLE952).......................................................................................................419
8.5.8 Stock removal residual (CYCLE952) .........................................................................................424
8.5.9 Grooving (CYCLE952) ...............................................................................................................426
8.5.10 Grooving residual material (CYCLE952) ...................................................................................430
8.5.11 Plunge turning (CYCLE952) ......................................................................................................432
8.5.12 Plunge turning residual material (CYCLE952)...........................................................................435
8.6 Further cycles and functions ......................................................................................................438
8.6.1 Swiveling plane/tool (CYCLE800)..............................................................................................438
8.6.2 Swiveling tool (CYCLE800)........................................................................................................448
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) .......................448
8.6.2.2 Swiveling aligning tool - only for G code program (CYCLE800)................................................449
8.6.3 High-speed settings (CYCLE832)..............................................................................................451
8.6.4 Subroutines ................................................................................................................................453
8.7 Further cycles and functions ShopMill .......................................................................................455
8.7.1 Transformations .........................................................................................................................455
8.7.2 Translation .................................................................................................................................456
8.7.3 Rotation......................................................................................................................................457
8.7.4 Scaling .......................................................................................................................................458
8.7.5 Mirroring .....................................................................................................................................459
8.7.6 Cylinder surface transformation .................................................................................................460
8.7.6.1 General programming ................................................................................................................462
8.7.7 Straight or circular machining ....................................................................................................463
8.7.8 Programming a straight line .......................................................................................................465
8.7.9 Programming a circle with known center point ..........................................................................466
8.7.10 Programming a circle with known radius ...................................................................................467
8.7.11 Helix ...........................................................................................................................................468
8.7.12 Polar coordinates .......................................................................................................................469
8.7.13 Straight polar..............................................................................................................................470
8.7.14 Circle polar .................................................................................................................................471
8.7.15 Obstacle .....................................................................................................................................472
9 Multi-channel view ................................................................................................................................. 473
9.1 Multi-channel view .....................................................................................................................473
9.2 Multi-channel view in the "Machine" operating area ..................................................................473
9.3 Multi-channel view for large operator panels .............................................................................476
9.4 Setting the multi-channel view ...................................................................................................478
10 User variables........................................................................................................................................ 481
10.1 Overview ....................................................................................................................................481
10.2 R parameters .............................................................................................................................482
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10.3 Global GUD ............................................................................................................................... 483

10.4 Channel GUD............................................................................................................................ 484
10.5 Local LUD.................................................................................................................................. 485
10.6 Program PUD............................................................................................................................ 486
10.7 Searching for user data............................................................................................................. 487
10.8 Defining and activating user variables ...................................................................................... 487
11 Teaching in a program........................................................................................................................... 489
11.1 Overview ................................................................................................................................... 489
11.2 General sequence..................................................................................................................... 489
11.3 Inserting a block ........................................................................................................................ 490
11.3.1 Input parameters for teach-in blocks......................................................................................... 491
11.4 Teach-in via window.................................................................................................................. 492
11.4.1 General...................................................................................................................................... 492
11.4.2 Teach in rapid traverse G0........................................................................................................ 494
11.4.3 Teach in straight G1.................................................................................................................. 494
11.4.4 Teaching in circle intermediate and circle end point CIP.......................................................... 494
11.4.5 Teach-in A spline ...................................................................................................................... 495
11.5 Editing a block........................................................................................................................... 497
11.6 Selecting a block ....................................................................................................................... 498
11.7 Deleting a block......................................................................................................................... 499
12 Tool management.................................................................................................................................. 501
12.1 Lists for the tool management................................................................................................... 501
12.2 Magazine management............................................................................................................. 502
12.3 Tool types.................................................................................................................................. 503
12.4 Tool dimensioning ..................................................................................................................... 505
12.5 Tool list ...................................................................................................................................... 512
12.5.1 Additional data .......................................................................................................................... 515
12.5.2 Creating a new tool ................................................................................................................... 516
12.5.3 Measuring the tool..................................................................................................................... 518
12.5.4 Managing several cutting edges ............................................................................................... 518
12.5.5 Delete tool ................................................................................................................................. 519
12.5.6 Loading and unloading tools ..................................................................................................... 520
12.5.7 Selecting a magazine................................................................................................................ 521
12.6 Tool wear................................................................................................................................... 523
12.6.1 Reactivating a tool..................................................................................................................... 525
12.7 Tool data OEM .......................................................................................................................... 527
12.8 Magazine................................................................................................................................... 528
12.8.1 Positioning a magazine ............................................................................................................. 530
12.8.2 Relocating a tool ....................................................................................................................... 530
12.9 Sorting tool management lists................................................................................................... 532
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12.10 Filtering the tool management lists ............................................................................................533

12.11 Specific search in the tool management lists.............................................................................534
12.12 Displaying tool details ................................................................................................................535
12.13 Changing a tool type ..................................................................................................................536
13 Program management ........................................................................................................................... 537
13.1 Overview ....................................................................................................................................537
13.1.1 NC memory ................................................................................................................................540
13.1.2 Local drive..................................................................................................................................540
13.1.3 USB drives .................................................................................................................................541
13.2 Opening and closing the program..............................................................................................542
13.3 Executing a program..................................................................................................................544
13.4 Creating a directory/program/job list/program list ......................................................................545
13.4.1 Creating a new directory ............................................................................................................545
13.4.2 Creating a new workpiece..........................................................................................................546
13.4.3 Creating a new G code program................................................................................................547
13.4.4 Creating a new ShopMill program..............................................................................................548
13.4.5 Storing any new file....................................................................................................................549
13.4.6 Creating a Joblist .......................................................................................................................550
13.4.7 Creating a program list...............................................................................................................551
13.5 Creating templates.....................................................................................................................552
13.6 Searching directories and files...................................................................................................553
13.7 Displaying the program in the Preview. .....................................................................................554
13.8 Selecting several directories/programs......................................................................................555
13.9 Copying and pasting a directory/program..................................................................................557
13.10 Deleting a program/directory......................................................................................................559
13.10.1 Deleting a program/directory......................................................................................................559
13.11 Renaming file and directory properties ......................................................................................560
13.12 EXTCALL ...................................................................................................................................562
13.13 Backing up data .........................................................................................................................564
13.13.1 Generating an archive in the Program Manager........................................................................564
13.13.2 Generating an archive via the system data ...............................................................................565
13.13.3 Reading in an archive in the Program Manager ........................................................................567
13.13.4 Read in archive from system data .............................................................................................569
13.14 Setup data..................................................................................................................................570
13.14.1 Backing up setup data ...............................................................................................................570
13.14.2 Reading-in set-up data...............................................................................................................573
13.15 V24.............................................................................................................................................575
13.15.1 Reading-in and reading-out archives.........................................................................................575
13.15.2 Setting V24 in the program manager.........................................................................................577
14 Setting up drives .................................................................................................................................... 579
14.1 Overview ....................................................................................................................................579
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14.2 Setting up drives ....................................................................................................................... 580

15 HT 8....................................................................................................................................................... 583
15.1 HT 8 overview ........................................................................................................................... 583
15.2 Traversing keys......................................................................................................................... 586
15.3 Machine control panel menu ..................................................................................................... 587
15.4 Virtual keyboard ........................................................................................................................ 588
15.5 Calibrating the touch panel ....................................................................................................... 590
16 Ctrl Energy............................................................................................................................................. 591
16.1 Overview ................................................................................................................................... 591
16.2 Displaying energy consumption ................................................................................................ 592
16.3 Measuring and saving the energy consumption ....................................................................... 593
16.4 Displaying measured curves ..................................................................................................... 594
16.5 Using the energy-saving profile ................................................................................................ 594
17 Easy Message (828D only).................................................................................................................... 597
17.1 Overview ................................................................................................................................... 597
17.2 Activating Easy Message .......................................................................................................... 598
17.3 Creating/editing a user profile ................................................................................................... 599
17.4 Setting-up events ...................................................................................................................... 600
17.5 Logging an active user on and off............................................................................................. 602
17.6 Displaying SMS logs ................................................................................................................. 603
17.7 Making settings for Easy Message ........................................................................................... 604
18 Easy Extend (828D only) ....................................................................................................................... 605
18.1 Overview ................................................................................................................................... 605
18.2 Enabling a device...................................................................................................................... 606
18.3 Activating and deactivating a device......................................................................................... 606
18.4 Commissioning Easy Extend .................................................................................................... 607
19 Service Planner (828D only) .................................................................................................................. 609
19.1 Performing and monitoring maintenance tasks......................................................................... 609
19.2 Set maintenance tasks.............................................................................................................. 610
20 Ladder Viewer and Ladder add-on (828D only) ..................................................................................... 613
20.1 PLC diagnostics ........................................................................................................................ 613
20.2 Structure of the user interface................................................................................................... 614
20.3 Control options .......................................................................................................................... 615
20.4 Displaying PLC properties......................................................................................................... 616
20.5 Displaying and editing NC/PLC variables ................................................................................. 617
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Table of contents
20.6 Displaying and editing PLC signals ...........................................................................................618

20.7 Displaying information on the program blocks...........................................................................619
20.8 Downloading a PLC user program.............................................................................................621
20.9 Editing the local variable table ...................................................................................................622
20.10 Creating a new block .................................................................................................................623
20.11 Editing block properties..............................................................................................................624
20.12 Inserting and editing networks ...................................................................................................625
20.13 Editing network properties .........................................................................................................627
20.14 Displaying and editing symbol tables.........................................................................................628
20.15 Inserting/deleting a symbol table ...............................................................................................629
20.16 Searching for operands..............................................................................................................630
20.17 Displaying the network symbol information table.......................................................................631
20.18 Displaying/canceling the access protection ...............................................................................632
20.19 Displaying cross references.......................................................................................................632
21 Alarms, error messages, and system alarms ......................................................................................... 635
21.1 Displaying alarms.......................................................................................................................635
21.2 Displaying an alarm log..............................................................................................................637
21.3 Displaying messages .................................................................................................................637
21.4 Sorting, alarms, faults and messages........................................................................................638
21.5 PLC and NC variables ...............................................................................................................639
21.5.1 Displaying and editing PLC and NC variables ...........................................................................639
21.5.2 Saving and loading screen forms ..............................................................................................643
21.5.3 Load symbols .............................................................................................................................644
21.6 Version .......................................................................................................................................645
21.6.1 Displaying version data..............................................................................................................645
21.6.2 Save information ........................................................................................................................646
21.7 Logbook .....................................................................................................................................647
21.7.1 Displaying and editing the logbook ............................................................................................648
21.7.2 Making a logbook entry..............................................................................................................648
21.8 Creating screenshots .................................................................................................................650
21.9 Remote diagnostics ...................................................................................................................651
21.9.1 Setting remote access ...............................................................................................................651
21.9.2 Permit modem............................................................................................................................653
21.9.3 Request remote diagnostics ......................................................................................................653
21.9.4 Exit remote diagnostics..............................................................................................................654
A Appendix................................................................................................................................................ 655
A.1 Overview ....................................................................................................................................655
Index...................................................................................................................................................... 657
Milling
Table of contents
Milling
Introduction 1
1.1 Product overview
The SINUMERIK controller is a CNC (Computerized Numerical Controller) for machine tools.
You can use the CNC to implement the following basic functions in conjunction with a
machine tool:
Creation and adaptation of part programs
Execution of part programs
Manual control
Access to internal and external data media
Editing of data for programs
Management of tools, zero points and further user data required in programs
Diagnostics of controller and machine
Operating areas
The basic functions are grouped in the following operating areas in the controller:
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Milling
Introduction
1.2 Operator panel fronts
1.2.1 Overview
Introduction
The display (screen) and operation (e.g. hardkeys and softkeys) of the SINUMERIK Operate
user interface use the operator panel front.
In this example, the OP 010 operator panel front is used to illustrate the components that are
available for operating the controller and machine tool.
Operator controls and indicators

(5)

(5)

Milling
Introduction
1 Status LED: POWER

2 Status LED: TEMP
(illuminated LEDs indicate increased wear)
3 Alphabetic key group
4 Numerical key group
5 Softkeys
6 Control key group
7 Hotkey group
8 Cursor key group
9 USB interface
10 Menu select key
11 Menu forward button
12 Machine area button
13 Menu back key
Figure 1-1 View of OP 010 operator panel front
References
A more precise description as well as a view of the other operator panel fronts that can be
used may be found in the following reference:
Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl
Milling
Introduction
1.2.2 Keys of the operator panel

The following keys and key combinations are available for operation of the control and the
machine tool.
Keys and key combinations
Key Function
<ALARM CANCEL>
Cancels alarms and messages that are marked with this
symbol.
<CHANNEL>
Advances for several channels.
<HELP>
Calls the context-sensitive online help for the selected window.
<NEXT WINDOW> *
Toggles between the windows.
For a multi-channel view or for a multi-channel functionality,
switches within a channel gap between the upper and lower
window.
Selects the first entry in selection lists and in selection fields.
Moves the cursor to the beginning of a text.
* on USB keyboards use the <Home> or <Pos 1> key

+ <NEXT WINDOW> + <SHIFT>
Selects the first entry in selection lists and in selection fields.
Moves the cursor to the beginning of a text.
Selects a contiguous selection from the current cursor
position up to the target position.
position up to the beginning of a program block.
+ <NEXT WINDOW> + <ALT>
Moves the cursor to the first object.
Moves the cursor in the first column of a table row.
Moves the cursor to the beginning of a program block.
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Introduction
Key Function
+ <NEXT WINDOW> + <CTRL>
Moves the cursor to the beginning of a program.
Moves the cursor in the first row of the current column.
+ + <NEXT WINDOW> + <CTRL> + <SHIFT>

Moves the cursor to the beginning of a program.
Moves the cursor in the first row of the current column.
position up to the target position.
position up to the beginning of the program.
<PAGE UP>
Scrolls upwards by one page in a window.
+ <PAGE UP> + <SHIFT>

In the program manager and in the program editor from the
cursor position, selects directories or program blocks up to the
beginning of the window.
+ <PAGE UP> + <CTRL>

Positions the cursor to the topmost line of a window.
<PAGE DOWN>
Scrolls downwards by one page in a window.
+ <PAGE DOWN> + <SHIFT>

In the program manager and in the program editor, from the
cursor position, selects directories or program blocks up to the
end of the window.
+ <PAGE DOWN> + <CTRL>

Positions the cursor to the lowest line of a window.
<Cursor right>
Editing box
Opens a directory or program (e.g. cycle) in the editor.
Navigation
Moves the cursor further to the right by one character.
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Introduction
Key Function
+ <Cursor right> + <CTRL>
Editing box
Moves the cursor further to the right by one word.
Navigation
Moves the cursor in a table to the next cell to the right.
<Cursor left>
Editing box
Closes a directory or program (e.g. cycle) in the program
editor. If you have made changed, then these are accepted.
Navigation
Moves the cursor further to the left by one character.
+ <Cursor left> + <CTRL>

Editing box
Moves the cursor further to the left by one word.
Navigation
Moves the cursor in a table to the next cell to the left.
<Cursor up>
Editing box
Moves the cursor into the next upper field.
Navigation
Moves the cursor in a table to the next cell upwards.
Moves the cursor upwards in a menu screen.
+ <Cursor up> + <CTRL>

Moves the cursor in a table to the beginning of the table.
Moves the cursor to the beginning of a window.
+ <Cursor up> + <SHIFT>

In the program manager and in the program editor, selects a
contiguous selection of directories and program blocks.
Milling
Introduction
Key Function
<Cursor down>
Editing box
Moves the cursor downwards.
Navigation
Moves the cursor in a table to the next cell downwards.
Moves the cursor in a window downwards.
+ <Cursor down> + <CTRL>

Navigation
Moves the cursor in a table to the end of the table.
Moves the cursor to the end of a window.
Simulation
Reduces the override.
+ <Cursor down> + <SHIFT>

In the program manager and in the program editor, selects a
contiguous selection of directories and program blocks.
<SELECT>
Switches between several specified options in selection drop
down list boxes and in selection boxes.
Activates check boxes.
In the program editor and in the program manager, selects a
program block or a program.
+ <SELECT> + <CTRL>
When selecting table rows, switches between selected and not
selected.
+ <SELECT> + <SHIFT>
Selects in selection lists and in selection fields the previous
entry or the last entry.
<END>
Moves the cursor to the last entry field in a window, to the end
of a table or a program block.
Selects the last entry in selection lists and in selection fields.
+ <END> + <SHIFT>
Moves the cursor to the last entry.
Selects a contiguous selection from the cursor position up to the
end of a program block.
Milling
Introduction
Key Function
+ <END> + <CTRL>
Moves the cursor to the last entry in the last line of the actual
column or to the end of a program.
+ + <END> + <CTRL> + <SHIFT>

Moves the cursor to the last entry in the last line of the actual
column or to the end of a program.
Selects a contiguous selection from the cursor position up to the
end of a program block.
<BACKSPACE>
Editing box
Deletes a character selected to the left of the cursor.
Navigation
Deletes all of the selected characters to the left of the cursor.
+ <BACKSPACE> + <CTRL>
Editing window
Deletes a word selected to the left of the cursor.
Navigation
Deletes all of the selected characters to the left of the cursor.
<TAB>
In the program editor, indents the cursor by one character.
In the program manager, moves the cursor to the next entry
to the right.
+ <TAB> + <SHIFT>
to the left.
<TAB> + <CTRL>
to the right.
<TAB> + <SHIFT> + <CTRL>
to the left.
Milling
Introduction
Key Function
+ <CTRL> + <A>
$
In the actual window, selects all entries (only in the program
editor and program manager).
+ <CTRL> + <C>
&
Copies the selected content.
+ <CTRL> + <E>
(
Calls the "Ctrl Energy" function.
+ <CTRL> + <F>
)
Opens the search dialog in the machine data and setting data
lists, when loading and saving in the MDI editor as well as in the
program manager and in the system data.
+ <CTRL> + <L>
/
Scrolls the actual user interface through all installed languages
one after the other.
+ + <CTRL> + <SHIFT> + <L>
/
Scrolls the actual operator interface through all installed
languages in the inverse sequence.
+ <CTRL> + <P>
3
Generates a screenshot from the actual operator interface and
saves it as file.
+ <CTRL> + <S>
6
Switches the single block in or out in the simulation.
+ <CTRL> + <V>
9
Pastes the text from the clipboard at the actual cursor
position.
Pastes text from the clipboard at the position of a selected
text.
+ <CTRL> + <X>
;
Cuts out the selected text. The text is located in the clipboard.
+ <CTRL> + <Y>
<
Reactivates changes that were undone (only in the program
editor).
+ <CTRL> + <Z>
=
Undoes the last action (only in the program editor).
Milling
Introduction
Key Function
+ + <CTRL> + <ALT> + <C>
&
Creates a complete archive on an external data carrier (USB-
FlashDrive).
+ + <CTRL> + <ALT> + <S>

6
Creates a complete archive on an external data carrier (USB-
FlashDrive).
+ + <CTRL> + <ALT> + <D>

'
Backs up the log files on the USB-FlashDrive. If a USB-
FlashDrive is not inserted, then the files are backed-up in the
manufacturer's area of the CF-Card.
+ + <SHIFT> + <ALT> + <D>

'
Backs up the log files on the USB-FlashDrive. If a USB-
FlashDrive is not inserted, then the files are backed-up in the
manufacturer's area of the CF-Card.
+ + <SHIFT> + <ALT> + <T>

7
Starts "HMI Trace".
+ + <SHIFT> + <ALT> + <T>

7
Exits "HMI Trace".
+ <ALT> + <S>
6
Opens the Editor to enter Asian characters.
<DEL>
Editing box
Deletes the first character right of the cursor.
Navigation
Deletes all characters.
+ <DEL> + <CTRL>
Editing box
Deletes the first word to the right of the cursor.
Navigation
Deletes all characters.
Milling
Introduction
Key Function
<Spacebar>
Editing window
Inserts a space
Switches between several specified options in selection drop
down list boxes and in selection boxes.
<Plus>
Opens a directory, which contains the element.
Increases the size of the graphic view for simulation and
traces.
<Minus>
Closes a directory, which contains the element.
Reduces the size of the graphic view for simulation and
traces.
<Equals>
Opens the calculator in the entry fields.
<Asterisk>

Opens a directory with all of the subdirectories.
<Tilde>
a
Changes the sign of a number between plus and minus.
<INSERT>
Opens an editing window in the insert mode. Press the key
again, exits the window and the entries are undone.
Opens a selection box and shows the selection possibilities.
In the machining step program, enters an empty line for G
code.
+ <INSERT> + <SHIFT>
For G code programming, for a cycle call activates or
deactivates the edit mode.
Milling
Introduction
Key Function
<INPUT>
Completes input of a value in the entry field.
Opens a directory or a program.
Inserts an empty program block if the cursor is positioned at
the end of a program block.
Inserts a character to select a new line and the program
block is split up into 2 parts.
In the G code, inserts a new line after the program block.
In the machining step program, inserts a new line for G code.
<ALARM> - only OP 010 and OP 010C

Select the "Diagnosis" operating area.
<PROGRAM> - only OP 010 and OP 010C

Calls the "Program Manager" operating area.
<OFFSET> - only OP 010 and OP 010C

Calls the "Parameter" operating area.
<PROGRAM MANAGER> - only OP 010 and OP 010C

Calls the "Program Manager" operating area.
Menu forward key

Advances in the extended horizontal softkey bar.
Menu back key

Returns to the higher-level menu.
<MACHINE>
Calls the "Machine" operating area.
<MENU SELECT>
Calls the main menu to select the operating area.
Milling
Introduction
1.3 Machine control panels
1.3.1 Overview
The machine tool can be equipped with a machine control panel by Siemens or with a
specific machine control panel from the machine manufacturer.
You use the machine control panel to initiate actions on the machine tool such as traversing
an axis or starting the machining of a workpiece.
1.3.2 Controls on the machine control panel

In this example, the MCP 483C IE machine control panel is used to illustrate the operator
controls and displays of a Siemens machine control panel.
Overview

(1) EMERGENCY STOP button

Activate the button in situations where
life is at risk.
there is the danger of a machine or workpiece being damaged.
All drives will be stopped with the greatest possible braking torque.
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Introduction
Machine manufacturer
For additional responses to pressing the Emergency Stop button, please
refer to the machine manufacturer's instructions.
(2) Installation locations for control devices (d = 16 mm)
(3) RESET
Stop processing the current programs.
The NCK control remains synchronized with the machine. It is in its initial
state and ready for a new program run.
Cancel alarm.
(4) Program control
<SINGLE BLOCK>
Single block mode on/off.
<CYCLE START>
The key is also referred to as NC Start.
Execution of a program is started.
<CYCLE STOP>
The key is also referred to as NC Stop.
Execution of a program is stopped.
(5) Operating modes, machine functions
<JOG>
Select "JOG" mode.
<TEACH IN>
Select "Teach In" submode.
<MDI>
Select "MDI" mode.
<AUTO>
Select "AUTO" mode.
<REPOS>
Repositions, re-approaches the contour.
<REF POINT>
Approach reference point.
Inc <VAR>(Incremental Feed Variable)

Incremental mode with variable increment size.
Inc (incremental feed)

Incremental mode with predefined increment size of 1, ..., 10000
increments.
...
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Introduction
A machine data code defines how the increment value is
interpreted.
(6) Customer keys
T1 to T15
(7) Traversal axes with rapid traverse superposition and coordinate exchange
Axis keys
; Selects an axis.
...
Direction keys
Select the traversing direction.
...

<RAPID>
Traverse axis in rapid traverse while pressing the direction key.
<WCS MCS>
Switches between the workpiece coordinate system (WCS) and machine
coordinate system (MCS).
(8) Spindle control with override switch
<SPINDLE STOP>
Stop spindle.
<SPINDLE START>
Spindle is enabled.
(9) Feed control with override switch

<FEED STOP>
Stops execution of the running program and shuts down axis drives.
<FEED START>
Enable for program execution in the current block and enable for ramp-up to
the feedrate value specified by the program.
(10) Keyswitch (four positions)
Figure 1-2 Front view of machine control panel (milling version)
Milling
Introduction
1.4 User interface
1.4 User interface
1.4.1 Screen layout
Overview

1 Active operating area and mode

2 Alarm/message line
3 Program name
4 Channel state and program control
5 Channel operational messages
6 Axis position display in actual value window
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Introduction
1.4 User interface
7 Display for
active tool T
current feedrate F
active spindle with current status (S)
Spindle utilization rate in percent
8 Operating window with program block display
9 Display of active G functions, all G functions, auxiliary functions and input window for different functions (for
example, skip blocks, program control).
10 Dialog line to provide additional user notes.
11 Horizontal softkey bar
12 Vertical softkey bar
Figure 1-3 User interface
1.4.2 Status display

The status display includes the most important information about the current machine status
and the status of the NCK. It also shows alarms as well as NC and PLC messages.
Depending on your operating area, the status display is made up of several lines:
Large status display
The status display is made up of three lines in the "Machine" operating area.
Small status display
In the "Parameter", "Program", "Program Manager", "Diagnosis" and "Start-up" operating
areas, the status display consists of the first line from the large display.
Status display of "Machine" operating area
First line
Display Description
Active operating area
"Machine" operating area
With touch operation, you can change the operating area here.
"Parameter" operating area
"Program" operating area
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Introduction
1.4 User interface
Display Description
"Program manager" operating area
"Diagnosis" operating area
"Start-up" operating area
Active mode or submode

"Jog" mode
"MDA" mode
"Auto" mode
"Teach In" submode
"Repos" submode
"Ref Point" submode
Alarms and messages

Alarm display
The alarm numbers are displayed in white lettering on a red
background. The associated alarm text is shown in red
lettering.
An arrow indicates that several alarms are active.
An acknowledgment symbol indicates that the alarm can be
acknowledged or canceled.
NC or PLC message
Message numbers and texts are shown in black lettering.
An arrow indicates that several messages are active.
Messages from NC programs do not have numbers and appear
in green lettering.
Second line
Display Description
Program path and program name
The displays in the second line can be configured.
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Introduction
1.4 User interface
Please also refer to the machine manufacturer's instructions.
Third line
Display Description
Display of channel status.
If several channels are present on the machine, the channel
name is also displayed.
If only one channel is available, only the "Reset" channel status
is displayed.
With touch operation, you can change the channel here.
Display of channel status:
The program was aborted with "Reset".
The program is started.
The program has been interrupted with "Stop".
Display of active program controls:

PRT: no axis motion
DRY: Dry run feedrate
RG0: reduced rapid traverse
M01: programmed stop 1
M101: programmed stop 2 (name varies)
SB1: Single block, coarse (program stops only after blocks
which perform a machine function)
SB2: Data block (program stops after each block)
SB3: Single block, fine (program also only stops after blocks
which perform a machine function in cycles)
Channel operational messages:
Stop: An operator action is usually required.
Wait: No operator action is required.
The machine manufacturer settings determine which program controls are displayed.
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Introduction
1.4 User interface
1.4.3 Actual value window

The actual values of the axes and their positions are displayed.
Work/Machine
The displayed coordinates are based on either the machine coordinate system or the
workpiece coordinate system. The machine coordinate system (Machine), in contrast to the
workpiece coordinate system (Work), does not take any work offsets into consideration.
You can use the "Machine actual values" softkey to toggle between the machine coordinate
system and the workpiece coordinate system.
The actual value display of the positions can also refer to the SZS coordinate system
(settable zero system). However the positions are still output in the Work.
The ENS coordinate system corresponds to the Work coordinate system, reduced by certain
components ($P_TRAFRAME, $P_PFRAME, $P_ISO4FRAME, $P_CYCFRAME), which are
set by the system when machining and are then reset again. By using the ENS coordinate
system, jumps into the actual value display are avoided, that would otherwise be caused by
the additional components.
Please refer to the machine manufacturer's specifications.
Maximize display
Press the ">>" and "Zoom act.val." softkeys.
Overview of display
Display Meaning
Header columns
Work/Machine Display of axes in selected coordinate system.
Item Position of displayed axes.
Display of distance-to-go The distance-to-go for the current NC block is displayed while the
program is running.
Feed/override The feed acting on the axes, as well as the override, are displayed
in the full-screen version.
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Introduction
1.4 User interface
Display Meaning
Repos offset The distances traversed in manual mode are displayed.
This information is only displayed when you are in the "Repos"
submode.
Footer Display of active work offsets and transformations.
The T, F, S values are also displayed in the full-screen version.
See also
Overview (Page 76)
Work offsets (Page 109)
1.4.4 T,F,S window

The most important data concerning the current tool, the feedrate (path feed or axis feed in
JOG) and the spindle are displayed in the T, F, and S windows.
Tool data
Display Meaning
T
Tool name Name of current tool
Location Location number of current tool
D Cutting edge of the current tool
The tool is displayed with the associated tool type symbol corresponding to
the actual coordinate system in the selected cutting edge position.
If the tool is swiveled, then this is taken into account in the display of the
cutting edge position.
In DIN-ISO mode the H number is displayed instead of the cutting edge
number.
H H number (tool offset data record for DIN-ISO mode)
If there is a valid D number, this is also displayed.
Diameter of current tool
R Radius of the actual tool
Z Z value of the actual tool
X X value of the actual tool
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Introduction
1.4 User interface
Feed data
Display Meaning
F
Feed disable
Actual feed value

If several axes traverse, is displayed for:
"JOG" mode: Axis feed for the traversing axis
"MDA" and "AUTO" mode: Programmed axis feed
Rapid traverse G0 is active
0.000 No feed is active
Override Display as a percentage
Spindle data
Display Meaning
S
S1 Spindle selection, identification with spindle number and main spindle
Speed Actual value (when spindle turns, display increases)
Setpoint (always displayed, also during positioning)
Symbol Spindle status
Spindle not enabled
Spindle is turning clockwise
Spindle is turning counterclockwise
Spindle is stationary
Override Display as a percentage

Spindle utilization Display between 0 and 100%
rate The upper limit value can be greater than 100%.
See machine manufacturer's specifications.
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Introduction
1.4 User interface
1.4.5 Current block display

The window of the current block display shows you the program blocks currently being
executed.
Display of current program

The following information is displayed in the running program:
The workpiece name or program name is entered in the title row.
The program block which is just being processed appears colored.
Editing a program directly

In the Reset state, you can edit the current program directly.
1. Press the <INSERT> key.
2. Place the cursor at the relevant position and edit the program block.
Direct editing is only possible for G code blocks in the NC memory, not
for external execution.
3. Press the <INSERT> key to exit the program and the edit mode again.
1.4.6 Operation via softkeys and buttons
Operating areas/operating modes

The user interface consists of different windows featuring eight horizontal and eight vertical
softkeys.
You operate the softkeys with the keys next to the softkey bars.
You can display a new window or execute functions using the softkeys.
The operating software is sub-divided into six operating areas (machine, parameter,
program, program manager, diagnosis, startup) and five operating modes or submodes
(JOG, MDA, AUTO, TEACH IN, REF POINT, REPOS).
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Introduction
1.4 User interface
Changing the operating area
Press the <MENU SELECT> key and select the desired operating area using
the horizontal softkey bar.
You can call the "Machine" operating area directly using the key on the operator panel.
Press the <MACHINE> key to select the "machine" operating area.
Changing the operating mode

You can select a mode or submode directly using the keys on the machine control panel or
using the vertical softkeys in the main menu.
General keys and softkeys
When the symbol appears to the right of the dialog line on the user
interface, you can change the horizontal softkey bar within an operating area.
To do so, press the menu forward key.
The symbol indicates that you are in the expanded softkey bar.
Pressing the key again will take you back to the original horizontal softkey bar.
Use the ">>" softkey to open a new vertical softkey bar.
Use the "<<" softkey to return to the previous vertical softkey bar.
Use the "Return" softkey to close an open window.
Use the "Cancel" softkey to exit a window without accepting the entered
values and return to the next highest window.
When you have entered all the necessary parameters in the parameter screen
form correctly, you can close the window and save the parameters using the
"Accept" softkey. The values you entered are applied to a program.
Use the "OK" softkey to initiate an action immediately, e.g. to rename or
delete a program.
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Introduction
1.4 User interface
1.4.7 Entering or selecting parameters

When setting up the machine and during programming, you must enter various parameter
values in the entry fields. The background color of the fields provides information on the
status of the entry field.
Orange background The input field is selected

Light orange background The input field is in edit mode
Pink background The entered value is incorrect
Selecting parameters
Some parameters require you to select from a number of options in the input field. Fields of
this type do not allow you to type in a value.
The selection symbol is displayed in the tooltip:
Associated selection fields

There are selection fields for various parameters:
Selection of units
Changeover between absolute and incremental dimensions
Procedure
1. Keep pressing the <SELECT> key until the required setting or unit is
selected.
The <SELECT> key only works if there are several selection options
available.
- OR -
Press the <INSERT> key.
The selection options are displayed in a list.
2. Select the required setting using the <Cursor down> and <Cursor up>
keys.
3. If required, enter a value in the associated input field.

4. Press the <INPUT> key to complete the parameter input.
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Introduction
1.4 User interface
Changing or calculating parameters

If you only want to change individual characters in an input field rather than overwriting the
entire entry, switch to insertion mode.
In this mode, you can also enter simple calculation expressions, without having to explicitly
call the calculator. You can execute the four basic calculation types, work with expressions in
brackets as well as generate square roots and squares.
Note
Generating square roots and squares
The extract roots and generate square functions is not available in the parameter screens of
the cycles and functions in the "Program" operating area.

The insert mode is activated.
You can navigate within the input field using the <Cursor left> and
<Cursor right> keys.
Use the <BACKSPACE> and <DEL> key to delete individual characters.
+ <*> Enter the multiplication characters using the <SHIFT> + <*> keys.
+ </> Enter the division character using the <SHIFT> + </> keys.
Enter bracket expressions using the <SHIFT> + <(> and <SHIFT> + <)>
keys.
+ <)>
+ <number> Enter "r" or "R" as well as the number x from which you would like to
5 extract the root.
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Introduction
1.4 User interface
+ <number> Enter "s" or "S" as well as the number x for which you would like to
6 generate the square.
Close the value entry using the <INPUT> key and the result is
transferred into the field.
Accepting parameters
When you have correctly entered all necessary parameters, you can close the window and
save your settings.
You cannot accept the parameters if they are incomplete or obviously erroneous. In this
case, you can see from the dialog line which parameters are missing or were entered
incorrectly.
Press the "OK" softkey.
- OR -
Press the "Accept" softkey.
1.4.8 Pocket calculator

You can use the calculator to quickly calculate parameter values during programming. If, for
example, the diameter of a workpiece is only dimensioned indirectly in the workpiece
drawing, i.e., the diameter must be derived from the sum of several other dimension
specifications, you can calculate the diameter directly in the input field of this parameter.
Calculation methods
The following arithmetic operations are available:
Addition
Subtraction
Multiplication
Division
Calculation with parentheses
Square root of x
x squared
You can input a maximum of 256 characters in a field.
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Introduction
1.4 User interface
Procedure
1. Position the cursor on the desired entry field.

2. Press the <=> key.
The calculator is displayed.

3. Input the arithmetic statement.
You can use arithmetic symbols, numbers, and commas.
4. Press the equals symbol on the calculator.
- OR -
Press the "Calculate" softkey.
- OR -
Press the <INPUT> key.
The new value is calculated and displayed in the entry field of the
calculator.
5. Press the "Accept" softkey.
The calculated value is accepted and displayed in the entry field of the
window.
Note
Input order for functions
When using the square root or squaring functions, make sure to press the "R" or "S" function
keys, respectively, before entering a number.
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Introduction
1.4 User interface
1.4.9 Context menu

When you right-click, the context menu opens and provides the following functions:
Cut
Cut Ctrl+X
Copy
Copy Ctrl+C
Paste
Paste Ctrl+V
Program editor
Additional functions are available in the editor
Undo the last change
Undo Ctrl+Z
Redo the changes that were undone
Redo Ctrl+Y
Up to 10 changes can be undone.
1.4.10 Touch operation

If you have an operator panel with a touch screen, you can perform the following functions
with touch operation:
Operating area switchover
You can display the operating area menu by touching the display symbol for
the active operating area in the status display.
Channel switchover
You can switch over to the next channel by touching the channel display
in the status display.
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Introduction
1.4 User interface
1.4.11 Changing the user interface language
Procedure
1. Select the "Startup" operating area.
2. Press the "Change language" softkey.

The "Language selection" window opens. The language set last is
selected.
3. Position the cursor on the desired language.
4. Press the "OK" softkey.
- OR -
The user interface changes to the selected language.
Note
Changing the language directly on the input screens
You can switch between the user interface languages available on the controller directly on
the user interface by pressing the key combination <CTRL + L>.
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Introduction
1.4 User interface
1.4.12 Entering Asian characters

You have the possibility of entering Asian characters.
Note
Call the input editor with <Alt + S>
The input editor can only be called there where it is permissible to enter Asian characters.
You can select a character by using the Pinyin phonetic notation, which enables Chinese
characters to be expressed by combining Latin letters.
The editor is available for the following Asian languages:
Simplified Chinese
Traditional Chinese
Korean
Note
You require a special keyboard to enter Korean characters.
Structure of editor
3KRQHWLFLQSXW )XQFWLRQVHOHFWLRQ
2IIHUHGFKDUDFWHUV
3KRQHWLFVHOHFWLRQIURPGLFWLRQDU\
Functions
Pinyin input
Editing of the dictionary
Input of Latin letters
Precondition
The control has been set to Chinese or Korean.
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Introduction
1.4 User interface
Procedure
Editing characters
1. Open the screen form and position the cursor on the entry field and
$ press the <Alt +S> keys.
The editor is displayed.
+
2. Enter the desired phonetic notation.

3. Click the <Cursor down> key to access the dictionary.
4. By keeping the <Cursor down> key pressed, displays all the entered
phonetic notations and the associated selection characters.
5. Press the <BACKSPACE> softkey to delete entered phonetic notations.
6. Press the number key to insert the associated character.

When a character is selected, the editor records the frequency with
which it is selected for a specific phonetic notation and offers this
character at the top of the list when the editor is next opened.
Editing the dictionary
1. Select the dictionary editing function in the selection box.
The editor provides a further line in which the combined characters and
phonetic notations are displayed.
2. Enter the desired phonetic notation in the phonetic input field.
Various characters are displayed for this phonetic notation, from which
you can select a character by entering either of the appropriate number
(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.
Combined characters are cancelled via the <BACKSPACE> key.
3. Press the <SELECT> key to take a combined phonetic notation into the
dictionary.
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Introduction
1.4 User interface
1.4.13 Protection levels

The input and modification of data in the control system is protected by passwords at
sensitive places.
Access protection via protection levels

The input or modification of data for the following functions depends on the protection level
setting:
Tool offsets
Work offsets
Setting data
Program creation / program editing
Note
Configuring access levels for softkeys
You have the option of providing softkeys with protection levels or completely hiding
them.
References
For additional information, please refer to the following documentation:
Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl
Softkeys
Machine operating area Protection level

End user
(protection level 3)
Parameters operating area Protection level

Tool management lists
Key switch 3
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Introduction
1.4 User interface
Diagnostics operating area Protection level

Keyswitch 3
End user
End user
Manufacturer
End user
Service
Startup operating area Protection levels

End user
Keyswitch 3
Keyswitch 3
Key switch 3
Keyswitch 3
Service
End user
End user
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Introduction
1.4 User interface
1.4.14 Online help in HMI sl

A comprehensive context-sensitive online help is stored in the control system.
A brief description is provided for each window and, if required, step-by-step instructions
for the operating sequences.
A detailed help is provided in the editor for every entered G code. You can also display all
G functions and take over a selected command directly from the help into the editor.
A help page with all parameters is provided on the input screen in the cycle programming.
Lists of the machine data
Lists of the setting data
Lists of the drive parameters
List of all alarms
Procedure
Calling context-sensitive online help

1. You are in an arbitrary window of an operating area.
2. Press the <HELP> key or on an MF2 keyboard, the <F12> key.
The help page of the currently selected window is opened in a
subscreen.
3. Press the "Full screen" softkey to use the entire user interface for the
display of the online help.
Press the "Full screen" softkey again to return to the subscreen.
4. If further helps are offered for the function or associated topics, position
the cursor on the desired link and press the "Follow reference" softkey.
The selected help page is displayed.
5. Press the "Back to reference" softkey to jump back to the previous help.
Calling a topic in the table of contents

1. Press the "Table of contents" softkey.
Depending on which technology you are using, the Operating Manuals
"Operator control Milling", "Operator control Turning" or "Operator
control Universal" as well as the "Programming" Programming Manual
are displayed.
2. Select the desired manual with the <Cursor down> and <Cursor up>
keys.
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Introduction
1.4 User interface
3 Press the <Cursor right> or <INPUT> key or double-click to open the

manual and the chapter.
4. Navigate to the desired topic with the "Cursor down" key.
5. Press the <Follow reference> softkey or the <INPUT> key to display the
help page for the selected topic.
6. Press the "Current topic" softkey to return to the original help.
Searching for a topic

1. Press the "Search" softkey.
The "Search in Help for: " window is opened.
2. Activate the "Full text " checkbox to search in all help pages.
If the checkbox is not activated, a search is performed in the table of
contents and in the index.
3. Enter the desired keyword in the "Text" field and press the "OK" softkey.
If you enter the search term on the operator panel, replace an umlaut
(accented character) by an asterisk (*) as dummy.
All entered terms and sentences are sought with an AND operation. In
this way, only documents and entries that satisfy all the search criteria
are displayed.
4. Press the "Keyword index" softkey if you only want to display the index
of the operating and programming manual.
Displaying alarm descriptions and machine data

1. If messages or alarms are pending in the "Alarms", "Messages" or
"Alarm Log" window, position the cursor at the appropriate display and
press the <HELP> or the <F12> key.
The associated alarm description is displayed.
2. If you are in the "Startup" operating area in the windows for the display
of the machine, setting and drive data, position the cursor on the
desired machine data or drive parameter and press the <HELP> or the
<F12> key.
The associated data description is displayed.
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Introduction
1.4 User interface
Displaying and inserting a G code command in the editor

1. A program is opened in the editor.
Position the cursor on the desired G code command and press the
<HELP> or the <F12> key.
The associated G code description is displayed.
2. Press the "Display all G functions" softkey.
3. With the aid of the search function, select, for example, the desired G
code command.
4. Press the "Transfer to editor" softkey.

The selected G function is taken into the program at the cursor position.
5. Press the "Exit help" softkey again to close the help.
See also
Additional functions in the input screens (Page 224)
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Introduction
1.4 User interface
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Setting up the machine 2
2.1 Switching on and switching off
Start-up
When the control starts up, the main screen opens according to the operating mode
specified by the machine manufacturer. In general, this is the main screen for the "REF
POINT" submode.
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Setting up the machine
2.2 Approaching a reference point
2.2.1 Referencing axes

Your machine tool can be equipped with an absolute or incremental path measuring system.
An axis with incremental path measuring system must be referenced after the control has
been switched-on however, an absolute path measuring system does not have to be
referenced.
For the incremental path measuring system, all the machine axes must therefore first
approach a reference point, the coordinates of which are known to be relative to the machine
zero-point.
Sequence
Prior to the approach, the axes must be in a position from where they can approach the
reference point without a collision.
The axes can also all approach the reference point simultaneously, depending on the
manufacturers settings.
NOTICE
If the axes are not in a collision-free position, you must first traverse them to safe positions
in "JOG" or "MDA" mode.
You must follow the axis motions directly on the machine!
Ignore the actual value display until the axes have been referenced!
The software limit switches are not active!
Procedure
1. Press the <JOG> key.
2. Press the <REF. POINT> key.
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3. Select the axis to be traversed.

;
4. Press the <-> or <+> key.

The selected axis moves to the reference point.
If you have pressed the wrong direction key, the action is not accepted
and the axes do not move.
A symbol is shown next to the axis if it has been referenced.
The axis is referenced as soon as the reference point is reached. The actual value display is
set to the reference point value.
From now on, path limits, such as software limit switches, are active.
End the function via the machine control panel by selecting operating mode "AUTO" or
"JOG".
2.2.2 User agreement

If you are using Safety Integrated (SI) on your machine, you will need to confirm that the
current displayed position of an axis corresponds to its actual position on the machine when
you reference an axis. Your confirmation is the precondition for the availability of other
Safety Integrated functions.
You can only give your user acknowledgement for an axis after it has approached the
reference point.
The displayed axis position always refers to the machine coordinate system (Machine).
Option
User acknowledgement with Safety Integrated is only possible with a software option.
Procedure
1. Select the "Machine" operating area.
2. Press the <REF POINT> key.
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;
4. Press the <-> or <+> key.

The selected axis moves to the reference point and stops. The
coordinate of the reference point is displayed.
The axis is marked with .
5. Press the "User enable" softkey.

The "User Acknowledge" window opens.
It shows a list of all machine axes with their current position and SI
position.
5. Position the cursor in the "Acknowledgement" field for the axis in
question.
6. Activate the acknowledgement with the <SELECT> key.
The selected axis is marked with an "x" meaning "safely referenced"

in the "Acknowledgement" column.
By pressing the <SELECT> key again, you deactivate the
acknowledgement again.
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2.3 Operating modes
2.3 Operating modes
2.3.1 General
You can work in three different operating modes.
"JOG" mode
"JOG" mode is used for the following preparatory actions:
Approach reference point, i.e. the machine axis is referenced
Preparing a machine for executing a program in automatic mode, i.e. measuring tools,
measuring the workpiece and, if necessary, defining the work offsets used in the program
Traversing axes, e.g. during a program interruption
Positioning axes
Select "JOG"
Press the <JOG> key.
"Ref Point" submode

The "REF POINT" submode is used to synchronize the control and the machine. For this
purpose, you approach the reference point in "JOG" mode.
Selecting "REF POINT"
Press the <REF POINT> key.
"REPOS" submode
The "REPOS" submode is used for repositioning to a defined position. After a program
interruption (e.g. to correct tool wear values) move the tool away from the contour in "JOG"
mode.
The distances traversed in "JOG" mode are displayed in the actual value window as the
"Repos" offset.
"REPOS" offsets can be displayed in the machine coordinate system (MCS) or workpiece
coordinate system (WCS).
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2.3 Operating modes
Selecting "Repos"
Press the <REPOS> key.
"MDA" mode (Manual Data Automatic)

In "MDA" mode, you can enter and execute G code commands non-modally to set up the
machine or to perform a single action.
Selecting "MDA"
Press the <MDA> key.
"AUTO" mode
In automatic mode, you can execute a program completely or only partially.
Select "AUTO"
Press the <AUTO> key.
"TEACH IN" submode

The "TEACH IN" submode is available in the "AUTO" and "MDA" modes.
There you may create, edit and execute part programs (main programs or subroutines) for
motional sequences or simple workpieces by approaching and saving positions.
Selecting "Teach In"
Press the <TEACH IN> key.
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2.3 Operating modes
2.3.2 Modes groups and channels

Every channel behaves like an independent NC. A maximum of one part program can be
processed per channel.
Control with 1channel
One mode group exists.
Control with several channels
Channels can be grouped to form several "mode groups."
Example
Control with 4 channels, where machining is carried out in 2 channels and 2 other channels
are used to control the transport of the new workpieces.
Mode group 1 channel 1 (machining)
Channel 2 (transport)
Mode group 2 channel 3 (machining)
Channel 4 (transport)
Mode groups (MGs)

Technologically-related channels can be combined to form a mode group.
Axes and spindles of the same mode group can be controlled by one or more channels.
An operating mode group is in one of "Automatic", "JOG" or "MDI" operating modes, i.e.,
several channels of an operating mode group can never assume different operating modes.
2.3.3 Channel switchover

It is possible to switch between channels when several are in use. Since individual channels
may be assigned to different mode groups, a channel switchover command is also an implicit
mode switchover command.
When a channel menu is available, all of the channels are displayed on softkeys and can be
switched over.
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2.3 Operating modes
Changing the channel
Press the <CHANNEL> key.
The channel changes over to the next channel.

- OR -
If the channel menu is available, a softkey bar is displayed. The active
channel is highlighted.
Another channel can be selected by pressing one of the other softkeys.
References
Channel switchover via touch operation

On the HT 8 and when using a touch screen operator panel, you can switch to the next
channel or display the channel menu via touch operation in the status display.
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2.4 Settings for the machine
2.4.1 Switching over the coordinate system (MCS/WCS)

The coordinates in the actual value display are relative to either the machine coordinate
system or the workpiece coordinate system.
By default, the workpiece coordinate system is set as a reference for the actual value
display.
The machine coordinate system (MCS), in contrast to the workpiece coordinate system
(WCS), does not take into account any work offsets, tool offsets and coordinate rotation.
Procedure
2. Press the <JOG> or <AUTO> key.
3. Press the "Act.vls. MCS" softkey.
The machine coordinate system is selected.

The title of the actual value window changes in the MCS.
The softkey to changeover the coordinate system can be hidden. Please refer to the
machine manufacturer's specifications.
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2.4.2 Switching the unit of measurement

You can set millimeters or inches as the unit of measurement. Switching the unit of
measurement always applies to the entire machine. All required information is automatically
converted to the new unit of measurement, for example:
Positions
Tool offsets
Work offsets
Proceed as follows
1. Select <JOG> or <AUTO> mode in the "Machine" operating area.
2. Press the menu forward key and the "Settings" softkey.

A new vertical softkey bar appears.
3. Press the "Switch to inch" softkey.

A prompt asks you whether you really want to switch over the unit of
measurement.
The softkey label changes to "Switch to metric".

The unit of measurement applies to the entire machine.
5. Press the "Switch to metric" softkey to set the unit of measurement of
the machine to metric again.
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2.4.3 Setting the work offset

You can enter a new position value in the actual value display for individual axes when a
settable work offset is active.
The difference between the position value in the machine coordinate system MCS and the
new position value in the workpiece coordinate system WCS is saved permanently in the
currently active work offset (e.g. G54).
Relative actual value

Further, you also have the possibility of entering position values in the relative coordinate
system.
Note
The new actual value is only displayed. The relative actual value has no effect on the axis
positions and the active work offset.
Resetting the relative actual value
Press the "Delete REL" softkey.
The actual values are deleted.

The softkeys to set the zero point in the relative coordinate system are only available if the
corresponding machine data is set.
Precondition
The control is in the workpiece coordinate system.
The actual value is set in the reset state.
Note
Setting the WO in the Stop state
If you enter the new actual value in the Stop state, the changes made are only visible and
only take effect when the program is continued.
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Procedure
1. Select the "JOG" mode in the "Machine" operating area.
2. Press the "Set WO" softkey.
- OR -
Press the ">>", "REL act. vals" and "Set REL" softkeys to set position
values in the relative coordinate system.
3. Enter the new required position value for X, Y or Z directly in the actual
value display (you can toggle between the axes with the cursor keys)
and press the "Input" key to confirm the entries.
- OR -
Press softkeys "X=0","Y=0" or "Z=0" to set the relevant position to zero.
...
- OR -
Press softkey "X=Y=Z=0" to set all axis positions to zero simultaneously.
Resetting the actual value
Press the "Delete active WO" softkey.

The offset is deleted permanently.
NOTICE
Irreversible active work offset
The current active work offset is irreversibly deleted by this action.
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2.5 Measuring the tool

The geometries of the machining tool must be taken into consideration when executing a
part program. These are stored as tool offset data in the tool list. Each time the tool is called,
the control considers the tool offset data.
When programming the part program, you only need to enter the workpiece dimensions from
the production drawing. After this, the controller independently calculates the individual tool
path.
You can determine the tool offset data, i.e. the length and radius or diameter, either manually
or automatically with tool probes.
See also
Tool dimensioning (Page 505)
Measuring the tool (Page 518)
2.5.1 Measuring a tool manually

For manual measurement, move the tool manually to a known reference point to determine
the tool length and the radius or diameter. The control then calculates the tool offset data
from the position of the tool carrier reference point and the reference point.
Reference point
When measuring the tool length you can either use the workpiece or a fixed point in the
machine coordinate system, e.g. a mechanical test socket or a fixed point in combination
with a distance gauge as the reference point.
When determining the radius/diameter, the workpiece is always used as the reference point
In the machine data, you define whether the radius or the diameter of the tool is to be
measured.
Note
You can enter the position of the workpiece during measurement.
However, you must declare the position of the fixed point before the measurement.
See also
Fixed point calibration (Page 72)
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2.5.2 Measuring the tool length with the workpiece as reference point
Procedure
1. Insert the tool you want to measure in the spindle.

2. Select "JOG" mode in the "Machine" operating area.
3. Press the "Meas. tool" and "Length manual" softkeys.

The "Length Manual" window opens.
4. Select the cutting edge number D and the number of the replacement
tool ST of the tool.
5. Approach the workpiece in the Z direction, scratch it with a turning

spindle and enter the set position Z0 of the workpiece edge.
6. Press the "Set length" softkey.
The tool length is calculated automatically and entered in the tool list.
Note
Tool measurement is only possible with an active tool.
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2.5.3 Measuring radius or diameter
Procedure
1. Insert the tool you want to measure in the spindle.

Select "JOG" mode in the "Machine" operating area.
2. Press the "Meas. tool" softkey.
3. Press the "Radius manual" or "Diam. manual" softkey.
4. Select the cutting edge number D and the the number of the
replacement tool ST.
5. Approach the workpiece in the X or Y direction and perform scratching

with the spindle rotating in the opposite direction.
6. Specify the setpoint position X0 or Y0 of the workpiece edge.
7. Press the "Set radius" or "Set diam." softkey.
The tool radius or diameter is calculated automatically and entered in
the tool list.
Note
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2.5.4 Fixed point calibration

If you want to use a fixed point as the reference point in manual measurement of the tool
length, you must first determine the position of the fixed point relative to the machine zero.
Test socket
You can use a mechanical test socket as the fixed point, for example. Mount the test socket
on the machine table in the machining space of the machine. Enter zero as the distance.
Distance gauge
However, you can also use any fixed point on the machine in combination with a distance
gauge. Enter the thickness of the plate as "DZ".
To calibrate the fixed point, use either a tool whose length is known (i.e. the tool length must
be entered in the tool list) or the spindle directly.
The position of the fixed point may have already been determined by the machine
manufacturer.
Procedure
1. Traverse the tool or spindle to the fixed point.

2. Press the "Measure tool" softkey in the "JOG" mode.
3. Press the "Calibrate fixed point" softkey.
4. Enter a correction value for "DZ".

If you have used a distance gauge, enter the thickness of the plate
used.
5. Press the "Calibrate" softkey.
6. The distance between machine zero and fixed point is calculated and
entered in the machine data.
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2.5.5 Measuring a tool with an electrical tool probe

For automatic measurement, you determine the length and radius or diameter of the tool with
the aid of a tool probe (table contact system). The control uses the known positions of the
toolholder reference point and tool probe to calculate the tool offset data.
Use the softkey to select whether you want to measure the length, the radius or the diameter
of the tool.
The corresponding windows can be adapted to the measurement tasks in order to
automatically measure tools.
Adapting the user interface to calibrating and measuring functions

The following selection options can be switched-in or switched-out:
Calibration plane, measurement plane
Probe
Calibration feedrate (measuring feedrate)
Preconditions
No function-related settings are necessary after the measuring cycles have been
installed.
Before the actual measurement, enter approximate values for length and radius or
diameter of the tool in the tool list.
Calibrate the probe first.
Lateral/longitudinal offset
If the widest part of the tool is not at the outer edge of the tool or the longest part is not at the
bottom edge of the tool, you can store this difference in the offset.
If measuring shows that the length of the tool diameter is greater than the probe diameter,
measurement is automatically performed with rotating spindle.
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Procedure
1. Insert the tool that you want to measure.

3. Press the "Meas. tool" softkey.
4. Press the "Length auto" softkey if you want to measure the length of the
tool.
- OR -
Press the "Radius auto" or "Diam. Auto", if you wish to measure the
radius or diameter of the tool.
tool ST.
6. If necessary, enter the lateral offset V.

7. Press the <CYCLE START> key.
This starts the automatic measuring process. When you measure the
tool radius or diameter, measurement is performed with a spindle
rotating in the opposite direction.
The tool length, radius, and diameter are calculated automatically and
entered in the tool list.
Note
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2.5.6 Calibrating the electrical tool probe

If you want to measure your tools automatically, you must first determine the position of the
tool probe on the machine table with reference to the machine zero.
Tool probes are typically shaped like a cube or a cylindrical disk. Install the tool probe in the
working area of the machine (e.g on the machine table) and align it relative to the machining
axes.
You must use a mill-type calibration tool to calibrate the tool probe. You must enter the
length and radius/diameter of the calibration tool in the tool list beforehand.
Note
Setting the protection level
The "Calibrate probe" function is only available if an adequate level of protection is set.
Procedure
1. Move the calibration tool until it is approximately over the center of the
measuring surface of the tool probe.
2. Select operating mode "JOG" in the "Machine" operating area and press
the "Measure tool" softkey.
3. Press the "Probe calibration softkey.
4. Choose whether you want to calibrate the length or the length and the
diameter.

Calibration is automatically executed at the measuring feedrate. The
distance measurements between the machine zero and tool probe are
calculated and stored in an internal data area.
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2.6 Measuring the workpiece zero
2.6.1 Overview
The reference point for programming a workpiece is always the workpiece zero. You can
determine the workpiece zero on the following workpiece elements:
Edges, (Page 86)
Corner (Page 89)
Pocket and hole (Page 92)
Spigot (Page 98)
Measuring methods
You can measure the workpiece zero either manually or automatically.
Manual measurement
To measure the zero point manually, you need to traverse your tool manually up to the
workpiece. You can use edge probes, sensing probes, or dial gauges with known radii and
lengths. You can also use any other tool of which you know the radius and length.
The tools used for measuring must not be electronic probes.
Automatic measurement
For automatic measurements, only use the electronic workpiece probe, tool type 710/712.
You must first calibrate the electronic workpiece probe.
In the case of automatic measuring, first position the workpiece probe manually. After
starting using the <CYCLE START> key, the workpiece probe is automatically extended to
the workpiece with the measuring feedrate. Retraction motion from the measuring point is
realized as a function of the setting data with the rapid traverse velocity or a user-specific
positioning velocity.
Adapting the user interface to calibrating and measuring functions

Activate the following selection options using setting data:
Calibration plane, measurement plane
Calibration feedrate (measuring feedrate)
Work offset as basis for the measuring process
Number of the probe calibration data set
Offset target, adjustable work offset
Offset target, basis reference
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Offset target, global basis work offset

Offset target, channel-specific basis work offset
Note
"Measuring only" for automatic measuring
If "Measuring only" is selected as offset target, then instead of the "Set WO" softkey, the
"Calculate" softkey is displayed.
The measuring versions "Set edge", "Rectangular pocket", "Rectangular spigot", "1 circular
spigot" and "1 hole" are an exception. For these single-point measurements, for "Measuring
only" neither the "Set WO" softkey nor the "Calculate" softkey is listed.
Preconditions
The automatic measurement in the JOG mode is completely installed and functional in
the default setting of the control.
When tool type 710/712 is active, the automatic measuring functions are always executed
in the JOG mode.
You specify user-specific settings (e.g. positioning velocity in the working plane or tool
axis, length of the measuring distance) using the appropriate parameters.
References
Information on user-specific settings is provided in the Chapter "Measuring in the JOG
mode".
Selecting the measuring plane

The measuring plane (G17,18,19) can be selected to flexibly adapt to measuring tasks. If the
measuring plane selection is not activated, then the measurement is performed based on the
currently active measuring plane.
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Selecting the probe number and the calibration data set number
Workpiece probe calibration data fields can be selected using this function. For different
measuring situations, in order to guarantee a high measuring accuracy, it may be necessary
to save the corresponding calibration data in different data fields, which can then be selected
for the measuring tasks.
If the probe number selection is not activated, then probe number "one" is always used.
Entering the calibration feedrate

The actual calibration feedrate can be entered into this entry field. The calibration feedrate is
stored in the calibration data and is used for the measurements.
If the entry field does not exist, then the calibration feedrate from a central parameter is
used.
Selecting the work offset as basis for the measurement

A work offset can be selected as measurement basis to flexibly adapt to the measuring
tasks.
If the work offset selection as measurement basis is not activated, then the measurement
refers to the currently active work offset.
Measuring sequence
To obtain the desired measuring results, you must keep to the measuring point sequence
shown in the help displays.
You can reject measuring points and then measure them again. This is done by pressing the
softkey that is currently active (measured value).
Measuring only
If you "only" want to measure the workpiece zero, the measured values are calculated and
displayed without changing the coordinate system.
Work offset
You usually store the measured workpiece zero in a work offset. The HMI allows rotations
and offsets to be measured.
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Zero point
The measurement values for the offsets are stored in the coarse offset and the relevant fine
offsets are deleted. If the zero point is stored in a non-active work offset, an activation
window is displayed in which you can activate this work offset directly.
Aligning
Alignment can be performed either by rotating the coordinate system or by rotating the
workpiece with a rotary axis. If your machine is equipped with two rotary axes and the
"swivel" function is set up, you can also align an inclined plane.
Rotary axes
If your machine has rotary axes, you can include these rotary axes in the measurement and
setup procedure. If you store the workpiece zero in a work offset, rotary axis positioning may
be necessary in the following cases.
Correcting the work offset requires you to position the rotary axes to align the workpiece
parallel with the coordinate system, e.g. with "Align edge".
Correcting the work offset rotates the workpiece coordinate system, which should align
the tool perpendicular to the plane, e.g. for "Align plane".
You are supported by one or two activation windows when you position the rotary axes (see
Corrections after measuring the zero point (Page 107)").
You can only select "Rotary axis <name of rotary axis>" for the "Angle corr." parameter, if
your machine has rotary axes.
They must also be assigned to geometry axes via the machine data.
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2.6.2 Sequence of operations

To measure the workpiece zero, the workpiece probe must always be located or set
perpendicular to the measuring plane (machining plane) (e.g. using "Align plane").
For the measuring versions "Set edge", "Distance 2 edges", "Rectangular pocket" and
"Rectangular spigot", the workpiece must first be aligned parallel to the coordinate system.
To do this, it may be necessary to perform the measuring process in several steps.
Possible step sequences

1. "Align plane" (to align the workpiece probe perpendicular to the plane)
2. "Align edge" (to align the workpiece parallel to the coordinate system)
3. "Set edge" or "Distance 2 edges" of "Rectangular pocket" or
"Rectangular spigot", to define the workpiece zero.
- OR -
1. "Align plane" (to align the workpiece probe perpendicular to the plane)
2. "Corner" or "2 holes" or "2 spigots", to align the the coordinate system parallel to the
workpiece and to determine the workpiece zero)
Pre-positioning
If you want to preposition a rotary axis before measuring with "Align edge", move the rotary
axis so that your workpiece is approximately parallel to the coordinate system.
Set the relevant rotary axis angle to zero with "Set WO". Measurement with "Align edge" will
then correct the value for rotary axis offset or include it in the coordinate rotation and align
the workpiece edge precisely.
If you want to preposition your workpiece with "Align plane" prior to measurement, you can
set the required angular values under "Manual swivel". With "Set zero plane"you transfer the
resulting rotations into the active work offset.
The measurement with "Align plane" will then correct the value for the coordinate rotations
and precisely align the workpiece.
If the function "Swivel Manual" is set up on your machine, we recommend that you perform
swivel to zero before starting measurement. In that way, you will ensure that the rotary axis
positions match the actual coordinate system.
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2.6.3 Examples with manual swivel

Two typical examples demonstrate the interaction and the use of "Measure workpiece" and
"Manual swivel" when measuring and aligning workpieces.
First example
The following steps are required when remachining a cylinder head with 2 holes on an
inclined plane.
1. Clamp the workpiece
2. T,S,M
Load the probe and activate the desired work offset.
3. Pre-position the workpiece
Manually rotate the rotary axes until the inclined surface is almost perpendicular to the
tool axis.
4. Manual swivel
Select "direct" swivel, press the "Teach rotary axes" softkey and press <CYCLE START>
key.
5. Manual swivel
Apply "Set zero plane" to store the resulting rotations in the work zero.
6. Measure workpiece
Apply "Align plane" to correct the alignment of the workpiece.
Apply "2 holes" to define the rotation and offset in the XY plane.
Apply "Set edge Z" to define the offset in Z.
9. Start part program to remachine under AUTO.
Start the program with swivel zero.
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Second example
Measuring workpieces in swiveled states. The workpiece is to be probed in the X direction
even though the probe cannot approach the workpiece in the X direction because of an
obstructing edge (e.g. due to clamping elements). However, with a swivel movement, the
measurement in the X direction can be replaced by a measurement in the Z direction.
1. Clamp the workpiece.
2. T,S,M
Load the probe and activate the desired work offset.
3. Manual swivel
With "direct" swiveling enter the required rotary axis positions or with "axis by axis" the
required rotations (e.g. Y=-90) and <CYCLE START>.
Apply "Set edge Z": The measured offset in Z is converted and entered as an X value in
the chosen work offset.
2.6.4 Calibrating the electronic workpiece probe

When the electronic probes are attached to the spindle, clamping tolerances usually occur.
This can lead to measurement errors.
In addition, you need to determine the trigger points of the probe relative to the spindle
center (trigger points).
Therefore, you need to calibrate the electronic probe. The radius is calibrated in a setting
ring (calibration ring) or a hole, the length is calibrated on a surface. The diameter of the
setting ring and the dimension of the surface in the Z direction (for G17) must be precisely
known and this is entered into the corresponding entry field when calibrating the probe. The
diameter of the workpiece probe ball and its length 1 must be stored in the tool list.
Procedure
1. Load the workpiece probe into the spindle.

2. Enter the approximate length and radius in the tool data.
Calibrating a radius
3. Move the workpiece probe into the hole and position it in the
approximate center of the hole.
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5. Press the "Workpiece zero" and "Probe calibration" softkeys.

The window "Calibration: Probe" is opened.
6. Press the "Radius" softkey.
7. In , enter the calibration bore corresponding to the diameter.

The calibration starts.
When calibrating the radius, the exact hole center point is determined
first. Then the four trigger points on the inside wall of the hole are
approached.
This procedure is carried out automatically twice: First with 180 (to the
starting position of the working spindle) and then in its starting position.
Calibrating a length
9. Move the workpiece probe over the surface.
10. Select operating mode "JOG" in the "Machine operating area" and press
the "Workpiece zero" and "Probe calibration" softkeys.
The "Calibrate Probe" window opens.
11. Press the "Length" softkey.
12. Specify reference point Z0 of the surface, e.g. of the workpiece or the
machine table.
The calibration starts.
When the length is calibrated, the length of the workpiece probe is

calculated and entered in the tool list.
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Note
User-specific defaults
"Setting ring diameter"
For the entry field "Diameter setting ring" (diameter, reference piece), fixed values can be
separately entered at parameters for each probe number (calibration data set number). If
these parameters are assigned, the values saved there are displayed in the entry field
"Diameter setting ring"; however, they can no longer be changed there.
"Height of the reference surface in the infeed axis"
For the entry field "Height of the reference surface" fixed values can be separately
entered at parameters for each probe number (calibration data set number). If these
parameters are assigned, the values saved there are displayed in the entry field "Height
of the reference surface"; however, they can no longer be changed there.
2.6.5 Setting the edge

The workpiece lies parallel to the coordinate system on the work table. You measure one
reference point in one of the axes (X, Y, Z).
Precondition
You can insert any tool in the spindle for scratching when measuring the workpiece zero
manually.
- OR -
An electronic workpiece probe is inserted in the spindle and activated when measuring the
workpiece zero automatically.
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Procedure
1. Select the "Machine" operating area and press the <JOG> key.
2. Press the "Workpiece zero" and "Set edge" softkeys.

The "Set edge" window opens.
3. Select "Measuring only" if you only want to display the measured

values.
- OR -
4. In the selection box, select the desired work offset in which you want to
store the zero point.
- OR -
Press the "Select WO" softkey to select an adjustable work offset.
In the window "Work offset G54 ... G599", select a work offset, in
which the zero point should be saved and press the "In manual" softkey.
You return to the measurement window.
5. Use the softkeys to select in which axis direction you want to approach
the workpiece first.
...
6. Select the measuring direction (+ or -) you want to approach the

workpiece in.
For Z0, the workpiece is always approached in the Z minus direction.
7. In X0, Y0, or Z0, specify the setpoint position of the workpiece edge.
The setpoint position corresponds, e.g. to the dimension specifications
of the workpiece edge from the workpiece drawing.
8. Traverse the workpiece probe close to the workpiece edge that you wish
to measure and press the <CYCLE START> key in order to measure
the workpiece zero automatically.
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Note
Settable work offsets
The labeling of the softkeys for the adjustable work offsets varies, i.e. the selectable work
offsets configured at the machine are displayed (examples: G54G57, G54G505,
G54G599).
2.6.6 Edge measurement

The following options are available to you when measuring an edge:
Aligning the edge

The workpiece lies in any direction, i.e. not parallel to the coordinate system on the work
table. By measuring two points on the workpiece reference edge that you have selected, you
determine the angle to the coordinate system.
Distance between 2 edges

The workpiece lies parallel to the coordinate system on the work table. You measure
distance L of two parallel workpiece edges in one of the axes (X, Y, or Z) and determine its
center.
Precondition
manually.
- OR -
Procedure
2. Press the "Workpiece zero" softkey.
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3. Press the "Align edge" softkey.
- OR -
Press the "Distance between 2 edges" softkey.
- OR -
If these softkeys are not listed, press any vertical softkey (with the
exception of "Set edge") and in the drop-down list, select the desired
measurement version.
values.
- OR -
- OR -
which the zero point should be saved and press the "In manual"
softkey.
6. Under "Measuring axis", select the axis in which you want to approach
the workpiece, and the measuring direction (+ or -).
7. Enter the setpoint angle between the workpiece edge and the reference
axis.
8. Traverse the tool to the workpiece edge.
9. Press the "Save P1" softkey.
10. Reposition the tool and repeat the measuring procedure (step 7) to
measure the second point, and then press the "Save P2" softkey.
11. Press the "Calculate" softkey.

The angle between the workpiece edge and reference axis is calculated
and displayed.
- OR -
Press the "Set WO" softkey.
With "Set WO", the workpiece edge now corresponds to the setpoint
angle.
The calculated rotation is stored in the work offset.
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Note
G54G599).
1. Prepare the measurement (see steps 1 to 5 above).

2. Traverse the workpiece probe close to the workpiece edge on which
you wish to measure and press the <CYCLE START> key.
This starts the automatic measuring process. The position of measuring
point 1 is measured and stored.
The "P1 stored" softkey becomes active.
3. Repeat the operation to measure and store P2.

The angle between the workpiece edge and reference axis is calculated
and displayed.
- OR -
With "Set WO", the workpiece edge now corresponds to the setpoint
angle.
The calculated rotation is stored in the correction target that you have
selected.
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2.6.7 Measuring a corner

You have the option to measure workpiece corners, which are defined by a right angle (90)
or any inner angle.
Measuring a right-angled corner

The workpiece corner to be measured has a 90 inner angle and is clamped to the worktable
in any position. By measuring 3 points you can determine the corner point (point of
intersection of the angle side) in the working plane and angle between the workpiece
reference edge (line through P1 and P2) and the reference axis in the working plane (1st
geometry axis of the working plane).
Measuring any corner

The workpiece corner to be measured has any (not right-angled) inner angle and is clamped
at any position on the worktable. By measuring 4 points you can determine the corner point
(point of intersection of the angle sides) in the working plane and angle between the
workpiece reference edge (line through P1 and P2) and the reference axis in the working
plane (1st geometry axis of the working plane) and inner angle of the corner.
Note
The coordinate system shown in the help displays is always in relation to the currently set
workpiece coordinate system.
Please be aware of this if you have swiveled or changed the WCS in any other form.
Precondition
manually.
- OR -
Procedure
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3. Press the "Right-angled corner" softkey if the workpiece has a right-

angled corner.
- OR -
Press the "Any corner" softkey, if you want to measure a corner not
equal to 90.
- OR -
values.
- OR -
- OR -
which the zero point should be saved and press the "In manual"
softkey.
6. Select the corner (inside corner or outside corner) that you wish to
measure and its position (position 1... position 4).
The position of the measuring points appear in the help display.
7. Specify the setpoint of the workpiece corner (Z0, X0) you want to
measure.
8. Traverse the tool (acc. to help display) to the first measuring point P1 if
you are measuring manually.
The coordinates of the first measuring point are measured and stored.
10. Reposition the spindle holding the tool each time, approach measuring
points P2 and P3 and press the "Save P2" and "Save P3" softkeys.
11. Repeat the procedure to measure the fourth measuring point when you
measure any corner.

The corner point and angle are calculated and displayed.
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- OR -
13. Press the "Set WO" softkey.
The corner point now corresponds to the setpoint position. The
calculated offset is stored in the work offset.
Note
G54G599).
1. Prepare the measurement (see steps 1 to 6 above).

2. Approach measuring point P1 with the workpiece probe and press the
<CYCLE START> key.
This starts the automatic measuring process. The position of measuring
point 1 is measured and stored.
The "P1 stored" softkey becomes active.
3. Repeat the operation to measure and store points P2 and P3.
If you are measuring a corner not equal to 90, repeat the procedure to
measure and store point P4.

The corner point and angle are calculated and displayed.
- OR -
The corner point now corresponds to the setpoint position. The
calculated offset is stored in the offset target that you have selected.
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2.6.8 Measuring a pocket and hole

You can measure rectangular pockets and one or more holes and then align the workpiece.
Measuring a rectangular pocket

The rectangular pocket must be aligned at right-angles to the coordinate system. By
automatically measuring 4 points inside the pocket, its length, width and center point can be
determined.
Measuring 1 hole
The workpiece with the hole to be measured is clamped to the work table in any position. In
the hole, 4 points are automatically measured, and from this measurement, the diameter and
center point of the hole are determined.
Measuring 2 holes
The workpiece with the two holes to be measured is clamped to the work table in any
position. 4 points are automatically measured in both holes and the hole centers are
calculated from them. Angle is calculated from the connecting line between both center
points and the reference axis, and the new zero point that corresponds to the center point of
the 1st hole is determined.
Measuring 3 holes
The workpiece with the three holes to be measured is clamped to the work table in any
position. 4 points are automatically measured in the three holes and the hole centers are
calculated from them. A circle is placed through the three center points. The center point and
the diameter are determined from this circle. This center point represents the new workpiece
zero to be determined. When an angular offset is selected, the base angle of rotation can
also be determined.
Measuring 4 holes
The workpiece with the four holes to be measured is clamped to the work table in any
position. 4 points are automatically measured in the four holes and the hole centers are
calculated from them. Two hole center points are diagonally connected in each case. The
point of intersection is determined from the two lines that are obtained. This point of
intersection represents the new workpiece zero to be determined. When an angular offset is
selected, the base angle of rotation can also be determined.
Note
The measuring versions "Rectangular pocket" and "1 hole" are an exception. For these
single-point measurements, for "Measuring only" neither the "Set WO" softkey nor the
"Calculate" softkey is listed.
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Note
You can only measure 2, 3, and 4 holes automatically.
Precondition
manually.
- OR -
Procedure
3. Press the "Rectangular pocket" softkey.
- OR -
Press the "1 hole" softkey.
- OR -
4. Select "Measuring only" if you only want to display the measured values.
- OR -
- OR -
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which the zero point should be saved and press the "In manual" softkey.
6. Specify the position setpoints (X0/Y0) of the pocket center point or hole
center point.
7. Traverse the tool to the first/next measuring point if you are measuring
manually.
The point is measured and stored.
9. Repeat steps 6 and 7 to measure and store measuring points P2, P3
and P4.
...

The length, width, and center point of the rectangular pocket or diameter
and center point of the hole are calculated and displayed.
- OR -
The setpoint position of the center point is stored as a new zero point
with "Set WO". The tool radius is automatically included in the
calculation.
Note
G54G599).
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1. Select the "Measure workpiece zero" function (see steps 1 and 2

above).
2. Press the "Rectangular pocket" softkey.
- OR -
Press the "1 hole" softkey.
- OR -
Press the "2 holes" softkey.
- OR -
- OR -
- OR -
3. Traverse the workpiece probe to approximately the center above the
rectangular pocket or the hole or for several, above the first hole to be
measured.
4. Specify whether you want "Measurement only" or in which work offset
you want to store the zero point.
Rectangular 5. If you do make any entry in the entry field "L" length (1st geometry
pocket axis of the working plane) or "W" width (2nd geometry axis of the
working plane) of the pocket, then the axis moves with the
measuring feedrate from the starting point.
If the measuring stroke does not reach the edge, then this data must
be approximately entered. However, the measuring sequence is
then also shortened as part of the measuring distance is moved with
rapid traverse.
- OR -
1 hole If you do not make any entry in the entry field "hole", then the axis
moves with the measuring feedrate from the starting point.
If the measuring stroke does not reach the edge of the hole, then the
approximate diameter must be entered. However, the measuring
sequence is then also shortened as part of the measuring distance is
moved with rapid traverse.
Enter an angle in "Probe angle". With the probe angle you can turn
the traversing direction of the probe through any angle.
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- OR -
2 holes If you do not make any entry in the entry field "hole", then the axis
moves with the measuring feed from the starting point. If the
measuring stroke does not reach the edge of the hole, then the
In "Angle offs.", select entry "Coord. rotation".
- OR -
In "Angle offs.", select the "Rotary axis A, B, C" entry.
Enter the setpoint angle.
Specify the position setpoints (X1/Y1) for the center point of the first
hole.
X1 and Y1 are only active, if the "Coor. rotation" entry is selected.
- OR -
In "Angle offs." select entry "No".
- OR -
In "Angle offs." select entry "Yes" if you want alignment to be
performed with coordinate rotation.
The angle entered here refers to the 1st axis of the working plane
(X/Y plane). This input field only appears if you specified "Yes" for
"Angle offs."
Specify setpoint positions X0 and Y0.
These determine the center point of the circle on which the center
points of the three holes are to lie.
- OR -
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In "Angle offs." select entry "No".
- OR -
In "Angle offs." select entry "Yes" if you want alignment to be
performed with coordinate rotation.
The angle entered here refers to the 1st axis of the working plane
(X/Y plane). This input field only appears if you specified "Yes" for
"Angle offs."
Specify setpoint positions X0 and Y0.
These determine the point of intersection of the lines connecting the
hole center points.
The tool automatically probes 4 points of the inner sides of the pocket
or hole in succession.
After the measurement has been successfully completed, the "P1
stored" softkey becomes active.
8. Then move the tool approximately to the center of the second, third,
and fourth hole and press the <CYCLE START> key.
After measuring points P2, P3, and P4 have been successfully

measured, the "P2 stored", "P3 stored", and "P4 stored" softkeys
become active.
9. Press the "Calculate" or "Set WO" softkey.
Rectangular The length, width, and center point of the rectangular pocket are
pocket calculated and displayed.
For "Set WO", the setpoint position of the center point is stored as new
zero point.
1 hole The diameter and center point of the hole are calculated and displayed.
The tool automatically probes 4 points of the inside wall of the hole one
after the other and the setpoint position of the center point is stored as
the new zero point.
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2 holes The tool automatically probes 4 points of the inside wall of the first hole
successively and after pressing <CYCLE START> again probes the 4
points of the inside wall of the second hole.
The angle between the line connecting the center points and the
reference axis is calculated and displayed.
With "Set WO", the center point of the first hole now corresponds to the
position setpoint. The calculated rotation is stored in the work offset.
successively and after pressing <CYCLE START> again, then the 4
points of the inside wall of the second or third hole are successively
probed.
The center point and the diameter of the circle on which the three hole
center points lie are calculated and displayed. If you selected entry
"Yes" for "Angle offs.", the angle is additionally calculated and
displayed.
With "Set WO", the center point of the first hole now corresponds to the
successively. After pressing <CYCLE START> again, the tool
automatically probes the 4 points of the inside wall of the second, third
and fourth holes.
The hole center points are connected diagonally and the intersection
point of the two connecting lines calculated and displayed. If you
selected entry "Yes" for "Angle offs.", the angle is additionally
calculated and displayed.
With "Set WO", the intersection point now corresponds to the position
setpoint. The calculated rotation is stored in the work offset.
2.6.9 Measuring a spigot

You have the option to measure and align rectangular spigots, and one or more circular
spigots.
Measuring a rectangular spigot

The rectangular spigot should be aligned at right-angles to the coordinate system. By
measuring four points at the spigot you can determine the length, width, and center point of
the spigot.
Please note that the straight lines between points P1 and P2 or P3 and P4 must intersect
with one another, in order that a measurement result is displayed.
Measuring 1 circular spigot

The workpiece is located anywhere on the work table and has a circular spigot. You can
determine the diameter and center point of the spigot with four measuring points.
Milling
Measuring 2 circular spigots

The workpiece is located anywhere on the work table and has 2 spigots. 4 points are
automatically measured at the two spigots and the spigot centers are calculated from them.
The angle is calculated from the connecting line between both center points and the
reference axis, and the new zero point that corresponds to the center point of the first spigot
is determined.

The workpiece is located anywhere on the work table and has three spigots. 4 points are
automatically measured at the three spigots and the spigot centers are calculated from them.
A circle is placed through the three center points and the circle center and circle diameter
are determined.
When an angular offset is selected, the base angle of rotation can also be determined.

The workpiece is located anywhere on the work table and has four spigots. 4 points are
automatically measured at the four spigots and the spigot centers are calculated from them.
Two spigot center points are each connected diagonally and the intersection point of the two
lines is then determined. When an angular offset is selected, the base angle of rotation can
also be determined.
Note
The measuring versions "Rectangular spigot" and "1 circular spigot" are an exception. For
these single-point measurements, for "Measuring only" neither the "Set WO" softkey nor the
"Calculate" softkey is listed.
Note
You can only measure 2, 3, and 4 circular spigots automatically.
Precondition
manually.
Milling
Procedure
3. Press the "Rectangular spigot" softkey.
- OR -
Press the "1 circular spigot" softkey.
- OR -
4. Select "Measuring only" if you only want to display the measured values.
- OR -
Select the desired work offset in which you want to store the zero point
(e.g. basis reference).
- OR -
Press the "Select WO" softkey and select the work offset in which the
zero point is to be saved in the "Work Offset G54 G599" window
and press the "In manual" softkey.
You return to the "1 Circular Spigot" window.
The selection of work offsets can differ.
5. Specify the position setpoints (X0/Y0) of the spigot center point P0.
6. Traverse the tool to the first measuring point.
The point is measured and stored.
8. Repeat steps 6 and 7 to measure and store measuring points P2, P3
and P4.
Milling

The diameter and center point of the spigot are calculated and
displayed.
- OR -
The setpoint position of the center point is stored as a new zero point
with "Set WO". The tool radius is automatically included in the
calculation.
Note
G54G599).
1. Select the "Measure workpiece zero" function (see steps 1 and 2

above).
2. Press the "Rectangular spigot" softkey.
- OR -
Press the "1 circular spigot" softkey.
- OR -
Press the "2 circular spigots" softkey.
- OR -
- OR -
- OR -
Milling
3. Traverse the workpiece probe to approximately the center above the

rectangular or circular spigot, or for several, above the first spigot to be
measured.
4. Specify whether you want "Measurement only" or in which work offset
you want to store the zero point.
Rectangular 5. Enter the infeed value in "DY" to determine the measuring depth.
spigot In field "L" enter the length (1st geometry axis of the working plane)
and in field "W" the width (2nd geometry axis of the working plane)
of the spigot.
- OR -
1 circular Enter the approximate diameter of the spigot into "spigot".
spigot Enter an angle in "Probe angle". With the probe angle you can turn
the traversing direction of the probe through any angle.
- OR -
spigots Enter the infeed value in "DY" to determine the measuring depth.
In "Angle offs.", select entry "Coor. rotation" or "Rotary axis A, B, C".
Enter the position setpoints (Z0/X0) for the center point of the first
spigot.
The setpoint angle refers to the 1st axis of the working plane (X/Y
plane).
The input fields for the setpoint positions are only active if you selected
the angle offset via coordinate rotation.
- OR -
spigots Enter the infeed value in "DY" to determine the measuring depth.
In "Angle offs.", select entry "No", or in "Angle offs." select entry
"Yes" if you want to align using coordinate rotation.
Specify the setpoint angle if you selected entry "Yes" for "Angle
offs."
Enter the setpoint positions Z0 and X0 to determine the center point
of the circuit on which the center points of three spigots lie.
plane). This input field only appears if you specified "Yes" for "Angle
offs."
- OR -
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spigots Enter the infeed value in "DZ" to determine the measuring depth.
In "Angle offs.", select entry "Yes" if you want to align using
coordinate rotation or select in "Angle offs." the entry "No".
Enter the setpoint positions X0 and Y0 to determine the point of
intersection of the connecting lines between the spigot center points.
plane). This input field only appears if you specified "Yes" for "Angle
offs."
This starts the automatic measuring process. The tool automatically
probes 4 points in succession of the rectangular or spigot outer wall or
the outer wall of the first spigot if several spigots are to be measured.
After the measurement has been successfully completed, the center of
the spigot is determined and the "P1 stored" softkey becomes active.
5 If you are measuring several spigots, then move the tool approximately
to the center of the second, third, and fourth spigot and press the
<CYCLE START> key.
After the measurement has been successfully completed, P2, P3 and
P4 are stored and the softkeys "P2 stored", "P3 stored", and "P4 stored"
become active.

6. Press the or "Calculate" or "Set WO"softkey.
Rectangular The length, width, and center point of the rectangular spigot are
spigot calculated and displayed.
zero point. The tool radius is automatically included in the calculation.
1 spigot The diameter and center point of the spigot are calculated and
displayed.
zero point. The tool radius is automatically included in the calculation.
2 spigots The angle between the line connecting the center points and the
reference axis is calculated and displayed.
For "Set WO", the center point of the first spigot now corresponds to the
Milling
3 spigots The center point and the diameter of the circle on which the three spigot
center points lie are calculated and displayed. If you selected entry
"Yes" in "Coor. rotation", then angle is additionally calculated and
displayed.
For "Set WO", the center point of the circle now corresponds to the
4 spigots The spigot center points are connected diagonally and the intersection
point of the two connecting lines calculated and displayed. If you
selected entry "Yes" in "Coor. rotation", then angle is additionally
calculated and displayed.
For "Set WO", the intersection point now corresponds to the position
setpoint. The calculated rotation is stored in the work offset.
2.6.10 Aligning the plane

You can measure an inclined plane of a workpiece in space and determine rotation angles
and . By subsequently performing coordinate rotation, you can align the tool axis
perpendicular to the workpiece plane.
In order to determine the position of the plane in space, three different points are measured
along the tool axis. To vertically align the tool axis, the "Swivel" function or the 5 axis
transformation (TRAORI) must be set-up at the machine.
In order to be able to measure the plane, the surface must be flat.
Precondition
manually.
Milling
Procedure
2. Press the "Workpiece zero" and "Align plane" softkeys.

The "Align plane" window opens.

values.
- OR -
Select the desired work offset in which you want to store the zero point
(e.g. basis reference).
- OR -
Press the "Select WO" softkey and select the work offset in which the
zero point is to be saved in the "Work Offset G54 G599" window
and press the "In manual" softkey.
You return to the appropriate measurement window.
You return to the "Align plane" window.

The selection of work offsets can differ.
4. Traverse the tool to the first measuring point that you want to
determine.
Milling
6. Then traverse the tool to the second and third measuring point and
press the "Save P2" and "Save P3" softkeys.
7. Press the "Set WO" or "Calculate" softkey.

Angles and are calculated and displayed.
For "Set WO" the angle offset is stored in the work offset.
See also
Corrections after measurement of the zero point (Page 107)
2.6.11 Defining the measurement function selection

The measurement versions "Set edge", "Align edge", "Rightangled corner", "1 hole" and "1
circular spigot" are listed in the "Measure workpiece zero" in the associated vertical softkey
bar.
You have the option of replacing these by softkeys with other measurement versions.
"Set edge" softkey

The "Set edge" softkey cannot be assigned the softkey of another
Software option
You require the "Extended operator function" option for the measurement function
selection (only for 828D).
Procedure
1. The "Measure workpiece zero" function is selected.
2. Press the softkey that you wish to assign to a new measurement

version, e.g. "1 circular spigot".
The "1 Circular Spigot" window opens.
Milling
3. Open the list of measurement versions, select the desired

measurement version using the <Cursor down> and the <Input> keys.
- OR -
3. Using the <Select> key, in the drop down list box, select the desired
measurement version, e.g. "Align plane".
The "Align plane" window opens.
4. Enter the required parameter in order to make the measurement as
usual.
- OR -
Press the "Back" softkey.
The selected softkey is assigned the new measurement version, in this

case, "Align plane".
2.6.12 Corrections after measurement of the zero point

If you store the workpiece zero in a work offset, changes to the coordinate system or axis
positions might be necessary in the following cases.
Correcting the work offset causes the workpiece coordinate system to rotate, after which
the tool can be aligned perpendicularly to the plane.
Correcting the work offset necessitates positioning of the rotary axis in order to align the
workpiece parallel with the coordinate system
Activation windows help you to adapt the coordinate system and the axis positions.
Procedure
Activating work offset

You stored the workpiece zero in a work offset that was not active
during measurement.
1. When you press the "Set WO" softkey, the activation window opens
asking whether you want to "Activate work offset Gxxx now?".
2. Press the "OK" softkey to activate the corrected work offset.
Aligning and retracting the tool (for aligning the plane)

Rotating the workpiece coordinate system makes it necessary to realign
the tool to the plane.
Milling
The activation window asking whether you want to "Position measuring

probe perpendicular to plane?" is displayed.
1. Select "Yes" if you want to swivel into the plane.
The query "Positioning by swiveling! Retract?" is displayed.
2. Select the retraction method you want to use.

When the axis has been retracted the tool is realigned with the help of
the swivel cycle.
You can now measure again.
Positioning a rotary axis and entering a feedrate

Once you have measured the workpiece zero you must reposition the
rotary axis.
Note:
Retract the probe to a safe position before the rotary axis should move.
The activation window asking whether you want to "Position rotary axis
X to align?" is displayed.
1. Select "Yes" if you want to position the rotary axis.
An input field for the feedrate and the softkey "Rapid traverse" are
displayed.
2. Press the "Rapid traverse" softkey to enter the feedrate in rapid
traverse.
- OR -
Enter the desired feedrate into input field "F".
The rotary axis is repositioned.
Milling
2.7 Work offsets
2.7 Work offsets

Following reference point approach, the actual value display for the axis coordinates is
based on the machine zero (M) of the machine coordinate system (Machine). The program
for machining the workpiece, however, is based on the workpiece zero (W) of the workpiece
coordinate system (Work). The machine zero and workpiece zero are not necessarily
identical. The distance between the machine zero and the workpiece zero depends on the
workpiece type and how it is clamped. This work offset is taken into account during
execution of the program and can be a combination of different offsets.
Following reference point approach, the actual value display for the axis coordinates is
based on the machine zero of the machine coordinate system (Machine).
The actual value display of the positions can also refer to the SZS coordinate system
(settable zero system). The position of the active tool relative to the workpiece zero is
displayed.
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Figure 2-1 Work offsets
When the machine zero is not identical to the workpiece zero, at least one offset (base offset
or work offset) exists in which the position of the workpiece zero is saved.
Base offset
The base offset is a work offset that is always active. If you have not defined a base offset,
its value will be zero. The base offset is specified in the "Work offset - Base" window.
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2.7 Work offsets
Coarse and fine offsets

Every work offset (G54 to G57, G505 to G599) consists of a coarse offset and a fine offset.
You can call the work offsets from any program (coarse and fine offsets are added together).
You can save the workpiece zero, for example, in the coarse offset, and then store the offset
that occurs when a new workpiece is clamped between the old and the new workpiece zero
in the fine offset.
Note
Deselect fine offset
You have the option of deselecting the fine offset via machine data
$MN_MM_FRAM_FINE_TRANS.
See also
Actual value window (Page 38)
2.7.1 Display active zero offset

The following work offsets are displayed in the "Work Offset - Active" window:
Work offsets, for which active offsets are included, or for which values are entered.
adjustable work offsets
Total work offset
This window is generally used only for monitoring.
The availability of the offsets depends on the setting.
Milling
2.7 Work offsets
Procedure
1. Select the "Parameter" operating area.
2. Press the "Work offset" softkey.

The "Work Offset - Active" window is opened.
Note
Further details on work offsets
If you would like to see further details about the specified offsets or if you would like to
change values for the rotation, scaling or mirroring, press the "Details" softkey.
2.7.2 Displaying the work offset "overview"

The active offsets or system offsets are displayed for all set-up axes in the "Work Offset -
Overview" window.
In addition to the offset (course and fine), the rotation, scaling and mirroring defined using
this are also displayed.
This window is generally used only for monitoring.
Display of active work offsets
Work offsets
DRF Displays the handwheel axis offset.
Basic reference Displays the additional work offsets programmed with $P_SETFRAME.
Access to the system offsets is protected via a keyswitch.
External WO frame Displays the additional work offsets programmed with $P_EXTFRAME.
Total base WO Displays all effective basis offsets.
G500 Displays the work offsets activated with G54 - G599.
Under certain circumstances, you can change the data using "Set
WO", i.e. you can correct a zero point that has been set.
Tool reference Displays the additional work offsets programmed with
$P_TOOLFRAME.
Workpiece reference Displays the additional work offsets programmed with $P_WPFRAME.
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2.7 Work offsets
Work offsets
Programmed WO Displays the additional work offsets programmed with $P_PFRAME.
Cycle reference Displays the additional work offsets programmed with
$P_CYCFRAME.
Total WO Displays the active work offset, resulting from the total of all work
offsets.
Procedure
2 Press the "Work offset" and "Overview" softkeys.

The "Work Offsets - Overview" window opens.
2.7.3 Displaying and editing base zero offset

The defined channel-specific and global base offsets, divided into coarse and fine offsets,
are displayed for all set-up axes in the "Work offset - Base" window.
Procedure
3. Press the "Base" softkey.

The "Work offset - Base" window is opened.
4. You can edit the values directly in the table.
Milling
2.7 Work offsets
Note
Activate base offsets
The offsets specified here are immediately active.
2.7.4 Displaying and editing settable zero offset

All settable offsets, divided into coarse and fine offsets, are displayed in the "Work Offset -
G54..G599" window.
Rotation, scaling and mirroring are displayed.
Procedure
3. Press the "G54G599" softkey.

The "Work Offset - G54..G599" window is opened.
Note
The labeling of the softkeys for the adjustable work offsets varies, i.e.
the selectable work offsets configured at the machine are displayed
(examples: G54G57, G54G505, G54G599).
Please observe the machine manufacturer's specifications.
Note
Activate settable work offsets
The settable work offsets must first be selected in the program before they have an impact.
Milling
2.7 Work offsets
2.7.5 Displaying the zero offset details.

For each work offset, you can display and edit all data for all axes. You can also delete work
offsets.
For every axis, values for the following data will be displayed:
Coarse and fine offsets
Rotation
Scaling
Mirroring
Note
Settings for rotation, scaling and mirroring are specified here and can only be changed here.
Procedure
3. Press the "Active", "Base" or "G54G599" softkey.

The corresponding window appears.
4. Place the cursor on the desired work offset to view its details.
5. Press the "Details" softkey.
A window opens, depending on the selected work offset, e.g. "Work

Offset - Details: G54 to G599".
- OR -
Press the "Clear offset" softkey to reset all entered values.
Milling
2.7 Work offsets
Press the "WO +" or "WO -" softkey to select the next or previous offset,
respectively, within the selected area ("Active", "Base", "G54 to G599")
without first having to switch to the overview window.
...
If you have reached the end of the range (e.g. G599), you will switch
automatically to the beginning of the range (e.g. G54).
These value changes are available in the part program immediately or after "Reset".
Press the "Back" softkey to close the window.
2.7.6 Deleting a work offset

You have the option of deleting zero offsets. This resets the entered values.
Proceed as follows
3. Press the "Active", "Base" or "G54G599" softkey.
5. Position the cursor on the zero offset you would like to delete.
6. Press the "Clear Offset" soft key.
Milling
2.7 Work offsets
2.7.7 Measuring the workpiece zero
Procedure
1. Select the "Parameter" operating area and press the "Work offset"
softkey.
2. Press the "G54...G599" softkey and select the work offset in which the
zero point is to be saved.
You change to the "Set Edge" window in the "JOG" mode.
4. Use the softkeys to select in which axis direction you want to approach
the workpiece first.
...
5. Select the measuring direction (+ or -) you want to approach the

workpiece in.
The measuring direction cannot be selected for Z0.
6. In X0, Y0, or Z0, specify the setpoint position of the workpiece edge you
are approaching.
Traverse the tool up to the workpiece edge and press the "Set WO"
softkey to measure the workpiece zero.
Milling
2.8 Monitoring axis and spindle data
2.8.1 Specify working area limitations

The "Working area limitation" function can be used to limit the range within which a tool can
traverse in all channel axes. These commands allow you to set up protection zones in the
working area which are out of bounds for tool movements.
In this way, you are able to restrict the traversing range of the axes in addition to the limit
switches.
Preconditions
You can only make changes in "AUTO" mode when in the RESET condition. These changes
are then immediate.
You can make changes in "JOG" mode at any time. These changes, however, only become
active at the start of a new motion.
Procedure
2. Press the "Setting data" softkey.
The "Working area limit." window appears.
3. Place the cursor in the required field and enter the new values via the
numeric keyboard.
The upper or lower limit of the protection zone changes according to
your inputs.
4. Click the checkbox to "active" to activate the protection zone.
Note
You will find all of the setting data in the "Start-up" operating area under "Machine data" via
the menu forward key.
Milling
2.8.2 Editing spindle data

The speed limits set for the spindles that must not be under- or overshot are displayed in the
"Spindles" window.
You can limit the spindle speeds in fields "Minimum" and "Maximum" within the limit values
defined in the relevant machine data.
Spindle speed limitation at constant cutting rate

In field "Spindle speed limitation at G96", the programmed spindle speed limitation at
constant cutting speed is displayed together with the permanently active limitations.
This speed limitation, for example, prevents the spindle from accelerating to the max. spindle
speed of the current gear stage (G96) when performing tapping operations or machining
very small diameters.
Note
The "Spindle data" softkey only appears if a spindle is configured.
Procedure
2. Press softkeys "Setting data" and "Spindle data".

The "Spindles" window opens.
3. If you want to change the spindle speed, place the cursor on the
"Maximum", "Minimum", or "Spindle speed limitation at G96" and enter a
new value.
Milling
2.9 Displaying setting data lists
2.9 Displaying setting data lists

You can display lists with configured setting data.
Procedure
2. Press "Setting data" and "Data lists" softkeys.

The "Setting data list" window opens.
3. Press the "Select data list" softkey and in the "View" list, select the
required list with setting data.
2.10 Handwheel assignment

You can traverse the axes in the machine coordinate system (Machine) or in the workpiece
coordinate system (Work) via the handwheel.
Software option
You require the "Extended operator functions" option for the handwheel offset
(only for 828D).
All axes are provided in the following order for handwheel assignment:
Geometry axes
When traversing, the geometry axes taken into account the actual machine status (e.g.
rotations, transformations). All channel machine axes, which are currently assigned to the
geometry axis, are in this case simultaneously traversed.
Channel machine axes
Channel machine axes are assigned to the particular channel. They can only be
individually traversed, i.e. the actual machine state has no influence.
The also applies to channel machine axes, that are declared as geometry axes.
Milling
Procedure
Press the <JOG>, <AUTO> or <MDI> key.
2. Press the menu forward key and the "Handwheel" softkey.

The "Handwheel" window appears.
A field for axis assignment will be offered for every connected
handwheel.
3. Position the cursor in the field next to the handwheel with which you
wish to assign the axis (e.g. No. 1).
4. Press the corresponding softkey to select the desired axis (e.g. "X").
- OR
Open the "Axis" selection box using the <INSERT> key, navigate to the
desired axis, and press the <INPUT> key.
Selecting an axis also activates the handwheel (e.g., "X" is assigned to
handwheel no. 1 and is activated immediately).
5. Press the "Handwheel" softkey again.
- OR -
The "Handwheel" window closes.
Milling
Deactivate handwheel
1. Position the cursor on the handwheel whose assignment you wish to

cancel (e.g. No. 1).
2. Press the softkey for the assigned axis again (e.g. "X").
- OR -
Open the "Axis" selection box using the <INSERT> key, navigate to the
empty field, and press the <INPUT> key.
Clearing an axis selection also clears the handwheel selection (e.g., "X"
is cleared for handwheel no. 1 and is no longer active).
Milling
2.11 MDA
2.11 MDA
In "MDA" mode (Manual Data Automatic mode), you can enter G-code commands block-by-
block and immediately execute them for setting up the machine.
You can load an MDA program straight from the Program Manager into the MDA buffer. You
may also store programs which were rendered or changed in the MDA operating window into
any directory of the Program Manager.
Software option
You require the "Extended operator functions" option to load and save MDA
programs (for 828D).
2.11.1 Loading an MDA program from the Program Manager
Procedure
2. Press the <MDI> key.
The MDI editor opens.

3. Press the "Load MDI" softkey.
A changeover is made into the Program Manager.

The "Load in MDI" window opens. It shows you a view of the program
manager.
4. Position the cursor to the corresponding storage location, press the
"Search" softkey and enter the required search term in the search
dialog if you wish to search for a specific file.
Note: The place holders "*" (replaces any character string) and "?"
(replaces any character) make it easier for you to perform a search.
5. Select the program that you would like to edit or execute in the MDI
window.
The window closes and the program is ready for operation.
Milling
2.11 MDA
2.11.2 Saving an MDA program
Procedure
2. Press the <MDI> key.
The MDI editor opens.

3. Create the MDI program by entering the G-code commands using the
operator's keyboard.
4. Press the "Store MDI" softkey.
The "Save from MDI: Select storage location" window opens. It shows
you a view of the program manager.
5. Select the drive to which you want to save the MDI program you
created, and place the cursor on the directory in which the program is to
be stored.
- OR -
Position the cursor to the required storage location, press the "Search"
softkey and enter the required search term in the search dialog if you
wish to search for a specific directory or subdirectory.
When you place the cursor on a folder, a window opens which prompts
you to assign a name.
- OR -
When you place the cursor on a program, you are asked whether the
file should be overwritten.
7. Enter the name for the rendered program and press the "OK" softkey.
The program will be saved under the specified name in the selected
directory.
Milling
2.11 MDA
2.11.3 Executing an MDA program
Proceed as follows
2. Press the <MDA> key.

The MDA editor opens.
3. Input the desired G-code commands using the operators keyboard.

The control executes the input blocks.
When executing the G-code commands, you can control the sequence as follows:
Executing the program block-by-block
Testing the program
Settings under program control
Setting the test-run feedrate
Settings under program control
2.11.4 Deleting an MDA program
Precondition
The MDA editor contains a program that you created in the MDI window or loaded from the
program manager.
Procedure
Press the "Delete blocks" softkey.
The program blocks displayed in the program window are deleted.
Milling
Execution in manual mode 3
3.1 General
Always use "JOG" mode when you want to set up the machine for the execution of a
program or to carry out simple traversing movements on the machine:
Synchronize the measuring system of the controller with the machine (reference point
approach)
Set up the machine, i.e. activate manually-controlled motions on the machine using the
keys and handwheels provided on the machine control panel.
You can activate manually controlled motions on the machine using the keys and
handwheels provided on the machine control panel while a part program is interrupted.
3.2 Selecting a tool and spindle
3.2.1 T, S, M windows
For the preparatory actions in manual mode, tool selection and spindle control are both
performed centrally in a screen form.
In manual mode, you can select a tool either by its name or its location number. If you enter
a number, a search is performed for a name first, followed by a location number. This means
that if you enter "5", for example, and no tool with the name "5" exists, the tool is selected
from location number "5".
Note
Using the location number, you can thus swing around an empty space into the machining
position and then comfortably install a new tool.
Milling
Execution in manual mode
Display Meaning
T Input of the tool (name or location number)
You can select a tool from the tool list using the "Select tool"
softkey.
D Cutting edge number of the tool (1 - 9)
Spindle Spindle selection, identification with spindle number
Spindle M function
Other M functions Input of machine functions

Refer to the machine manufacturer's table for the correlation
between the meaning and number of the function.
G work offset Selection of the work offset (basic reference, G54 - 57)
You can select work offsets from the tool list of settable work
offsets via the "Work offset" softkey.
Unit of measurement Selection of the unit of measurement (inch, mm)
The setting made here has an effect on the programming.
Machining plane Selection of the machining plane (G17(XY), G18 (ZX), G19 (YZ))
Gear stage Specification of the gear stage (auto, I - V)
Stop position Input of the spindle position in degrees
Note
Spindle positioning
You can use this function to position the spindle at a specific angle, e.g. during a tool
change.
A stationary spindle is positioned via the shortest possible route.
A rotating spindle is positioned as it continues to turn in the same direction.
Milling
3.2.2 Selecting a tool
Procedure
1. Select the "JOG" operating mode.
2. Press the "T, S, M" softkey.
3. Enter the name or the number of the tool T in the input field.
- OR -
Press the "Select tool" softkey to open the tool list, position the cursor
on the desired tool and press the "In Manual" softkey.
The tool is transferred to the "T, S, M... window" and displayed in the
field of tool parameter "T".
4. Select tool edge D or enter the number directly in field "D".

The tool is loaded into the spindle.
3.2.3 Starting and stopping a spindle manually
Procedure
Milling
3. Select the desired spindle (e.g. S1) and enter the desired spindle speed
(rpm) in the adjacent input field.
The spindle remains stationary.
4. If the machine has a gearbox for the spindle, set the gear stage (e.g.
auto).
5. Select a spindle direction of rotation (clockwise or counterclockwise) in

the "Spindle M function" field.

The spindle rotates.
7. Select the "Stop" setting in the "Spindle M function" field.
Press the <CYCLE START> key.

The spindle stops.
Note
Changing the spindle speed
If you enter the speed in the "Spindle" field while the spindle is rotating, the new speed is
applied.
3.2.4 Position spindle
Procedure
3. Select the "Stop Pos." setting in the "Spindle M function" field.

The "Stop Pos." entry field appears.
Milling
4. Enter the desired spindle stop position.

The spindle position is specified in degrees.
The spindle is moved to the desired position.
Note
You can use this function to position the spindle at a specific angle, e.g. during a tool
change.
A stationary spindle is positioned via the shortest possible route.
A rotating spindle is positioned as it continues to turn in the same direction.
Milling
3.3 Traversing axes
3.3 Traversing axes

You can traverse the axes in manual mode via the Increment or Axis keys or handwheels.
During a traverse initiated from the keyboard, the selected axis moves at the programmed
setup feedrate. During an incremental traverse, the selected axis traverses a specified
increment.
Set the default feedrate

Specify the feedrate to be used for axis traversal in the set-up, in the "Settings for Manual
Operation" window.
3.3.1 Traverse axes by a defined increment

You can traverse the axes in manual mode via the Increment and Axis keys or handwheels.
Procedure
3. Press keys 1, 10, etc. up to 10000 in order to move the axis in a defined
increment.
The numbers on the keys indicate the traverse path in micrometers or
micro-inches.
Example: Press the "100" button for a desired increment of 100 m (=
0.1 mm).
Milling
3.3 Traversing axes

;
5. Press the <+> or <-> key.

Each time you press the key the selected axis is traversed by the
defined increment.
Feedrate and rapid traverse override switches can be operative.
Note
When the control is switched on, the axes can be traversed right up to the limits of the
machine as the reference points have not yet been approached and the axes referenced.
Emergency limit switches might be triggered as a result.
The software limit switches and the working area limitation are not yet operative!
The feed enable signal must be set.
3.3.2 Traversing axes by a variable increment
Procedure
Press the <JOG> key.
2. Press the "Settings" softkey.

The "Settings for manual operation" window is opened.
3. Enter the desired value for the "Variable increment" parameter.
Example: Enter 500 for a desired increment of 500 m (0.5 mm).
4. Press the <Inc VAR> key.
Milling
3.4 Positioning axes

6. Press the <+> or <-> key.
Each time you press the key the selected axis is traversed by the set
increment.
Feedrate and rapid traverse override switches can be operative.
3.4 Positioning axes

In manual mode, you can traverse individual or several axes to certain positions in order to
implement simple machining sequences.
The feedrate / rapid traverse override is active during traversing.
Procedure
1. If required, select a tool.

3. Press the "Positions" softkey.
4. Specify the desired value for the feedrate F.

- OR -
Press the "Rapid traverse" softkey.
The rapid traverse is displayed in field "F".
5. Enter the target position or target angle for the axis or axes to be
traversed.
The axis is traversed to the specified target position.
If target positions were specified for several axes, the axes are
traversed simultaneously.
Milling
3.5 Swiveling
3.5 Swiveling
Manual swivel in the JOG mode provides functions that make it far easier to setup, measure,
and machine workpieces with swiveled surfaces.
If you want to create or correct an inclined position, the required rotations of the workpiece
coordinate system around the geometry axes (X, Y, Z) are automatically converted into
suitable positions of the machine kinematics.
Alternatively, you can program the swivel axes of the machine "directly" and generate a
matching workpiece coordinate system for those swivel axis positions. After swiveling, the
tool axis (for G17 Z) is always perpendicular to the working plane (for G17 XY).
The swiveled coordinates are maintained in the Reset status and after Power On, if the
machine manufacturer has correspondingly set the machine data. With these settings, after
a program interrupt, e.g. as a result of a retraction in the +Z direction, you can retract from an
inclined hole.
Important parameters
TC - name of swivel data set
Here you can select the swivel data set.
Retraction
Before swiveling the axes you can move the tool to a safe retraction position. The
retraction methods available to you are defined in the "Retraction position" parameter
during set-up of the swivel data set.
"Retraction" corresponds to Parameter _FR of CYCLE800.
Please refer to the machine manufacturer's specifications. Due to additional swivel
data sets (e.g. for tool change) additional retraction versions can be enabled.
WARNING
Select a retraction position so that no collision can occur between the tool and workpiece
when swiveling.
Milling
3.5 Swiveling
Swivel plane
You can start the swivel plane as "new" or "additive" to a swivel plane that is already
active.
Swivel mode
Swiveling can be axis by axis or direct.
Axis-by-axis swiveling is based on the coordinate system of the workpiece (X, Y, Z).
The coordinate axis sequence can be selected freely. Rotations are applied in the
selected sequence. The rotation of the two rotary axes (A, B or C) is calculated from
this.
For direct swiveling, the required positions of the rotary axes are specified. A suitable
new coordinate system is calculated based on those values. The tool axis is aligned in
the Z direction. You can derive the resulting direction of the X and Y axis by traversing
the axes.
Note
The positive direction of each rotation for the different swivel methods is shown in the
help displays.
Direction
"Direction" corresponds to the parameter _DIR of CYCLE800.
For swivel systems with 2 rotary axes, a particular plane can be reached in two different
ways. You can choose between these two different positions in the "Direction" parameter.
The +/- corresponds to the larger or smaller value of a rotary axis. This may affect the
working area.
When the swivel data set is set up, the entries in the "Direction" parameter determine for
which rotary axis you can select each of the two settings.
If one of the two positions cannot be reached for mechanical reasons, the alternative
position is automatically selected irrespective of the setting of the "Direction" parameter.
Correcting tool
"Tool" corresponds to the Parameter _ST=1x (correct tool tip) of CYCLE800.
To avoid collisions, you can use the 5-axis transformation (software option) to retain the
position of the tool tip during swiveling.
When machine manufacturer commissions the function "Swivel Manual", "Track Tool"
must be enabled.
Milling
3.5 Swiveling
Zero plane
The zero plane corresponds to the tool plane (G17, G18, G19) including the active work
offset (G500, G54, ...). Rotations of the active work offset and the rotary axes are taken
into account for manual swiveling.
The "Swivel Manual" function only writes rotations either in the workpiece reference
($_WPFRAME) or in the active work offset.
You can use the "Swivel Manual" function not only for machining, but also for setting-up.
You can bring the machine into the initial position using the "Basic setting" softkey and
the <CYCLE START> key. If the actual work offset does not include a rotation, then
the rotary axes of the swivel data set are moved to zero. The tool is located vertically
to the machining plane.
If you want to use the actual swiveled plane as the reference plane for setting up your
workpiece, you must define this plane as the zero plane.
With "Set zero plane" the actual swivel plane in the active work offset is stored as the
zero plane. As a result, the rotations in the active work offset are overwritten.
With "Delete zero plane", the rotations in the active work offset are set to zero.
Note
The overall coordinate system does not change with "Set zero plane" or "Delete zero
plane".
Basic setting of the machine kinematics for "Swivel Manual" and "5-axis
transformation".
Procedure
2. Press the <JOG> key
3. Press the "Swivel" softkey.
4. Enter the desired value for the parameter and press the <CYCLE
START> key.
The "Swivel" cycle is started.
Milling
3.5 Swiveling
Press the "Basic setting" softkey and the <CYCLE START> key to
move the machine into the initial position.
If the actual work offset does not include a rotation, then the rotary axes
of the swivel data set are moved to zero. The tool is located vertically to
the machining plane.
This is done, for example, to swivel the coordinate system back to its
original orientation.
Press the "Set zero plane" softkey to set the actual swivel plane to the
new zero plane.
Press the "Delete zero plane" softkey to delete the actual swivel plane.
Parameter Description Unit

TC Name of the swivel data set
0: Remove the swivel head, deselect the swivel data set
No entry: No change to the set swivel data set
Retraction No: No retraction before swiveling
Fixed point 1: Retraction in the direction of machine axis Z to the fixed point of
machine axis Z defined by the machine manufacturer Z.
Fixed point 2: Retraction in the direction of machine axis Z and then in X,Y to the
fixed points defined by the machine manufacturer
Retraction, maximum in the tool direction up to the software end position
Retraction, incremental in the tool direction up to a maximum of the software end
position. The retraction path is entered into parameter ZR.
Swivel plane New: New swivel plane
Additive: Additive swivel plane
Swivel mode Axis by axis: Rotate coordinate system axis-by-axis
Direct: Directly position rotary axes
Positions the rotary axes of the active swivel data set
Angle of rotation in the plane around the tool axes

Z Angle of rotation in the plane (direct swivel) Degrees
Axis sequence Sequence of the axes which are rotated around:
XYZ, XZY, YXZ, YZX, ZXY, ZYX
X Rotation around X Degrees
Y Rotation around Y Degrees
Z Rotation around Z Degrees
Name of rotary axis Axis angle for swivel, direct Degrees
1
Name of rotary axis Axis angle for swivel, direct Degrees
2
Milling
3.6 Simple face milling of workpiece

Direction Preferred direction of rotation for 2 alternatives (swiveling axis-by-axis)
+: Larger angle of the axis on the scale of the swivel head / swivel table
-: Smaller angle of the axis on the scale of the swivel head / swivel table
Tool Correction: The position of the tool tip is maintained during swiveling
No correction: The position of the tool tip changes during swiveling

You can use this cycle to face mill any workpiece. A rectangular surface is always machined.
Selecting the machining direction

In the "Direction" field, using the select key, select the desired machining direction:
Same direction of machining
Alternating direction of machining
Selecting limits
You can select the limits using the appropriate softkeys:
Left
Bottom
Top
Right
See also
Face milling (CYCLE61) (Page 307)
Prerequisite
To carry out simple stock removal of a workpiece in manual mode, a measured tool must be
in the machining position.
Milling
Procedure
3. Press the <Face milling> softkey.
4. Press the relevant softkey to specify the lateral limitations of the

workpiece.
5. Select the machining type (e.g. roughing) in the "Machining" field.
4. Select the machining direction in the "Direction" field.
5. Enter all other parameters in the input screen.

The parameter screen is closed.
The face milling cycle is started.
You can return to the parameter screen at any time to check and
correct the inputs.
Note
You cannot use the "Repos" function while face milling.
Milling
Parameters, G code program Parameters, ShopMill program

PL Machining plane T Tool name
Milling direction D Cutting edge number
RP Retraction plane mm F Feedrate mm/min
mm/rev
SC Safety clearance mm S/V Spindle speed or constant rpm
cutting rate m/min
F Feedrate mm/min
Parameters Description Unit

Machining The following machining operations can be selected:
(roughing)
(finishing)
Direction Same direction of machining


X0 Corner point 1 of surface in X direction (abs. or inc.) mm

Y0 Corner point 1 of surface in Y direction (abs. or inc.) mm
Z0 Height of blank (abs. or inc.) mm
X1 Corner point 2 of surface in X direction (abs. or inc.) mm
Y1 Corner point 2 of surface in Y direction (abs. or inc.) mm
Z1 Height of finished part (abs. or inc.) mm
DXY Max. infeed in the XY plane (dependent on milling cutter diameter) mm
Alternatively, you can specify the plane infeed as a %, as a ratio plane infeed %
(mm) to milling cutter diameter (mm).
DZ Max. infeed in Z direction - (only for roughing) mm
UZ Finishing allowance, depth mm
Note
The same finishing allowance must be entered for both roughing and finishing. The finishing
allowance is used to position the tool for retraction.
See also
Tool, offset value, feed and spindle speed (T, D, F, S, V) (Page 240)
Milling
3.7 Default settings for manual mode
3.7 Default settings for manual mode

Specify the configurations for manual mode in the "Settings for manual operation" window.
Presettings
Settings Description
Type of feedrate Here, you select the type of feedrate.
G94: Axis feedrate/linear feedrate
G95: Rev. feedrate
Default feedrate G94 Enter the desired feedrate in mm/min.
Default feedrate G95 Enter the desired feedrate in mm/r.
Variable increment Enter the desired increment for axis traversal by variable increments.
Spindle speed Enter the desired spindle speed in rpm.
Proceed as follows

The "Settings for manual operation" window is opened.
Milling
Machining the workpiece 4
4.1 Starting and stopping machining
During execution of a program, the workpiece is machined in accordance with the
programming on the machine. After the program is started in automatic mode, workpiece
machining is performed automatically.
Requirements
The following requirements must be met before executing a program:
The measuring system of the controller is referenced with the machine.
The necessary tool offsets and work offsets have been entered.
The necessary safety interlocks implemented by the machine manufacturer are activated.
General sequence
1. Use the Program manager to select the desired program.
Select the desired program under "NC", "Local drive", "USB" or set-up
network drives.
3. Press the "Select" softkey.

The program is selected for execution and automatically switched to the
"Machine" operating area.
The program is started and executed.
Note
Starting the program in any operating area
If the control is in "AUTO" mode, you can also start the selected program when you are in
any operating area.
Milling
Machining the workpiece
4.2 Selecting a program
Stopping machining
Press the <CYCLE STOP> key.

Machining stops immediately. Individual program blocks are not
executed to the end. On the next start, machining is resumed
from the point where it left off.
Canceling machining
Press the <RESET> key.

Execution of the program is interrupted. On the next start, machining
will start from the beginning.
4.2 Selecting a program
Procedure
1. Select the "Program manager" operating area.

The directory overview is opened.
2. Place the cursor on the directory containing the program that you want
to select.
3. Press the <INPUT> key
- OR -
Press the <Cursor right> key.
The directory contents are displayed.
Milling
4.3 Testing a program
4. Place the cursor on the desired program.

The program is selected.
When the program has been successfully selected, an automatic
changeover to the "Machine" operating area occurs.

When testing a program, the system can interrupt the machining of the workpiece after each
program block, which triggers a movement or auxiliary function on the machine. In this way,
you can control the machining result block-by-block during the initial execution of a program
on the machine.
Note
Settings for the automatic mode
Rapid traverse reduction and dry run feed rate are available to run-in or to test a program.
Move by single block

In "Program control" you may select from among several types of block processing:
SB mode Scope
SB1 Single block, The machining stops after every machine block (except for cycles)
coarse
SB2 Data block The machining stops after every block, i.e. also for data blocks (except for
cycles)
SB3 Single block, The machining stops after every machine block (also in cycles)
fine
Precondition
A program must be selected for execution in "AUTO" or "MDA" mode.
Procedure
1. Press the "Prog. ctrl." softkey and select the desired variant in the "SBL"
field.
2. Press the <SINGLE BLOCK> key.
Milling

Depending on the execution variant, the first block will be executed.
Then the machining stops.
In the channel status line, the text Stop: Block in single block ended"
appears.
Depending on the mode, the program will continue executing until the
next stop.
5. Press the <SINGLE BLOCK> key again, if the machining is not
supposed to run block-by-block.
The key is deselected again.
If you now press the <CYCLE START> key again, the program is
executed to the end without interruption.
See also
Setting for automatic mode (Page 185)
Milling
4.4 Displaying the current program block
4.4.1 Current block display

The window of the current block display shows you the program blocks currently being
executed.
Display of current program

The following information is displayed in the running program:
The workpiece name or program name is entered in the title row.
The program block which is just being processed appears colored.
Editing a program directly

In the Reset state, you can edit the current program directly.
1. Press the <INSERT> key.
2. Place the cursor at the relevant position and edit the program block.
Direct editing is only possible for G code blocks in the NC memory, not
for external execution.
3. Press the <INSERT> key to exit the program and the edit mode again.
4.4.2 Displaying a basic block

If you want precise information about axis positions and important G functions during testing
or program execution, you can call up the basic block display. This is how you can check,
when using cycles, for example, whether the machine is actually traversing.
Positions programmed by means of variables or R parameters are resolved in the basic
block display and replaced by the variable value.
You can use the basic block display both in test mode and when machining the workpiece on
the machine. All G code commands that initiate a function on the machine are displayed in
the "Basic Blocks" window for the currently active program block:
Absolute axis positions
G functions for the first G group
Other modal G functions
Milling
Other programmed addresses

M functions
Procedure
1. A program is selected for execution and has been opened in the

2. Press the "Basic blocks" softkey.
The "Basic Blocks" window opens.
3. Press the <SINGLE BLOCK> key if you wish to execute the program
block-by-block.
4. Press the <CYCLE START> key to start the program execution.

The axis positions to be approached, modal G functions, etc., are
displayed in the "Basic Blocks" window for the currently active program
block.
5. Press the "Basic blocks" softkey once again to hide the window again.
4.4.3 Display program level

You can display the current program level during the execution of a large program with
several subprograms.
Several program run throughs

If you have programmed several program run throughs, i.e. subprograms are run through
several times one after the other by specifying the additional parameter P, then during
processing, the program runs still to be executed are displayed in the "Program Levels"
window.
Program example
N10 subprogram P25
If, in at least one program level, a program is run through several times, a horizontal scroll
bar is displayed that allows the run through counter P to be viewed in the righthand window
section. The scroll bar disappears if multiple run-through is no longer applicable.
Milling
Display of program level

The following information will be displayed:
Level number
Program name
Block number, or line number
Remain program run throughs (only for several program run throughs)
Precondition
A program must be selected for execution in "AUTO" mode.
Procedure
Press the "Program levels" softkey.

The "Program levels" window appears.
Milling
4.5 Correcting a program
4.5 Correcting a program

As soon as a syntax error in the part program is detected by the controller, program
execution is interrupted and the syntax error is displayed in the alarm line.
Correction possibilities
Depending on the state of the control system, you can make the following corrections using
the Program editing function.
Stop mode
Only program lines that have not yet been executed can be edited.
Reset mode
All program lines can be edited.
Note
The "program correction" function is also available for execute from external; however,
when making program changes, the NC channel must be brought into the reset state.
Requirement
A program must be selected for execution in "AUTO" mode.
Procedure
1. The program to be corrected is in the Stop or Reset mode.

2. Press the "Prog. corr. softkey
The program is opened in the editor.
The program preprocessing and the current block are displayed. The
current block is also updated in the running program, but not the
displayed program section, i.e. the current block moves out of the
displayed program section.
If a subprogram is executed, it is not opened automatically.
3. Make the necessary corrections.
4. Press the "NC Execute" softkey.
The system switches back to the "Machine" operating area and selects
"AUTO" mode.
5. Press the <CYCLE START> key to resume program execution.
Milling
4.6 Repositioning axes
Note
Exit the editor using the "Close" softkey to return to the "Program manager" operating area.
4.6 Repositioning axes

After a program interruption in automatic mode (e.g. after a tool breaks) you can move the
tool away from the contour in manual mode.
The coordinates of the interrupt position will be saved. The distances traversed in manual
mode are displayed in the actual value window. This path difference is called "Repos-offset".
Resuming program execution

Using the "Repos" function, you can return the tool to the contour in order to continue
executing the program.
You cannot traverse the interrupt position, because it is blocked by the control system.
The feedrate/rapid traverse override is in effect
WARNING
When repositioning, the axes move with the programmed feedrate and linear interpolation,
i.e. in a straight line from the current position to the interrupt point. Therefore, you must first
move the axes to a safe position in order to avoid collisions.
If you do not use the "Repos" function and subsequently move the axes in manual mode
after a program interrupt, the control automatically moves the axes during the switch to
automatic mode and the subsequent start of the machining process in a straight line back
to the point of interruption.
Requirement
The following prerequisites must be met when repositioning the axes:
The program execution was interrupted using <CYCLE STOP>.
The axes were moved from the interrupt point to another position in manual mode.
Milling
4.7 Starting machining at a specific point
Proceed as follows
1. Press the <REPOS> key.
2. Select the axes to be traversed one after the other.

;
3. Press the <+> or <-> key for the relevant direction.

The axes are moved to the interrupt position.
4.7.1 Use block search

If you would only like to perform a certain section of a program on the machine, then you
need not start the program from the beginning. You can also start the program from a
specified program block.
Applications
Stopping or interrupting program execution
Specify a target position, e.g. during remachining
Milling
Determining a search target

User-friendly search target definition (search positions)
Direct specification of the search target by positioning the cursor in the selected
program (main program)
Search target via text search
The search target is the interruption point (main program and subprogram)
The function is only available if there is an interruption point. After a program
interruption (CYCLE STOP or RESET), the controller saves the coordinates of the
interruption point.
The search target is the higher program level of the interruption point (main program
and subprogram)
The level can only be changed if it was previously possible to select an interruption
point in a subprogram. It is then possible to change the program level up to the main
program level and back to the level of the interruption point.
Search pointer
Direct entry of the program path
Note
Searching for point in subprogram
You can search for a specific point in subprograms with the search pointer if there is
no interruption point.
Software option
You require the "Extended operator functions" option for the "Search pointer"
function (only for 828D).
Cascaded search
You can start another search from the "Search target found" state. The cascading can be
continued any number of times after every search target found.
Note
Another cascaded block search can be started from the stopped program execution only if
the search target has been found.
Milling
References
Function Manual Basic Functions; Block Search
Preconditions
1. You have selected the desired program.
2. The control system is in the RESET condition.
3. The desired search mode is selected.
NOTICE
Collision-free start position
Pay attention to a collision-free start position and appropriate active tools and other
technological values.
If necessary, manually approach a collision-free start position. Select the target block
considering the selected block search type.
Toggling between search pointer and search positions
Press the "Search pointer" softkey again to exit the "Search Pointer"
window and return to the "Program" window to define search positions.
- OR -
You have now exited the block search function.
See also
Selecting a program (Page 142)
4.7.2 Continuing program from search target

To continue the program at the desired position, press the <CYCLE START> key twice.
The first CYCLE START outputs the auxiliary functions collected during the search. The
program is then in the Stop state.
Before the second CYCLE START, you can use the "Overstore" function to create states
that are required, but not yet available, for the further program execution.
By changing to the JOG REPOS mode, you can also manually traverse the tool from the
current position to the setpoint position, if the setpoint position is not to be automatically
approached after the program start
Milling
4.7.3 Simple search target definition
Requirement
The program is selected and the controller is in Reset mode.
Procedure
1. Press the "Block search" softkey.
2. Place the cursor on a particular program block.

- OR -
Press the "Find text" softkey, select the search direction, enter the
search text and confirm with "OK".
3. Press the "Start search" softkey.
The search starts. Your specified search mode will be taken into
account.
The current block will be displayed in the "Program" window as soon
as the target is found.
4. If the located target (for example, when searching via text) does not
correspond to the program block, press the "Start search" softkey
again until you find your target.
Press the <CYCLE START> key twice.
Processing is continued from the defined position.
4.7.4 Defining an interruption point as search target
Precondition
A program was selected in "AUTO" mode and interrupted during execution through CYCLE
STOP or RESET.
Software option
You require the "Extended operator functions" option (only for 828D).
Milling
Procedure
2. Press the "Interrupt point" softkey.

The interruption point is loaded.
3. If the "Higher level" and "Lower level" softkeys are available, use these
to change the program level.
account.
The search screen closes.
The current block will be displayed in the "Program" window as soon as
the target is found.
5. Press the <CYCLE START> key twice.
The execution will continue from the interruption point.
4.7.5 Entering the search target via search pointer

Enter the program point which you would like to proceed to in the "Search Pointer" window.
Software option
You require the "Extended operator functions" option for the "Search pointer"
function (only for 828D).
Precondition
The program is selected and the controller is in Reset mode.
Screen form
Each line represents one program level. The actual number of levels in the program depends
on the nesting depth of the program.
Level 1 always corresponds to the main program and all other levels correspond to
subprograms.
You must enter the target in the line of the window corresponding to the program level in
which the target is located.
Milling
For example, if the target is located in the subprogram called directly from the main program,
you must enter the target in program level 2.
The specified target must always be unambiguous. This means, for example, that if the
subprogram is called in the main program in two different places, you must also specify a
target in program level 1 (main program).
Procedure
2. Press the "Search pointer" softkey.
3. Enter the full path of the program as well as the subprograms, if

required, in the input fields.
account.
The Search window closes. The current block will be displayed in the
"Program" window as soon as the target is found.
5. Press the <CYCLE START> key twice.
Processing is continued from the defined location.
Note
Interruption point
You can load the interruption point in search pointer mode.
4.7.6 Parameters for block search in the search pointer
Parameter Meaning
Number of program level
Program: The name of the main program is automatically entered
Ext: File extension
P: Pass counter
If a program section is performed several times, you can enter the number of
the pass here at which processing is to be continued
Line: Is automatically filled for an interruption point
Milling
Parameter Meaning
Type " " search target is ignored on this level
N no. Block number
Label Jump label
Text string
Subprg. Subprogram call
Line Line number
Search target Point in the program at which machining is to start
4.7.7 Block search mode

Set the desired search variant in the "Search Mode" window.
The set mode is retained when the the controller is shut down. When you activate the
"Search" function after restarting the controller, the current search mode is displayed in the
title row.
Search variants
Block search mode Meaning

With calculation It is used in order to be able to approach a target position in any
- without approach circumstance (e.g. tool change position).
The end position of the target block or the next programmed position is
approached using the type of interpolation valid in the target block. Only the
axes programmed in the target block are moved.
With calculation It is used to be able to approach the contour in any circumstance.
- with approach The end position of the block prior to the target block is found with <CYCLE
START>. The program runs in the same way as in normal program
processing.
With calculation This is used to speed-up a search with calculation when using EXTCALL
- skip extcall programs: EXTCALL programs are not taken into account.
Notice: Important information, e.g. modal functions, which are located in the
EXTCALL program, are not taken consideration. In this case, after the
search target has been found, the program is not able to be executed.
Information such as this should programmed in the main program.
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Block search mode Meaning

Without calculation For a quick search in the main program.
Calculations will not be performed during the block search, i.e. the
calculation is skipped up to the target block.
All settings required for execution have to be programmed from the target
block (e.g. feedrate, spindle speed, etc.).
With program test Multi-channel block search with calculation (SERUPRO).
All blocks are calculated during the block search. Absolutely no axis motion
is executed, however, all auxiliary functions are output.
The NC starts the selected program in the program test mode. If the NC
reaches the specified target block in the actual channel, it stops at the
beginning of the target block and deselects program test mode again. After
continuing the program with NC start (after REPOS motion) the auxiliary
functions of the target block are output.
For single-channel systems, the coordination is supported with events
running in parallel, such as e.g. synchronized actions.
Note
The search speed depends on MD settings.
References
Procedure
2. Press the <AUTO> key.
3. Press the "Block search" and "Block search mode" softkeys.

The "Search Mode" window will open.
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4.8 Intervening in the program sequence
4.8.1 Program control

You can change the program sequence in the "AUTO" and "MDA" modes.
Abbreviation/program Scope
control
PRT The program is started and executed with auxiliary function outputs and dwell times. In this
no axis motion mode, the axes are not traversed.
The programmed axis positions and the auxiliary function outputs are controlled this way.
Note: Program processing without axis motion can also be activated with the function "Dry
run feedrate".
DRY The traversing velocities programmed in conjunction with G1, G2, G3, CIP and CT are
Dry run feedrate replaced by a defined dry run feedrate. The dry run feedrate also applies instead of the
programmed revolutional feedrate.
Caution: Workpieces must not be machined when "Dry run feedrate" is active because the
altered feedrates might cause the permissible tool cutting rates to be exceeded and the
workpiece or machine tool could be damaged.
RG0 In the rapid traverse mode, the traversing speed of the axes is reduced to the percentage
Reduced rapid traverse value entered in RG0.
Note: You define the reduced rapid traverse in the settings for automatic operation.
M01 The processing of the program stops at every block in which supplementary function M01 is
Programmed stop 1 programmed. In this way you can check the already obtained result during the processing of
a workpiece.
Note: In order to continue executing the program, press the <CYCLE START> key again.
Programmed stop 2 The processing of the program stops at every block in which the "Cycle end" is programmed
(e.g. M101) (e.g. with M101).
Note: In order to continue executing the program, press the <CYCLE START> key again.
Note: The display can be changed. Please refer to the machine manufacturer's
specifications.
DRF Enables an additional incremental zero offset while processing in automatic operation mode
Handwheel offset with an electronic handwheel.
This function can be used to compensate for tool wear within a programmed block.
Note: You require the "Extended operator functions" option to use the handwheel offset (for
828D).
SB Individual blocks are configured as follows.
Single block, coarse: The program stops only after blocks which perform a machine function.
Data block: The program stops after each block.
Single block, fine: The program also only stops after blocks which perform a machine function
in cycles.
Select the desired setting using the <SELECT> key.
SKP Skip blocks are skipped during machining.
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Activating program control

You can control the program sequence however you wish by selecting and clearing the
relevant check boxes.
Display / response of active program controls:

If a program control is activated, the abbreviation of the corresponding function appears in
the status display as response.
Procedure
2. Press the <AUTO> or <MDA> key.
3. Press the "Prog. ctrl. softkey.

The "Program control" window appears.
See also
Setting for automatic mode (Page 185)
4.8.2 Skip blocks

It is possible to skip program blocks, which are not to be executed every time the program
runs.
The skip blocks are identified by placing a "/" (forward slash) or "/x (x = number of skip level)
character in front of the block number. Several consecutive blocks can also be skipped.
The statements in the skipped blocks are not executed, i.e. the program continues with the
next block, which is not skipped.
The number of skip levels that can be used depends on a machine datum.
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Software option
In order to have more than two skip levels, for 828D you require the
"Extended operator functions" option.
Skip levels, activate

Select the corresponding check box to activate the desired skip level.
Note
The "Program control - skip blocks" window is only available when more than one skip level
is set up.
Procedure
3 Press the "Prog. ctrl." and "Skip blocks" softkeys.

The "Program control" window appears and shows a list of skip levels.
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4.9 Overstore
4.9 Overstore
With overstore, you have the option of executing technological parameters (for example,
auxiliary functions, axis feed, spindle speed, programmable instructions, etc.) before the
program is actually started. The program instructions act as if they are located in a normal
part program. These program instructions are, however, only valid for one program run. The
part program is not permanently changed. When next started, the program will be executed
as originally programmed.
After a block search, the machine can be brought into another state with overstore (e.g. M
function, tool, feed, speed, axis positions etc.), in which the normal part program can be
successfully continued.
Software option
You require the "Extended operator functions" option for the overstore function
(for 828D).
Precondition
The program to be corrected is in the Stop or Reset mode.
Procedure
1. Open the program in the "AUTO" mode.
2. Press the "Overstore" softkey.

The "Overstore" window opens.
3. Enter the required data and NC block.
The blocks you have entered are stored. You can observe execution in
the "Overstore" window.
After the entered blocks have been executed, you can append blocks
again.
You cannot change the operating mode while you are in overstore
mode.
5. Press the "Back" softkey.
The "Overstore" window closes.
6. Press the <CYCLE START> key again.
The program selected before overstoring continues to run.
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4.10 Editing a program
Note
Block-by-block execution
The <SINGLE BLOCK> key is also active in the overstore mode. If several blocks are
entered in the overstore buffer, then these are executed block-by-block after each NC start
Deleting blocks
Press the "Delete blocks" softkey to delete program blocks you have
entered.

With the editor, you are able to render, supplement, or change part programs.
Note
The maximum block length is 512 characters.
Calling the editor

The editor is started via the "Program correction" function in the "Machine" operating
area.
The editor is called via the "Open" softkey as well as with the <INPUT> or <Cursor right>
key in the "Program manager" operating area.
The editor opens in the "Program" operating area with the last executed part program,
when this was not explicitly exited via the "Close" softkey.
Note
Please note that the changes to programs stored in the NC memory take immediate
effect. You can exit the editor only after you have saved the changes.
If you are editing on a local drive or external drives, you can also exit the editor without
saving, depending on the setting.
Exit the program correction mode using the "Close" softkey to return to the "Program
manager" operating area.
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See also
Editor settings (Page 169)
Opening and closing the program (Page 542)
Correcting a program (Page 148)
Generating a G code program (Page 214)
4.10.1 Searching in programs

You can use the search function to quickly arrive at points where you would like to make
changes, e.g. in very large programs.
Note
Search with place holders
When searching for specific program locations, you have the option of using place holders:
"*": replaces any character string
"?": replaces any character
Precondition
The desired program is opened in the editor.
Procedure

The "Search" window opens at the same time.
2. Enter the desired search term in the "Text" field.
3. Select "Whole words" if you want to search for whole words only.
4. Position the cursor in the "Direction" field and choose the search
direction (forward, backward) with the <SELECT> key.
5. Press the "OK" softkey to start the search.
If the text you are searching for is found, the corresponding line is
highlighted.
6. Press the "Continue search" softkey if the text located during the search
does not correspond to the point you are looking for.
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- OR -
Press the "Cancel" softkey when you want to cancel the search.
Further search options
Softkey Function
The cursor is set to the first character in the program.
The cursor is set to the last character in the program.
4.10.2 Replacing program text

You can find and replace text in one step.
Requirement
The desired program is opened in the editor.
Proceed as follows

2. Press the "Find + replace" softkey.
The "Find and replace" window appears.
3. In the "Text" field, enter the term you are looking for and in the "Replace
with" field, enter the text you would like to insert automatically during the
search.
4. Position the cursor in the "Direction" field and choose the search
direction (forward, backward) with the <SELECT> key.

If the text you are searching for is found, the corresponding line is
highlighted.
6. Press the "Replace" softkey to replace the text.
- OR -
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Press the "Replace all" softkey to replace all text in the file that
corresponds to the search term.
- OR -
Press the "Continue search" softkey if the text located during the search
should not be replaced.
- OR -
4.10.3 Copying/pasting/deleting a program block
Precondition
Procedure
1. Press the "Mark" softkey.
- OR -
Press the <SELECT> key.
2. Select the desired program blocks with the cursor or mouse.

3. Press the "Copy" softkey in order to copy the selection to the buffer
memory.
4. Place the cursor on the desired insertion point in the program and press
the "Paste" softkey.
The content of the buffer memory is pasted.
Deleting program blocks
Use the "Cut" softkey to delete selected program blocks.

Note: When editing a program, you cannot copy or cut more than 1024
lines. While a program that is not on the NC is opened (progress display
less than 100%), you cannot copy or cut more than 10 lines or insert more
than 1024 characters.
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Note
The buffer memory contents are retained even after the editor is closed, enabling you to
paste the contents in another program, as well.
See also
Opening additional programs (Page 168)
4.10.4 Renumber program

You can modify the block numbering of programs opened in the editor at a later point in time.
Requirement
Procedure
1. Press the ">>" softkey.

2. Press the "Renumber" softkey.
The "Renumbering" window appears.
3. Enter the values for the first block number and the increment to be used
for numbering.
The program is renumbered.
Note
If you only want to renumber a section, select the program blocks whose block numbering
you want to edit.
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4.10.5 Creating a program block

In order to structure programs to achieve a higher degree of transparency, you have the
option of combining several blocks (G-code and/or ShopMill machining steps) to form
program blocks.
You then have the option of opening and closing these blocks depending on your
requirement.
Structuring programs
Before generating the actual program, generate a program frame using empty blocks.
By forming blocks, structure existing G code or ShopMill programs.
Procedure
2. Select the storage location and create a program or open a program.

The program editor is opened.
3. Select the required program blocks that you wish to combine to form a
block.
4. Press the "Build group" softkey.
The "Build new group" window is opened.
5. Enter a designation for the block and press the "OK" softkey.
6. Press the ">>" and "View" softkeys.
7. Press the "Open all blocks" softkey if you wish to display the program
with all blocks.
8. Press the "Close all blocks" softkey, if you wish to display the program
again in a structured form.
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4.10.6 Opening additional programs

You have the option of viewing and editing two programs simultaneously in the editor.
For instance, you can copy program blocks or machining steps of a program and paste them
into another program.
Opening several programs

You have the option of opening up to 10 program blocks.
1. In the Program Manager, select the programs that you wish to open and
view in the dual editor and then press on the "Open" softkey.
The dual editor is opened and the first two programs are displayed.
2. Press the <NEXT WINDOW> key to change to the next opened
program.
3. Press the "Close" softkey to close the actual program.
Note
Pasting program blocks
JobShop machining steps cannot be copied into a G code program.
Precondition
You have opened a program in the Editor.
Procedure
1. Press the ">>" and "Open additional program" softkeys.
The "Select additional program" window is opened.
2. Select the program or programs that you wish to display in addition to

the already opened program.
The dual editor opens and displays both of the programs next to one
another.
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See also
Copying/pasting/deleting a program block (Page 165)
4.10.7 Editor settings

Enter the default settings in the "Settings" window that are to take effect automatically when
the editor is opened.
Presettings
Setting Meaning
Number Yes: A new block number will automatically be assigned after every line
automatically change. In this case, the specifications provided under "First block number"
and "Increment" are applicable.
No: No automatic numbering.
First block number Specifies the starting block number of a newly created program.
The field is only editable when "Yes" is available under "Number
automatically".
Increment Defines the increment used for the block numbers.
The field is only editable when "Yes" is available under "Number
automatically".
Display hidden lines Hidden lines marked with "*HD" (hidden) will be displayed.
Display block end as The "CFLF" (line feed) symbol is displayed at the block end.
an icon
Scroll horizontally A horizontal scrollbar is displayed. In this way, you can scroll horizontally to
the end of long lines that would otherwise wrap.
Automatic save (only Yes: The changes are saved automatically when you change to another
local and external operating area.
drives) No: You are prompted to save when changing to another operating area.
Save or reject the changes with the "Yes" or "No" softkeys.
Visible programs 1 - 10
Select how many programs can be displayed next to one another in the
editor.
Auto
Specifies that the number of programs entered in a job list will be visible
next to each other.
Width of the program Here, you enter the width of the selected program in the editor as a
with focus percentage of the window width.
Note
All entries that you make here are effective immediately.
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Procedure
1. Select the "Program" operating area
You have activated the editor.
2. Press the ">>" and "Settings" softkeys.

The "Settings" window appears.
3. Make the desired changes here and press the "OK" softkey to confirm
your settings.
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4.11 Mold making view

For large mold making programs, as provided by CAD systems, you have the option, using a
fast view, to display the machining paths. This allows you to obtain a fast overview of the
program and possibly correct it.
Checking the program

For instance, you can check whether
the programmed workpiece has the correct form (shape),
whether there are large traversing errors,
if yes, which block must be corrected,
how the approach and exits are.
Simultaneous view of the program and mold making view

In the editor, next to the program block display, switch-in the graphic view.
At the left in the editor, if you set the cursor to an NC block with position data, then this NC
block is selected in the graphic view.
If you select a point to the right in the graphic view - then the NC block is selected in the left-
hand part of the editor - i.e. in the other direction. This is how you jump directly to a position
in the program in order to edit a program block for example.
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NC blocks that can be interpreted

Following NC blocks are supported for the mold building view.
Types
Lines
G0, G1 with X Y Z
Circles
G2, G3 with center point I, J, K or radius CR, depending on the working plane G17,
G18, G19, CIP with circular point I1, J1, K1 or radius CR
Polynomial
POLY with X, Y, Z or PO[X] PO[Y] PO[Z]
B-splines
BSPLINE with degree SD (SD < 6) node PL weights PW
Absolute data IC and incremental data are AC possible
For G2, G3 and different radii at the start and end, an Archimedes spiral is used
Orientation
Rotary axis programming with ORIAXES or ORIVECT using ABC for G0, G1, G2, G3,
CIP, POLY
Rotary axis programming with ORIAXES or ORIVECT using PO[A] POS[b] PO[C] for
POLY
Orientation vector programming with ORIVECT using A3, B3, C3 for G0, G1, G2, G3,
CIP
Orientation curve with ORICURVE using XH, YH, ZH, for G0, G1, G2, G3, CIP, POLY,
BSPLINE
Orientation curve with ORICURVE using PO[XH] PO[YH] PO[ZH] for POLY
Rotary axes can be specified using DC
G codes
Working planes (for circle definition G2, G3): G17 G18 G19
Incremental or absolute data: G90 G91
Following NC blocks are not supported for the mold building view.
Helix programming
Rational polynomials
Other G codes or language commands
All blocks that cannot be interpreted are simply ignored
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Changing and adapting the mold making view

Just the same as for simulation and simultaneous recording, you have the option of changing
and adapting the simulation graphical representation in order to achieve the optimum view.
Increasing or reducing the size of the graphic
Moving the graphic
Rotating the graphic
Changing the section
4.11.1 Starting the mold making view
Procedure
2. Select the desired storage location and position the cursor on the
program that you would like to display in the mold making view.
3. Press the "Open" softkey.
4. Press the ">>" and "Mold making view" softkeys.
The editor splits up into two areas.
The G code blocks are displayed in the left half of the editor.
The workpiece graphic is displayed in the right half of the editor.
All of the points and paths programmed in the part program are shown
in the graphical representation.
5. Press the "Graphic" softkey in order to hide the graphic and to view the
program as usual in the editor
- OR -
Press the "NC blocks" softkey in order to hide the G code blocks and
therefore only to display the graphic.
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4.11.2 Specifically jump to the program block

If you notice anything peculiar in the graphic or identify an error, then from this location, you
can directly jump to the program block involved to possibly edit the program.
Preconditions
The required program is opened in the mold making view.
The "Graphic" softkey is active.
Procedure
1. Press the ">>" and "Select point" softkeys.

Cross-hairs for selecting a point is shown in the diagram.
2. Using the cursor keys, move the cross-hairs to the appropriate position
in the graphic.
3. Press the "Select NC block" softkey.

The cursor jumps to the associated program block in the editor.
4.11.3 Searching for program blocks

Using the "Search" function, you can search for specific program blocks as well as edit
programs; you can do this in one step by replacing the text that you are searching for by a
new text.
Precondition
The required program is opened in the mold making view.
The "NC blocks" softkey is active.
Procedure

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See also
Searching in programs (Page 163)
Replacing program text (Page 164)
4.11.4 Changing the view
4.11.4.1 Enlarging or reducing the graphical representation
Precondition
The mold making view has been started.
Procedure
1. Press the <+> and <-> keys if you wish to enlarge or reduce the graphic
display.
The graphic display enlarged or reduced from the center.
...
- OR -
Press the "Details" and "Zoom +" softkeys if you wish to increase the
size of the segment.
- OR -
Press the "Details" and "Zoom -" softkeys if you wish to decrease the
- OR -
Press the "Details" and "Auto zoom" softkeys if you wish to
automatically adapt the segment to the size of the window.
The automatic scaling function "Fit to size" takes account of the largest
expansion of the workpiece in the individual axes.
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Note
Selected section
The selected sections and size changes are kept as long as the program is selected.
4.11.4.2 Modifying the viewport

Use the magnifying glass if you would like to move, increase or reduce the size of the
section of the mold making view, e.g. to view details or display the complete workpiece.
Using the magnifying glass, you can define your own segment and then increase or
decrease its size.
Precondition
The mold making view has been started.
Procedure
2. Press the "Zoom" softkey.

A magnifying glass in the shape of a rectangular frame appears.
3. Press the "Magnify +" or <+> softkey to enlarge the frame.
- OR -
Press the "Magnify -" or <-> softkey to reduce the frame.
- OR -
Press one of the cursor keys to move the frame up, down, left or right.
4. Press the "Accept" softkey to accept the section.
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4.12 Displaying G Functions and Auxiliary Functions
4.12.1 Selected G functions

16 selected G groups are displayed in the "G Function" window.
Within a G group, the G function currently active in the controller is displayed.
Some G codes (e.g. G17, G18, G19) are immediately active after switching the machine
control on.
Which G codes are always active depends on the settings.
G groups displayed by default
Group Meaning
G group 1 Modally active motion commands (e.g. G0, G1, G2, G3)
G group 2 Non-modally active motion commands, dwell time (e.g. G4, G74, G75)
G group 3 Programmable offsets, working area limitations and pole programming (e.g.
TRANS, ROT, G25, G110)
G group 6 Plane selection (e.g. G17, G18)
G group 7 Tool radius compensation (e.g. G40, G42)
G group 8 Settable work offset (e.g. G54, G57, G500)
G group 9 Offset suppression (e.g. SUPA, G53)
G group 10 Exact stop - continuous-path mode (e.g. G60, G641)
G group 13 Workpiece dimensioning inches/metric (e.g. G70, G700)
G group 14 Workpiece dimensioning absolute/incremental (G90)
G group 15 Feedrate type (e.g. G93, G961, G972)
G group 16 Feedrate override on inside and outside curvature (e.g. CFC)
G group 21 Acceleration profile (e.g. SOFT, DRIVE)
G group 22 Tool offset types (e.g. CUT2D, CUT2DF)
G group 29 Radius/diameter programming (e.g. DIAMOF, DIAMCYCOF)
G group 30 Compressor ON/OFF (e.g. COMPOF)
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G groups displayed by default (ISO code)
Group Meaning
G group 1 Modally active motion commands (e.g. G0, G1, G2, G3)
G group 2 Non-modally active motion commands, dwell time (e.g. G4, G74, G75)
G group 3 Programmable offsets, working area limitations and pole programming (e.g.
TRANS, ROT, G25, G110)
G group 6 Plane selection (e.g. G17, G18)
G group 7 Tool radius compensation (e.g. G40, G42)
G group 8 Settable work offset (e.g. G54, G57, G500)
G group 9 Offset suppression (e.g. SUPA, G53)
G group 10 Exact stop - continuous-path mode (e.g. G60, G641)
G group 13 Workpiece dimensioning inches/metric (e.g. G70, G700)
G group 14 Workpiece dimensioning absolute/incremental (G90)
G group 15 Feedrate type (e.g. G93, G961, G972)
G group 16 Feedrate override on inside and outside curvature (e.g. CFC)
G group 21 Acceleration profile (e.g. SOFT, DRIVE)
G group 22 Tool offset types (e.g. CUT2D, CUT2DF)
G group 29 Radius/diameter programming (e.g. DIAMOF, DIAMCYCOF)
G group 30 Compressor ON/OFF (e.g. COMPOF)
Procedure
2. Press the <JOG>, <MDA> or <AUTO> key.
...
3. Press the "G functions" softkey.

The "G Functions" window is opened.
4. Press the "G functions" softkey again to hide the window again.
The G groups selection displayed in the "G Functions" window may differ.
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References
For more information about configuring the displayed G groups, refer to the following
document:
4.12.2 All G functions

All G groups and their group numbers are listed in the "G Functions" window.
Within a G group, only the G function currently active in the controller is displayed.
Additional information in the footer

The following additional information is displayed in the footer:
Current transformations
Display Meaning
TRANSMIT Polar transformation active
TRACYL Cylinder surface transformation active
TRAORI Orientation transformation active
TRAANG Inclined axis transformation active
TRACON Cascaded transformation active
For TRACON, two transformations (TRAANG and TRACYL or TRAANG and
TRANSMIT) are activated in succession.
Current zero offsets

Spindle speed
Path feedrate
Active tool
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Procedure
...
3. Press the ">>" and "All G functions" softkeys.

The "G Functions" window is opened.
4.12.3 Auxiliary functions

Auxiliary functions include M and H functions preprogrammed by the machine manufacturer,
which transfer parameters to the PLC to trigger reactions defined by the manufacturer.
Displayed auxiliary functions

Up to five current M functions and three H functions are displayed in the "Auxiliary
Functions" window.
Procedure
...
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3. Press the "H functions" softkey.

The "Auxiliary Functions" window opens.
4. Press the "H functions" softkey again to hide the window again.
You can display status information for diagnosing synchronized actions in the "Synchronized
Actions" window.
You get a list with all currently active synchronized actions.
In this list, the synchronized action programming is displayed in the same form as in the part
program.
References
Programming Guide Job Planning (PGA) Chapter: Motion-synchronous actions
Status of synchronized actions

You can see the status of the synchronized actions in the "Status" column.
Waiting
Active
Blocked
Non-modal synchronized actions can only be identified by their status display. They are only
displayed during execution.
Synchronization types
Synchronization types Meaning

ID=n Modal synchronized actions in the automatic mode up to the end of
program, local to program; n = 1... 254
IDS=n Static synchronized actions, modally effective in every operating type,
also beyond the end of program; n = 1... 254
Without ID/IDS Non-modal synchronized actions in automatic mode
Note
Numbers ranging from 1 to 254 can only be assigned once, irrespective of the identification
number.
Display of synchronized actions

Using softkeys, you have the option of restricting the display to activated synchronized
actions.
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Procedure
2. Press the <AUTO>, <MDA> or <JOG> key.
3. Press the menu forward key and the "Synchron." softkey.

The "Synchronized Actions" window appears.
You obtain a display of all activated synchronized actions.
4. Press the "ID" softkey if you wish to hide the modal synchronized
actions in the automatic mode.
- AND / OR -
Press the "IDS" softkey if you wish to hide static synchronized actions.
- AND / OR -
Press the "Blockwise" softkey if you wish to hide the non-modal
synchronized actions in the automatic mode.
5. Press the "ID", "IDS" or "Blockwise" softkeys to re-display the

corresponding synchronized actions.
...
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4.13 Displaying the program runtime and counting workpieces

To gain an overview of the program runtime and the number of machined workpieces, open
the "Times, Counter" window.
Displayed times
Program
Pressing the softkey the first time shows how long the program has already been running.
At every further start of the program, the time required to run the entire program the first
time is displayed.
If the program or the feedrate is changed, the new program runtime is corrected after the
first run.
Program remainder
Here you can see how long the current program still has to run. In addition, you can
track how much of the current program has been completed as a percentage by using the
progress bar.
The display only appears when the program is run a second time.
If you are executing the program from an external location, the program loading progress
is displayed here.
Influencing the time measurement
The time measurement is started with the start of the program and ends with the end of
the program (M30) or with an agreed M function.
When the program is running, the time measurement is interrupted with CYCLE STOP
and continued with CYCLE START.
The time measurement starts at the beginning with RESET and subsequent CYCLE
START.
The time measurement stops with CYCLE STOP or a feedrate override = 0.
Counting workpieces
You can also display program repetitions and the number of completed workpieces. For the
worpiece count, enter the actual and planned workpiece numbers.
Workpiece count
Completed workpieces can be counted via the end of program command (M30) or an M
command.
Milling
Procedure
3. Press the "Times, Counter" softkey.

The "Times, Counter" window opens.
4. Select "Yes" under "Count workpieces" if you want to count completed
workpieces.
5. Enter the number of workpieces needed in the "Desired workpieces"

field.
The number of workpieces already finished is displayed in "Actual
workpieces". This value can be corrected if necessary.
After the defined number of workpieces is reached, the current
workpieces display is automatically reset to zero.
See also
Specifying the number of workpieces (Page 247)
Milling
4.14 Setting for automatic mode

Before machining a workpiece, you can test the program in order to identify programming
errors early on. Use the dry run feedrate for this purpose.
In addition, you have the option of additionally limiting the traversing speed for rapid traverse
so that when running-in a new program with rapid traverse, no undesirable high traversing
speeds occur.
Dry run feedrate

The feedrate defined here replaces the programmed feedrate during execution if you have
selected "DRY dry run feedrate" under program control.
Reduced rapid traverse

This value entered here reduces the rapid traverse to the entered percentage value if you
selected "RG0 reduced rapid traverse" under program control.
Displaying measurement results

Using an MMC command, you can display measurement results in a part program:
You set
whether, when the control reaches the command, it automatically jumps into the
"Machine" operating area and the window with the measurement results is displayed,
or
whether the window with the measurement results is opened by pressing the
"Measurement result" softkey.
Procedure

The "Settings for Automatic Operation" window is opened.
4. In "DRY run feedrate," enter the desired dry run speed.
Milling
5. Enter the desired percentage in the "Reduced rapid traverse RG0" field.
RG0 has not effect if you do not change the specified amount of 100%.
6. Enter "Automatic" in the "Display measurement result" box if the
measurement result window should be automatically opened, or
"Manual", if the measurement result window should be opened by
pressing the "Measurement result" softkey.
References
Programming Manual Measuring Cycles / 840D sl/828D
Note
The feedrate can be changed while the operation is running.
See also
Program control (Page 158)
Milling
Simulating machining 5
5.1 Overview
During simulation, the current program is calculated in its entirety and the result displayed in
graphic form. The result of programming is verified without traversing the machine axes.
Incorrectly programmed machining steps are detected at an early stage and incorrect
machining on the workpiece prevented.
Graphic display
The simulation represented on the screen uses the correct workpiece and tool proportions.
For simulation at milling machines, the workpiece is located, fixed in space. Only the tool
moves, independent of the machine type.
Definition of blank
The blank dimensions that are entered in the program editor are used for the workpiece.
The blank is clamped with reference to the coordinate system, which is valid at the time that
the blank was defined. This means that before defining the blank in G code programs, the
required output conditions must be established, e.g. by selecting a suitable work offset.
Programming a blank (example)
G54 G17 G90

CYCLE800(0,"TISCH", 100000,57,0,0,0,0,0,0,0,0,0,-1,100,1)
WORKPIECE(,,,"Box",112,0,-50,-80,00,155,100)
T="NC-SPOTDRILL_D16
Note
Blank offset for a changed work offset
The blank is always created in the work offset, which is presently active.
If you select another work offset, then the coordinate system is converted, however, the
display of the blank is not changed.
Display of the traversing paths

The traversing paths are displayed in color. Rapid traverse is red and the feedrate is green.
Depth display
The depth infeed is color-coded. The depth display indicates the actual depth at which
machining is currently taking place. The following applies to the color-coded depth display:
"The deeper, the darker".
Milling
Simulating machining
5.1 Overview
Machine references
The simulation is implemented as workpiece simulation. This means that it is not assumed
that the work offset has already been precisely scratched or is known.
In spite of this, unavoidable Machine references are in the programming, such as for
example, the tool change point in the Machine, the retraction position when swiveling and
the table components of a swivel kinematic. Depending on the actual work offset - in the
worst case - these Machine references can mean that collisions are shown in the simulation
that would not occur for a realistic work offset - or vice versa, collisions are not shown, which
could occur for a realistic work offset.
Programmable frames
All frames and work offsets taken into account in the simulation.
Simulation display
You can choose one of the following types of display:
Material removal simulation
During simulation or simultaneous recording you can follow stock removal from the
defined blank.
Path display
You have the option of including the display of the path. The programmed tool path is
displayed.
Note
Tool display in the simulation and for simultaneous recording
In order that workpiece simulation is also possible for tools that have either not been
measured or have been incompletely entered, certain assumptions are made regarding
the tool geometry.
For instance, the length of a miller or drill is set to a value proportional to the tool radius
so that cutting can be simulated.
Milling
5.1 Overview
Display variants
You can choose between three variants of graphical display:
Simulation before machining of the workpiece
Before machining the workpiece on the machine, you can perform a quick run-through in
order to graphically display how the program will be executed.
Simultaneous recording before machining of the workpiece
Before machining the workpiece on the machine, you can graphically display how the
program will be executed during the program test and dry run feedrate. The machine
axes do not move if you have selected "no axis motion".
Simultaneous recording during machining of the workpiece
You can follow machining of the workpiece on the screen while the program is being
executed on the machine.
Views
The following views are available for all three variants:
Top view
3D view
Side views
Status display
The current axis coordinates, the override, the current tool with cutting edge, the current
program block, the feedrate and the machining time are displayed.
In all views, a clock is displayed during graphical processing. The machining time is
displayed in hours, minutes and seconds. It is approximately equal to the time that the
program requires for processing including the tool change.
Software options
You require the option "3D simulation of the finished part" for the 3D view.
You require the option "Simultaneous recording (real-time simulation)" for the
"Simultaneous recording" function.
Determining the program runtime

The program runtime is determined when executing the simulation. The program runtime is
temporarily displayed in the editor at the end of the program.
Milling
5.1 Overview
Properties of simultaneous recording and simulation
Traversing paths
For the simulation, the displayed traversing paths are saved in a ring buffer. If this buffer is
full, then the oldest traversing path is deleted with each new traversing path.
Optimum display
If simultaneous machining is stopped or has been completed, then the display is again
converted into a high-resolution screen. In some cases this is not possible. In this case, the
following message is output: "High-resolution image cannot be generated".
Working zone limiting

No working zone limits and software limit switches are effective in the tool simulation.
Constraint
Traori: 5-axis motion is linearly interpolated. More complex motion cannot be displayed.
Spines and polynomials are not supported.
Referencing: G74 from a program run does not function.
Alarm 15110 "REORG block not possible" is not displayed.
Compile cycles are not supported.
No PLC support.
Axis containers are not supported.
Supplementary conditions
All of the existing data records (Toolcarrier / TRAORI, TRACYL) are evaluated and must
be correctly commissioned for correct simulation.
Transformations with swiveled linear axis (TRAORI 64 - 69) as well as OEM
transformations (TRAORI 4096 - 4098) are not supported.
Changes to the toolcarrier or transformation data only become effective after Power On.
Transformation change and swivel data record change are supported. However, a real
kinematic change is not supported, where a swivel head is physically changed out.
The simulation of mold building programs with extremely short block change times can
take longer than machining, as the computation time distribution for this application is
dimensioned in favor of the machining and to the detriment of simulation.
Examples
Several examples for machine types that are supported:
Milling
5.1 Overview
Swivel head 90/90
Swivel head 90/45
Milling
5.1 Overview
Swivel table 90/90
Swivel table 90/45
Milling
5.1 Overview
Swivel combination 90/90
Swivel combination 45/90
Milling
5.2 Simulation before machining of the workpiece
5.2 Simulation before machining of the workpiece

Before machining the workpiece on the machine, you have the option of performing a quick
run-through in order to graphically display how the program will be executed. This provides a
simple way of checking the result of the programming.
Feedrate override
Feedrate override is also active during simulation.
You can change the feedrate during the simulation via the user interface.
0 %: The simulation stops.
100 %: The program is executed as quickly as possible.
Procedure
1. Select the "Program Manager" operating area.
2. Select the storage location and position the cursor on the program to be
simulated.
3. Press the <INPUT> or <Cursor right> key.
- OR -
Double-click the program.

The selected program is opened in the "Program" operating area.
4. Press the "Simulation" softkey.
The program execution is displayed graphically on the screen. The
machine axes do not move.
5. Press the "Stop" softkey if you wish to stop the simulation.
- OR -
Press the "Reset" softkey to cancel the simulation.
6. Press the "Start" softkey to restart or continue the simulation.
Milling
5.3 Simultaneous recording before machining of the workpiece
Note
Operating area switchover
The simulation is exited if you switch into another operating area. If you restart the
simulation, then this starts again at the beginning of the program.
5.3 Simultaneous recording before machining of the workpiece

Before machining the workpiece on the machine, you can graphically display the execution
of the program on the screen to monitor the result of the programming.
Software option
simultaneous recording.
You can replace the programmed feedrate with a dry run feedrate to influence the speed of
execution and select the program test to disable axis motion.
If you would like to view the current program blocks again instead of the graphical display,
you can switch to the program view.
Procedure
1. Load a program in the "AUTO" mode.

2. Press the "Prog. ctrl." softkey and activate the checkboxes "PRT no axis
movement" and "DRY run feedrate".
The program is executed without axis movement. The programmed
feedrate is replaced by a dry run feedrate.
3. Press the "Sim. rec." softkey.

The program execution is displayed graphically on the screen.
5. Press the "Sim. rec." softkey again to stop the recording.
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5.4 Simultaneous recording during machining of the workpiece
5.4 Simultaneous recording during machining of the workpiece

If the view of the work space is blocked by coolant, for example, while the workpiece is being
machined, you can also track the program execution on the screen.
Software option
simultaneous recording.
Procedure
1. Load a program in the "AUTO" mode.

2. Press the "Sim. rec." softkey.

The machining of the workpiece is started and graphically displayed on
the screen.
4. Press the "Sim. rec." softkey again to stop the recording.
Note
If you switch-on simultaneous recording after the unmachined part information has
already been processed in the program, only traversing paths and tool are displayed.
If you switch-off simultaneous recording during machining and then switch-on the function
again at a later time, then the traversing paths generated in the intermediate time will not
be displayed.
Milling
5.5 Different views of a workpiece

In the graphical display, you can choose between different views so that you constantly have
the best view of the current workpiece machining, or in order to display details or the overall
view of the finished workpiece.
The following views are available:
Top view
3D view
Side views
5.5.1 Plan view
1. Start the simulation.

2. Press the "Top view" softkey.
The workpiece is shown from above in the top view.
Changing the display

You can increase or decrease the size of the simulation graphic and move it, as well as
change the segment.
5.5.2 3D view
1. Starting the simulation.

2. Press the "Other views" and "3D view" softkeys.
Software option
You require the option "3D simulation (finished part)" for the simulation.

You can increase or decrease the size of the simulation graphic, move it, turn it, or change
the segment.
Milling
Displaying and moving cutting planes

You can display and move cutting planes X, Y, and Z.
See also
Defining cutting planes (Page 205)
5.5.3 Side view
1. Starting the simulation.

2. Press the "Other views" softkey.
3. Press the "From front" softkey if you wish to view the workpiece from
the front.
- OR -
Press the "From rear" softkey if you wish to view the workpiece from the
rear.
- OR -
Press the "From left" softkey if you wish to view the workpiece from the
left.
- OR -
Press the "From right" softkey if you wish to view the workpiece from
the right.

You can increase or decrease the size of the simulation graphic and move it, as well as
change the segment.
Milling
5.6 Editing the simulation display
5.6 Editing the simulation display
5.6.1 Blank display

You have the option of replacing the blank defined in the program or to define a blank for
programs in which a blank definition cannot be inserted.
Note
The unmachined part can only be entered if simulation or simultaneous recording is in the
reset state.
Procedure
1. The simulation or the simultaneous recording is started.

2. Press the ">>" and "Blank" softkeys.
The "Blank Input" windows opens and displays the pre-assigned values.
3. Enter the desired values for the dimensions.

4. Press the "Accept" softkey to confirm your entries. The newly defined
workpiece is displayed.
5.6.2 Showing and hiding the tool path

The path display follows the programmed tool path of the selected program. The path is
continuously updated as a function of the tool movement. The tool paths can be shown or
hidden as required.
Procedure
1. The simulation or the simultaneous recording is started.

The tool paths are displayed in the active view.
3. Press the softkey to hide the tool paths.
The tool paths are still generated in the background and can be shown
again by pressing the softkey again.
4. Press the "'Delete tool path" softkey.
All of the tool paths recorded up until now are deleted.
Milling
5.7 Program control during the simulation
5.7.1 Changing the feedrate

You can change the feedrate at any time during the simulation.
You can track the changes in the status line.
Note
If you are working with the "Simultaneous recording" function, the rotary switch (override) on
the control panel is used.
Procedure
1. Simulation is started.
2. Press the "Program control" softkey.
3. Press the "Override +" or "Override -" softkey to increase or decrease

the feedrate by 5%.
- OR -
Press the "Override 100%" softkey to set the feedrate to the maximum
value.
- OR -
Press the "<<" softkey to return to the main screen and perform the
simulation with changed feedrate.
Note
Toggling between "Override +" and "Override -"
Press the <CTRL> and <Cursor down> or <Cursor up> keys to toggle
between the "Override +" and "Override -" softkeys.
Milling
5.7.2 Simulating the program block by block

You can control the program execution during simulation, i.e. execute a program block by
block, as when executing a program.
Procedure
1. Simulation is started.
2. Press the "Program control" and "Single block" softkeys.
3. Press the "Back" and "Start SBL" softkeys.

The pending block of the program is simulated and then stops.
4. Press "Start SBL" as many times as you want to simulate a single

program block.
5. Press the "Program control" and the "Single block" softkeys to exist the
single block mode.
Note
Enabling/disabling single block
Press the <CTRL> and <S> keys simultaneously to enable and disable
the single block mode.
Milling
5.8 Changing and adapting a simulation graphic
5.8.1 Enlarging or reducing the graphical representation
Precondition
The simulation or the simultaneous recording is started.
Procedure
1. Press the <+> and <-> keys if you wish to enlarge or reduce the graphic
display.
The graphic display enlarged or reduced from the center.
...
- OR -
Press the "Details" and "Zoom +" softkeys if you wish to increase the
- OR -
Press the "Details" and "Zoom -" softkeys if you wish to decrease the
- OR -
Press the "Details" and "Auto zoom" softkeys if you wish to
automatically adapt the segment to the size of the window.
The automatic scaling function "Fit to size" takes account of the largest
expansion of the workpiece in the individual axes.
Note
Selected section
The selected sections and size changes are kept as long as the program is selected.
Milling
5.8.2 Panning a graphical representation
Precondition
Procedure
1. Press a cursor key if you wish to move the graphic up, down, left, or
right.
5.8.3 Rotating the graphical representation

In the 3D view you can rotate the position of the workpiece to view it from all sides.
Precondition
Simulation has been started and the 3D view is selected.
Procedure
2. Press the "Rotate view" softkey.
Milling
2. Press the "Arrow right", "Arrow left", "Arrow up", "Arrow down", "Arrow
clockwise" and "Arrow counterclockwise" softkeys to change the
position of the workpiece.
...
- OR -
...
Keep the <Shift> key pressed and then turn the workpiece in the desired
direction using the appropriate cursor keys.
5.8.4 Modifying the viewport

If you would like to move, enlarge or decrease the size of the segment of the graphical
display, e.g. to view details or display the complete workpiece, use the magnifying glass.
Using the magnifying glass, you can define your own segment and then increase or
decrease its size.
Precondition
Procedure
2. Press the "Magnifying glass" softkey.

A magnifying glass in the shape of a rectangular frame appears.
3. Press the "Magnify +" or <+> softkey to enlarge the frame.
- OR -
Press the "Magnify -" or <-> softkey to reduce the frame.
- OR -
Milling
Press one of the cursor keys to move the frame up, down, left or right.
4. Press the "Accept" softkey to accept the section.
5.8.5 Defining cutting planes

In the 3D view, you have the option of "cutting" the workpiece and therefore displaying
certain views in order to show hidden contours.
Precondition
Procedure
2. Press the "Cut" softkey.
The workpiece is displayed in the cut state.
3. Press the corresponding softkey to shift the cutting plane in the required
direction.

Milling
5.9 Displaying simulation alarms
5.9 Displaying simulation alarms

Alarms might occur during simulation. If an alarm occurs during a simulation run, a window
opens in the operating window to display it.
The alarm overview contains the following information:
Date and time
Deletion criterion
Specifies with which softkey the alarm is acknowledged
Alarm number
Alarm text
Precondition
Simulation is running and an alarm is active.
Procedure
1. Press the "Program control" and "Alarm" softkeys.

The "Simulation Alarms" window is opened and a list of all pending
alarms is displayed.
Press the "Acknowledge alarm" softkey to reset the simulation alarms

indicated by the Reset or Cancel symbol.
The simulation can be continued.
- OR -
Press the "Simulation Power On" softkey to reset a simulation alarm
indicated by the Power On symbol.
Milling
Creating G code program 6
6.1 Graphical programming
Functions
The following functionality is available:
Technology-oriented program step selection (cycles) using softkeys
Input windows for parameter assignment with animated help screens
Context-sensitive online help for every input window
Support with contour input (geometry processor)
Call and return conditions

The G functions active before the cycle call and the programmable frame remain active
beyond the cycle.
The starting position must be approached in the higher-level program before the cycle is
called. The coordinates are programmed in a clockwise coordinate system.
Milling
Creating G code program
6.2 Program views
6.2 Program views

You can display a G code program in various ways.
Program view
Parameter screen, either with help screen or graphic view
Program view
The program view in the editor provides an overview of the individual machining steps of a
program.
Figure 6-1 Program view of a G code program
In the program view, you can move between the program blocks using
the <Cursor up> and <Cursor down> keys.
Milling
6.2 Program views
Parameter screen with help display
Press the <Cursor right> key to open a selected program block or cycle
in the program view.
The associated parameter screen with help screen is then displayed.
Figure 6-2 Parameter screen with help display
The animated help displays are always displayed with the correct orientation to the selected
coordinate system. The parameters are dynamically displayed in the graphic. The selected
parameter is displayed highlighted in the graphic.
The color symbols

Red arrow = tool traverses in rapid traverse
Green arrow = tool moves with the machining feedrate
Milling
6.2 Program views
Parameter screen with graphic view
Using the "Graphic view" softkey, you can toggle between the help
screen and the graphic view in the screen.
Figure 6-3 Parameter screen with a graphical view of a G code program block
Milling
6.3 Program structure

G_code programs can always be freely programmed. The most important commands that
are included in the rule:
Set a machining plane
Call a tool (T and D)
Call a work offset
Technology values such as feedrate (F), feedrate type (G94, G95,....), speed and
direction of rotation of the spindle (S and M)
Positions and calls, technology functions (cycles)
End of program
For G code programs, before calling cycles, a tool must be selected and the required
technology values F, S programmed.
A blank can be specified for simulation.
See also
Blank input (Page 215)
6.4 Basics
6.4.1 Machining planes

A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is
perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2-D
machining).
When programming, it is necessary to specify the working plane so that the control system
can calculate the tool offset values correctly. The plane is also relevant to certain types of
circular programming and polar coordinates.
=
<
=
<

*
=
;
*

;
* <

Milling
6.4 Basics
Working planes
Working planes are defined as follows:
Plane Tool axis

X/Y G17 Z
Z/X G18 Y
Y/Z G19 X
6.4.2 Current planes in cycles and input screens

Each input screen has a selection box for the planes, if the planes have not been specified
by NC machine data.
Empty (for compatibility reasons to screen forms without plane)
G17 (XY)
G18 (ZX)
G19 (YZ)
There are parameters in the cycle screens whose names depend on this plane setting.
These are usually parameters that refer to positions of the axes, such as reference point of a
position pattern in the plane or depth specification when drilling in the tool axis.
For G17, reference points in the plane are called X0 Y0, for G18 they are called Z0 X0 - and
for G19, they are called Y0 Z0. The depth specification in the tool axis for G17 is called Z1,
for G18, Y1 and for G19, X1.
If the entry field remains empty, the parameters, the help screens and the broken-line
graphics are displayed in the default plane (can be set via machine data):
Turning: G18 (ZX)
Milling: G17 (XY)
The plane is transferred to the cycles as new parameter. The plane is output in the cycle, i.e.
the cycle runs in the entered plane. It is also possible to leave the plane fields empty and
thus create a plane-independent program.
The entered plane only applies for this cycle (not modal)! At the end of the cycle, the plane
from the main program applies again. In this way, a new cycle can be inserted in a program
without having to change the plane for the remaining program.
Milling
6.4 Basics
6.4.3 Programming a tool (T)
Calling a tool
1. You are in a part program
2. Press the "Select tool softkey.
The "Tool selection" window is opened.
3. Position the cursor on the desired tool and press the "To program"
softkey.
The selected tool is loaded into the G code editor. Text such as the
following is displayed at the current cursor position in the G code editor:
T="ROUGHINGTOOL100"
- OR -
4. Press the "Tool list" and "New tool" softkeys.
5. Then select the required tool using the softkeys on the vertical softkey
bar, parameterize it and then press the softkey "To program".
The selected tool is loaded into the G code editor.
6. Then program the tool change (M6), the spindle direction (M3/M4), the
spindle speed (S...), the feedrate (F), the feedrate type (G94, G95,...),
the coolant (M7/M8) and, if required, further tool-specific functions.
Milling
6.5 Generating a G code program
6.5 Generating a G code program

Create a separate program for each new workpiece that you would like to produce. The
program contains the individual machining steps that must be performed to produce the
workpiece.
Part programs in the G code can be created under the "Workpiece" folder or under the "Part
programs" folder.
Procedure
2. Select the required archiving location.
Creating a new part program

3. Position the cursor on the folder "Part programs" and press the "New"
softkey.
The "New G Code Program" window opens.
4. Enter the required name and press the "OK" softkey.

The name can contain up to 28 characters (name + dot + 3-character
extension). You can use all letters (except accented characters), digits
and underscores (_).
The program type (MPF) is set by default.
The project is created and opened in the Editor.
Creating a new part program for a workpiece

5. Position the cursor on the folder "Workpieces" and press the "New"
softkey.
6. Select the file type (MPF or SPF), enter the desired name of the
program and press the "OK" softkey.
The project is created and opened in the Editor.
7. Enter the desired G code commands.
Milling
6.6 Blank input
See also
Changing a cycle call (Page 223)
Creating a new workpiece (Page 546)
Selection of the cycles via softkey (Page 218)
6.6 Blank input
Function
The blank is used for the simulation and the simultaneous recording. A useful simulation can
only be achieved with a blank that is as close as possible to the real blank.
program contains the individual machining steps that are performed to produce the
workpiece.
For the blank of the workpiece, define the shape (cuboid, tube, cylinder, polygon or centered
cuboid) and your dimensions.
Manually reclamping the blank

If the blank is to be manually reclamped from the main spindle to the counterspindle for
example, then delete the blank.
Example
Blank, main spindle, cylinder
Machining
M0 ; Manually reclamping the blank
Blank, main spindle, delete
Blank, counterspindle, cylinder
Machining
The blank entry always refers to the work offset currently effective at the position in the
program.
Note
Swiveling
For programs that use "Swiveling", a 0 swivel must first be made and then the blank defined.
Milling
6.6 Blank input
Procedure
1. Select the "Program" operating area.
2. Press the "Misc." and "Blank" softkeys.

The "Blank Input" window opens.

Data for Selection of the spindle for blank
Main spindle
Counterspindle
Note:
If the machine does not have a counterspindle, then the entry field "Data for" is not
applicable.
Blank Selecting the blank
Cuboid
Tube
Cylinder
Polygon
Centered cuboid
Delete
X0 1. Rectangular point X - (only for cuboid)
Y0 1. Rectangular point Y - (only for cuboid)
X1 2. Rectangular point X (abs) or 2nd rectangular point X referred to X0 (inc) - (only for
cuboid)
Y1 2. Rectangular point Y (abs) or 2nd rectangular point Y referred to Y0 (inc) - (only for
cuboid)
ZA Initial dimension
ZI Final dimension (abs) or final dimension in relation to ZA (inc)
ZB Machining dimension (abs) or machining dimension in relation to ZA (inc)
XA Outside diameter (only for tube and cylinder) mm
XI Inside diameter (abs) or wall thickness (inc) (only for tube) mm
N Number of edges (only for polygon)
SW or L Width across flats or edge length (only for polygon)
W Width of the blank - (only for centered cuboid) mm
L Length of the blank - (only for centered cuboid) mm
Milling
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP, SC, F)
6.7 Machining plane, milling direction, retraction plane, safe clearance

and feedrate (PL, RP, SC, F)
In the program header, cycle input screens have general parameters that are always
repeated. You will find the following parameters in every input screen for a cycle in a G code
program.

PL Each input screen has a selection box for the planes, if the planes have not been
specified by NC machine data.
Machining plane:
G17 (XY)
G18 (ZX)
G19 (YZ)
Milling direction When milling, the machining direction of rotation (climbing or conventional) and the
spindle direction of rotation in the tool list are taken into consideration. The pocket is
then machined in a clockwise or counterclockwise direction.
During path milling, the programmed contour direction determines the machining
direction.
RP Retraction plane (abs) mm
During machining the tool travels in rapid traverse from the tool change point to the
return plane and then to the safety clearance. The machining feedrate is activated at
this level. When the machining operation is finished, the tool travels at the machining
feedrate away from the workpiece to the safety clearance level. It travels from the safety
clearance to the retraction plane and then to the tool change point in rapid traverse.
The retraction plane is entered as an absolute value.
Normally, reference point Z0 and retraction plane RP have different values. The cycle
assumes that the retraction plane is in front of the reference point.
SC Safety clearance (inc) mm
Acts in relation to the reference point. The direction in which the safety clearance is
effective is automatically determined by the cycle.
The safety clearance must be entered as an incremental value (without sign).
F Feedrate
The feedrate F (also referred to as the machining feedrate) specifies the speed at which
the axes move during machining of the workpiece. The unit of the feedrate (mm/min,
mm/rev, mm/tooth etc. ) always refers to the feedrate type programmed before the cycle
call.
The maximum feedrate is determined via machine data.
Milling
6.8 Selection of the cycles via softkey
Overview of machining steps

The following softkey bars are available to insert machining steps.
All of the cycles/functions available in the control are shown in this display. However, at a
specific system, only the steps possible corresponding to the selected technology can be
selected.
Milling
Milling
Milling
A menu tree with all of the available measuring versions of the measuring
cycle function "Measure workpiece" can be found in the following
reference:
Programming Manual Measuring cycles / SINUMERIK 840D sl/828D
cycle function "Measure tool" can be found in the following reference:
Milling
6.9 Calling technology functions
See also
General (Page 275)
6.9.1 Hiding cycle parameters

The documentation describes all the possible input parameters for each cycle. Depending on
the settings of the machine manufacturer, certain parameters can be hidden in the screens,
i.e. not displayed. These are then generated with the appropriate default values when the
cycles are called.
Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl
Cycle support
Example
1. Use the softkeys to select whether you want support for programming
contours, drilling or milling cycles.
2. Select the desired cycle via the softkey.
3. Enter the parameters and press the "Accept" key.
The cycle is transferred to the editor as G code.
6.9.2 Setting data for cycles

Cycle functions can be influenced and configured using machine and setting data.
Milling
6.9.3 Checking cycle parameters

The entered parameters are already checked during the program creation in order to avoid
faulty entries.
If a parameter is assigned an illegal value, this is indicated in the input screen and is
designated as follows:
The entry field has a colored background (background color, pink).
A note is displayed in the comment line.
If the parameter input field is selected using the cursor, the not is also displayed as
tooltip.
The programming can only be completed after the incorrect value has been corrected.
Faulty parameter values are also monitored with alarms during the cycle runtime.
6.9.4 Changing a cycle call

You have called the desired cycle via softkey in the program editor, entered the parameters
and confirmed with "Accept".
Procedure
1. Select the desired cycle call and press the <Cursor right> key.
The associated input screen of the selected cycle call is opened.
- OR -
Press the <SHIFT + INSERT> key combination.
This starts the edit mode for this cycle call and you can edit it like a
normal NC block. This means that it is possible to generate an empty
block before the cycle is called. For instance, to insert something before
a cycle that is located at the beginning of the program.
Note: In edit mode, the cycle call can be changed in such a way that it
can no longer be recompiled in the parameter screen.
You exit the edit mode by pressing the <SHIFT + INSERT> key
combination.
- OR -
You are in the edit mode and press the <INPUT> key.
A new line is created after the cursor position.
See also
Milling
6.9.5 Compatibility for cycle support

The cycle support is generally upwards compatible. This means that cycle calls in NC
programs can always be recompiled with a higher software version, changed and then run
again.
When transferring NC programs to a machine with a lower software version, it cannot be
guaranteed, however, that the program will be able to be changed by recompiling cycle calls.
6.9.6 Additional functions in the input screens
Selection of units
If, for example, the unit can be switched in a field, this is highlighted as soon as the
cursor is positioned on the element. In this way, the operator recognizes the
dependency.
The selection symbol is also displayed in the tooltip.
Display of abs or inc

The abbreviations "abs" and "inc" for absolute and incremental values are displayed behind
the entry fields when a switchover is possible for the field.
Help screens
2D and 3D graphics or sectional views are displayed for the parameterization of the cycles.
Online help
If you wish to obtain more detailed information about certain G code commands or cycle
parameters, then you can call a context-sensitive online help.
Milling
6.10 Measuring cycle support

Measuring cycles are general subroutines designed to solve specific measurement tasks.
They can be adapted to specific problems via parameter settings.
Software option
You require the "Measuring cycles" option to use "Measuring cycles".
References
You will find a more detailed description on how to use measuring cycles in:
Milling
Milling
Creating a ShopMill program 7
The program editor offers graphic programming to generate machining step programs that
you can directly generate at the machine.
Software option
You require the "ShopMill/ShopTurn" option to generate ShopMill machining
step programs.
Program loops
When you open a ShopMill program a program test is always executed. For larger program
loops or nested program loops, this can result in performance problems in the editor.
Therefore, always program program repetitions in the program end block.
Functions
The following functionality is available:
Technology-oriented program step selection (cycles) using softkeys
Input windows for parameter assignment with animated help screens
Context-sensitive online help for every input window
Support with contour input (geometry processor)
See also
Repeating program blocks (Page 245)
Milling
Creating a ShopMill program
7.1 Program views
7.1 Program views

You can display a ShopMill program in various views:
Machining schedule
Programming graphics
Parameter screen, either with help display or programming graphics
Machining schedule
The machining schedule in the editor provides an overview of the individual machining steps
of a program.
Figure 7-1 Machining schedule of a ShopMill program
1. You can move between the program blocks in the machining

schedule using the <Cursor up> and <Cursor down> keys.
2. Press the "Graphics view" softkey to display the programming

graphics.
Milling
7.1 Program views
Programming graphics
The programming graphics show the contour of the workpiece as a dynamic graphic with
dotted lines. The program block selected in the machining schedule is highlighted in color in
the programming graphics.
Figure 7-2 Programming graphics of a ShopMill program
Parameter screen with help display
Press the <Cursor right> key to open a selected program block or

cycle in the machining schedule.
The associated parameter screen with help screen is then
displayed.
Milling
7.1 Program views
Figure 7-3 Parameter screen with help display
The animated help displays are always displayed with the correct orientation to the selected
coordinate system. The parameters are dynamically displayed in the graphic. The selected
parameter is displayed highlighted in the graphic.
The color symbols

Red arrow = tool traverses in rapid traverse
Green arrow = tool moves with the machining feedrate
Parameter screen with programming graphics
In the screen, you can toggle between the help display and the program
graphics using the "Graphic view".
Milling
7.1 Program views
Figure 7-4 Parameter screen with programming graphics
Milling

A machining step program is divided into three sub-areas:
Program header
Program blocks
End of program
These sub-areas form a work plan.
Program header
The program header contains parameters that affect the entire program, such as blank
dimensions or retraction planes.
Program blocks
You determine the individual machining steps in the program blocks. In doing this, you
specify the technology data and positions, among other things.
Linked blocks
For the "Contour milling", "Milling", and "Drilling" functions, program the technology blocks
and contours or positioning blocks separately. These program blocks are automatically
linked by the control and connected by brackets in the work plan.
In the technology blocks, you specify how and in what form the machining should take place,
e.g. centering first, and then drilling. In the positioning blocks, you define the positions for
drilling or milling operations.
End of program
End of program signals to the machine that the machining of the workpiece has ended.
Further, here you set whether program execute should be repeated.
Note
Number of workpieces
You can enter the number of required workpieces using the "Times, counters" window.
Milling
7.3 Basic information
7.3.1 Machining planes

A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is
perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2-D
machining).
When programming, it is necessary to specify the working plane so that the control system
can calculate the tool offset values correctly. The plane is also relevant to certain types of
circular programming and polar coordinates.
=
<
=
<

*
=
;
*

;
* <

Working planes
Working planes are defined as follows:
Plane Tool axis

X/Y G17 Z
Z/X G18 Y
Y/Z G19 X
7.3.2 Polar coordinates

The rectangular coordinate system is suitable in cases where dimensions in the production
drawing are orthogonal. For workpieces dimensioned with arcs or angles, it is better to
define positions using polar coordinates. This is possible if you are programming a straight
line or a circle.
Polar coordinates have their zero point at the "pole".
Milling
Example
<
3
3

r
r
3RO

;

Points P1 and P2 can then be described with reference to the pole as follows:
P1: Radius =100 / angle =30
P2: Radius =60 / angle =75
7.3.3 Absolute and incremental dimensions
Absolute dimensions
With absolute dimensions, all the position specifications refer to the currently valid zero
point. Applied to tool movement this means: The absolute dimension data defines the
position, to which the tool is to travel.
Example
<
3
3

3

;

The position data points P1 to P3 in absolute dimensions relative to the zero point are the
following:
P1: X20 Y35
P2: X50 Y60
P3: X70 Y20
Milling
Incremental dimensions
In the case of production drawings in which dimensions refer to some other point on the
workpiece rather than the zero point, it is possible to enter an incremental dimension.
When incremental dimensions are entered, each item of position data refers to a point
programmed beforehand.
Example
Y
P2
20
P1
15 P3
20
X
20 30 20
The position data for points P1 to P3 in incremental dimensions are:

P1: X20 Y35 ;(referred to the zero point)
P2: X30 Y20 ;(referred to P1)
P3: X20 Y-35 ;(referred to P2)
Milling
7.4 Creating a ShopMill program
7.4 Creating a ShopMill program

program contains the individual machining steps that must be performed to produce the
workpiece.
If you create a new program, a program header and program end are automatically
generated.
ShopMill programs can be created in a new workpiece or under the folder "Part programs".
Procedure
2. Select the desired storage location and position the cursor on the folder
"Part programs" or under the folder "Workpieces" on the workpiece for
which you wish to create a program.
3. Press the "New" and "ShopMill" softkeys.
The "New machining step programming" window opens.

The name can contain up to 28 characters (name + dot + 3-character
extension). You can use all letters (except accented characters), digits
and underscores (_). The "ShopMill" program type is selected.
The editor is opened and the "Program header" parameter screen is
displayed.
Filling-out the program header
5. Select a work offset and enter the dimensions of the blank and the
parameters, which are effective over the complete program, e.g.
dimension units in mm or inch, tool axis, retraction plane, safety
clearance and machining direction.
The work plan is displayed. Program header and end of program are
created as program blocks.
The end of program is automatically defined.
See also
Changing program settings (Page 249)
Creating a new workpiece (Page 546)
Milling
7.5 Program header
7.5 Program header

In the program header, set the following parameters, which are effective for the complete
program.

Measurement unit The dimension unit (mm or inch) set in the program header only refers to the mm
position data in the actual program. All other data, such as feedrate or tool offsets, inch
are entered in the dimension unit that you have set for the entire machine.
Work offset The work offset in which the workpiece zero is saved.
You can also delete the pre-setting of the parameter if you do not want to specify a
work offset.
Blank Define the form and dimensions of the workpiece
Cylinder
XA Outer diameter mm
Polygon
N Number of edges
SW / L Width across flats
Edge length
Centered cuboid
W Width of blank mm
L Length of blank mm
Cuboid
X0 1. Corner point X mm
Y0 1. Corner point Y mm
X1 2. Corner point X (abs) or 2nd corner point X referred to X0 (inc) mm
Y1 2. Corner point Y (abs) or 2nd corner point Y referred to Y0 (inc) mm
Tube
XA Outer diameter mm
XI Inner diameter (abs) or wall thickness (inc) mm
ZA Initial dimension mm
ZI Final dimension (abs) or final dimension in relation to ZA (inc) mm
PL Machining plane
G17 (XY)
G18 (ZX)
G19 (YZ)
Note: The plane settings can already be defined. Ask the machine manufacturer in
order that the selection box is available.
Milling
7.5 Program header

Retraction plane RP Planes above the workpiece.
Safety clearance SC: During machining the tool travels in rapid traverse from the tool change point to the
return plane (RP) and then to the safety clearance (SC). The machining feedrate is
activated at this level. When the machining operation is finished, the tool travels at
the machining feedrate away from the workpiece to the safety clearance level. It
travels from the safety clearance to the retraction plane and then to the tool change
point in rapid traverse. The retraction plane is entered as an absolute value.
The safety clearance must be entered as an incremental value (without sign).
Machining direction When machining a pocket, a longitudinal slot or a spigot, ShopMill takes the
machining direction (climbing or conventional) and the spindle direction in the tool
list into account. The pocket is then machined in a clockwise or counterclockwise
direction.
During path milling, the programmed contour direction determines the machining
direction.
Retraction position optimized
pattern
When machining with optimized retraction, the tool travels across the workpiece
at the machining feedrate depending on the contour and with a safety clearance
(SC).
to RP
When retracting to RP, the tool is retracted to the retraction plane when the
machining step is complete and infeeds at the new position. Collisions with
workpiece obstacles are thus prevented when the tool is retracted and fed in,
e.g. when holes in pockets or grooves are machined at different levels and
positions.
Milling
7.6 Generating program blocks
7.6 Generating program blocks

After a new program is created and the program header is filled out, define the individual
machining steps in program blocks that are necessary to produce the workpiece.
You can only generate program blocks between the program header and the end of the
program.
Procedure
Selecting a technological function

1. Position the cursor in the work plan on the line behind which a new
program block is to be inserted.
2. Using the softkeys, select the desired function. The associated
parameter screen is displayed.
...
3. First, program the tool, offset value, feedrate and spindle speed (T, D,
F, S, V) and then enter the values for the other parameters.
Selecting a tool from the tool list
4. Press the "Select tools" softkey if you wish to select the tool for
parameter "T".
5. Position the cursor on the tool that you wish to use for machining and
press the "To program" softkey.
The selected tool is accepted into the parameter screen form.
- OR -
Press the "Tool list" and "New tool" softkeys.
Using the softkeys on the vertical softkey bar, select the required tool
with the data and press the "To program" softkey.
The selected tool is accepted into the parameter screen form.
The process plan is displayed and the newly generated program block
is marked.
Milling
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V)

Generally, the following parameters are entered for a program block.
Tool (T)
Each time a workpiece is machined, you must program a tool. Tools are selected by name,
and the selection is integrated in all parameter screen forms of the machining cycles (with
the exception of the straight line/circle).
The tool length offsets become active as soon as the tool is changed.
Tool selection is modal for the straight line/circle, i.e. if the same tool is used to perform
several machining steps occur in succession, you only have to program one tool for the first
straight line/circle.
Cutting edge (D)

In the case of tools with several cutting edges, there is a separate set of individual tool offset
data for each edge. For these tools, you must select or specify the number of the cutting
edge that you would like to use for machining.
CAUTION
Collisions may occur if you specify the wrong cutting edge number for some tools (e.g. a
flat chamfering drill with guide spigot or step drill) and then traverse the tool. Always ensure
that you enter the correct cutting edge number.
Tool length compensation

Tool length compensation takes effect as soon as the tool is loaded into the spindle.
Different tool offsets can be assigned to each tool with multiple cutting edges.
The tool length compensation of the spindle tool remains active even after the program has
been executed (RESET).
Radius compensation
The tool radius compensation is automatically included in the machining cycles except for
path milling.
For path milling and straight line/circle, you have the option of programming the machining
with or without radius compensation. The tool radius compensation is modal for straight
lines/circles, i.e. you have to deselect the radius compensation if you want to traverse
without radius compensation.
Milling
Radius compensation to right of contour
Radius compensation to left of contour
Radius compensation off
Radius compensation remains as previously set
Feedrate (F)
The feedrate F (also referred to as the machining feedrate) specifies the speed at which the
tool moves when machining the workpiece. The machining feedrate is entered in mm/min,
mm/rev or in mm/tooth. The feedrate for milling cycles is automatically converted when
switching from mm/min to mm/rev and vice versa.
It is only possible to enter the feedrate in mm/tooth during milling; this ensures that each
cutting edge of the milling cutter is cutting under the best possible conditions. The feedrate
per tooth corresponds to the linear path traversed by the milling cutter when a tooth is
engaged.
With milling cycles, the feedrate for rough cutting is relative to the milling tool center point.
This also applies to finish cutting, with the exception of concave curves where the feedrate is
relative to the contact point between the tool and workpiece.
The maximum feedrate is determined via machine data.
Converting the feedrate (F) for drilling and milling

The feedrate entered for drilling cycles is automatically converted when switching from
mm/min to mm/rev and vice versa using the selected tool diameter.
The feedrate entered for milling cycles is automatically converted when switching from mm/Z
to mm/min and vice versa using the selected tool diameter.
Spindle speed (S) / cutting rate (V)

You have the option of either programming the spindle speed (S) or the cutting rate (V). You
can toggle between them using the <SELECT> key.
In the milling cycles, the spindle speed is automatically converted to the cutting rate and vice
versa.
Spindle speed and cutting rate remain valid until you program a new tool.
Spindle speeds are programmed in rev/min.
Cutting rates are programmed in m/min
You can set the direction of rotation of a tool in the tool list.
Converting the spindle speed (S) / cutting rate (V) when milling.
Milling
7.8 Defining machine functions

You can switch-on the coolant or stop machining between the individual machining steps.
You have the option of defining machine functions as well as your own texts in the "Machine
functions" window.
References
A description of the configuration options is provided in
Procedure
1. The ShopMill program to be edited has been created and you are in the
editor.
2. Press the menu forward key and the "Straight Circle" softkey.
3. Press the "Machine functions" softkey.

The "Machine functions" window opens.
4. Enter the desired parameters.
See also
Starting and stopping a spindle manually (Page 127)
Milling

Spindle M function, defines the spindle direction of rotation or spindle position
Spindle off
Spindle rotates clockwise
Spindle rotates counterclockwise
Spindle positions
Stop position Spindle stop position - (only for spindle M function SPOS) Degrees
Other M function Machine functions, e.g. "Close door" that are additionally provided by the
machine manufacturer.
Coolant 1 Selects coolant (switches coolant 1 on or off)
with
without
Coolant 2 Selects coolant (switches coolant 2 on or off)
with
without
Tool-spec. function 1 User machine functions on/off
DT Dwell time in seconds s
Time after which machining is continued.
Programmed stop Programmed stop on
Stops machining at the machine if, under Machine in the "Program control"
window, the check box "Programmed stop" was activated.
Stop Stop on
Stops machining at the machine.
Milling
7.9 Call work offsets
7.9 Call work offsets

You can call work offsets (G54, etc.) from any program.
You define work offsets in work offset lists. You can also view the coordinates of the selected
offset here.
Procedure
1. Press the "Various", "Transformations" and "Work offset" softkeys.

The "Work offset" window opens.
2. Select the desired work offset (e.g. G54).

The work offset is transferred into the work plan.
Milling
7.10 Repeating program blocks

If certain steps when machining a workpiece have to be executed more than once, it is only
necessary to program these steps once. You have the option of repeating program blocks.
NOTICE
Machining several workpieces
The program repeat function is not suitable to program repeat machining of parts.
In order to repeatedly machine the same workpieces (Page 247) program this using end of
program.
Start and end marker

You must mark the program blocks that you want to repeat with a start and end marker. You
can then call these program blocks up to 200 times within a program. The markers must be
unique, i.e. they must have different names. No names used in the NCK can be used.
You can also set markers and repeats after creating the program, but not within linked
program blocks.
Note
You can use one and the same marker as end marker for preceding program blocks and as
start marker for following program blocks.
Procedure
1. Position the cursor at the program block, behind which a program block
that will be repeated should follow.
2. Press the "Various" softkey.
3. Press the ">>" and "Repeat progr." softkeys.
3. Press the "Set marker" and "Accept" softkeys.

A start marker is inserted behind the actual block.
4. Enter the program blocks that you want to repeat later.
Milling
5. Press the "Set marker" and "Accept" softkeys again.

An end marker is inserted after the actual block.
6. Continue programming up to the point where you want to repeat the

program blocks.
7. Press the "Various" and "Repeat progr." softkeys.
8. Enter the names of the start and end markers and the number of times
the blocks are to be repeated.
The marked program blocks are repeated.
Milling
7.11 Specifying the number of workpieces
7.11 Specifying the number of workpieces

If you wish to produce a certain quantity of the same workpiece, then at the end of the
program, specify that you wish to repeat the program.
Control the numbers of times that the program is repeated using the "Times, counters"
window. Enter the number of required workpieces using the target number. You can track
the number of machined and completed workpieces in the actual counter window.
Controlling program repetition
End of program: Times, counter:

Repeat Counts the
workpieces
No No A CYCLE START is required for each workpiece.
No Yes A CYCLE START is required for each workpiece.
The workpieces are counted.
Yes Yes The program is repeated without a new CYCLE START
until the required number of workpieces have been
machined.
Yes No Without a new CYCLE START, the program is repeated
an infinite number of times.
You can interrupt program execution with <RESET>.
Procedure
1. Open the "Program end" program block, if you want to machine more
than one workpiece.
2. In the "Repeat" field, enter "Yes".
If you start the program later, program execution is repeated.
Depending on the settings in the "Times, counters" window, the
program is repeated until the set number of workpieces has been
machined.
See also
Displaying the program runtime and counting workpieces (Page 183)
Milling
7.12 Changing program blocks
7.12 Changing program blocks

You can subsequently optimize the parameters in the programmed blocks or adapt them to
new situations, e.g. if you want to increase the feedrate or shift a position. In this case, you
can directly change all the parameters in every program block in the associated parameter
screen form.
Procedure
1. Select the program that you wish to change in the "Program Manager"
operating area.
2. Press the <Cursor right> or <INPUT> key.

The work plan of the program is displayed.
3. Position the cursor in the work plan at the desired program block and
press the <Cursor right> key.
The parameter screen for the selected program block is displayed.
4. Make the desired changes.
- OR -
Press the <Cursor left> key.
The changes are accepted in the program.
Milling
7.13 Changing program settings
7.13 Changing program settings
Function
All parameters defined in the program header, with the exception of the dimension unit, can
be changed at any location in the program.
The settings in the program header are modal, i.e. they remain active until they are changed.
Define a new blank, e.g. in the machining step program, if you want to change the visible
section during simulation.
This is useful for the work offset, coordinate transformation, cylinder peripheral surface
transformation and swiveling functions. First program the functions listed above and then
define a new blank.
Procedure
1. Select the "Program" operating area.
2. Press the "Various" and "Settings" softkeys.

The "Settings" input window opens.

PL Machining plane
G17 (XY)
G18 (ZX)
G19 (YZ)
RP Retraction plane (abs) mm
SC Safety clearance (inc) mm
Acts in relation to the reference point. The direction in which the safety clearance is
effective is automatically determined by the cycle.
Machining Milling direction:
direction
Climbing
Conventional
Retraction position Lift mode before new infeed mm
pattern
to RP
optimized
Milling
Overview of machining steps

The following machining steps are available for insertion.
All of the cycles/functions available in the control are shown in this display. However, at a
specific system, only the steps possible corresponding to the selected technology can be
selected.
Milling
Milling
Milling
cycle function "Measure workpiece" can be found in the following
reference:
cycle function "Measure tool" can be found in the following reference:
Milling
7.15.1 Additional functions in the input screens
Selection of units
If, for example, the unit can be switched in a field, this is highlighted as soon as the
cursor is positioned on the element. In this way, the operator recognizes the
dependency.
The selection symbol is also displayed in the tooltip.
Display of abs or inc

The abbreviations "abs" and "inc" for absolute and incremental values are displayed behind
the entry fields when a switchover is possible for the field.
Help screens
2D and 3D graphics or sectional views are displayed for the parameterization of the cycles.
Online help
If you wish to obtain more detailed information about certain G code commands or cycle
parameters, then you can call a context-sensitive online help.
7.15.2 Checking input parameters

When generating the program, the parameters that are entered are already checked in order
to avoid making incorrect entries.
If a parameter is assigned an illegal value, this is indicated in the input screen and is
designated as follows:
The entry field has a colored background (background color, pink).
A note is displayed in the comment line.
If the parameter input field is selected using the cursor, the note is also displayed as
tooltip.
The programming can only be completed after the incorrect value has been corrected.
Incorrect parameter values are also monitored with alarms during the cycle runtime.
Milling
7.15.3 Setting data for technological functions

Technological functions can be influenced and corrected using machine or setting data.
7.15.4 Changing a cycle call

You have called the desired cycle via softkey in the program editor, entered the parameters
and confirmed with "Accept".
Procedure
1. Select the desired cycle call and press the <Cursor right> key.
The associated input screen of the selected cycle call is opened.
- OR -
Press the <SHIFT + INSERT> key combination.
This starts the edit mode for this cycle call and you can edit it like a
normal NC block. This means that it is possible to generate an empty
block before the cycle is called. For instance, to insert something before
a cycle that is located at the beginning of the program.
Note: In edit mode, the cycle call can be changed in such a way that it
can no longer be recompiled in the parameter screen.
You exit the edit mode by pressing the <SHIFT + INSERT> key
combination.
- OR -
You are in the edit mode and press the <INPUT> key.
A new line is created after the cursor position.
Milling
7.15.5 Compatibility for cycle support

The cycle support is generally upwards compatible. This means that cycle calls in NC
programs can always be recompiled with a higher software version, changed and then run
again.
When transferring NC programs to a machine with a lower software version, it cannot be
guaranteed, however, that the program will be able to be changed by recompiling cycle calls.

Measuring cycles are general subroutines designed to solve specific measurement tasks.
They can be adapted to specific problems via parameter settings.
Software option
You require the "Measuring cycles" option to use "Measuring cycles".
References
You will find a more detailed description on how to use measuring cycles in:
Milling
7.17 Example, standard machining
General
The following example is described in detail as ShopMill program. A G code program is
generated in the same way; however, some differences must be observed.
If you copy the G code program listed below, read it into the control and open it in the editor,
then you can track the individual program steps.
Under all circumstances, observe the machine manufacturers instructions.
Tools
The following tools are saved in the tool manager:
Tool name Tool diameter Cutting materials Number of teeth

Face miller D80 mm HM Z=8
End mill D20 mm HM Z=3
Centering tool D10 mm HM -
(NC spotdrill)
Twist drill D10 mm HSS -
The correction (compensation) values for length and radius as well as the tip angle for drills
and number of teeth for milling tools should be entered into the tool list. If you are working
with ShopMill, in addition, enter the spindle direction of rotation and coolant.
Adapt the cutting data to the tools used and the specific application conditions.
Blank
Dimensions: 185 x 185 x 50
Material: Aluminum
Milling
7.17.1 Workpiece drawing

5

5
5

5
5
R

5

7LHIH
R

5
5

5
R

6WDUWSXQNW
<

;

7.17.2 Programming
1. Program header
1. Specify the blank.

Measurement unit mm
Work offset G54
Blank Cuboid
X0 -2.5abs
Y0 -2.5abs
X1 182.5abs
Y1 182.5abs
ZA 1abs
Milling
ZI -20abs
RP 100
SC 1
Machining direction Climbing
Retraction position pattern Optimized
The work plan is displayed. Program header and end of program are
created as program blocks.
The end of program is automatically defined.
2. Rectangular spigots, face milling
1. Press the "Milling" and "Face milling" softkeys.
2. Enter the following technology parameters:

T FACING TOOL D1 F 0.1 mm/tooth V 750 m/min
3. Enter the following parameters:
Machining Roughing ()
Direction
X0 -2,5abs
Y0 -2,5abs
Z0 1abs
X1 185abs
Y1 185abs
Z1 0abs
DXY 80%
DZ 2,0
UZ 0
Milling
3. Outside contour of the workpiece
1. Press the "Milling", "Multi-edge spigot" and "Rectangular spigot"

softkeys.

T MILLER20 D1 F 0.14 mm/tooth V 240 m/min
Position of reference point Bottom left
Type of position Single position
X0 0abs
Y0 0abs
Z0 0abs
W1 185(fictitious blank dimension)
L1 185(fictitious blank dimension)
W 180abs
L 180abs
R 10abs
0 0degrees
Z1 20inc
DZ 5
UXY 0
UZ 0
Milling
4. Outside contour islands

To simply machine the entire surface outside the island, define a contour pocket around the
blank and then program the island. In this way, the entire surface area is machined and no
residual material is left behind.
Outside contour of the pocket
1. Press the "Contour milling", "Contour" and "New contour" softkeys.

The "New Contour" input window opens.
2. Enter the contour name (in this case: Part_4_pocket).

The contour calculated as NC code is written as internal subprogram
between a start and an end marker containing the entered name.
The "Starting point" input window opens.
4. Enter the starting point of the contour.
X -10abs Y -10abs
6. Enter the following contour elements and acknowledge using the

"Accept" softkey.
6.1. X 190abs
6.2. Y 190abs
6.3. X -10abs
6.4. Press the ">>" and "Close contour" softkeys, to close the contour.
Milling
Outside contour of the island
1. Press the "Contour milling", "Contour" and "New contour" softkeys.

2. Enter the contour name (in this case: Part_4_island).

The contour calculated as NC code is written as internal subprogram
between a start and an end marker containing the entered name.
The "Starting point" input window opens.
4. Enter the starting point of the contour.
X 90abs Y 25abs
6. Enter the following contour elements and acknowledge using the

"Accept" softkey.
6.1. X 25abs FS 15
6.2. Y 115abs R 20
6.3. X 15abs Y 135abs
6.4. Y 155abs R 10
6.5. X 60abs R 15
6.6. Y 135abs
7. Direction of rotation
8. R 25 X 110abs
9.1 Y 155abs R 15
Milling
9.2 R 0
9.3 X 165abs Y 95abs 1290 degreesR 0
9.4 X 155abs 1 240 degre R 28

es
9.5 FS 0
9.6 X 140abs Y 25 abs 1225 degreesR 0
10. Press the ">>" and "Close contour" softkeys, to close the contour.
Contour milling/solid machining
1. Press the "Contour milling" and "Pocket" softkeys.

Machining
Z0 0abs
Z1 10inc
DXY 40%
DZ 3.5
UXY 0mm
UZ 0
Starting point Auto
Insertion Helical
EP 1.0
ER 2.0
Lift mode Select, e.g. to the retraction plane
Milling
Note
When selecting the milling tool, please make sure that the tool diameter is large enough
to cut the intended pocket. A message will be displayed if you make a mistake.
If you want to finish cut the pocket, you must assign parameters UXY and UZ accordingly
and add a second solid machining cycle for finishing.
5. Milling a rectangular pocket (large)
1. Press the "Milling", "Pocket" and "Rectangular pocket" softkeys.

The "Rectangular Pocket" input window opens.

Reference point Center
Machining position Single position
X0 90abs
Y0 60abs
Z0 0abs
W 40
L 70
R 10
0 15degrees
Z1 4inc
DXY 40%
DZ 4
UXY 0
UZ 0
Insertion Helical
EP 1
ER 2
Solid machining Complete machining
Milling
6. Milling a rectangular pocket (small)
1. Press the "Milling", "Pocket" and "Rectangular pocket" softkeys.

The "Rectangular Pocket" input window opens.

Reference point Center
X0 90abs
Y0 60abs
Z0 -4abs
W 20
L 35
R 5
0 15degrees
Z1 2inc
DXY 40%
DZ 2
UXY 0
UZ 0
Insertion Oscillation
7. Milling a circumferential slot
1. Press the "Milling", "Groove" and "Circ. groove" softkeys.

The "Circumferential Groove" input window opens.

T MILLER8 D1 F 0.018 mm/tooth FZ 0.01 mm/tooth
Milling
V 230 m/min
Circular pattern Pitch circle
X0 85abs
Y0 135abs
Z0 0abs
N 1
R 40
0 180degrees
1 180degrees
W 10
Z1 3inc
DZ 3
UXY 0mm
8. Drilling/centering
1. Press the "Drilling" and "Centering" softkeys.

The "Centering" input window opens.

T CENTERING D1 F 1000 mm/min S 12000 rev/min
TOOL10
Diameter/tip Diameter
5
Milling
9. Drilling/reaming
1. Press the "Drilling", "Drilling reaming" and "Drilling" softkeys.

The "Drilling" input window opens.

T DRILL10 D1 F 500 mm/min S 1600 rev/min
Diameter/tip Tip
Z1 -25abs
DT 0
10. Positions
1. Press the "Drilling", "Positions" and "Drilling Positions" softkeys.

The "Any positions" input window opens.

Rectangular
Z0 -10abs
X0 15abs
Y0 15abs
X1 165abs
Y1 15abs
Milling
11. Obstacle
1. Press the "Drilling", "Positions", and Obstacle softkeys.

The "obstacle" input window opens.

Z 2abs
Note
If this obstacle cycle is not inserted, the drill will violate the right-hand corner of the island
contour. Alternately, you could increase the safety clearance.
12. Positions
1. Press the "Drilling", "Positions" and "Drilling Positions" softkeys.

The "Any positions" input window opens.

Rectangular
Z0 -10abs
X2 165abs
Y2 165abs
X3 15abs
Y3 165abs
Milling
13. Milling the circular pocket
1. Press the "Milling", "Pocket" and "Circular pocket" softkeys.

The "Circular Pocket" input window opens.

Machining type Plane by plane
X0 85abs
Y0 135abs
Z0 -10abs
Diameter 30
Z1 12inc
DXY 40%
DZ 5
UXY 0mm
UZ 0
Insertion Helical
EP 1.0
ER 2.0
You also program the 4 countersinks 16 and 4 deep using a circular pocket and repeating
positions 1, 2 and 4.
Milling
7.17.3 Results/simulation test
Figure 7-5 Programming graphics
Figure 7-6 Machining schedule
Milling
Program test by means of simulation

During simulation, the current program is calculated in its entirety and the result displayed in
graphic form.
Figure 7-7 3D view
Milling
7.17.4 G code machining program
G17 G54 G71

WORKPIECE(,,"","BOX",112,1,-20,-100,-2.5,-2.5,182.5,182.5)
;****************Tool change****************
T="FACING TOOL" D1 M6
G95 FZ=0.1 S3000 M3 M8
CYCLE61(50,1,1,0,-2.5,-2.5,185,185,2,80,0,0.1,31,0,1,10)
G0 Z200 M9
;****************Tool change****************
T="MILLER20" D1 M6
G95 FZ=0.14 S3900 M3 M8
CYCLE76(50,0,1,,20,180,180,10,0,0,0,5,0,0,0.14,0.14,0,1,185,185,1,2,2100,1,101)
;CYCLE62(,2,"MA1","MA0")
CYCLE62(,2,"E_LAB_A_PART_4_POCKET","E_LAB_E_PART_4_POCKET")
CYCLE62(,2,"E_LAB_A_PART_4_ISLAND","E_LAB_E_PART_4_ISLAND")
CYCLE63("PART_4_GEN_01",11,50,0,1,10,0.1,0.3,40,3.5,0,0,0,0,0,2,1,15,1,2,,,,0,101,111)
G0 Z200 M9
;****************Tool change****************
T="MILLER10" D1 M6
G95 FZ=0.04 S8500 M3 M8
POCKET3(50,0,1,4,70,40,10,90,60,15,4,0,0,0.04,0.2,0,21,40,8,3,15,2,1,0,1,2,11100,11,111)
POCKET3(50,-4,1,2,35,20,6,90,60,15,2,0,0,0.04,0.2,0,31,40,8,3,15,10,2,0,1,2,11100,11,111)
G0 Z200 M9
;****************Tool change****************
T="MILLER8" D1 M6
G95 FZ=0.018 S9000 M3 M8
SLOT2(50,0,1,,3,1,180,10,85,135,40,180,90,0.01,0.018,3,0,0,2001,0,0,0,,0,1,2,100,1001,101)
G0 Z200 M9
;****************Tool change****************
T="CENTERING TOOL10" D1 M6
G94 F1000 S12000 M3 M8
MCALL CYCLE81(50,-10,1,5,,0,10,1,11)
POS_1: CYCLE802(111111111,111111111,15,15,165,15,165,165,15,165,,,,,,,,,,,0,0,1)
MCALL
G0 Z200 M9
;****************Tool change****************
T="DRILL10" D1 M6
G94 F500 S1600 M3 M8
MCALL CYCLE82(50,-10,1,-25,,0,0,1,12)
REPEATB POS_1 ;#SM
MCALL
G0 Z200 M9
;****************Tool change****************
Milling
T="MILLER8" D1 M06
G95 FZ=0.018 S12000 M3 M8
POCKET4(50,-10,1,12,30,85,135,5,0,0,0.018,0.01,0,21,40,9,15,2,1,0,1,2,10100,111,111)
MCALL POCKET4(50,-10,1,4,16,0,0,5,0,0,0.018,0.018,0,11,40,9,15,0,2,0,1,2,10100,111,111)
REPEATB POS_1 ;#SM
MCALL
G0 Z200 M9
;****************Tool change****************
;Contour chamfering
T="CENTERING TOOL10" D1 M6
G94 F500 S8000 M3 M8
CYCLE62(,2,"E_LAB_A_PART_4_ISLAND","E_LAB_E_PART_4_ISLAND")
CYCLE72("",100,0,1,20,2,0.5,0.5,500,100,305,41,1,0,0.1,1,0,0,0.3,2,101,1011,101)
POCKET3(50,0,1,4,70,40,10,90,60,15,4,0,0,500,0.2,0,25,40,8,3,15,2,1,0,0.3,2,11100,11,111)
POCKET3(50,-4,1,2,35,20,6,90,60,15,2,0,0,500,0.2,0,35,40,8,3,15,10,2,0,0.3,2,11100,11,111)
SLOT2(50,0,1,,3,1,180,10,85,135,40,180,90,0.01,500,3,0,0,2005,0,0,0,,0,0.3,2,100,1001,101)
POCKET4(50,-10,1,12,30,85,135,5,0,0,500,0.01,0,15,40,9,15,0,2,0,0.3,2,10100,111,111)
MCALL POCKET4(50,-10,1,4,16,0,0,5,0,0,500,0.025,0,15,40,9,15,0,2,0,0.3,4,10100,111,111)
REPEATB POS_1 ;#SM
MCALL
G0 Z200 M9
M30
;*******************Contour********************
E_LAB_A_PART_4_POCKET: ;#SM Z:5
;#7__DlgK contour definition begin - Don't change!;*GP*;*RO*;*HD*
G17 G90 DIAMOF;*GP*
G0 X-10 Y-10 ;*GP*
G1 X190 ;*GP*
Y190 ;*GP*
X-10 ;*GP*
Y-10 ;*GP*
;CON,0,0.0000,4,4,MST:0,0,AX:X,Y,I,J;*GP*;*RO*;*HD*
;S,EX:-10,EY:-10;*GP*;*RO*;*HD*
;LR,EX:190;*GP*;*RO*;*HD*
;LU,EY:190;*GP*;*RO*;*HD*
;LL,EX:-10;*GP*;*RO*;*HD*
;LA,EX:-10,EY:-10;*GP*;*RO*;*HD*
;#End contour definition end - Don't change!;*GP*;*RO*;*HD*
E_LAB_E_PART_4_POCKET:
;
E_LAB_A_PART_4_ISLAND: ;#SM Z:2
;#7__DlgK contour definition begin - Don't change!;*GP*;*RO*;*HD*
G17 G90 DIAMOF;*GP*
G0 X90 Y25 ;*GP*
G1 X25 CHR=15 ;*GP*
Milling
Y115 RND=20 ;*GP*

X15 Y135 ;*GP*
Y155 RND=10 ;*GP*
X60 RND=15 ;*GP*
Y135 ;*GP*
G3 X110 I=AC(85) J=AC(135) ;*GP*
G1 Y155 RND=15 ;*GP*
X143.162 ;*GP*
X165 Y95 ;*GP*
X155 Y77.679 RND=28 ;*GP*
Y40 ;*GP*
X140 Y25 ;*GP*
X90 ;*GP*
;CON,0,0.0000,14,14,MST:0,0,AX:X,Y,I,J;*GP*;*RO*;*HD*
;S,EX:90,EY:25;*GP*;*RO*;*HD*
;LL,EX:25;*GP*;*RO*;*HD*
;F,LFASE:15;*GP*;*RO*;*HD*
;R,RROUND:20;*GP*;*RO*;*HD*
;LA,EX:15,EY:135;*GP*;*RO*;*HD*
;LR,EX:60;*GP*;*RO*;*HD*
;LD,EY:135;*GP*;*RO*;*HD*
;ACCW,EX:110,RAD:25;*GP*;*RO*;*HD*
;LU,EY:155,AT:0;*GP*;*RO*;*HD*
;LR;*GP*;*RO*;*HD*
;LA,EX:165,EY:95,ASE:290;*GP*;*RO*;*HD*
;LA,EX:155,ASE:240;*GP*;*RO*;*HD*
;LD;*GP*;*RO*;*HD*
;LA,EX:140,EY:25,ASE:225;*GP*;*RO*;*HD*
;LA,EX:90,EY:25;*GP*;*RO*;*HD*
;#End contour definition end - Don't change!;*GP*;*RO*;*HD*
E_LAB_E_PART_4_ISLAND:
Milling
Programming technological functions (cycles) 8
8.1 Drilling
8.1.1 General
General geometry parameters

Retraction plane RP and reference point Z0
Normally, reference point Z0 and retraction plane RP have different values. The cycle
assumes that the retraction plane is in front of the reference point.
Note
If the values for reference point and retraction planes are identical, a relative depth
specification is not permitted. Error message "Reference plane defined incorrectly" is
output and the cycle is not executed.
This error message is also output if the retraction plane is located after the reference
point, i.e. its distance to the final drilling depth is smaller.
Safety clearance SC
Acts in relation to the reference point. The direction in which the safety clearance is active
is automatically determined by the cycle.
Drilling depth
Depending on the selection of the drill shank or drill tip or the centering diameter, the
programmed drilling depth refers to the following for cycles with a selection field:
Tip (drilling depth in relation to the tip)
The drill is inserted into the workpiece until the drill tip reaches the value programmed
for Z1.
Shank (drilling depth in relation to the shank)
The drill is inserted into the workpiece until the drill shank reaches the value
programmed for Z1. The angle entered in the tool list is taken into account.
Diameter (centering in relation to the diameter, only for CYCLE81)
The diameter of the centering hole is programmed at Z1. In this case, the tip angle of
the tool must be specified in the tool list. The drill is inserted into the workpiece until
the specified diameter is reached.
Milling
Programming technological functions (cycles)
8.1 Drilling
Drilling positions
The cycle assumes the tested hole coordinates of the plane.
The hole centers should therefore be programmed before or after the cycle call as follows
(see also Section, Cycles on single position or position pattern (MCALL)):
A single position should be programmed before the cycle call
Position patterns (MCALL) should be programmed after the cycle call
as drilling pattern cycle (line, circle, etc.) or
as a sequence of positioning blocks for the hole centers
8.1.2 Centering (CYCLE81)
8.1.2.1 Function
Function
With the "Centering" function, the tool drills with the programmed spindle speed and feedrate
either:
Down to the programmed final drilling depth or
So deep until the programmed diameter of the centering is reached
The tool is retracted after a programmed dwell time has elapsed.
Approach/retraction
1. The tool moves with G0 to safety clearance of the reference point.
2. Inserted into the workpiece with G1 and the programmed feedrate F until the depth or the
centering diameter is reached.
3. On expiry of a dwell time DT, the tool is retracted at rapid traverse G0 to the retraction
plane.
Procedure
1. The part program or ShopMill program to be processed has been

created and you are in the editor.
2. Press the "Drilling" softkey.
3. Press the "Center" softkey.

Milling
8.1 Drilling

RP Retraction plane mm D Cutting edge number
SC Safety clearance mm F Feedrate mm/min
mm/rev
S/V Spindle speed or constant rpm
cutting rate m/min

Machining Single position
position (only
for G code) Drill hole at programmed position
Position pattern
Position with MCALL

Z0 (only for G Reference point Z mm
code)
Centering Diameter (centered with reference to the diameter)
The angle for the center drill entered in the tool list is applied.
Tip (centered with reference to the depth)
The drill is inserted into the workpiece until the programmed insertion depth is
reached.
It is inserted into the workpiece until the diameter is correct. - (for diameter centering mm
only)
Z1 Drilling depth (abs) or drilling depth in relation to Z0 (inc) mm
It is inserted into the workpiece until it reaches Z1. - (for tip centering only)
DT Dwell time (at final drilling depth) in seconds s
rev
Dwell time (at final drilling depth) in revolutions
Milling
8.1 Drilling
8.1.3 Drilling (CYCLE82)
8.1.3.1 Function
Function
With the "Drilling" function, the tool drills with the programmed spindle speed and feedrate
down to the specified final drilling depth (shank or tip).
The tool is retracted after a programmed dwell time has elapsed.
Approach/retraction
2. The tool is inserted into the workpiece with G1 and the programmed feedrate F until it
reaches the programmed final depth Z1.
3. When a dwell time DT expires, the tool is retracted at rapid traverse G0 to the retraction
plane.
Procedure

3. Press the "Drilling Reaming" softkey.

The "Drilling" input window opens.

mm/rev
cutting rate m/min
Milling
8.1 Drilling

position (only
Position pattern
Position with MCALL

code)
Drilling depth Shank (drilling depth in relation to the shank)
The drill is inserted into the workpiece until the drill tip reaches the value
programmed for Z1.
It is inserted into the workpiece until it reaches Z1.
rev
8.1.4 Reaming (CYCLE85)
8.1.4.1 Function
Function
With the "Reaming" cycle, the tool is inserted in the workpiece with the programmed spindle
speed and the feedrate programmed at F.
If Z1 has been reached and the dwell time expired, the reamer is retracted at the
programmed retraction feedrate to the retraction plane.
Approach/retraction
2. The tool is inserted into the workpiece with the programmed feedrate F until it reaches
the final depth Z1.
3. Dwell time DT at final drilling depth.
4. Retraction to retraction plane with programmed retraction feedrate FR.
Milling
8.1 Drilling
Procedure

3. Press the "Drilling Reaming" softkey.
4. Press the "Reaming" softkey

The "Reaming" input window opens.

mm/rev
F Feedrate * S/V Spindle speed or constant rpm
cutting rate m/min

position (only
Position pattern
Position with MCALL

code)
FR (only for G Feedrate during retraction *
code)
FR (only for Feedrate during retraction mm/min
ShopMill) mm/rev
It is inserted into the workpiece until it reaches Z1. - (for tip centering only)
rev
* Unit of feedrate as programmed before the cycle call
Milling
8.1 Drilling
8.1.5 Deep-hole drilling (CYCLE83)
8.1.5.1 Function
Function
With the "Deep-hole drilling" cycle, the tool is inserted in the workpiece with the programmed
spindle speed and feedrate in several infeed steps until the depth Z1 is reached. The
following can be specified:
Number of infeed steps constant or decreasing (via programmable degression factor)
Chip breaking without lifting or swarth removal with tool retraction
Feedrate factor for 1st infeed to reduce the feedrate or increase the feedrate (e.g. if a
hole has already be predrilled)
Dwell times
Depth in relation to drill shank of drill tip
Approach/retraction during chipbreaking

2. The tool drills with the programmed spindle speed and feedrate F = F FD1 [%] up to the
1st infeed depth.
3. Dwell time at drilling depth DTB.
4. The tool is retracted by retraction distance V2 for chipbreaking and drills up to the next
infeed depth with programmed feedrate F.
5. Step 4 is repeated until the final drilling depth Z1 is reached.
6. Dwell time at final drilling depth DT.
7. The tool retracts to the retraction plane at rapid traverse.
Approach/retraction during stock removal

2. The tool drills with the programmed spindle speed and feedrate F = F FD1 [%] up to the
1st infeed depth.
3. Dwell time at drilling depth DTB.
4. The tool retracts from the workpiece for the stock removal with rapid traverse to the safety
clearance.
5. Dwell time at starting point DTS.
6. Approach of the last drilling depth with G0, reduced by the clearance distance V3.
7. Drilling is then continued to the next drilling depth.
Milling
8.1 Drilling
8. Steps 4 to 7 are repeated until the programmed final drilling depth Z1 is reached.
9. The tool retracts to the retraction plane at rapid traverse.
Procedure

3. Press the "Deep-hole drilling" softkey.

The "Deep-hole Drilling" input window opens.

mm/rev
S/V Spindle speed or constant cutting rpm
rate m/min

position
Drill hole at programmed position.
(only for G
code) Position pattern
Position with MCALL
code)
Machining Stock removal
The drill is retracted from the workpiece for stock removal.

Chipbreaking
The drill is retracted by the retraction distance V2 for chipbreaking.

Drilling depth Shank (drilling depth in relation to the shank)
The drill is inserted into the workpiece until the drill tip reaches the value
programmed for Z1.
Milling
8.1 Drilling

D - (only for G 1. Drilling depth (abs) or 1st drilling depth in relation to Z0 (inc) mm
code)
D - (only for Maximum depth infeed mm
ShopMill)
FD1 Percentage for the feedrate for the first infeed %
DF Infeed:
Amount for each additional infeed mm
%
Percentage for each additional infeed
DF = 100%: Infeed increment remains constant
DF < 100%: Infeed increment is reduced in direction of final drilling depth.
Example: Last infeed was 4 mm; DF is 80%
next infeed = 4 x 80% = 3.2 mm
next infeed = 3.2 x 80% = 2.56 mm etc.
V1 Minimum infeed - (only for DF in %) mm
Parameter V1 is only provided if DF<100 has been programmed.
If the infeed increment becomes very small, a minimum infeed can be programmed in
parameter "V1".
V1 < Infeed increment: The tool is inserted by the infeed increment
V1 > Infeed increment: The tool is inserted by the infeed value programmed under V1.
V2 Retraction distance after each machining step (for chipbreaking only) mm
Distance by which the drill is retracted for chipbreaking.
V2 = 0: The tool is not retracted but is left in place for one revolution.
Clearance Manual
distance
The clearance distance must be entered manually.
(for stock removal
only) Automatic
The clearance distance is calculated by the cycle.

DTB - (only for G Dwell time at drilling depth in seconds s
code) rev
Dwell time at drilling depth in revolutions
DT Dwell time at final drilling depth in seconds s
rev
Dwell time at final drilling depth in revolutions
DTS - (only for G Dwell time for stock removal in seconds s
code) rev
Dwell time for stock removal in revolutions
Milling
8.1 Drilling
8.1.6 Boring (CYCLE86)
8.1.6.1 Function
Function
With the "Boring" cycle, the tool approaches the programmed position in rapid traverse,
allowing for the retraction plane and safety clearance. It is then inserted into the workpiece at
the feedrate programmed under F until it reaches the programmed depth (Z1). There is an
oriented spindle stop with the SPOS command. After the dwell time has elapsed, the tool is
retracted either with or without lift of the tool.
Lift
For "lift off contour", the retraction distance D and the tool orientation angle can either be
defined via machine data or in the parameter screen. If both parameters are pre-assigned
via machine data, they do not appear in the parameter screen.
NOTICE
The "Boring" cycle can be used if the spindle to be used for the boring operation is
technically able to go into position-controlled spindle operation.
Approach/retraction
2. Travel to the final drilling depth with G1 and the speed and feedrate programmed before
the cycle call.
3. Dwell time at final drilling depth.
4. Oriented spindle hold at the spindle position programmed under SPOS.
5. With the "Lift" selection, the cutting edge retracts from the hole edge with G0 in up to
three axes.
6. Retraction with G0 to the safety clearance of the reference point.
7. Retraction to retraction plane with G0 to drilling position in the two axes of the plane
(coordinates of the hole center point).
Milling
8.1 Drilling
Procedure

3. Press the "Boring" softkey.

The "Boring" input window opens.

mm/rev
cutting rate m/min

position (only
Position pattern
Position with MCALL

code)
DIR Direction of rotation
(only for G
code)


DT Dwell time at final drilling depth in seconds s
rev
Dwell time at final drilling depth in revolutions
SPOS Spindle stop position Degrees
Lift mode Do not lift off contour
The cutting edge is not fully retracted, but traverses back to the retraction plane.
Lift
The cutting edge retracts from the edge of the hole and then retracts to the safety
clearance from the reference point and then positions at the retraction plane and
hole center point.
DX (only G Code) Retraction distance in the X direction (incremental) - (for lift only) mm
DY (only G code) Retraction distance in the Y direction (incremental) - (for lift only) mm
Milling
8.1 Drilling

DZ (only G code) Retraction distance in the Z direction (incremental) - (for lift only) mm
D (only ShopMill) Retraction distance (incremental) - (for lift only) mm
8.1.7 Tapping (CYCLE84, 840)
8.1.7.1 Function
Function
You can machine an internal thread with the "tapping" cycle.
The tool moves to the safety clearance with the active speed and rapid traverse. The spindle
stops, spindle and feedrate are synchronized. The tool is then inserted in the workpiece with
the programmed speed (dependent on %S).
You can choose between drilling in one cut, chipbreaking or retraction from the workpiece for
stock removal.
Depending on the selection in the "Compensating chuck mode" field, alternatively the
following cycle calls are generated:
With compensating chuck: CYCLE840
Without compensating chuck: CYCLE84
When tapping with compensating chuck, the thread is produced in one cut. CYCLE84
enables tapping to be performed in several cuts, when the spindle is equipped with a
measuring system.
Approach/retraction - CYCLE840 - with compensating chuck

2. The tool drills with G1 and the programmed spindle speed and direction of rotation to
depth Z1. The feedrate F is calculated internally in the cycle from the speed and pitch.
3. The direction of rotation is reversed.
4. Dwell time at final drilling depth.
5. Retraction to safety clearance with G1.
6. Reversal of direction of rotation or spindle stop.
7. Retraction to retraction plane with G0.
Milling
8.1 Drilling
Approach/retraction - CYCLE84 - without compensating chuck

One cut:
1. Travel with G0 to the safety clearance of the reference point.
2. Spindle is synchronized and started with the programmed speed (dependent on %S).
3. Tapping with spindle-feedrate synchronization to Z1.
4. Spindle stop and dwell time at drilling depth.
5. Spindle reverse after dwell time has elapsed.
6. Retraction with active spindle retraction speed (dependent on %S) to safety clearance
7. Spindle stop.
8. Retraction to retraction plane with G0.
Approach/retraction during stock removal

1. The tool drills at the programmed spindle speed S (dependent on %S) as far as the first
infeed depth (maximum infeed depth D).
2. Spindle stop and dwell time DT.
3. The tool retracts from the workpiece for the stock removal with spindle speed SR to the
safety clearance.
5. The tool then drills with spindle speed S as far as the next infeed depth.
7. On expiry of dwell time DT, the tool is retracted with spindle speed SR to the safety
clearance. The spindle stops and retracts to the retraction plane.
Approach/retraction during chipbreaking

1. The tool drills at the programmed spindle speed S (dependent on %S) as far as the first
infeed depth (maximum infeed depth D).
3. The tool retracts by the retraction distance V2 for chipbreaking.
4. The tool then drills to the next infeed depth at spindle speed S (dependent on %S).
6. On expiry of dwell time DT, the tool is retracted with spindle speed SR to the safety
clearance. The spindle stops and retracts to the retraction plane.
Milling
8.1 Drilling
Procedure

3. Press the "Thread" and "Tap" softkeys.

The "tapping" input window opens.

cutting rate m/min

Compensating With compensating chuck
chuck mode
Without compensating chuck

position (only
Position pattern
Position with MCALL

code)
Z1 End point of the thread (abs) or thread length (inc) mm
Machining - (with You can select the following technologies for tapping:
compensating
With encoder
chuck)
(only for G code) Tapping with spindle encoder
Without encoder
Tapping without spindle encoder; selection:
- Define "Pitch" parameter

SR (only for Spindle speed for retraction - (only for S) rev/min
ShopMill)
VR (only for Constant cutting rate for retraction (only for V) m/min
ShopMill)
Milling
8.1 Drilling

Pitch - (only User input
machining without
encoder) Pitch results from the input
(only for G code) Active feedrate
Pitch results from the feedrate
Thread Direction of rotation of the thread

Right-hand thread
(only for G code) Left-hand thread
(only in mode "without compensating chuck")
Table Thread table selection:
Without
ISO metric
Whitworth BSW
Whitworth BSP
UNC
Selection Selection of table value: e.g.
M3; M10; etc. (ISO metric)
W3/4"; etc. (Whitworth BSW)
G3/4"; etc. (Whitworth BSP)
1" - 8 UNC; etc. (UNC)
P Pitch ...
- (selection in MODULUS: MODULUS = Pitch/ MODULUS
option only for Turns/"
in turns per inch: Used with pipe threads, for example.
table selection
"without") When entered per inch, enter the integer number in front of the decimal point in the
first parameter field and the figures after the decimal point as a fraction in the
mm/rev
second and third field.
in/rev
in mm/rev
in inch/rev
The pitch is determined by the tool used.
S Starting angle offset - (for rigid tapping only) Degrees
(only for G code)
S Spindle speed - (for rigid tapping only) rev/min
(only for G code)
1 cut
(not for G code
The thread is drilled in one cut without stopping
"with
compensating Chipbreaking
chuck")
The drill is retracted by the retraction amount V2 for chipbreaking.
Stock removal
The drill is retracted from the workpiece for stock removal.
Milling
8.1 Drilling

D Maximum depth infeed - (only when used without compensating chuck, stock removal mm
or chipbreaking)
Retraction Retraction distance - (for chipbreaking only)
Manual
Retraction distance after each machining step (V2)

Automatic
Without retraction distance after each machining step

V2 Retraction distance after each machining step (only without compensating chuck, mm
chipbreaking and manual retraction)
Distance by which the drill is retracted for chipbreaking.
V2 = automatic: The tool is retracted by one revolution.
DT (only for G Dwell time at final drilling depth in seconds s
code)
SR (only for G Spindle speed for retraction - (only for when a compensating chuck is not used) rev/min
code)
SDE (only for Direction of rotation after end of cycle:
G code)

Technology Yes
Exact stop
Precontrol
Acceleration
Spindle
No
Exact stop (only Behavior the same as it was before the cycle was called
for technology,
G601: Block advance for exact stop fine
yes)
G602: Block advance for exact stop coarse
G603: Block advance if the setpoint has been reached
Precontrol (only Behavior the same as it was before the cycle was called
for technology,
FFWON: with precontrol
yes)
FFWOF: without precontrol
Acceleration (only Behavior the same as it was before the cycle was called
for technology,
SOFT: Jerk-limited (soft) acceleration of the axes
yes)
BRISK: Abrupt acceleration of the axes
DRIVE: Reduced axis acceleration
Spindle (only for Speed controlled: Spindle for MCAL; speed controlled operation
technology, yes)
Position controlled: Spindle for MCALL; position controlled operation
Milling
8.1 Drilling
8.1.8 Drill and thread milling (CYCLE78)
8.1.8.1 Function
Function
You can use a drill and thread milling cutter to manufacture an internal thread with a specific
depth and pitch in one operation. This means that you can use the same tool for drilling and
thread milling, a change of tool is superfluous.
The thread can be machined as a right- or left-hand thread.
Approach/retraction
1. The tool traverses with rapid traverse to the safety clearance.
2. If pre-drilling is required, the tool traverses at a reduced drilling feedrate to the predrilling
depth defined in a setting data (ShopMill/ShopTurn). When programming in G code, the
predrilling depth can be programmed using an input parameter.
1. The tool bores at drilling feedrate F1 to the first drilling depth D. If the final drilling depth
Z1 is not reached, the tool will travel back to the workpiece surface in rapid traverse for
stock removal. Then the tool will traverse with rapid traverse to a position 1 mm above the
drilling depth previously achieved - allowing it to continue drilling at drill feedrate F1 at the
next infeed. Parameter "DF" is taken into account from the 2nd infeed and higher (refer to
the table "Parameters").
2. If another feedrate FR is required for through-boring, the residual drilling depth ZR is
drilled with this feedrate.
3. If required, the tool traverses back to the workpiece surface for stock removal before
thread milling with rapid traverse.
4. The tool traverses to the starting position for thread milling.
5. The thread milling is carried out (climbing, conventional or conventional + climbing) with
milling feedrate F2. The thread milling acceleration path and deceleration path is
traversed in a semicircle with concurrent infeed in the tool axis.
Milling
8.1 Drilling
Procedure

3. Press the "Thread" and "Drill and thread mill" softkeys.

The "Drilling and thread milling" input window opens.

mm/rev
cutting rate m/min

position (only
Position pattern
Position with MCALL

F1 Drilling feedrate mm/min
(only for G-code) mm/rev

code)
Z1 Thread length (inc) or end point of the thread (abs) mm
D Maximum depth infeed mm
D Z1: Infeed to the final drilling depth
D < Z1: Several infeeds with stock removal
Milling
8.1 Drilling

DF Percentage for each additional infeed %
DF=100: Infeed increment remains constant
DF<100: Amount of infeed is reduced in direction of final drilling depth Z1
Example: last infeed 4 mm; DF 80% mm

next infeed = 4 x 80% = 3.2 mm
next but one infeed = 3.2 x 80% = 2.56 mm etc.

Amount for each additional infeed
V1 Minimum infeed - (only for DF, percentage for each additional infeed) mm
Parameter V1 is only provided if DF<100 has been programmed.
If the infeed increment becomes very small, a minimum infeed can be programmed in
parameter "V1".
V1 < Infeed increment: The tool is inserted by the infeed increment
V1 > Infeed increment: The tool is inserted by the infeed value programmed under
V1.
Predrilling Predrilling with reduced feedrate
Yes
No
The reduced drilling feedrate is obtained as follows:
Drilling feedrate F1 < 0.15 mm/rev: Predrilling feedrate = 30% of F1
Drilling feedrate F1 0.15 mm/U: Predrilling feedrate = 0.1 mm/rev
AZ (only for G Predrilling depth with reduced drilling feedrate (inc) - ("yes", only for pre-drilling) mm
code)
Through boring Remaining drilling depth with drilling feedrate
Yes
No
ZR Residual drilling depth for through boring - ("yes", only for through boring) mm
FR Drilling feedrate for remaining drilling depth - ("yes", only for through boring) mm/min
mm/rev
Stock removal Stock removal before thread milling
Yes
No
Return to workpiece surface for stock removal before thread milling.
Thread Direction of rotation of the thread
Right-hand thread
Left-hand thread
F2 Feedrate for thread milling mm/min
mm/tooth
Milling
8.1 Drilling

without
ISO metric
Whitworth BSW
Whitworth BSP
UNC
Selection - (not Selection of table value: e.g.
for table
"Without")
N1" - 8 UNC; etc. (UNC)
P Pitch ...
- (selection MODULUS
in MODULUS: MODULUS = Pitch/
option only for
in turns per inch: Used with pipe threads, for example. Turns/"
table selection
"without")
When entered per inch, enter the integer number in front of the decimal point in the
mm/rev
in/rev
in mm/rev
in inch/rev
The pitch is determined by the tool used.
Z2 Retraction amount before thread milling mm
The thread depth in the direction of the tool axis is defined using Z2. Z2 is relative to
the tool tip.
Nominal diameter mm
Milling direction Climb milling: Mill thread in one cycle.
Conventional milling: Mill thread in one cycle.
Climbing - conventional: Mill thread in two cycles: rough cutting is performed by
conventional milling with defined allowances, then finish cutting is performed by
climb milling with milling feedrate FS.
FS Finishing feedrate - (only for climbing - conventional milling) mm/min
mm/tooth
Milling
8.1 Drilling
8.1.9 Positioning and position patterns
Function
After you have programmed the technology (cycle call), you must program the positions.
Several position patterns are available:
Arbitrary positions
Position on a line, on a grid or frame
Position on a full or pitch circle
Several position patterns can be programmed in succession. They are executed in the order
in which you program them.
Note
The number of positions that can be programmed in the one "Positions" step is limited to a
maximum of 400!
Programming a position pattern in ShopMill

Several position patterns can be programmed in succession (up to 20 technologies and
position patterns in total). They are executed in the order in which you program them.
The programmed technologies and subsequently programmed positions are automatically
linked by the control.
Displaying and hiding positions

You can display or hide any positions(Chapter "Displaying and hiding positions".
Rotary axis
If an A or B axis is set up on your machine, this is supported during drilling (any position
pattern, full circle, and pitch circle).
You set as to which rotary axis is listed as selection in position patterns.
If the machine has an A or B axis, it makes sense to define a work offset with
X / Y = end face of the cylinder (X for an A axis / Y for a B axis)
X / Y = center point of the cylinder (Y for an A axis / X for a B axis)
Z = center point of the cylinder
The "cylinder" in this case refers to any part that is clamped in the A/B axis.
Milling
8.1 Drilling
Cylinder surface transformation

When working with the cylinder surface transformation, please note that the A axis or B axis
is not supported in all cases. Programming of any position in the XYA plane is not possible
while cylinder surface transformation is active.
Note
A work offset in the rotary axis A or B is effective even while cylinder surface transformation
is active.
Approach/retraction
1. Within a position pattern, or while approaching the next position pattern, the tool is
retracted to the retraction plane and the new position or position pattern is then
approached at rapid traverse.
2. With technological follow-up operations (e.g. centering - drilling - tapping), the respective
drilling cycle must programmed after calling the next tool (e.g. drill) and immediately
afterwards the call of the position pattern to be machined.
Tool traverse path

ShopMill
The programmed positions are machined with the previously programmed tool (e.g.
center drill). Machining of the positions always starts at the reference point. In the case of
a grid, machining is performed first in the direction of the 1st axis and then meandering
back and forth. The frame and hole circle are machined counterclockwise.
G codes
For G code, for lines/frames/grids, a start is always made at the next corner of the frame
or grid or the end of the row. The frame and hole circle are machined counterclockwise.
Milling
8.1 Drilling
8.1.10 Arbitrary positions (CYCLE802)
Function
The "Arbitrary positions" cycle allows you to program positions freely, i.e. rectangular or
polar. Individual positions are approached in the order in which you program them. Press
softkey "Delete all" to delete all positions programmed in X/Y.
Rotary axis
XA plane
You program in XA to prevent the Y axis moving during machining.
To ensure that the holes point to the center of the "Cylinder", you must first position the Y
axis centrally above the "Cylinder".
<
=
<
<
Milling
8.1 Drilling
XYA plane
You program in XYA if the Y axis should also move during machining. A value can be
specified for each position. In addition to the possibilities of XA, the following is also possible,
for example.
=
< <
<
Procedure

3. Press the "Positions" softkey.

The "Positions" input window opens.

LAB - (only for G Repeat jump label for position
code)
PL - (only for G Machining plane
code)
Milling
8.1 Drilling

Axes Selection of the participating axes
XY (1st and 2nd axis of the plane)
(only for ShopMill) XA (1st rotary axis and assigned linear axis)
XYA (1st rotary axis and both axes of the plane)
YB (2nd rotary axis and assigned linear axis)
XYB (2nd rotary axis and both axes of the plane)
Note:
Rotary axes are only displayed in the selection field if they have been released for use
in the position pattern.
Please observe the information provided by your machine manufacturer.
Selection - Coordinate system (only available for axis selection XY) mm
(only for ShopMill)
Rectangular
Polar
Z0 Z coordinate of the reference point (abs) mm
(only for ShopMill)
(only for ShopMill) Axes: XY / coordinate system polar
XP X coordinate of the reference point pole (abs) mm
YP Y coordinate of the reference point pole (abs) mm
L0 Length (abs) distance of the 1st Position from the pole mm
C0 Angle (abs) Angle of the 1st position referred to the reference axis Degrees
L1 ... L7 Lengths of additional positions (abs or inc) mm
C1 ... C7 Angles of additional positions (abs or inc) Degrees
(only for ShopMill) Axes: XY / coordinate system right angled
X0 X coordinate of the 1st position (abs) mm
Y0 Y coordinate of the 1st position (abs) mm
X1 ... X8 X coordinate for further positions (abs. or inc.) mm
Y1 ... Y8 Y coordinate for further positions (abs. or inc.) mm
(only for G code) (only "right angled")
X1 ... X8 X coordinate of additional positions (abs or inc) mm
Y1 ... Y8 Y coordinate of additional positions (abs or inc) mm
(only for ShopMill) Axes: XA
A0 A coordinate (angle) of the 1st position (abs) Degrees
X1 ... X8 X coordinates of additional positions (abs or inc) mm
A1 ... A8 A coordinates (angle) of additional positions (abs or inc) mm
(only for ShopMill) Axes: YB
B0 B coordinate (angle) of the 1st position (abs) Degrees
Y1 ... Y8 Y coordinates of additional positions (abs or inc) mm
B1 ... B8 B coordinates (angle) of additional positions (abs or inc) mm
Milling
8.1 Drilling

(only for ShopMill) Axes: XYA
A0 A coordinate (angle) of the 1st position (abs) Degrees
A1 ... A5 A coordinates (angle) of additional positions (abs or inc) Degrees
(only for ShopMill) Axes: XYB
B0 B coordinate (angle) of the 1st position (abs) Degrees
B1 ... B5 B coordinates (angle) of additional positions (abs or inc) Degrees
8.1.11 Position pattern Line (HOLES1), Grid or Frame (CYCLE801)
Function
You can program the following pattern using the "Position pattern" cycle:
Line (HOLES1)
In the "Line" selection option you can program any number of positions at equal distances
along a line.
Grid (CYCLE801)
You can use the "Grid" selection option to program any number of positions spaced at an
equal distance along one or several parallel lines.
If you want to program a rhombus-shaped grid, enter angle X or Y.
Frame (CYCLE801)
You can use the "Frame" selection option to program any number of positions spaced at
an equal distance on a frame. The spacing may be different on both axes.
If you want to program a rhombus-shaped frame, enter angle X or Y.
Milling
8.1 Drilling
Procedure

3. Press the "Positions" and "Line" softkeys.

The "Position pattern" input window opens.

LAB Repeat jump label for position
(only for G code)
PL Machining plane
(only for G code)
Position pattern Selection option for the following patterns:
Line
(only for G code)
Grid
Frame
Z0 (only for Z coordinate of reference point Z (abs) mm
ShopMill)
X0 X coordinate of the reference point X (abs) mm
This position must be programmed absolutely in the 1st call.
Y0 Y coordinate of the reference point Y (abs) mm
This position must be programmed absolutely in the 1st call.
0 Angle of rotation of the line referred to the X axis Degrees
Positive angle: Line is rotated counterclockwise.
Negative angle: Line is rotated clockwise.
Line
L0 Distance of the 1st position to reference point mm
L Distance between the positions mm
N Number of positions
Grid or frame
X Shear angle X Degrees
Y Shear angle Y Degrees
L1 Distance between columns mm
L2 Distance between rows mm
N1 Number of columns
N2 Number of rows
Milling
8.1 Drilling
8.1.12 Circle position pattern (HOLES2)
Function
You can program holes on a full circle or pitch circle with defined radius with the "Circle
position pattern" cycle. The basic angle of rotation (0) for the 1st position is relative to the X
axis. The control calculates the angle of the next hole position as a function of the total
number of holes. The angle it calculates is identical for all positions.
The tool can approach the next position along a linear or circular path.
Procedure

3. Press the "Positions" and "Circle" softkeys.

The "Position circle" input window opens.

LAB Repeat jump label for position
(only for G code)
PL Machining plane
(only for G code)
Axes Selection of the participating axes
(only for ShopMill) XY (1st and 2nd axis of the plane)
XA (1st rotary axis and assigned linear axis)
YB (2nd rotary axis and assigned linear axis)
Note:
Rotary axes are only displayed in the selection field if they have been released for use
in the position pattern.
Please observe the information provided by your machine manufacturer.
Circular pattern Selection option for the following patterns:
Pitch circle
Full circle
Z0 (only for Z coordinate of the reference point mm
ShopMill)
Milling
8.1 Drilling

For G code and ShopMill axes XY (right angled)
X0 X coordinate of the reference point X (abs) mm
Y0 Y coordinate of the reference point Y (abs) mm
0 Starting angle for first position. Degrees
Positive angle: Full circle is rotated counterclockwise.
Negative angle: Full circle is rotated in clockwise direction.
1 Advance angle - (for pitch circle pattern only) Degrees
After the first hole has been drilled, all further positions are advanced by this angle.
Positive angle: Further positions are rotated counterclockwise.
Negative angle: Further positions are rotated clockwise.
Radius
R Number of positions mm
N Positioning motion between the positions
Positioning
Straight line
Next position is approached linearly at rapid traverse.

Circle
Next position is approached along a circular path at the feedrate defined in the
machine data.
(only for ShopMill) Axes: XA
X0 X coordinate of the reference point (abs) mm
A0 Start angle of the A axis (abs) Degrees
A1 Advance angle of the A axis (inc) - (for pitch circle pattern only) Degrees
(only for ShopMill) Axes: YB
Y0 Y coordinate of the reference point (abs) mm
B0 Start angle of the B axis (abs) Degrees
B1 Advance angle of the B axis (inc) - (for pitch circle pattern only) Degrees
Milling
8.1 Drilling
8.1.13 Displaying and hiding positions
Function
You can hide any positions in the following position patterns:
Position pattern line
Position pattern grid
Position pattern frame
Full circle position pattern (only for axis selection XY)
Pitch circle position pattern (only for axis selection XY)
The hidden positions are skipped when machining.
Display
The programmed positions of the position pattern are shown as follows in the programming
graphic:
x Position is activated = displayed (position is shown as a cross)

o Position deactivated = hidden (position shown as a circle)
Selecting positions
You have the option of either displaying or hiding positions - by activating the checkbox in
the displayed position table either using the keyboard or mouse.
Procedure

2. Press the "Drilling" and "Positions" softkeys.
3. Press the "Line/Grid/Frame" or "Full/Pitch Circle" softkeys.
Milling
8.1 Drilling
4. Press the "Hide position" softkey.

The "Hide position" window opens on top of the input form of the
position pattern. The positions are displayed in a table.
The numbers of the positions, their coordinates (X, Y) as well as a
checkbox with the state (activated = on / deactivated = off) are
displayed.
The selected position in the graphic is highlighted in color.
5. Using the mouse, select the required position and deactivate or activate
the checkbox in order to hide the position or display it again.
In the diagram, skipped positions are shown in the form of a circle and
displayed (active) positions are shown in the form of a cross.
Note: You have the option of selecting individual positions using the
<Cursor up> or <Cursor down> keys and hiding and displaying using
the <SELECT> key.
Display or hide all positions at once
1. Press the "Hide all" softkey to hide all positions.
2. Press the "Show all" softkey to display all positions again.
8.1.14 Repeating positions
Function
If you want to approach positions that you have already programmed again, you can do this
quickly with the function "Repeat position".
You must specify the number of the position pattern. The cycle automatically assigns this
number (for ShopMill). You will find this position pattern number in the work plan (program
view) or G-code program after the block number.
Milling
8.1 Drilling
Procedure

2. Press the "Drilling", and "Repeat position" softkeys.
The "Repeat positions" input window opens.
3. After you have entered the label or the position pattern number, e.g. 1,
press the "Accept" softkey. The position pattern you have selected is
then approached again.

LAB (only for G Repeat jump label for position
code)
Position (only for Enter the number of the position pattern
ShopMill)
Milling
8.2 Milling
8.2 Milling
8.2.1 Face milling (CYCLE61)
8.2.1.1 Function
Function
You can face mill any workpiece with the "Face milling" cycle.
A rectangular surface is always machined.
Workpieces with and without limits can be face-milled.
Approach/retraction
1. For vertical machining, the starting point is always at the top or bottom. For horizontal
machining, it is at the left or right.
The starting point is marked in the help display.
2. Machining is performed from the outside to the inside.
Machining type
The cycle makes a distinction between roughing and finishing:
Roughing:
Milling the surface
Tool turns above the workpiece edge
Finishing:
Milling the surface once
Tool turns at safety distance in the X/Y plane
Retraction of milling cutter
Depth infeed always takes place outside the workpiece.
For a workpiece with edge breaking, select the rectangular spigot cycle.
In face milling, the effective tool diameter for a tool of type "Milling cutter" is stored in a
machine data item.
Milling
8.2 Milling
Selecting the machining direction

Toggle the machining direction in the "Direction" field until the symbol for the required
machining direction appears.
Same direction of machining
Selecting limits
Press the respective softkey for the required limit.
Left
Top
Bottom
Right
The selected limits are shown in the help screen and in the broken-line graphics.
Procedure

2. Press the "Milling" softkey.
3. Press the "Face milling" softkey.

The "Face Milling" input window opens.


mm/tooth

cutting rate m/min
Milling
8.2 Milling

(roughing)
(finishing)
Direction Same direction of machining


The positions refer to the reference point:

X0 Corner point 1 in X mm
Y0 Corner point 1 in Y mm
Z0 Height of blank mm
X1 Corner point 2X (abs) or corner point 2X in relation to X0 (inc) mm
Y1 Corner point 2Y (abs) or corner point 2Y in relation to Y0 (inc) mm
Z1 Height of blank (abs) or height of blank in relation to Z0 (inc) mm
DXY Maximum plane infeed mm
Alternately, you can specify the plane infeed in %, as a ratio plane infeed (mm) to the %
milling cutter diameter (mm).
DZ Maximum depth infeed (for roughing only) mm
Note
The same finishing allowance must be entered for both roughing and finishing. The finishing
allowance is used to position the tool for retraction.
Milling
8.2 Milling
8.2.2 Rectangular pocket (POCKET3)
Function
You can mill any rectangular pocket with the "rectangular pocket milling" function.
The following machining variants are available:
Mill rectangular pocket from solid material.
Pre-drill rectangular pocket in the center first if, for example, the milling cutter does not
cut in the center (program the drilling, rectangular pocket and position program blocks in
succession).
Machine pre-machined rectangular pocket (see "Solid machining" parameter).
Depending on the dimensions of the rectangular pocket in the workpiece drawing, you can
select a corresponding reference point for the rectangular pocket.
Approach/retraction
1. The tool approaches the center point of the rectangular pocket in rapid traverse at the
height of the retraction plane and adjusts to the safety clearance.
2. The tool is inserted into the material according to the chosen strategy.
3. The rectangular pocket is always machined with the chosen machining type from inside
out.
4. The tool moves back to the safety clearance at rapid traverse.
Machining type
Roughing
During roughing, the individual planes of the rectangular pocket are machined one after
the other from center point until depth Z1 is reached.
Finishing
During finishing, the edge is always machined first. The rectangular pocket edge is
approached on the quadrant that joins the corner radius. In the last infeed, the base is
finished from the center out.
Finishing of edge
Edge finishing is performed in the same way as finishing, except that the last infeed
(finish base) is omitted.
Chamfering
Chamfering involves edge breaking at the upper edge of the rectangular pocket.
Milling
8.2 Milling
Procedure

3. Press the "Pocket" and "Rectangular pocket" softkeys.

The "Rectangular pocket" input window opens.


mm/tooth

cutting rate m/min
F Feedrate *

Reference point The following different reference point positions can be selected:
(center)
(bottom left)
(bottom right)
(top left)
(top right)
The reference point (highlighted in blue) is displayed in the Help screen.
(roughing)
(finishing)
edge (edge finishing)
Chamfering
Milling
8.2 Milling

position
Mill rectangular pocket to the programmed position (X0, Y0, Z0).
Position pattern
Position with MCALL

X0 Reference point X (single position only) mm
Y0 Reference point Y (single position only) mm
Z0 Reference point Z (single position only and G Code position pattern) mm
W Pocket width mm
L Pocket length mm
R Corner radius mm
0 Angle of rotation Degrees
Z1 Depth referred to Z0 (inc) or pocket depth (abs) - (only for , or edge) mm

%
Maximum plane infeed as a percentage of the milling cutter diameter
- (only for and )
DZ Maximum depth infeed (only for , or edge) mm
UXY Plane finishing allowance (only for , or edge) mm
UZ Depth finishing allowance (only for , or edge) mm
Insertion The following insertion modes can be selected (only for , or edge)
Predrilled: (only for G code)
With G0, the pocket center point is approached at the retraction level, and then,
from this position, the reference point brought forward by the safety clearance is
approached also with G0. The machining of the rectangular pocket is then
performed according to the selected insertion strategy, taking into account the
programmed blank dimensions.
Perpendicular: Insert vertically at the center of pocket
The tool executes the calculated actual depth infeed at the pocket center in a single
block. This setting can be used only if the cutter can cut across center or if the
pocket has been predrilled.
Helical: Insert along helical path
The cutter center point traverses along the helical path determined by the radius
and depth per revolution (helical path). If the depth for one infeed has been
reached, a full circle motion is executed to eliminate the inclined insertion path.
Oscillating: Insert with oscillation along center axis of rectangular pocket
The cutter center point oscillates back and forth along a linear path until it reaches
the depth infeed. When the depth has been reached, the path is traversed again
without depth infeed in order to eliminate the inclined insertion path.
FZ Depth infeed rate (for perpendicular insertion only) *
(only for G code)
Milling
8.2 Milling

FZ Depth infeed rate (for perpendicular insertion only) mm/min
(only for ShopMill) mm/tooth
EP Maximum pitch of helix (for helical insertion only) mm/rev
ER Radius of helix (for helical insertion only) mm
The radius cannot be any larger than the cutter radius; otherwise, material will remain.
EW Maximum insertion angle (for insertion with oscillation only) Degrees
(for roughing only)
The rectangular pocket is milled from the solid material.
Editing
A rectangular pocket or hole has already been machined in the workpiece. This
needs to be enlarged in one or several axes. You must program parameters AZ,
W1 and L1 for this purpose.
AZ Depth of premachining (for remachining only) mm
W1 Width of premachining (for remachining only) mm
L1 Length of premachining (for remachining only) mm
FS Chamfer width for chamfering - (for chamfering only) mm
ZFS Insertion depth of tool tip (abs or inc) (for chamfer only) mm
8.2.3 Circular pocket (POCKET4)
Function
You can mill any circular pocket with the "Circular pocket" cycle.
The following machining methods are available:
Mill circular pocket from solid material.
Pre-drill circular pocket in the center first if, for example, the milling cutter does not cut in
the center (program the drilling, circular pocket and position program blocks in
succession).
Machine pre-machined circular pocket (see "Solid machining" parameter).
Complete machining
Remachining
The following machining types are available for milling using the "Circular pocket" function:
Plane-by-plane
Helical
Milling
8.2 Milling
Approach/retraction for plane-by-plane solid machining

In plane-by-plane machining of the circular pocket, the material is removed horizontally, one
layer at a time.
1. The tool approaches the center point of the pocket at rapid traverse at the height of the
retraction plane and adjusts to the safety clearance.
3. The circular pocket is always machined from inside out using the selected machining
method.
Approach/retraction for helical solid machining

In helical reaming, the material is removed down to pocket depth in a helical movement.
1. The tool approaches the center point of the pocket at rapid traverse at the height of the
retraction plane and adjusts to the safety clearance.
2. Infeed to the first machining diameter.
3. The circular pocket is machined with the chosen machining type up to pocket depth or up
to pocket depth with finishing allowance.
5. Lateral infeed to the next machining diameter.
Machining type: Plane-by-plane

When milling circular pockets, you can select the following machining types:
Roughing
During roughing, the individual planes of the circular pocket are machined one after the
other from center point until depth Z1 is reached.
Finishing
During finishing, the edge is always machined first. The pocket edge is approached on
the quadrant, which joins the pocket radius. In the last infeed, the base is finished from
the center out.
Finishing of edge
Chamfering
Chamfering involves edge breaking at the upper edge of the circular pocket.
Milling
8.2 Milling
Machining type: Helical

When milling circular pockets, you can select the following machining types:
Roughing
During roughing, the circular pocket is machined downward with helical movements.
A full circle is effected down to pocket depth to remove the residual material.
The tool is retracted from the edge and base of the pocket in a quadrant and retracted
with rapid traverse to a safety clearance.
This process is repeated layer-by-layer, from inside out, until the circular pocket has been
completely machined.
Finishing
In finishing mode, the edge is machined first with a helical movement down to the bottom.
The base is milled from outside in a spiral movement.
The tool is retracted from the center of the pocket to a safety clearance.
Finishing of edge
In edge finishing, the edge is machined first with a helical movement down to the bottom.
The tool is retracted from the edge and base of the pocket in a quadrant and retracted
with rapid traverse to a safety clearance.
Procedure

3. Press the "Pocket" and "Circular pocket" softkeys.

The "Circular Pocket" input window opens.
Milling
8.2 Milling


mm/tooth

cutting rate m/min
F Feedrate *

Machining (roughing, plane-by-plane or helical)
(finishing, plane-by-plane or helical)
edge (edge finishing, plane-by-plane or helical)
Chamfering
Machining type Plane-by-plane
Machine circular pocket plane-by-plane

Helical
Machine circular pocket using helical type

position
A circular pocket is machined at the programmed position (X0, Y0, Z0).
Position pattern
Several circular pockets are machined in a position pattern

(e.g. full circle, pitch circle, grid, etc.).
The reference points refer to the center point of the circular pocket:
X0 Reference point X (for single position only) mm
Y0 Reference point Y (for single position only) mm
Diameter of pocket mm
Z1 Pocket depth (abs) or depth relative to Z0 (inc) (only for , and mm
edge)
DXY Maximum plane infeed In

%
- (only for and )
DZ Maximum depth infeed - (only for , and Rand) mm
UXY Plane finishing allowance - (only for , and edge) mm
Milling
8.2 Milling

UZ Depth finishing allowance (only for and ) mm
Insertion Various insertion modes can be selected (only for plane-by-plane
machining method and for , or edge)
Predrilled (only for G code)
Perpendicular: Insert vertically at the center of pocket
The tool executes the calculated depth infeed vertically in the center of
the pocket.
Feedrate: Infeed rate as programmed under FZ

Helical: Insert along helical path
The cutter center point traverses along the helical path determined by
the radius and depth per revolution. If the depth for one infeed has been
reached, a full circle motion is executed to eliminate the inclined
insertion path.
Feedrate: Machining feedrate
Note: The vertical insertion into pocket center method can be used only
if the tool can cut across center or if the workpiece has been predrilled.
FZ Depth infeed rate (only for perpendicular insertion and vertical) *
(only for G code)
FZ Depth infeed rate (only for perpendicular insertion and vertical) mm/min
EP Maximum pitch of helix - (for helical insertion only) mm/rev
The helix pitch may be lower due to the geometric conditions.
ER Radius of helix - (only for helical insertion) mm
The radius must not be larger than the cutter radius, otherwise material will
remain. Also make sure the circular pocket is not violated
Stock removal Complete machining
The circular pocket must be milled from a solid workpiece (e.g. casting).
Editing
A small pocket or hole has already been machined in the workpiece.

This needs to be enlarged. Parameters AZ, and 1 must be
programmed.
ZFS Insertion depth of tool tip (abs or inc) - (for chamfering only) mm
AZ Depth of premachining - (for remachining only) mm

1 Diameter of premachining - (for remachining only) mm
Milling
8.2 Milling
8.2.4 Rectangular spigot (CYCLE76)
Function
You can mill various rectangular spigots with the "Rectangular spigot" cycle.
You can select from the following shapes with or without a corner radius:
Depending on the dimensions of the rectangular spigot in the workpiece drawing, you can
select a corresponding reference point for the rectangular spigot.
In addition to the required rectangular spigot, you must also define a blank spigot, i.e. the
outer limits of the material. The tool moves at rapid traverse outside this area. The blank
spigot must not overlap adjacent blank spigots and is automatically placed by the cycle in a
central position on the finished spigot.
The rectangular spigot is machined using only one infeed. If you want to machine the spigot
using multiple infeeds, you must program the "Rectangular spigot" cycle several times with a
reducing finishing allowance.
Sequence
1. The tool approaches the starting point at rapid traverse at the height of the retraction
plane and is fed in to the safety clearance. The starting point is on the positive X axis
rotated through 0.
2. The tool approaches the spigot contour sideways in a semicircle at machining feedrate.
The tool first executes infeed at machining depth and then moves in the plane. The
rectangular spigot is machined depending on the programmed machining direction (up-
cut/down-cut) in a clockwise or counterclockwise direction.
3. When the rectangular spigot has been traversed once, the tool retracts from the contour
in a semicircle and then infeed to the next machining depth is performed.
4. The rectangular spigot is approached again in a semicircle and traversed once. This
process is repeated until the programmed spigot depth is reached.
Milling
8.2 Milling
Machining type
Roughing
Roughing involves moving around the rectangular spigot until the programmed finishing
allowance has been reached.
Finishing
If you have programmed a finishing allowance, the rectangular spigot is moved around
until depth Z1 is reached.
Chamfering
Chamfering involves edge breaking at the upper edge of the rectangular spigot.
Procedure

3. Press the "Multi-edge spigot" and "Rectangular spigot" softkeys.

The "Rectangular Spigot" input window opens.


mm/tooth

cutting rate m/min
F Feedrate *
Milling
8.2 Milling

FZ Depth infeed rate *
(only for G code)
Reference point The following different reference point positions can be selected:
(center)
(bottom left)
(bottom right)
(top left)
(top right)
Machining (roughing)
(finishing)
Chamfering
position
A rectangular spigot is machined at the programmed position (X0, Y0, Z0).
Position pattern
Several rectangular spigots are machined in a position pattern

W Width of spigot mm
L Length of spigot mm
R Corner radius mm
Z1 Spigot depth (abs) or depth relative to Z0 (inc) - (only for and ) mm
DZ Maximum depth infeed - (only for and ) mm

UXY Plane finishing allowance for the length (L) and width (W) of the rectangular spigot. mm
Smaller rectangular spigot dimensions are obtained by calling the cycle again and
programming it with a lower finishing allowance. - (only for and )
UZ Depth finishing allowance (tool axis) - (only for and ) mm
W1 Width of blank spigot (important for determining approach position) - (only for and mm
)
L1 Length of blank spigot (important for determining approach position) - (only for and mm
)
Milling
8.2 Milling
8.2.5 Circular spigot (CYCLE77)
8.2.5.1 Function
Function
You can mill various circular spigots with the "Circular spigot" function.
In addition to the required circular spigot, you must also define a blank spigot, i.e. the outer
limits of the material. The tool moves at rapid traverse outside this area. The blank spigot
must not overlap adjacent blank spigots and is automatically placed on the finished spigot in
a centered position.
The circular spigot is machined using only one infeed. If you want to machine the spigot
using multiple infeeds, you must program the "Circular spigot" function several times with a
reducing finishing allowance.
Approach/retraction
plane and is fed in to the safety clearance. The starting point is always on the positive X
axis.
2. The tool approaches the spigot contour sideways in a semicircle at machining feedrate.
The tool first executes infeed at machining depth and then moves in the plane. The
circular spigot is machined depending on the programmed machining direction (up-
cut/down-cut) in a clockwise or counterclockwise direction.
3. When the circular spigot has been traversed once, the tool retracts from the contour in a
semicircle and then infeed to the next machining depth is performed.
4. The circular spigot is approached again in a semicircle and traversed once. This process
is repeated until the programmed spigot depth is reached.
Machining type
You can select the machining mode for milling the circular spigot as follows:
Roughing
Roughing involves moving round the circular spigot until the programmed finishing
allowance has been reached.
Finishing
If you have programmed a finishing allowance, the circular spigot is moved around until
depth Z1 is reached.
Chamfering
Chamfering involves edge breaking at the upper edge of the circular spigot.
Milling
8.2 Milling
Procedure

3. Press the "Multi-edge spigot" and "Circular spigot" softkeys.

The "Circular Spigot" input window opens.


mm/tooth

cutting rate m/min
F Feedrate *

(only for G code)
(finishing)
Chamfering
position
A circular spigot is machined at the programmed position (X0, Y0, Z0).
Position pattern
Several circular spigots are machined in a position pattern

Diameter of spigot mm
Z1 Spigot depth (abs) or depth relative to Z0 (inc) - (only for and ) mm
Milling
8.2 Milling

UXY Plane finishing allowance for the length (L) and width (W) of the circular spigot. mm
Smaller circular spigot dimensions are obtained by calling the cycle again and
programming it with a lower finishing allowance. - (only for and )
UZ Depth finishing allowance (tool axis) - (only for and ) mm
1 Diameter of blank spigot (important for determining approach position) - (only for and mm
)
8.2.6 Multi-edge (CYCLE79)
8.2.6.1 Function
Function
You can mill a multi-edge with any number of edges with the "Multi-edge" cycle.
You can select from the following shapes with or without a corner radius or chamfer:
Approach/retraction
plane and is fed in to the safety clearance.
2. The tool traverses the multi-edge in a quadrant at machining feedrate. The tool first
executes infeed at machining depth and then moves in the plane. The multi-edge is
machined depending on the programmed machining direction (up-cut/down-cut) in a
clockwise or counterclockwise direction.
3. When the first plane has been machined, the tool retracts from the contour in a quadrant
and then infeed to the next machining depth is performed.
Milling
8.2 Milling
4. The multi-edge is traversed again in a quadrant. This process is repeated until the depth
of the multi-edge has been reached.
5. The tool retracts to the safety clearance at rapid traverse.
Note
A multi-edge with more than two edges is traversed helically; with a single or double
edge, each edge is machined separately.
Procedure

3. Press the "Multi-edge spigot" and "Multi-edge" softkeys.

The "Multi-edge" input window opens.


mm/tooth

cutting rate m/min
F Feedrate *
Milling
8.2 Milling

(only for G code)
(finishing)
Chamfering
position
A polygon is milled at the programmed position (X0, Y0, Z0).
Position pattern
Several polygons are milled at the programmed position pattern (e.g. pitch circle,
grid, line).
Diameter of blank spigot mm
N Number of edges
SW or L Width across flats or edge length mm
R1 or FS1 Rounding radius or chamfer width mm
Z1 Multi-edge depth (abs) or depth in relation to Z0 (inc) - (only for , and edge) mm
%
- (only for and )
UZ Depth finishing allowance (only for and ) mm
%
Milling
8.2 Milling
8.2.7 Longitudinal groove (SLOT1)
Function
You can mill any longitudinal groove with the "longitudinal groove" milling function.
The following machining methods are available:
Mill longitudinal groove from solid material.
Pre-drill longitudinal groove in the center first if, for example, the milling cutter does not
cut in the center (e.g. for ShopMill, program the drilling, rectangular pocket and position
program blocks in succession).
Depending on the dimensions of the longitudinal groove in the workpiece drawing, you can
select a corresponding reference point for the longitudinal groove.
Approach/retraction
1. The tool moves at rapid traverse to the retraction plane and infeeds at safety clearance.
3. The longitudinal slot is always machined with the chosen machining type from inside out.
Machining type
You can select the machining mode for milling the longitudinal slot as follows:
Roughing
During roughing, the individual planes of the slot are machined one after the other until
depth Z1 is reached.
Finishing
During finishing, the edge is always machined first. The slot edge is approached on the
quadrant, which joins the corner radius. In the last infeed, the base is finished from the
center out.
Finishing of edge
Chamfer
Chamfering involves edge breaking at the upper edge of the longitudinal slot.
Milling
8.2 Milling
Procedure

3. Press the "Groove" and "Longitudinal groove" softkeys.

The "Longitudinal Groove (SLOT1)" input window opens.


mm/tooth

cutting rate m/min
F Feedrate *

Reference point Position of the reference point:
(lefthand edge)
(inside left)
(center)
(inside right)
(righthand edge)
Milling
8.2 Milling
(finishing)
Chamfering
position
A slot is milled at the programmed position (X0, Y0, Z0).
Position pattern
Several slots are milled at the programmed position pattern (e.g. pitch circle, grid,
line).
W Slot width mm
L Slot length mm
Z1 Slot depth (abs) or depth relative to Z0 (inc) (only for , and edge) mm

%
- (only for and )
UZ Depth finishing allowance (slot base) - (only for and ) mm
Insertion The following insertion modes can be selected: mm
Predrilled: (only for G code)
Approach of reference point shifted by the amount of the safety clearance with G0.
Perpendicular: Insert vertically in longitudinal groove center
The tool is inserted to infeed depth in the pocket center.
Note: This setting can be used only if the cutter can cut across center.
Helical: Insertion on helical path (only for G code)
reached, a full longitudinal slot is machined to eliminate the inclined insertion path.
Oscillating: Insert with oscillation along center axis of longitudinal slot
The cutter center point oscillates along a linear path until it reaches the depth
infeed. When the depth has been reached, the path is traversed again without
depth infeed in order to eliminate the inclined insertion path.
FZ Depth infeed rate (for perpendicular insertion only) *
(only for G code)
Milling
8.2 Milling
FZ Depth infeed rate (for perpendicular insertion only) mm/min

(only for G code)
(only for G code) The radius cannot be any larger than the cutter radius; otherwise, material will remain.
EW Maximum insertion angle - (for insertion with oscillation only) Degrees
FS Chamfer width for chamfering (inc) - (for chamfering only), mm
8.2.8 Circumferential groove (SLOT2)
Function
You can mill one or several circumferential grooves of equal size on a full or pitch circle with
the "circumferential groove" cycle.
Tool size
Please note that there is a minimum size for the milling cutter used to machine the
circumferential groove:
Roughing:
12 groove width W finishing allowance UXY milling cutter diameter
Finishing:
12 groove width W milling cutter diameter
Edge finishing:
Finishing allowance UXY milling cutter diameter
Annular groove
To create an annular groove, you must enter the following values for the "Number N" and
"Aperture angle 1" parameters:
N=1
1 = 360
Milling
8.2 Milling
Approach/retraction
1. The tool approaches the center point of the semicircle at the end of the slot at rapid
traverse at the height of the retraction plane and adjusts to the safety clearance.
2. Then, the tool enters the workpiece at machining infeed (taking into consideration the
maximum infeed in the Z direction and the finishing allowance). The circumferential slot is
machined in the programmed machining direction (up-cut or down-cut) in a clockwise or
counterclockwise direction.
3. When the first circumferential slot is finished, the tool moves to the retraction plane at
rapid traverse.
4. The next circumferential slot is approached along a straight line or circular path and then
machined.
Machining type
You can select the machining mode for milling the circumferential slot as follows:
Roughing
During roughing, the individual planes of the slot are machined one after the other from
center point of the semicircle at the end of the slot until depth Z1 is reached.
Finishing
In "Finishing" mode, the edge is always machined first until depth Z1 is reached. The slot
edge is approached on the quadrant, which joins the radius. In the last infeed, the base is
finished from the center point of the semicircle to the end of the slot.
Finishing of edge
Chamfer
Chamfering involves edge breaking at the upper edge of the circumferential groove.
Procedure

3. Press the "Groove" and "Circumferential groove" softkeys.

The "Circumferential Groove" input window opens.
Milling
8.2 Milling


mm/tooth

cutting rate m/min
F Feedrate *

FZ Depth infeed rate (only for and ) mm/min
(only for ShopMill) in/tooth
FZ Depth infeed rate (only for and ) *
(only for G code)
(finishing)
Chamfering
Circular pattern Full circle
The circumferential grooves are positioned around a full circle. The groove spacing
is uniform and is calculated by the controller.
Pitch circle
The circumferential grooves are positioned around a pitch circle. The groove
spacing can be determined on the basis of angle 2.
The positions refer to the center point:
X0 Reference point X mm
Y0 Reference point Y mm
Z0 Reference point Z mm
N Number of grooves
R Radius of circumferential groove mm
0 Starting angle Degrees
1 Opening angle of the groove Degrees
2 Advance angle - (for pitch circle only) Degrees
W Slot width mm
Z1 Slot depth (abs) or depth relative to Z0 (inc) (only for , and mm
edge)
Milling
8.2 Milling

FS Chamfer width for chamfering (inc) - (for chamfering only), mm
ZFS Insertion depth of tool tip (abs or inc) - (for chamfering only), mm
Positioning Positioning motion between the grooves:
Straight line:
Next position is approached linearly at rapid traverse.

Circular:
Next position is approached along a circular path at the feedrate defined in the
machine data.
8.2.9 Open groove (CYCLE899)
Function
Use the "Open slot" function if you want to machine open slots.
For roughing, you can choose between the following machining strategies, depending on
your workpiece and machine properties.
Vortex milling
Plunge cutting
The following machining types are available to completely machine the slot:
Roughing
Rough-finishing
Finishing
Base finishing
Edge finishing
Chamfering
Vortex milling
Particularly where hardened materials are concerned, this process is used for roughing and
contour machining using coated VHM milling cutters.
Vortex milling is the preferred technique for HSC roughing, as it ensures that the tool is
never completely inserted. This means that the set overlap is precisely maintained.
Milling
8.2 Milling
Plunge cutting
Plunge cutting is the preferred method of machining slots for "unstable" machines and
workpiece geometries. This method generally only exerts forces along the tool axis, i.e.
perpendicular to the surface of the pocket/slot to be machined (with the XY plane in Z
direction). Therefore, the tool is subject to virtually no deformation. As a result of the axial
loading of the tool, there is hardly any danger of vibration occurring for unstable workpieces.
The cutting depth can be considerably increased. The plunge cutter, as it is known, ensures
a longer service life due to less vibration for long overhangs.
Approach/retraction for vortex milling

1. The tool approaches the starting point in front of the slot in rapid traverse and maintains
the safety clearance.
2. The tool goes to the cutting depth.
3. The open slot is always machined along its entire length using the selected machining
method.
4. The tool retracts to the safety clearance in rapid traverse.
Approach/retraction for plunge cutting

1. The tool moves in rapid traverse to the starting point in front of the slot at the safety
clearance.
2. The open slot is always machined along its entire length using the selected machining
method.
3. The tool retracts to the safety clearance in rapid traverse.
Machining type, roughing vortex milling

Roughing is performed by moving the milling cutter along a circular path.
While performing this motion, the milling cutter is continuously fed into the plane. Once the
milling cutter has traveled along the entire slot, it returns to its starting point, while continuing
to move in a circular fashion. By doing this, it removes the next layer (infeed depth) in the Z
direction. This process is repeated until the set slot depth plus the finishing allowance has
been reached.
Milling
8.2 Milling
Vortex milling: Climbing or conventional Vortex milling: Climbing - conventional milling

milling
Supplementary conditions for vortex milling

Roughing
1/2 slot width W finishing allowance UXY milling cutter diameter
Slot width
minimum 1.15 x milling cutter diameter + finishing allowance
maximum, 2 x milling cutter diameter + 2 x finishing allowance
Radial infeed
minimum, 0.02 x milling cutter diameter
maximum, 0.25 x milling cutter diameter
Maximum infeed depth cutting height of milling cutter
Please note that the cutting height of the milling cutter cannot be checked.
The maximum radial infeed depends on the milling cutter.
For hard materials, use a lower infeed.
Milling
8.2 Milling
Machining type, roughing plunge cutting

Roughing of the slot takes place sequentially along the length of the groove, with the milling
cutter performing vertical insertions at the machining feedrate. The milling cutter is then
retracted and repositioned at the next insertion point.
The milling cutter moves along the length of the slot, at half the infeed rate, and inserts
alternately at the left-hand and right-hand walls.
The first insertion motion takes place at the slot edge, with the milling cutter inserted at half
the infeed, less the safety clearance. (if the safety clearance is greater than the infeed, this
will be on the outside). For this cycle, the maximum width of the slot must be less than
double the width of the milling cutter + the finishing allowance.
Following each insertion, the milling cutter is lifted by the height of the safety clearance at the
machining feedrate. As far as possible, this occurs during what is known as the retraction
process, i.e. if the milling cutter's wrap angle is less than 180, it is lifted at a 45- angle from
the base in the opposite direction to the bisector of the wrap area.
The milling cutter then traverses over the material in rapid traverse.
Supplementary conditions for plunge cutting

Roughing
1/2 slot width W - finishing allowance UXY milling cutter diameter
Maximum radial infeed
The maximum infeed depends on the cutting edge width of the milling cutter.
Increment
The lateral increment is calculated on the basis of the required slot width, milling cutter
diameter and finishing allowance.
Retraction
Retraction involves the milling cutter being retracted at a 45 angle if the wrap angle is
less than 180. Otherwise, retraction is perpendicular, as is the case with drilling.
Milling
8.2 Milling
Retraction
Retraction is performed perpendicular to the wrapped surface.
Safety clearance
Traverse through the safety clearance beyond the end of the workpiece to prevent
rounding of the slot walls at the ends.
Please note that the milling cutters cutting edge cannot be checked for the maximum radial
infeed.
Machining type, rough finishing

If there is too much residual material on the slot walls, unwanted corners are removed to the
finishing dimension.
Machining type, finishing:

When finishing walls, the milling cutter travels along the slot walls, whereby just like for
roughing, it is again fed in the Z direction, increment by increment. During this process, the
milling cutter travels through the safety clearance beyond the beginning and end of the slot,
so that an even slot wall surface can be guaranteed across the entire length of the slot.
Machining type, edge finishing

Edge finishing is performed in the same way as finishing, except that the last infeed (finish
base) is omitted.
Machining type, finishing base:

When finishing the base, the milling cutter moves backwards and forwards once in the
finished slot.
Machining type, chamfering

Chamfering involves breaking the edge at the upper slot edge.
Additional supplementary conditions

Finishing
1/2 slot width W milling cutter diameter
Edge finishing
Finishing allowance UXY milling cutter diameter
Chamfering
The tip angle must be entered into the tool table.
Milling
8.2 Milling
Procedure

3. Press the "Slot" and "Open slot" softkeys.

The "Open slot" input window opens.


mm/tooth

cutting rate m/min

(lefthand edge)
(center)
(righthand edge)
(pre-finishing)
(finishing)
base (base finishing)
Chamfering
Milling
8.2 Milling

Technology Vortex milling
The milling cutter performs circular motions along the length of the slot and back
again.
Plunge cutting
Sequential drilling motion along the tool axis.
Milling direction: - (except plunge cutting).
Climbing
Conventional
Climbing conventional milling
position
Mill a slot at the programmed position (X0, Y0, Z0).
Position pattern
Mill slots at a programmed position pattern (e.g. full circle or grid).

W Slot width mm
L Slot length mm
0 Angle of rotation of slot Degrees
Z1 Slot depth (abs) or depth relative to Z0 (abs) (only for , , base and mm
rough finishing)
%
- (only for )
DZ Maximum depth infeed - (only for , rough finishing, and edge) mm
- (only for vortex milling)
UXY Plane finishing allowance (slot edge) - (only for , rough finishing and base) mm
UZ Depth finishing allowance (slot base) - (only for , rough finishing and edge ) mm
FS Chamfer width for chamfering (inc) - (for chamfering only) mm
Milling
8.2 Milling
8.2.10 Long hole (LONGHOLE) - only for G code programs
Function
In contrast to the groove, the width of the elongated hole is determined by the tool diameter.
Internally in the cycle, an optimum traversing path of the tool is determined, ruling out
unnecessary idle passes. If several depth infeeds are required to machine an elongated
hole, the infeed is carried out alternately at the end points. The path to be traversed in the
plane along the longitudinal axis of the elongated hole changes its direction after each
infeed. The cycle searches for the shortest path when changing to the next elongated hole.
NOTICE
The cycle requires a milling cutter with a "face tooth cutting over center" (DIN 844).
Approach/retraction
1. Using G0, the starting position for the cycle is approached. In both axes of the current
plane, the closest end point of the first elongated hole to be machined is approached at
the level of the retraction plane in the tool axis and then lowered to the reference point
shifted by the amount of the safety clearance.
2. Each elongated hole is milled in a reciprocating motion. The machining in the plane is
performed using G1 and the programmed feedrate. At each reversal point, the infeed to
the next machining depth calculated internally in the cycle is performed with G1 and the
feedrate, until the final depth is reached.
3. Retraction to the retraction plane using G0 and approach to the next elongated hole on
the shortest path.
4. After the last elongated hole has been machined, the tool at the position reached last in
the machining plane is moved with G0 to the retraction plane, and the cycle terminated.
Procedure

3. Press the "Groove" and "Elongated hole" softkeys.

The "Elongated Hole" input window opens.
Milling
8.2 Milling

PL Machining plane
RP Retraction plane (abs)
SC Safety clearance (inc)
F Feedrate *
Machining type Plane-by-plane mm
The tool is inserted to infeed depth in the pocket center.
Note: This setting can be used only if the cutter can cut across center.
Oscillating
Insert with oscillation along center axis of longitudinal slot:
The cutter center point oscillates along a linear path until it reaches the depth
infeed. When the depth has been reached, the path is traversed again without
depth infeed in order to eliminate the inclined insertion path.

position
An elongated hole is machined at the programmed position (X0, Y0, Z0).
Position pattern
Several elongated holes are machined in the programmed position pattern (e.g.
pitch circle, grid, line).
L Elongated hole length mm
Z1 Elongated hole depth (abs) or depth in relation to Z0 (inc) mm
DZ Maximum depth infeed mm
Milling
8.2 Milling
8.2.11 Thread milling (CYCLE70)
Function
Using a thread cutter, internal or external threads can be machined with the same pitch.
Threads can be machined as right-hand or left-hand threads and from top to bottom or vice
versa.
For metric threads (thread pitch P in mm/rev), the cycle assigns a value (calculated on the
basis of the thread pitch) to the thread depth H1 parameter. You can change this value. The
default selection must be activated via a machine data code.
The entered feedrate acts on the workpiece contour, i.e. it refers to the thread diameter.
However the feedrate of the cutter center point is displayed. That is why a smaller value is
displayed for internal threads and a larger value is displayed for external threads than was
entered.
Approach/retraction when milling internal threads

1. Positioning on retraction plane with rapid traverse.
2. Approach of starting point of the approach circle in the current plane with rapid traverse.
3. Infeed to a starting point in the tool axis calculated internally in the controller with rapid
traverse.
4. Approach motion to thread diameter on an approach circle calculated internally in the
controller with the programmed feedrate, taking into account the finishing allowance and
maximum plane infeed.
5. Thread cutting along a spiral path in clockwise or counterclockwise direction (depending
on whether it is left-hand/right-hand thread, for number of cutting teeth of a milling plate
(NT) 2 only 1 rotation, offset in the Z direction).
6. Exit motion along a circular path in the same rotational direction at programmed feedrate.
7. With a programmed number of threads per cutting edge NT > 2, the tool is fed in (offset)
by the amount NT-1 in the Z direction. Points 4 to 7 are repeated until the programmed
thread depth is reached.
8. If the plane infeed is less than the thread depth, points 3 to 7 are repeated until the thread
depth + programmed allowance is reached.
9. Retract on the thread center point and then to retraction plane in the tool axis in rapid
traverse.
Please note that when milling an internal thread the tool must not exceed the following value:
Milling cutter diameter < (nominal diameter - 2 thread depth H1)
Milling
8.2 Milling
Approach/retraction when milling external threads

1. Positioning on retraction plane with rapid traverse.
2. Approach of starting point of the approach circle in the current plane with rapid traverse.
3. Infeed to a starting point in the tool axis calculated internally in the controller with rapid
traverse.
4. Approach motion to thread core diameter on an approach circle calculated internally in
the controller with the programmed feedrate, taking into account the finishing allowance
and maximum plane infeed.
5. Cut thread along a spiral path in clockwise or counterclockwise direction (depending on
whether it is left-hand/right-hand thread, with NT 2 only one rotation, offset in Z
direction).
6. Exit motion along a circular path in opposite rotational direction at programmed feedrate.
7. With a programmed number of threads per cutting edge NT > 2, the tool is fed in (offset)
by the amount NT-1 in the Z direction. Points 4 to 7 are repeated until the programmed
thread depth is reached.
8. If the plane infeed is less than the thread depth, points 3 to 7 are repeated until the thread
depth + programmed allowance is reached.
9. Retraction on the retraction plane in the tool axis with rapid traverse.
Procedure

3. Press the "Thread milling" softkey.

The "thread milling" input window opens.


mm/tooth

cutting rate m/min
Milling
8.2 Milling

(finishing)
Machining direction:
Z0 Z1
Machining from top to bottom

Z1 Z0
Machining from bottom to top

Direction of rotation of the thread:
Right-hand thread
A right-hand thread is cut.

Left-hand thread
A left-hand thread is cut.

Position of the thread:
Internal thread
An internal thread is cut.

External thread
An external thread is cut.

NT Number of teeth per cutting edge
Single or multiple toothed milling inserts can be used. The motions required are
executed by the cycle internally, so that the tip of the bottom tooth on the milling insert
corresponds to the programmed end position when the thread end position is reached.
Depending on the cutting edge geometry of the milling insert, the retraction path must
be taken into account at the base of the workpiece.
Machining position:
Single position
(only for G code)
Position pattern (MCALL)
The positions refer to the center point:
Reference point X (for single position only) mm
X0
Reference point Y (for single position only) mm
Y0
Reference point Z mm
Z0
(only for G code)
Without
ISO metric
Whitworth BSW
Whitworth BSP
UNC
Milling
8.2 Milling

Selection (not Selection of table value: e.g.
for table "without")
N1" - 8 UNC; etc. (UNC)
P Display of the thread pitch for the parameter input in the input field "Table" and MODULUS
"Selection". Turns/"
mm/rev
inch/rev
P Pitch ...
- (selection MODUL
in MODULUS: For instance, used for worms that mesh with a gearwheel.
option only for Turns/"
table selection per inch: Used with pipe threads, for example.
"without")
When entered per inch, enter the integer number in front of the decimal point in the
mm/rev
in/rev
in mm/rev
in inch/rev
The tool used depends on the thread pitch.
Nominal diameter mm
Example: Nominal diameter of M12 = 12 mm
H1 Thread depth mm
S Starting angle Degrees
rev Finishing allowance in X and Y - (only for ) mm
8.2.12 Engraving (CYCLE60)
Function
The "Engraving" function is used to engrave a text on a workpiece along a line or arc.
You can enter the text directly in the text field as "fixed text" or assign it via a variable as
"variable text".
Engraving uses a proportional font, i.e., the individual characters are of different widths.
Approach/retraction
plane and adjusts to the safety clearance.
2. The tool moves to the machining depth FZ at the infeed feedrate Z1 and mills the
characters.
Milling
8.2 Milling
3. The tool retracts to the safety clearance at rapid traverse and moves along a straight line
to the next character.
4. Steps 2 and 3 are repeated until the entire text has been milled.
5. The tool moves to the retraction plane in rapid traverse.
Procedure

3. Press the "Engraving" softkey.

The "Engraving" input window opens.
Entering the engraving text
4. Press the "Special characters" softkey if you need a character that does
not appear on the input keys.
The "Special characters" window appears.
Position the cursor on the desired character.
The selected character is inserted into the text at the cursor position.
5. If you wish to delete the complete text, press the "Delete text" and
"Delete" softkeys one after the other.
6. Press the "Lowercase" softkey to enter lowercase letters. Press it again

to enter uppercase letters.
7. Press the "Variable" and "Date" softkeys if you want to engrave the
current date.
The data is inserted in the European date format

(<DD>.<MM>.<YYYY>).
To obtain a different date format, you must adapt the format specified in
the text field. For example, to engrave the date in the American date
format (month/day/year => 8/16/04), change the format to
<M>/<D>/<YY> .
7. Press the "Variable" and "Time" softkeys if you want to engrave the
current time.
Milling
8.2 Milling
The time is inserted in the European format (<TIME24>).

To have the time in the American format, change the format to
<TIME12>.
Example:
Text entry: Time: <TIME24> Execute: Time: 16.35
Time: <TIME12> Execute: Time: 04.35 PM
7. Press the "Variable" and "Workpiece count 000123" softkeys to
engrave a workpiece count with a fixed number of digits and leading
zeroes.
The format text <######,_$AC_ACTUAL_PARTS> is inserted and
you return to the engraving field with the softkey bar.
Define the number of digits by adjusting the number of place holders
(#) in the engraving field.
If the specified number of positions (e.g. ##) is not sufficient to
represent the unit quantity, then the cycle automatically increases
the number of positions.
- OR
7. Press the "Variable" and "Workpiece count 123" softkeys if you want
to engrave a workpiece count without lead zeroes.
The format text <#,_$AC_ACTUAL_PARTS> is inserted and you
return to the engraving field with the softkey bar.
Define the number of digits by adjusting the number of place holders

in the engraving field.
If the specified number of digits is not enough to display the
workpiece count (e.g. 123), the cycle will automatically increase the
number digits.
7. Press the "Variable" and "Number 123.456" softkeys if you want to
engrave a any number in a certain format.
The format text <#.###,_VAR_NUM> is inserted and you return to
the engraving field with the softkey bar.
The place holders #.### define the digit format in which the number
defined in _VAR_NUM will be engraved.
For example, if you have stored 12.35 in _VAR_NUM, you can
format the variable as follows.
Entry Release Meaning
<#,_VAR_NUM> 12 Places before decimal point
unformatted, no places after the
decimal point
<####,_VAR_NUM> 0012 4 places before decimal point,
leading zeros, no places after the
decimal point
Milling
8.2 Milling
< #,_VAR_NUM> 12 4 places before decimal point,

leading blanks, no places after the
decimal point
<#.,_VAR_NUM> 12.35 Integer and fractional digits not
formatted.
<#.#,_VAR_NUM> 12.4 Places before decimal point
unformatted,
1 place after the decimal point
(rounded)
<#.##,_VAR_NUM> 12.35 Places before decimal point
unformatted,
2 places after the decimal point
(rounded)
<#.####,_VAR_NUM> 12.3500 Places before decimal point
unformatted,
4 places after the decimal point
(rounded)
If there is insufficient space in front of the decimal point to display the
number entered, it is automatically extended. If the specified number of
digits is larger than the number to be engraved, the output format is
automatically filled with the appropriate number of leading and trailing
zeroes.
Instead of the decimal point you can also use a blank.
Instead of _VAR_NUM you can use any other numerical variable (e.g.
R0).
7. Press the "Variable" and "Variable text" softkeys if you want to take the
text to be engraved (up to 200 characters) from a variable.
The format text <Text, _VAR_TEXT> is inserted and you return to the
engraving field with the softkey bar.
You can use any other text variable instead of _VAR_TEXT.
Note
Entering the engraving text
Only single-line entries without line break are permissible!
Milling
8.2 Milling
Variable texts
There are various ways of defining variable text:
Date and time
For example, you can engrave the time and date of manufacture on a workpiece. The
values for date and time are read from the NCK.
Quantity
Using the workpiece variables you can assign a consecutive number to the workpieces.
You can define the format (number of digits, leading zeroes).
The place holder (#) is used to format the number of digits at which the workpiece counts
output will begin.
If you do not want to output a count of 1 for the first workpiece, you can specify an
additive value (e.g., <#,$AC_ACTUAL_PARTS + 100>). The workpiece count output is
then incremented by this value (e. g. 101, 102, 103,...).
Numbers
When outputting number (e. g. measurement results), you can select the output format
(digits either side of the point) of the number to be engraved.
Text
Instead of entering a fixed text in the engraving text field, you can specify the text to be
engraved via a text variable (e. g., _VAR_TEXT="ABC123").
Mirror writing
You can engrave the text mirrored on the workpiece.
Full circle
If you want to distribute the characters evenly around a full circle, enter the arc angle
2=360. The cycle then distributes the characters evenly around the full circle.


mm/tooth

cutting rate m/min
Milling
8.2 Milling

(only for G code)
FZ Depth infeed rate mm/min
Alignment (linear alignment)
(curved alignment)
(curved alignment)
Reference point Position of the reference point
bottom left
bottom center
bottom right
top left
top center
top right
left-hand edge
center
right-hand edge
Mirror writing Yes
The mirrored text is engraved on the workpiece.

No
The text is engraved on the workpiece without mirroring.

Engraving text maximum 100 characters
X0 or R Reference point X (abs) or reference point length polar mm
(in ShopMill for curved alignment only)
Y0 or 0 Reference point Y (abs) or reference point angle polar mm or
(in ShopMill for curved alignment only) degrees
X0 Reference point Y (abs) mm
(for linear alignment only)
Y0 Reference point Y (abs) mm
(for linear alignment only)
Z0 Reference point Z (abs) mm
Z1 Engraving depth (abs) or depth referred to Z0 (inc) mm
W Character height mm
DX1 or 2 Distance between characters or angle of opening (for curved alignment only) mm or
degrees
DX1 or DX2 Distance between characters or total width (for linear alignment only) mm
1 Text direction (for linear alignment only) Degrees
XM or LM Center point X (abs) or center point length polar mm
(only for G code) (for curved alignment only)
YM or M Center point Y (abs) or center point angle polar mm or
(only for G code) (for curved alignment only) degrees
Milling
8.2 Milling

XM Center point X (abs) mm
(ShopMill only) (only for curved alignment)
YM Center point Y (abs) mm
(ShopMill only) (only for curved alignment)
Milling
8.3 Contour milling
8.3 Contour milling
8.3.1 General
Function
You can mill simple or complex contours with the "Contour milling" cycle. You can define
open contours or closed contours (pockets, islands, spigots).
A contour comprises separate contour elements, whereby at least two and up to 250
elements result in a defined contour. Radii, chamfers and tangential transitions are available
as contour transition elements.
The integrated contour calculator calculates the intersection points of the individual contour
elements taking into account the geometrical relationships, which allows you to enter
incompletely dimensioned elements.
With contour milling, you must always program the geometry of the contour before you
program the technology.
8.3.2 Representation of the contour
G Code program
In the editor, the contour is represented in a program section using individual program
blocks. If you open an individual block, then the contour is opened.
ShopMill program
The cycle represents a contour as a program block in the program. If you open this block,
the individual contour elements are listed symbolically and displayed in broken-line graphics.
Symbolic representation
The individual contour elements are represented by symbols adjacent to the graphics
window. They appear in the order in which they were entered.
Contour element Symbol Meaning

Starting point Starting point of the contour
Straight line up Straight line in 90 grid

Straight line down Straight line in 90 grid
Straight line left Straight line in 90 grid

Straight line right Straight line in 90 grid
Milling
8.3 Contour milling

Straight line in any direction Straight line with any gradient
Arc right Circle

Arc left Circle
Pole Straight diagonal or circle in

polar coordinates
Finish contour END End of contour definition
The different colors of the symbols indicate their status:
Foreground Background Meaning

Black Blue Cursor on new element
Black Orange Cursor on current element
Black White Normal element
Red White Element not currently evaluated
(element will only be evaluated
when it is selected with the
cursor)
Graphical display
The progress of contour programming is shown in broken-line graphics while the contour
elements are being entered.
When the contour element has been created, it can be displayed in different line styles and
colors:
Black: Programmed contour
Orange: Current contour element
Green dashed: Alternative element
Blue dotted: Partially defined element
The scaling of the coordinate system is adjusted automatically to match the complete
contour.
The position of the coordinate system is displayed in the graphics window.
Milling
8.3 Contour milling
8.3.3 Creating a new contour
Function
For each contour that you want to mill, you must create a new contour.
The contours are stored at the end of the program.
Note
When programming in the G code, it must be ensured that the contours are located after the
end of program identifier!
The first step in creating a contour is to specify a starting point. Enter the contour element.
The contour processor then automatically defines the end of the contour.
If you alter the tool axis, the cycle will automatically adjust the associated starting point axes.
You can enter any additional commands (up to 40 characters) in G code format for the
starting point.
Additional commands
You can program feedrates and M commands, for example, using additional G code
commands. You can enter the additional commands (max. 40 characters) in the extended
parameter screens ("All parameters" softkey). However, make sure that the additional
commands do not collide with the generated G code of the contour. Therefore, do not use
any G code commands of group 1 (G0, G1, G2, G3), no coordinates in the plane and no G
code commands that have to be programmed in a separate block.
Procedure

2. Press the "Contour milling" and "New contour" softkeys.
3. Enter a contour name.

The input screen for the starting point of the contour appears. You can
enter Cartesian or polar coordinates.
Milling
8.3 Contour milling
Cartesian starting point
1. Enter the starting point for the contour.

2. Enter any additional commands in G code format, as required.
4. Enter the individual contour elements.
Polar starting point
1. Press the "Pole" softkey.
2. Enter the pole position in Cartesian coordinates.

3. Enter the starting point for the contour in polar coordinates.
4. Enter any additional commands in G code format, as required.
6. Enter the individual contour elements.

PL Machining plane
Cartesian:
X Starting point X (abs) mm
Y Starting point Y (abs) mm
Polar:
X Position pole (abs) mm
Y Position pole (abs) Degrees
Starting point
L1 Distance to pole, end point (abs) mm
1 Polar angle to the pole, end point (abs) Degrees
Additional The contour is finished in continuous-path mode (G64). As a result, contour transitions
commands such as corners, chamfers or radii may not be machined precisely.
If you wish to avoid this, there is a possibility to use additional commands when
programming.
Example: For a contour, first program the X parallel straight line and then enter "G9"
(non-modal exact stop) for the additional command parameter. Then program the Y-
parallel straight line. The corner will be machined exactly, as the feedrate at the end of
the X-parallel straight line is briefly zero.
Note:
The additional commands are only effective for path milling!
Milling
8.3 Contour milling
8.3.4 Creating contour elements

After you have created a new contour and specified the starting point, you can define the
individual elements that make up the contour.
The following contour elements are available for the definition of a contour:
Straight vertical line
Straight horizontal line
Diagonal line
Circle/arc
Pole
For each contour element, you must parameterize a separate parameter screen.
The coordinates for a horizontal or vertical line are entered in Cartesian format; however, for
the contour elements Diagonal line and Circle/arc you can choose between Cartesian and
polar coordinates. If you wish to enter polar coordinates you must first define a pole. If you
have already defined a pole for the starting point, you can also refer the polar coordinates to
this pole. Therefore, in this case, you do not have to define an additional pole.
Cylinder surface transformation

For contours (e.g. slots) on cylinders, lengths are frequently specified in the form of angles. If
the "Cylinder surface transformation" function is activated, you can also define on a cylinder
the length of contours (in the circumferential direction of the cylinder surface) using angles.
This means instead of X, Y and I, J, you enter X, Y and I, J.
Parameter input
Parameter entry is supported by various help screens that explain the parameters.
If you leave certain fields blank, the geometry processor assumes that the values are
unknown and attempts to calculate them from other parameters.
Conflicts may result if you enter more parameters than are absolutely necessary for a
contour. In such a case, try to enter fewer parameters and allow the geometry processor to
calculate as many parameters as possible.
Contour transition elements

As a transition between two contour elements, you can choose a radius or a chamfer. The
transition element is always attached at the end of a contour element. The contour transition
element is selected in the parameter screen of the respective contour element.
You can use a contour transition element whenever there is an intersection between two
successive elements which can be calculated from the input values. Otherwise you must use
the straight/circle contour elements.
Milling
8.3 Contour milling
The contour end is an exception. Although there is no intersection to another element, you
can still define a radius or a chamfer as a transition element for the blank.
Additional functions
The following additional functions are available for programming a contour:
Tangent to preceding element
You can program the transition to the preceding element as tangent.
Dialog box selection
If two different possible contours result from the parameters entered thus far, one of the
options must be selected.
Close contour
From the actual position, you can close the contour with a straight line to the starting
point.
Procedure for entering contour elements
1. The part program or the machining schedule is opened. Position the

cursor at the desired entry position.
2. Contour input using contour support:
2.1 Press the "Contour milling", "Contour" and "New contour" softkeys.
2.2 In the opened input window, enter a name for the contour, e.g.
contour_1.
2.3 The input screen to enter the contour opens, in which you initially enter
a starting point for the contour. This is marked in the lefthand navigation
bar using the "+" symbol.
3. Enter the individual contour elements of the machining direction.
Select a contour element via softkey.
The "Straight (e.g. X)" input window opens.
- OR
The "Straight (e.g. Y)" input window opens.
- OR
Milling
8.3 Contour milling
The "Straight (e.g. XY)" input window opens.
- OR
The "Circle" input window opens.
- OR
The "Pole Input" input window opens.
4. Enter all the data available from the workpiece drawing in the input
screen (e.g. length of straight line, target position, transition to next
element, angle of lead, etc.).
The contour element is added to the contour.
6. When entering data for a contour element, you can program the
transition to the preceding element as a tangent.
Press the "Tangent to prec. elem." softkey. The "tangential" selection
appears in the parameter 2 entry field.
7. Repeat the procedure until the contour is complete.
The programmed contour is transferred into the process plan (program
view).
9. If you want to display further parameters for certain contour elements,
e.g. to enter additional commands, press the "All parameters" softkey.
Contour element "Straight line, e.g. X"

X End point X (abs or inc) mm
1 Starting angle e.g. to the X axis Degrees
2 Angle to the preceding element Degrees
Transition to next Type of transition
element
Radius
Chamfer
Radius R Transition to following element - radius mm
Chamfer FS Transition to following element - chamfer mm
Additional commands Additional G code commands
Milling
8.3 Contour milling
Contour element "straight line, e.g. Y"

Y End point Y (abs or inc) mm
1 Starting angle to X axis Degrees
element
Radius
Chamfer
Contour element "Straight line, e.g. XY"

X End point X (abs or inc) mm
Y End point Y (abs or inc) mm
L Length mm
1 Starting angle e.g. to the X axis Degrees
element
Radius
Chamfer
Contour element "Circle"

Direction of rotation
Clockwise direction of rotation
Counterclockwise direction of rotation

R Radius mm
e.g. X End point X (abs or inc) mm
e.g. Y End point Y (abs or inc) mm
e.g. I Circle center point I (abs or inc) mm
Milling
8.3 Contour milling

e.g. J Circle center point J (abs or inc) mm
1 Starting angle to X axis Degrees
1 End angle to Z axis Degrees
2 Angle of opening Degrees
element
Radius
Chamfer
Contour element "Pole"

X Position pole (abs) mm
Y Position pole (abs) mm
Contour element "End"

The data for the transition at the contour end of the previous contour element is displayed in
the "End" parameter screen.
The values cannot be edited.
Milling
8.3 Contour milling
8.3.5 Changing the contour
Function
You can change a previously created contour later.
If you want to create a contour that is similar to an existing contour, you can copy the
existing one, rename it and just alter selected contour elements.
Individual contour elements can be
added,
changed,
inserted or
deleted.
Procedure for changing a contour element
1. Open the part program or ShopMill program to be executed.

2. With the cursor, select the program block where you want to change the
contour. Open the geometry processor.
The individual contour elements are listed.
3. Position the cursor at the position where a contour element is to be
inserted or changed.
4. Select the desired contour element with the cursor.
5. Enter the parameters in the input screen or delete the element and
select a new element.
The desired contour element is inserted in the contour or changed.
Procedure for deleting a contour element
1. Open the part program or ShopMill program to be executed.

2. Position the cursor on the contour element that you want to delete.
3. Press the "Delete element" softkey.
4. Press the "Delete" softkey.
Milling
8.3 Contour milling
8.3.6 Contour call (CYCLE62) - only for G code program
Function
The input creates a reference to the selected contour.
There are four ways to call the contour:
1. Contour name
The contour is in the calling main program.
2. Labels
The contour is in the calling main program and is limited by the labels that have been
entered.
3. Subprogram
The contour is located in a subprogram in the same workpiece.
4. Labels in the subprogram
The contour is in a subprogram and is limited by the labels that have been entered.
Procedure
1. The subprogram to be edited has been created and you are in the
editor.
2. Press the "Contour milling" softkey.
3. Press the "Contour" and "Contour call" softkeys.

The "Contour Call" input window opens.
4. Assign parameters to the contour selection.

Contour selection Contour name
Labels
Subprogram
Labels in the subprogram
Contour name CON: Contour name
Labels LAB1: Label 1
LAB2: Label 2
Milling
8.3 Contour milling

Subprogram PRG: Subprogram
Labels in the PRG: Subprogram
subprogram
LAB1: Label 1
LAB2: Label 2
8.3.7 Path milling (CYCLE72)
Function
You can mill along any programmed contour with the "Path milling" cycle. The function
operates with cutter radius compensation. Machining can be performed in either direction,
i.e. in the direction of the programmed contour or in the opposite direction.
It is not imperative that the contour is closed. You can perform any of the following
operations:
Inside or outside machining (on left or right of the contour).
Machining along center-point path.
For machining in the opposite direction, contours must not consist of more than 170 contour
elements (incl. chamfers/radii). Special aspects (except for feed values) of free G code input
are ignored during path milling in the opposite direction to the contour.
Programming of arbitrary contours

The machining of arbitrary open or closed contours is generally programmed as follows:
1. Enter contour
You build up the contour gradually from a series of different contour elements.
2. Contour call (CYCLE62)
You select the contour to be machined.
3. Path milling (roughing)
The contour is machined taking into account various approach and retract strategies.
4. Path milling (finishing)
If you programmed a finishing allowance for roughing, the contour is machined again.
5. Path milling (chamfering)
If you have planned edge breaking, chamfer the workpiece with a special tool.
Milling
8.3 Contour milling
Path milling on right or left of the contour

A programmed contour can be machined with the cutter radius compensation to the right or
left. You can also select various modes and strategies of approach and retraction from the
contour.
Approach/retraction mode
The tool can approach or retract from the contour along a quadrant, semi-circle or straight
line.
With a quadrant or semi-circle, you must specify the radius of the cutter center point path.
With a straight line, you must specify the distance between the cutter outer edge and the
contour starting or end point.
You can also program a mixture of modes, e.g. approach along quadrant, retract along semi-
circle.
Approach/retraction strategy
You can choose between planar approach/retraction and spatial approach/retraction:
Planar approach:
Approach is first at depth and then in the machining plane.
Spatial approach:
Approach is at depth and in machining plane simultaneously.
Retraction is performed in reverse order.
Mixed programming is possible, for example, approach in the machining plane, retract
spatially.
Path milling along center-point path.

A programmed contour can also be machined along the center-point path if the radius
correction was switched-out. In this case, approaching and retraction is only possible along a
straight line or vertical. Vertical approach/retraction can be used for closed contours, for
example.
Procedure

2. Press the "Contour milling" and "Path milling" softkeys.
The "Path Milling" input window opens.
Milling
8.3 Contour milling

mm/tooth

cutting rate m/min

(finishing)
Chamfering
Machining Machining in the programmed contour direction
direction
Forward:
Machining is performed in the programmed contour direction

Backward:
Machining is performed in the opposite direction to the programmed contour

Radius Left (machining to the left of the contour)
compensation
Right (machining to the right of the contour)
off
A programmed contour can also be machined on the center-point path. In this case,
approaching and retraction is only possible along a straight line or vertical. Vertical
approach/retraction can be used for closed contours, for example.
Z0 Reference point Z (abs or inc)
Z1 Final depth (abs) or final depth referred to Z0 (inc) - (only for and ) mm
UZ Depth finishing allowance - (only for ) mm
FS Chamfer width for chamfering (inc) - (for chamfering only) mm
UXY Finishing allowance, plane - (only for and G code, not for radius compensation off) mm
Milling
8.3 Contour milling

Approach Planar approach mode:
Straight line:
Slope in space
Quadrant:
Part of a spiral (only with path milling left and right of the contour)
Semi-circle:
Perpendicular:
Perpendicular to the path (only with path milling on the center-point path)
Approach strategy Axis by axis
Spatial (only for "quadrant, semi-circle or straight line" approach)
R1 Approach radius - (only for "quadrant or semi-circle" approach) mm

L1 Approach distance - (only for "straight line" approach) mm
Retraction Planar retraction mode:
Straight line
Quadrant:
Semi-circle:
Retraction Axis by axis
strategy
Spatial (not with perpendicular approach mode)
R2 Retraction radius - (only for "quadrant or semi-circle" retraction) mm

L2 Retraction distance - (only for "straight line" retraction) mm
Lift mode If more than one depth infeed is necessary, specify the retraction height to which the
tool retracts between the individual infeeds (at the transition from the end of the contour
to the start).
Lift mode before new infeed
Z0 + safety clearance
By the safety clearance
to RP
No retraction
Milling
8.3 Contour milling

FZ Depth infeed rate (only for axis-by-axis approach strategy) mm/min
FZ - (only for G Depth infeed rate (only for axis-by-axis approach strategy) *
code)
FS Chamfer width for chamfering - (only for chamfering machining) mm
ZFS Insertion depth of tool tip (abs or inc) - (for machining only) mm
Note
Cylinder surface transformation with slot side compensation
For cylinder surface transformation with selected slot side compensation and
approach/retraction in quadrant or semi-circle, the approach/retraction radius must be
greater than Offset to programmed path tool radius.
8.3.8 Contour pocket/contour spigot (CYCLE63/64)
Contours for pockets or islands

Contours for pockets or islands must be closed, i.e. the starting point and end point of the
contour are identical. You can also mill pockets that contain one or more islands. The islands
can also be located partially outside the pocket or overlap each other. The first contour you
specify is interpreted as the pocket contour and all the others as islands.
Automatically calculating/Manually entering the starting point

Using "Automatic starting point" you have the option of calculating the optimum plunge point.
By selecting "Manual starting point", you define the plunge point in the parameter screen.
If the islands and the miller diameter, which must be plunged at various locations, are
obtained from the pocket contour, then the manual entry only defines the first plunge point;
the remaining plunge points are automatically calculated.
Contours for spigots

Contours for spigots must be closed, i.e. the starting point and end point of the contour are
identical. You can define multiple spigots, which can also overlap. The first contour specified
is interpreted as a blank contour and all others as spigots.
Milling
8.3 Contour milling
Machining
You program the machining of contour pockets with islands/blank contour with spigots e.g.
as follows:
1. Enter the pocket contour/blank contour
2. Enter the island/spigot contour
3. Call the contour for pocket contour/blank contour or island/spigot contour (only for G code
program)
4. Center (this is only possible for pocket contour)
5. Predrill (this is only possible for pocket contour)
6. Solid machine/machine pocket / spigot - roughing
7. Solid machine/machine remaining material - roughing
8. Finishing (base/edge)
9. Chamfering
Software option
For solid machining residual material, you require the option "residual material
detection and machining".
Name convention
For multi-channel systems, cycles attach a "_C" and a two-digit number of the specific
channel to the names of the programs to be generated, e.g. for channel 1 "_C01". This is the
reason that the name of the main program must not end with "_C" and a two-digit number.
This is monitored by the cycles.
For single-channel systems, cycles do not extend the name for the programs to be
generated.
Note
G code programs
For G code programs, the programs to be generated, which do not include any path data,
are saved in the directory in which the main program is located. In this case, it must be
ensured that programs, which already exist in the directory and which have the same name
as the programs to be generated, are overwritten.
Milling
8.3 Contour milling
8.3.9 Predrilling contour pocket (CYCLE64)
Function
In addition to predrilling, the cycle can be used for centering. The centering or predrilling
program generated by the cycle is called for this purpose.
The number and positions of the required predrilled holes depends on the specific
conditions, e.g. type of contour, tool, plane infeed, finishing allowances.
If you mill several pockets and want to avoid unnecessary tool changes, predrill all the
pockets first and then remove the stock. In this case, for centering/predrilling, you also have
to enter the parameters that appear when you press the "All parameters" softkey. These
parameters must correspond to the parameters from the previous stock removal step.
Programming
When programming, proceed as follows:
1. Contour pocket 1
2. Centering
3. Contour pocket 2
4. Centering
5. Contour pocket 1
6. Predrilling
7. Contour pocket 2
8. Predrilling
9. Contour pocket 1
10.Stock removal
11.Contour pocket 2
12.Stock removal
If you are doing all the machining for the pocket at once, i.e. centering, rough-drilling and
removing stock directly in sequence, and do not set the additional parameters for
centering/rough-drilling, the cycle will take these parameter values from the stock removal
(roughing) machining step. When programming in G code, these values must be specifically
re-entered.
Milling
8.3 Contour milling
Procedure when centering

2. Press the "Cont. mill.", "Predrilling", and "Centering" softkeys.

PRG Name of the program to be generated T Tool name
PL Machining plane D Cutting edge number
Milling direction Climbing F Feedrate mm/min

mm/tooth
Conventional
RP Retraction plane mm S/V Spindle speed or constant rpm

cutting rate m/min
SC Safety clearance mm
F Feedrate mm/min

TR Reference tool Tool, which is used in the "solid machining" machining step. This is
used to determine the plunge position.
Z1 Depth with reference to Z0 (inc.) mm
%
UXY Finishing allowance, plane mm

Lift mode Lift mode before new infeed
If the machining operation requires several points of insertion, the retraction height to
which the tool is retracted, is selected as follows:
To retraction plane mm
Z0 + safety clearance mm
If there are no elements larger than Z0 in the pocket area, "Z0 + safety clearance" can
be selected as the lift mode.
Milling
8.3 Contour milling
Predrilling procedure

2. Press the "Cont. mill.", "Predrilling", and "Predrilling" softkeys.
The "Predrilling" input window opens.


mm/tooth
Conventional

cutting rate m/min
F Feedrate mm/min

used to determine the plunge position.
Z0 Reference point in the tool axis Z mm
Z1 Pocket depth (abs) or depth referred to Z0 (inc) mm
%

Milling
8.3 Contour milling
8.3.10 Milling contour pocket (CYCLE63)
Function
Before you can machine a pocket with islands, you must enter the contour of the pocket and
islands. The first contour you specify is interpreted as the pocket contour and all the others
as islands.
From the programmed contours and the input screen form for stock removal, the cycle
generates a program that removes the pockets with islands from inside to outside in parallel
to the contour.
The islands can also be located partially outside the pocket or overlap each other.
Procedure

2. Press the "Contour milling" and "Pocket" softkeys.
The "Mill pocket" input window opens.


mm/tooth
Conventional

cutting rate m/min
F Feedrate mm/min
Milling
8.3 Contour milling

(roughing)
Chamfering
Z1 Pocket depth (abs) or depth relative to Z0 (inc) mm
- (only for , base or edge)
%
- (only for or base)
DZ Maximum depth infeed (only for or edge) mm
UXY Plane finishing allowance (only for , base or edge) mm
UZ Depth finishing allowance (only for or base) mm
Starting point Manual
Starting point is manually entered

Automatic
Starting point is automatically calculated

- (only for or base)
XS Starting point X - (only for "manual" starting point) mm
YS Starting point Y - (only for "manual" starting point) mm
Insertion The following insertion modes can be selected (only for , base or edge):
Vertical insertion
The calculated current infeed depth is executed at the calculated position for
"automatic" starting point or at the specified position for "manual" starting point.
Note:
This setting can be used only if the cutter can cut across center or if the pocket has
been predrilled.
Helical insertion
reached, a full circle motion is executed to eliminate the inclined insertion path.
Oscillating insertion
The cutter center point oscillates back and forth along a linear path until it reaches
the depth infeed. When the depth has been reached, the path is traversed again
without depth infeed in order to eliminate the inclined insertion path.
FZ (only for Depth infeed rate (only for perpendicular insertion and ) mm/min
ShopMill) mm/tooth
FZ (only for G Depth infeed rate (only for perpendicular insertion and ) *
code)
Milling
8.3 Contour milling

The radius cannot be any larger than the cutter radius; otherwise, material will remain.
EW Maximum insertion angle (for insertion with oscillation only) Degrees
Lift mode Lift mode before new infeed - (only for , base or edge)
To retraction plane
mm
mm
Note
When input manually, the starting point can also be located outside the pocket. This can be
useful, for example, when machining a pocket which is open on one side. The machining
operation then begins without insertion with a linear movement into the open side of the
pocket.
8.3.11 Residual material contour pocket (CYCLE63)
Function
When you have removed stock from a pocket (with/without islands) and there is residual
material, then this is automatically detected. You can use a suitable tool to remove this
residual material without having to machine the whole pocket again, i.e. avoiding
unnecessary non-productive motion. Material that remains as part of the finishing allowance
is not residual material.
The residual material is calculated on the basis of the milling cutter used for stock removal.
If you mill several pockets and want to avoid unnecessary tool changes, remove stock from
all the pockets first and then remove the residual material. In this case, for removing the
residual material, you also have to enter a value for the reference tool TR parameter, which,
for the ShopMill program, additionally appears when you press the "All parameters" softkey.
When programming, you must then proceed as follows:
1. Contour pocket 1
2. Solid machining
3. Contour pocket 2
4. Solid machining
5. Contour pocket 1
Milling
8.3 Contour milling
6. Remove residual material

7. Contour pocket 2
8. Remove residual material
Software option
Procedure

2. Press the "Contour milling" and "Pocket Res. Mat." softkeys.
The "Pocket Res. Mat." input window opens.
3. For the ShopMill program, press the "All parameters" softkey if you
want to enter additional parameters.

PL Machining plane F Feedrate mm/min
mm/tooth
Milling direction Climbing S/V Spindle speed or constant cutting rpm

rate m/min
Conventional
RP Retraction plane mm
F Feedrate mm/min

(roughing)
TR Reference tool Tool, which is used in the "solid machining" machining step. Is used to
determine the residual material.
D Cutting edge number
Milling
8.3 Contour milling

%
mm
To retraction plane
mm
8.3.12 Milling contour spigot (CYCLE63)
Function
You can mill any spigot using the "Mill spigot" cycle.
Before you mill the spigot, you must first enter a blank contour and then one or more spigot
contours. The blank contour defines the area, outside of which there is no material, i.e. the
tool moves with rapid traverse there. Material is then removed between the blank contour
and spigot contour.
Machining type
You can select the machining mode (roughing, base finishing, edge finishing, chamfer) for
milling. If you want to rough and then finish, you have to call the machining cycle twice
(Block 1 = roughing, Block 2 = finishing). The programmed parameters are retained when
the cycle is called for the second time.
Approach/retraction
1. The tool approaches the starting point in rapid traverse at the height of the retraction
plane and goes to the safety clearance. The cycle calculates the starting point.
2. The tool first infeeds to the machining depth and then approaches the spigot contour from
the side in a quadrant at machining feedrate.
3. The spigot is machined in parallel with the contours from the outside in. The direction is
determined by the machining direction (climbing or conventional).
4. When the first plane of the spigot has been machined, the tool retracts from the contour
in a quadrant and then infeeds to the next machining depth.
Milling
8.3 Contour milling
5. The spigot is again approached in a quadrant and machine in parallel with the contours
from outside in.
6. Steps 4 and 5 are repeated until the programmed spigot depth is reached.
7. The tool moves back to the safety clearance in rapid traverse.
Procedure

2. Press the "Contour milling" and "Spigot" softkeys.
The "Mill spigot" input window opens.
3. Select the "Roughing" machining type.


mm/tooth
Conventional

cutting rate m/min
F Feedrate mm/min

(roughing)
Chamfering
Z1 Pocket depth (abs) or depth relative to Z0 (inc) mm
- (only for , base or edge)
%
- (only for and base)
Milling
8.3 Contour milling

DZ Maximum depth infeed (only for or edge) mm
UXY Plane finishing allowance (only for , base or edge) mm
UZ Depth finishing allowance (only for or base) mm
If there are no elements larger than Z0 (X0) in the pocket area, then Z0 (X0) + safety mm
clearance can be programmed as the lift mode.
8.3.13 Residual material contour spigot (CYCLE63)
Function
When you have milled a contour spigot and residual material remains, then this is
automatically detected. You can use a suitable tool to remove this residual material without
having to machine the whole spigot again, i.e. avoiding unnecessary non-productive motion.
Material that remains as part of the finishing allowance is not residual material.
The residual material is calculated on the basis of the milling cutter used for clearing.
If you mill several spigots and want to avoid unnecessary tool changes, clear all the spigots
first and then remove the residual material. In this case, for removing the residual material,
you also have to enter a value for the reference tool TR parameter, which, for the ShopMill
program, additionally appears when you press the "All parameters" softkey. When
programming, you must then proceed as follows:
1. Contour blank 1
2. Contour spigot 1
3. Clear spigot 1
4. Contour blank 2
5. Contour spigot 2
6. Clear spigot 2
7. Contour blank 1
8. Contour spigot 1
9. Clear residual material spigot 1
10.Contour blank 2
Milling
8.3 Contour milling
11.Contour spigot 2
12.Clear residual material spigot 2
Software option
Procedure

2. Press the "Contour milling" and "Spigot Res. Mat." softkeys.
The "Spigot Res. Mat." input window opens.
3. For the ShopMill program, press the "All parameters" softkey if you
want to enter additional parameters.

PL Machining plane F Feedrate mm/min
mm/tooth
Milling direction Climbing S/V Spindle speed or constant rpm

cutting rate m/min
Conventional
RP Retraction plane mm
F Feedrate mm/min

used to determine the residual corners.
%
Milling
8.3 Contour milling

Milling
8.4 Turning - only for G code programs
8.4.1 General
In all turning cycles apart from contour turning (CYCLE95), in the combined roughing and
finishing mode, when finishing it is possible to reduce the feedrate as a percentage.
Please also refer to the machine manufacturer's specifications.
8.4.2 Stock removal (CYCLE951)
Function
You can use the "Stock removal" cycle for longitudinal or transverse stock removal of
corners at outer or inner contours.
Note
Removing stock from corners
For this cycle, the safety clearance is additionally limited using setting data. The lower value
is taken for machining.
Machining method
Roughing
In roughing applications, paraxial cuts are machined to the finishing allowance that has
been programmed. If no finishing allowance has been programmed, the workpiece is
roughed down to the final contour.
During roughing, the cycle reduces the programmed infeed depth D if necessary so that it
is possible for cuts of an equal size to be made. For example, if the overall infeed depth is
10 and you have specified an infeed depth of 3, this would result in cuts of 3, 3, 3 and 1.
The cycle would reduce the infeed depth to 2.5 to create 4 equally sized cuts.
The angle between the contour and the tool cutting edge determines whether the tool
rounds the contour at the end of each cut by the infeed depth D, in order to remove
residual corners, or is raised immediately. The angle beyond which rounding is performed
is stored in a machine data element.
Milling
If the tool does not round the corner at the end of the cut, it is raised by the safety distance
or a value specified in the machine data at rapid traverse. The cycle always observes the
lower value; otherwise, stock removal at inner contours, for example, could cause the
contour to be damaged.
Finishing
Finishing is performed in the same direction as roughing. The cycle automatically selects
and deselects tool radius compensation during finishing.
Procedure
1. The part program to be executed has been created and you are in the
editor.
2. Press the "Turning" softkey.
3. Press the "Stock removal" softkey.

The "Stock Removal" input window opens.
4. Select one of the three stock removal cycles via the softkeys:
Simple straight stock removal cycle.
The "Stock removal 1" input window opens.
- OR
Straight stock removal cycle with radii or chamfers.
The "Stock removal 2" input window opens.
- OR
Stock removal cycle with oblique lines, radii, or chamfers.
The "Stock Removal 3" input window opens.
Milling
Parameters, G code program

PL Machining plane
F Feedrate *

(finishing)
Position Stock removal position:
Machining Stock removal direction (longitudinal or transverse) in the coordinate system

direction Parallel to the Z axis (longitudinal) Parallel to the X axis (transverse)
External Internal External internal
X0 Reference point in X (abs, always diameter) mm

Z0 Reference point in Z (abs) mm
X1 End point X (abs) or end point X in relation to X0 (inc) mm
Z1 End point Z (abs) or end point Z in relation to Z0 (inc) mm
D Maximum depth infeed (not for finishing) mm
UX Finishing allowance in X (not for finishing) mm
UZ Finishing allowance in Z (not for finishing) mm
FS1...FS3 or R1...R3 Chamfer width (FS1...FS3) or rounding radius (R1...R3) - (not for mm
stock removal 1)
Milling

Parameter selection of intermediate point
The intermediate point can be determined through position specification or angle.
The following combinations are possible - (not for stock removal 1 and 2)
XM ZM
XM 1
XM 2
1 ZM
2 ZM
1 2
XM Intermediate point X (abs) or intermediate point X in relation to X0 (inc) mm
ZM Intermediate point Z (abs or inc) mm
1 Angle of the 1st edge Degrees
2 Angle of the 2nd edge Degrees
8.4.3 Groove (CYCLE930)
Function
You can use the "Groove" cycle to manufacture symmetrical and asymmetrical grooves on
any straight contour elements.
You can machine outer or inner grooves in the longitudinal or transverse directions. Use the
"Groove width" and "Groove depth" parameters to determine the shape of the groove. If a
groove is wider than the active tool, it is machined in several cuts. The tool is moved by a
maximum of 80% of the tool width for each groove.
You can specify a finishing allowance for the groove base and the flanks; roughing is then
performed down to this point.
The dwell time between recessing and retraction is stored in a setting data element.
Please also refer to the machine manufacturer's specifications.
Approach/retraction during roughing

Infeed depth D > 0
1. The tool first moves to the starting point calculated internally in the cycle at rapid traverse.
2. The tool cuts a groove in the center of infeed depth D.
3. The tool moves back by D + safety clearance with rapid traverse.
4. The tool cuts a groove next to the first groove with infeed depth 2 D.
Milling
5. The tool moves back by D + safety clearance with rapid traverse.

6. The tool cuts alternating in the first and second groove with the infeed depth 2 D, until
the final depth T1 is reached.
Between the individual grooves, the tool moves back by D + safety clearance with rapid
traverse. After the last groove, the tool is retracted at rapid traverse to the safety
distance.
7. All subsequent groove cuts are made alternating and directly down to the final depth T1.
Between the individual grooves, the tool moves back to the safety distance at rapid
traverse.
Approach/retraction during finishing

2. The tool moves at the machining feedrate down one flank and then along the bottom to
the center.
3. The tool moves back to the safety distance at rapid traverse.
4. The tool moves at the machining feedrate along the other flank and then along the bottom
to the center.
Procedure
editor.
3. Press the "Groove" softkey.

The "Groove" input window opens.
4. Select one of the three groove cycles with the softkey:
Simple groove cycle
The "Groove 1" input window opens.
- OR
Groove cycle with inclines, radii, or chamfers.
- OR
Groove cycle on an incline with inclines, radii or chamfers.
Milling

PL Machining plane
F Feedrate *

(finishing)
+ (roughing and finishing)
Position Groove position/reference point:
X0 Reference point in X mm
Z0 Reference point in Z mm
B1 Groove width mm
T1 Groove depth (abs) or groove depth referred to X0 or Z0 (inc) mm
1, 2 Flank angle 1 or flank angle 2 - (only for grooves 2 and 3) Degrees
Asymmetric grooves can be described by separate angles. The angles can be
between 0 and < 90.
0 Angle of inclinations (only for groove 3) Degrees
FS1...FS4 or R1...R4 Chamfer width (FS1...FS4) or rounding radius (R1...R4) - (only for grooves 2 and mm
3)
D Maximum depth infeed for insertion (only for and + ) mm
For zero: Insertion in a cut (only for and + )
D = 0: 1. cut is made directly to final depth T1
D > 0: 1st and 2nd cuts are made alternately to infeed depth D, in order to achieve
a better chip flow and prevent the tool from breaking, refer to
approaching/retraction when roughing.
Alternate cutting is not possible if the tool can only reach the groove base at one
position.
UX or U Finishing allowance in X or finishing allowance in X and Z (only for and + mm
)
UZ Finishing allowance in Z (for UX, only for and + ) mm
N Number of grooves (N = 1....65535)
DP Distance between grooves (inc) mm
DP is not displayed when N = 1
Milling
8.4.4 Undercut form E and F (CYCLE940)
Function
You can use the "Undercut form E" or "Undercut form F" cycle to turn form E or F undercuts
in accordance with DIN 509.
Approach/retraction
2. The undercut is made in one cut at the machining feedrate, starting from the flank
through to the cross-feed VX.
3. The tool moves back to the starting point at rapid traverse.
Procedure
editor.
3. Press the "Undercut" softkey.

The "Undercut" input window opens.
4. Select one of the following undercut cycles via the softkeys:
Press the "Undercut form E" softkey.
The "Undercut form E (DIN 509)" input window opens.
- OR
Press the "Undercut form F" softkey.
The "Undercut form F (DIN 509)" input window opens.
Milling
Parameters, G code program (undercut, form E)

PL Machining plane
F Feedrate *

Position Form E machining position:
Undercut size according to DIN table:

E.g.: E1.0 x 0.4 (undercut form E)
X1 Allowance in X (abs) or allowance in X (inc) mm
UX Cross feed (abs) or cross feed (inc) mm
Parameters, G code program (undercut, form F)

PL Machining plane
F Feedrate *
Milling

Position Form F machining position:
Undercut size according to DIN table:

e.g.: F0.6 x 0.3 (undercut form F)
X1 Allowance in X (abs) or allowance in X (inc) mm
Z1 Allowance in Z (abs) or allowance in Z (inc) (for undercut form F only) mm
VX Cross feed (abs) or cross feed (inc) mm
8.4.5 Thread undercut (CYCLE940)
Function
You can use the "Thread undercut DIN" or "Thread undercut" cycle to program thread
undercuts to DIN 76 for workpieces with a metric ISO thread, or freely definable thread
undercuts.
Approach/retraction
2. The first cut is made at the machining feedrate, starting from the flank and traveling along
the shape of the thread undercut as far as the safety distance.
3. The tool moves to the next starting position at rapid traverse.
4. Steps 2 and 3 are repeated until the thread undercut is finished.
5. The tool moves back to the starting point at rapid traverse.
During finishing, the tool travels as far as cross-feed VX.
Milling
Procedure
editor.
3. Press the "Undercut" softkey.
4. Press the "Thread undercut DIN" softkey.

The "Thread Undercut (DIN 76)" input window opens.
- OR -
Press the "Thread undercut" softkey.
The "Thread Undercut" input window opens.
Parameters, G code program (undercut, thread DIN)

PL Machining plane
F Feedrate *

(finishing)
Position Machining position:
Machining Longitudinal
direction
Parallel to the contour
Form Normal (form A)
Short (form B)
P Thread pitch (select from the preset DIN table or enter) mm/rev
Milling

Insertion angle Degrees
VX Cross feed (abs) or cross feed (inc) - (only for and + ) mm
D Maximum depth infeed (only for and + ) mm
U or UX Finishing allowance in X or finishing allowance in X and Z (only for and + mm
)
UZ Finishing allowance in Z (only for UX, and + ) mm
Parameters, G code program (undercut, thread)

PL Machining plane
F Feedrate *

(finishing)
Machining Longitudinal
direction
Position Machining position:
X1 Undercut depth referred to X (abs) or undercut depth referred to X (inc)
Z1 Allowance Z (abs or inc)
R1 Rounding radius 1 mm
R2 Rounding radius 2 mm
VX Cross feed (abs) or cross feed (inc) - (only for and + )
D Maximum depth infeed (only for and + ) mm
Milling

U or UX Finishing allowance in X or finishing allowance in X and Z (only for and + mm
)
UZ Finishing allowance in Z (only for UZ, and + ) mm
8.4.6 Thread turning (CYCLE99)
Function
You can use the "Longitudinal thread", "Tapered thread" or "Face thread" cycle to turn
external or internal threads with a constant or variable pitch.
There may be single or multiple threads.
For metric threads (thread pitch P in mm/rev), the cycle assigns a value (calculated on the
basis of the thread pitch) to the thread depth H1 parameter. You can change this value.
The default must be activated via setting data SD 55212
$SCS_FUNCTION_MASK_TECH_SET.
The cycle requires a speed-controlled spindle with a position measuring system.
Interruption of thread cutting

You have the option to interrupt thread cutting (for example if the cutting tool is broken).
1. Press the <CYCLE STOP> key.
The tool is retracted from the thread and the spindle is stopped.
2. Replace the tool and press the <CYCLE START> key.
The aborted thread cutting is started again with the interrupted cut at the same depth.
Thread re-machining
You have the option of subsequently machining threads. To do this, change into the "JOG"
operating mode and carry out a thread synchronization.
Milling
Approach/retraction
1. The tool moves to the starting point calculated internally in the cycle at rapid traverse.
2. Thread with advance:
The tool moves at rapid traverse to the first starting position displaced by the thread
advance LW.
Thread with run-in:
The tool moves at rapid traverse to the starting position displaced by the thread run-in
LW2.
3. The first cut is made with thread pitch P as far as the thread run-out LR.
4. Thread with advance:
The tool moves at rapid traverse to the return distance VR and then to the next starting
position.
Thread with run-in:
The tool moves at rapid traverse to the return distance VR and then back to the starting
position.
5. Steps 3 and 4 are repeated until the thread is finished.
6. The tool moves back to the retraction plane at rapid traverse.
Thread machining can be stopped at any time with the "Rapid lift" function. It ensures that
the tool does not damage the thread when it is raised.
Procedure for longitudinal thread, tapered thread, or face thread
editor.
3. Press the "Thread" softkey.

The "Thread" input window opens.
4. Press the "Longitudinal thread" softkey.
The "Longitudinal Thread" input window opens.
- OR -
Press the "Tapered thread" softkey.
The "Tapered Thread" input window opens.
- OR -
Press the "Face thread" softkey.
The "Face Thread" input window opens.
Milling
Parameters, G code program (thread, longitudinal)

PL Machining plane

without
ISO metric
Whitworth BSW
Whitworth BSP
UNC
Selection - (not for Data, table value, e.g. M10, M12, M14, ...
table "Without")
P Select the thread pitch / turns for table "without" or specify the thread pitch/turns mm/rev
corresponding to the selection in the thread table: in/rev
turns/"
Thread pitch in mm/revolution
MODULUS
Thread pitch in inch/revolution
Thread turns per inch
Thread pitch in MODULUS
G Change in thread pitch per revolution (only for P = mm/rev or in/rev) mm/rev2
G = 0: The thread pitch P does not change.
G > 0: The thread pitch P increases by the value G per revolution.
G < 0: The thread pitch P decreases by the value G per revolution.
If the start and end pitch of the thread are known, the pitch change to be
programmed can be calculated as follows:
|Pe2 - P2 |
G = ----------------- [mm/rev2]
2 * Z1
The meanings are as follows:
Pe: End pitch of thread [mm/rev]
P: Start pitch of thread [mm/rev]
Z1: Thread length [mm]
A larger pitch results in a larger distance between the thread turns on the
workpiece.
(finishing)
Infeed (only for and Linear:
+ )
Infeed with constant cutting depth
Degressive:
Infeed with constant cutting cross-section
Milling

Thread Internal thread
External thread
X0 Reference point X from thread table (abs) mm
Incremental dimensions: The sign is also evaluated.
LW Thread advance (inc) mm
The starting point for the thread is the reference point (X0, Z0) brought forward by
the thread advance W. The thread advance can be used if you wish to begin the
individual cuts slightly earlier in order to also produce a precise start of thread.
or Thread run-in (inc)
LW2 The thread run-in can be used if you cannot approach the thread from the side and mm
instead have to insert the tool into the material (e.g. lubrication groove on a shaft).
Thread run-in = thread run-out (inc)
or
LW2 = LR mm
LR Thread run-out (inc) mm

The thread run-out can be used if you wish to retract the tool obliquely at the end
of the thread (e.g. lubrication groove on a shaft).
H1 Thread depth from thread table (inc) mm
DP Infeed slope as flank (inc) (alternative to infeed slope as angle)
DP > 0: Infeed along the rear flank
or DP < 0: Infeed along the front flank
P Infeed slope as angle (alternative to infeed slope as flank) Degrees
> 0: Infeed along the rear flank
< 0: Infeed along the front flank
= 0: Infeed at right angle to cutting direction
If you wish to infeed along the flanks, the maximum absolute value of this
parameter may be half the flank angle of the tool.
Infeed along the flank
Infeed with alternating flanks (alternative)
Instead of infeed along one flank, you can infeed along alternating flanks to avoid
always loading the same tool cutting edge. As a consequence you can increase
the tool life.
> 0: Start at the rear flank
< 0: Start at the front flank
D1 or ND First infeed depth or number of roughing cuts mm
(only for and The respective value is displayed when you switch between the number of
+ ) roughing cuts and the first infeed.
rev Finishing allowance in X and Z (only for and + ) mm
NN Number of noncuts - (only for and + )
VR Return distance (inc) mm
Multiple threads No
0 Starting angle offset Degrees
Milling

Yes
N Number of thread turns
The thread turns are distributed evenly across the periphery of the
turned part; the 1st thread turn is always located at 0.
DA Thread changeover depth (inc) mm
First machine all thread turns sequentially to thread changeover
depth DA, then machine all thread turns sequentially to depth 2
DA, etc. until the final depth is reached.
DA = 0: Thread changeover depth is not taken into account, i.e.
finish machining each thread before starting the next thread.
Machining: Complete, or
from turn N1
N1 (1...4) start thread N1 = 1...N or

only thread NX
NX (1...4) 1 from N threads
Parameters, G code program (thread, face)

PL Machining plane

P Thread pitch in mm/revolution mm/rev
in/rev
turns/"
Thread turns per inch MODULUS
|Pe2 - P2 |
G = ----------------- [mm/rev2]
2 * Z1
workpiece.
Milling

(finishing)
+ )
Degressive:

External thread
X0 Reference point X (abs, always diameter) mm
X1 End point of the thread (abs) or thread length (inc) mm
or
LW2 = LR mm

H1 Thread depth (inc) mm
the tool life.
Milling

Multiple threads No
Yes
from turn N1

only thread NX
Parameters, G code program (thread, conical)

PL Machining plane
Milling

P Thread pitch in mm/revolution mm/rev
in/rev
turns/"
Thread turns per inch MODULUS
|Pe2 - P2 |
G = ----------------- [mm/rev2]
2 * Z1
workpiece.
(finishing)
+ )
Degressive:

External thread
X1 or End point X (abs) or end point in relation to X0 (inc) or mm or
X1 Thread taper degrees
Z1 End point Z (abs) or end point in relation to Z0 (inc) mm
Incremental dimension: The sign is also evaluated.
Milling

or
LW2 = LR mm

H1 Thread depth (inc) mm
the tool life.
Multiple threads No
Yes
Milling

from turn N1

only thread NX
8.4.7 Thread chain (CYCLE98)
Function
With this cycle, you can produce several concatenated cylindrical or tapered threads with a
constant pitch in longitudinal and face machining, all of which can have different thread
pitches.
There may be single or multiple threads. With multiple threads, the individual thread turns
are machined one after the other.
You define a right or left-hand thread by the direction of spindle rotation and the feed
direction.
The infeed is performed automatically with a constant infeed depth or constant cutting cross-
section.
With a constant infeed depth, the cutting cross-section increases from cut to cut. The
finishing allowance is machined in one cut after roughing.
A constant infeed depth can produce better cutting conditions at small thread depths.
With a constant cutting cross-section, the cutting pressure remains constant over all
roughing cuts and the infeed depth is reduced.
The feedrate override has no effect during traversing blocks with thread. The spindle
override must not be changed during the thread machining.
Milling
Interruption of thread cutting

You have the option to interrupt thread cutting (for example if the cutting tool is broken).
1. Press the <CYCLE STOP> key.
The tool is retracted from the thread and the spindle is stopped.
2. Replace the tool and press the <CYCLE START> key.
The aborted thread cutting is started again with the interrupted cut at the same depth.
Approach/retraction
1. Approach of the starting point determined in the cycle at the beginning of the run-in path
for the first thread with G0
2. Infeed for roughing according to the defined infeed type.
3. Thread cutting is repeated according to the programmed number of roughing cuts.
4. The finishing allowance is removed in the following step with G33.
5. This cut is repeated according to the number of noncuts.
6. The whole sequence of motions is repeated for each further thread.
Procedure for thread chain
editor.
3. Press the "Thread" softkey.

The "Thread" input window opens.
4. Press the "Thread chain" softkey.
The "Thread Chain" input window opens.
Milling

PL Machining plane

(finishing)
+ )
Constant cutting depth infeed
Degressive:
Constant cutting cross-section infeed

External thread
P0 Thread pitch 1 mm/rev
in/rev
turns/"
MODULUS
X1 or X1 Intermediate point 1 X (abs) or mm
Intermediate point 1 in relation to X0 (inc) or
Degrees
Thread taper 1
Z1 Intermediate point 1 Z (abs) or mm
Intermediate point 1 in relation to Z0 (inc)
P1 Thread pitch 2 (unit as parameterized for P0) mm/rev
in/rev
turns/"
MODULUS
X2 or X2 Intermediate point 2 X (abs) or mm
Intermediate point 2 in relation to X1 (inc) or
Degrees
Thread taper 2
Z2 Intermediate point 2 Z (abs) or mm
Intermediate point 2 in relation to Z1 (inc)
P2 Thread pitch 3 (unit as parameterized for P0) mm/rev
in/rev
turns/"
MODULUS
Milling

X3 End point X (abs) or mm
End point 3 in relation to X2 (inc) or
Degrees
Thread taper 3
Z3 End point Z (abs) or mm
End point with reference to Z2 (inc)
LW Thread run-in mm
LR Thread run-out mm
H1 Thread depth mm
DP or P Infeed slope (flank) or infeed slope (angle) mm or
degrees
Infeed along a flank
Infeed with alternating flanks
D1 or ND First infeed depth or number of roughing cuts - (only for and + ) mm

rev Finishing allowance in X and Z - (only for and + ) mm
VR Return distance mm
Multiple threads No
Yes
8.4.8 Cut-off (CYCLE92)
Function
The "Cut-off" cycle is used when you want to cut off dynamically balanced parts (e.g. screws,
bolts, or pipes).
You can program a chamfer or rounding on the edge of the machined part. You can machine
at a constant cutting rate V or speed S up to a depth X1, from which point the workpiece is
machined at a constant speed. As of depth X1, you can also program a reduced feedrate FR
or a reduced speed SR, in order to adapt the velocity to the smaller diameter.
Use parameter X2 to enter the final depth that you wish to reach with the cut-off. With pipes,
for example, you do not need to cut-off until you reach the center; cutting off slightly more
than the wall thickness of the pipe is sufficient.
Milling
Approach/retraction
2. The chamfer or radius is machined at the machining feedrate.
3. Cut-off down to depth X1 is performed at the machining feedrate.
4. Cut-off is continued down to depth X2 at reduced feedrate FR and reduced speed SR.
If your turning machine is appropriately set up, you can extend a workpiece drawer (part
catcher) to accept the cut-off workpiece. Extension of the workpiece drawer must be enabled
in a machine data element.
Procedure
editor.
3. Press the "Cut-off softkey.

The "Cut-off" input window opens.

PL Machining plane
F Feedrate *

DIR Direction of spindle rotation
S Spindle speed rev/min

V Constant cutting rate mm/min
SV Maximum speed limit - (only for constant cutting rate V) rev/min
X0 Reference point in X (abs, always diameter) mm
Z0 Reference point in Z (abs) mm
Milling

FS or R Chamfer width or rounding radius mm
X1 Depth for speed reduction (abs) or depth for speed reduction in relation to X0 mm
(inc)
FR Reduced feedrate *
SR Reduced speed rev/min
X2 Final depth (abs) or final depth in relation to X1 (inc) mm
Milling
8.5 Contour turning - only for G code programs
8.5.1 General information
Function
You can machine simple or complex contours with the "Contour turning" cycle. A contour
comprises separate contour elements, whereby at least two and up to 250 elements result in
a defined contour.
You can program chamfers, radii, undercuts or tangential transitions between the contour
elements.
The integrated contour calculator calculates the intersection points of the individual contour
elements taking into account the geometrical relationships, which allows you to enter
incompletely dimensioned elements.
When you machine the contour, you can make allowance for a blank contour which must be
entered before the finished-part contour. You then choose one of the following machining
technologies:
Stock removal
Grooving
Plunge-turning
You can rough, remove residual material and finish for each of the three technologies above.
Programming
For example, the programming procedure for stock removal is as follows:
Note
When programming in the G code, it must be ensured that the contours are located after the
end of program identifier!
1. Enter the unmachined-part contour

If, when removing stock along the contour, you want to take into account an unmachined
part contour (and no cylinder or no allowance) as unmachined part shape, then you must
define the contour of the unmachined part before you define the finished-part contour.
Compile the unmachined-part contour step-by-step from various contour elements.
2. Enter finished-part contour
You build up the finished-part contour gradually from a series of different contour
elements.
3. Contour call
Milling
4. Stock removal along the contour (roughing)

The contour is machined longitudinally, transversely or parallel to the contour.
5. Remove residual material (roughing)
For G code programming, when removing stock, it must first be decided whether to rough
(machine) with residual material detection or not. A suitable tool will allow you to remove
this without having to machine the contour again.
6. Stock removal along the contour (finishing)
If you programmed a finishing allowance for roughing, the contour is machined again.
8.5.2 Representation of the contour
G code program
In the editor, the contour is represented in a program section using individual program
blocks. If you open an individual block, then the contour is opened.
Symbolic representation
The individual contour elements are represented by symbols adjacent to the graphics
window. They appear in the order in which they were entered.

Starting point Starting point of the contour
Straight line up Straight line in 90 grid
Straight line down Straight line in 90 grid
Straight line left Straight line in 90 grid
Straight line right Straight line in 90 grid
Straight line in any direction Straight line with any gradient
Arc right Circle
Arc left Circle
Pole Straight diagonal or circle in

polar coordinates
Finish contour END End of contour definition
The different colors of the symbols indicate their status:
Milling
Foreground Background Meaning

Black Blue Cursor on new element
Black Orange Cursor on current element
Black White Normal element
Red White Element not currently evaluated
(element will only be evaluated
when it is selected with the
cursor)
Graphical display
The progress of contour programming is shown in broken-line graphics while the contour
elements are being entered.
When the contour element has been created, it can be displayed in different line styles and
colors:
Black: Programmed contour
Orange: Current contour element
Green dashed: Alternative element
Blue dotted: Partially defined element
The scaling of the coordinate system is adjusted automatically to match the complete
contour.
The position of the coordinate system is displayed in the graphics window.
8.5.3 Creating a new contour
Function
For each contour that you want to cut, you must create a new contour.
The first step in creating a contour is to specify a starting point. Enter the contour element.
The contour processor then automatically defines the end of the contour.
Procedure
editor.
2. Press the "Turning" and "Contour turning" softkeys.
Milling
3. Press the "Contour" and "New contour" softkeys.

4. Enter a name for the new contour. The contour name must be unique.
The input window for the starting point of the contour appears.
Enter the individual contour elements (see Section "Creating contour
elements").

Z Starting point Z (abs) mm
X Starting point X (abs) mm
Transition to Type of transition
contour start
Radius
Chamfer
FS=0 or R=0: No transition element
R Transition to following element radius mm
FS Transition to following element chamfer mm
Milling

Direction in front Direction of the contour element towards the starting point:
of the contour
In the negative direction of the horizontal axis
In the positive direction of the horizontal axis
In the negative direction of the vertical axis
In the positive direction of the vertical axis
Additional You can enter additional commands in the form of G code for each contour element.
commands You can enter the additional commands (max. 40 characters) in the extended
parameter screens ("All parameters" softkey). The softkey is always available at the
starting point, it only has to be pressed when entering additional contour elements.
commands. However, carefully ensure that the additional commands do not collide with
the generated G code of the contour and are compatible with the machining type
required. Therefore, do not use any G code commands of group 1 (G0, G1, G2, G3), no
coordinates in the plane and no G code commands that have to be programmed in a
separate block.
The contour is finished in continuous-path mode (G64). As a result, contour transitions
such as corners, chamfers or radii may not be machined precisely.
If you wish to avoid this, then it is possible to use additional commands when
programming.
Example: For a contour, first program the straight X parallel and then enter "G9" (non-
modal exact stop) for the additional command parameter. Then program the Z-parallel
straight line. The corner will be machined exactly, as the feedrate at the end of the X-
parallel straight line is briefly zero.
Note:
The additional commands are only effective for finishing!
Milling
8.5.4 Creating contour elements
Creating contour elements

After you have created a new contour and specified the starting point, you can define the
individual elements that make up the contour.
The following contour elements are available for the definition of a contour:
Straight vertical line
Straight horizontal line
Diagonal line
Circle/arc
For each contour element, you must parameterize a separate parameter screen. Parameter
entry is supported by various help screens that explain the parameters.
If you leave certain fields blank, the cycle assumes that the values are unknown and
attempts to calculate them from other parameters.
Conflicts may result if you enter more parameters than are absolutely necessary for a
contour. In such a case, try entering less parameters and allowing the cycle to calculate as
many parameters as possible.
Contour transition elements

As transition element between two contour elements, you can select a radius or a chamfer
or, in the case of linear contour elements, an undercut. The transition element is always
attached at the end of a contour element. The contour transition element is selected in the
parameter screen of the respective contour element.
You can use a contour transition element whenever there is an intersection between two
successive elements which can be calculated from the input values. Otherwise you must use
the straight/circle contour elements.
Additional commands
You can enter additional commands in the form of G code for each contour element. You
can enter the additional commands (max. 40 characters) in the extended parameter screens
("All parameters" softkey).
commands. However, make sure that the additional commands do not collide with the
generated G code of the contour. Therefore, do not use any G code commands of group 1
(G0, G1, G2, G3), no coordinates in the plane and no G code commands that have to be
programmed in a separate block.
Milling
Additional functions
The following additional functions are available for programming a contour:
Tangent to preceding element
You can program the transition to the preceding element as tangent.
Selecting a dialog box
If two different possible contours result from the parameters entered thus far, one of the
options must be selected.
Close contour
From the actual position, you can close the contour with a straight line to the starting point.
Producing exact contour transitions

The axis moves in the continuous path mode (G64). As a result, contour transitions such as
corners, chamfers or radii may not be machined precisely.
If you wish to avoid this, there are two different options when programming. Use the
additional programs or program the special feedrate for the transition element.
Additional command
For a contour, first program the vertical straight line and then enter "G9" (non-modal exact
stop) for the additional command parameter. Then program the horizontal straight line. The
corner will be machined exactly, since the feedrate at the end of the vertical straight line is
briefly zero.
Feedrate, transition element
If you have chosen a chamfer or a radius as the transition element, enter a reduced feedrate
in the "FRC" parameter. The slower machining rate means that the transition element is
machined more accurately.
Procedure for entering contour elements
1. The part program is opened. Position the cursor at the required input
position, this is generally at the physical end of the program after M02
or M30.
2. Contour input using contour support:
2.1 Press the "Contour turning", "Contour" and "New contour" softkeys.
2.2 In the opened input window, enter a name for the contour, e.g.
contour_1.
Milling
2.3 The input screen to enter the contour opens, in which you initially enter
a starting point for the contour. This is marked in the lefthand navigation
bar using the "+" symbol.
3. Enter the individual contour elements of the machining direction.
Select a contour element via softkey.
The "Straight (e.g. Z)" input window opens.
- OR
The "Straight (e.g. X)" input window opens.
- OR
The "Straight (e.g. ZX)" input window opens.
- OR
The "Circle" input window opens.
4. Enter all the data available from the workpiece drawing in the input
screen (e.g. length of straight line, target position, transition to next
element, angle of lead, etc.).
The contour element is added to the contour.
6. When entering data for a contour element, you can program the
transition to the preceding element as a tangent.
Press the "Tangent to prec. elem." softkey. The "tangential" selection
appears in the parameter 2 entry field.
7. Repeat the procedure until the contour is complete.
The programmed contour is transferred into the process plan (program
view).
9. If you want to display further parameters for certain contour elements,
e.g. to enter additional commands, press the "All parameters" softkey.
Milling
Contour element "Straight line e.g. Z"

Z End point Z (abs or inc) mm
1 Starting angle to Z axis Degrees
element
Radius
Undercut
Chamfer
Undercut Form E Undercut size
e.g. E1.0x0.4
Form F Undercut size
e.g. F0.6x0.3
DIN thread P Thread pitch mm/rev
Thread Z1 Length Z1 mm
Z2 Length Z2 mm
R1 Radius R1 mm
R2 Radius R2 mm
T Insertion depth mm
CA Grinding allowance mm
Grinding allowance to right of contour
Grinding allowance to left of contour
Contour element "Straight line e.g. X"

X End point X (abs) or end point X (inc) mm
element
Radius
Undercut
Chamfer
Undercut Form E Undercut size
e.g. E1.0x0.4
Form F Undercut size
e.g. F0.6x0.3
Milling

DIN thread P Thread pitch mm/rev
Thread Z1 Length Z1 mm
Z2 Length Z2 mm
R1 Radius R1 mm
R2 Radius R2 mm
T Insertion depth mm
Contour element "Straight line e.g. ZX"

element
Radius
Chamfer
Contour element "Circle"

Direction of rotation Clockwise direction of rotation
Milling

K Circle center point K (abs or inc) mm
I Circle center point I (abs or circle center point I (inc) mm
1 End angle to Z axis Degrees
2 Opening angle Degrees
element
Radius
Chamfer
Contour element "End"

The data for the transition at the contour end of the previous contour element is displayed in
the "End" parameter screen.
Milling
8.5.5 Changing the contour
Function
You can change a previously created contour later.
Individual contour elements can be
added,
changed,
inserted or
deleted.
Procedure for changing a contour element
1. Open the part program to be executed.

2. With the cursor, select the program block where you want to change the
contour. Open the geometry processor.
The individual contour elements are listed.
3. Position the cursor at the position where a contour element is to be
inserted or changed.
4. Select the desired contour element with the cursor.
5. Enter the parameters in the input screen or delete the element and
select a new element.
The desired contour element is inserted in the contour or changed.
Procedure for deleting a contour element
1. Open the part program to be executed.

2. Position the cursor on the contour element that you want to delete.
3. Press the "Delete element" softkey.
4. Press the "Delete" softkey.
Milling
8.5.6 Contour call (CYCLE62)
Function
The input creates a reference to the selected contour.
There are four ways to call the contour:
1. Contour name
The contour is in the calling main program.
2. Labels
The contour is in the calling main program and is limited by the labels that have been
entered.
3. Subprogram
The contour is located in a subprogram in the same workpiece.
4. Labels in the subprogram
The contour is in a subprogram and is limited by the labels that have been entered.
Procedure
editor.
3. Press the "Contour" and "Contour call" softkeys.

The "Contour Call" input window opens.
4. Assign parameters to the contour selection.

Contour selection Contour name
Labels
Subprogram
Labels in the subprogram
Contour name CON: Contour name
Labels LAB1: Label 1
LAB2: Label 2
Milling

Subprogram PRG: Subprogram
Labels in the PRG: Subprogram
subprogram
LAB1: Label 1
LAB2: Label 2
8.5.7 Stock removal (CYCLE952)
Function
For stock removal, the cycle takes into account a blank that can comprise a cylinder, an
allowance on the finished-part contour or any unmachined-part contour. You must define an
unmachined-part contour as a separate closed contour in advance of the finished-part
contour.
Precondition
For a G-code program, at least one CYCLE62 is required before CYCLE952.
If CYCLE62 is only present once, then this involves the finished part contour.
If CYCLE62 is present twice, then the first call is the unmachined part contour and the
second call is the finished-part contour (also see Chapter "Programming (Page 406)").
Rounding the contour

In order to avoid residual corners during roughing, you can enable the "Always round the
contour" function. This will remove the protrusions that are always left at the end with each
cut (due to the cut geometry). The "Round to the previous intersection" setting accelerates
machining of the contour. However, any resulting residual corners will not be recognized or
machined. Thus, it is imperative that you check the behavior before machining using the
simulation.
When set to "automatic", rounding is always performed if the angle between the cutting edge
and the contour exceeds a certain value. The angle is set in a machine data element.
Alternating cutting depth

Instead of working with constant cutting depth D, you can use an alternating cutting depth to
vary the load on the tool edge, As a consequence you can increase the tool life.
The percentage for the alternating cutting depth is saved in a machine data element.
Milling
Cut segmentation
To avoid the occurrence of very thin cuts in cut segmentation due to contour edges, you can
align the cut segmentation to the contour edges. During machining the contour is then
divided by the edges into individual sections and cut segmentation is performed separately
for each section.
Set machining area limits

If, for example, you want to machine a certain area of the contour with a different tool, you
can set machining area limits so that machining only takes place in the area of the contour
you have selected. You can define between 1 and 4 limit lines.
Feedrate interruption
To prevent the occurrence of excessively long chips during machining, you can program a
feedrate interruption. Parameter DI specifies the distance after which the feedrate
interruption should occur.
Residual material machining / naming conventions
G Code program
For multi-channel systems, cycles attach a "_C" and a two-digit number of the specific
channel to the names of the programs to be generated, e.g. for channel 1 "_C01".
This is the reason that the name of the main program must not end with "_C" and a two-digit
number. This is monitored by the cycles.
For programs with residual machining, when specifying the name for the file, which includes
the updated blank contour, it must be ensured that this does not have the attached
characters ("_C" and double-digit number).
For single-channel systems, cycles do not extend the name for the programs to be
generated.
Note
G code programs
For G code programs, the programs to be generated, which do not include any path data,
are saved in the directory in which the main program is located. In this case, it must be
ensured that programs, which already exist in the directory and which have the same name
as the programs to be generated, are overwritten.
Milling
Machining type
You can select the machining mode (roughing or finishing). During contour roughing, parallel
cuts of maximum programmed infeed depth are created. Roughing is performed to the
programmed allowance.
You can also specify a compensation allowance U1 for finishing operations, which allows
you to either finish several times (positive allowance) or to shrink the contour (negative
allowance). Finishing is performed in the same direction as roughing.
Procedure
editor.
3. Press the "Stock removal" softkey.

The "Stock Removal" input window opens.

PRG Name of the program to be generated
PL Machining plane
RP Retraction plane (only for mm
machining direction,
longitudinal, inner)
F Feedrate *
Residual With subsequent residual material removal
material
Yes
No
CONR Name to save the updated unmachined-part
contour for residual material removal (only
"Yes" for residual material removal)
Milling

(finishing)
Machining Face From inside to outside
direction
Longitudinal
From outside to inside
From end face to rear side
From rear side to end face
The machining direction depends on the stock removal direction and choice of tool.
Position front
back
internal
external
D Maximum depth infeed - (only for ) mm
DX Maximum depth infeed - (only for parallel to the contour, as an alternative to D) mm
Do not round contour at end of cut.
Always round contour at end of cut.
Uniform cut segmentation

Round cut segmentation at the edge
Constant cutting depth

Alternating cutting depth - (only with align cut segmentation to edge)
DZ Maximum depth infeed - (only for position parallel to the contour and UX) mm
UX or U Finishing allowance in X or finishing allowance in X and Z (only for ) mm
UZ Finishing allowance in Z (only for UX) mm
DI For zero: Continuous cut - (only for ) mm
Milling

BL Blank (unmachined part) description (only for )
Cylinder (described using XD, ZD)
Allowance (XD and ZD on the finished part contour)
Contour (additional CYCLE62 call with blank contour e.g. cast iron mold)
XD - (only for machining) mm
- (only for unmachined part description, cylinder and allowance)
For unmachined part description, cylinder
Version, absolute:
Cylinder dimension (abs)
Version incremental:
Allowance (inc) to maximum values of the CYCLE62 finished part contour
For unmachined part description, allowance
Allowance on the CYCLE62 finished part contour (inc)
ZD - (only for machining) mm
Version, absolute:
Allowance Allowance for pre-finishing - (only for )
Yes
U1 contour allowance
No
U1 Compensation allowance in X and Z direction (inc) (only for allowance) mm
Positive value: Compensation allowance is kept
Negative value: Compensation allowance is removed in addition to finishing
allowance
Set machining area Set machining area limits
limits
Yes
No
with limited machining area only, yes: mm
XA 1. Limit XA
XB 2. Limit XB (abs) or 2nd limit referred to XA (inc)
ZA 1. Limit ZA
ZB 2. Limit ZB (abs) or 2nd limit referred to ZA (inc)
Milling

Relief cuts Machine relief cuts
Yes
No
FR Insertion feedrate, relief cuts *
8.5.8 Stock removal residual (CYCLE952)
Function
Using the "Stock removal residual" function, you can remove material that has remained for
stock removal along the contour.
During stock removal along the contour, the cycle automatically detects any residual material
and generates an updated blank contour. For a G code program, for stock removal residual
material, "Yes" must be programmed. Material that remains as part of the finishing allowance
is not residual material. Using the "Stock removal residual material" function, you can
remove unwanted material with a suitable tool.
The "Stock removal residual material" function is a software option.
Procedure
editor.
3. Press the "Stock removal residual material" softkey.

The "Stock removal residual material" input window opens.
Milling

PL Machining plane
F Feedrate *
CON Name of the updated blank contour for
residual material machining (without the
attached character "_C" and double-digit
number)
material
Yes
No

(finishing)
Machining Face From inside to outside
direction
Longitudinal From outside to inside
Parallel to the contour From end face to rear side
From rear side to end face
The machining direction depends on the stock removal direction and choice of tool.
Position front
back
internal
external
XDA 1. Grooving limit tool (abs) (only for face machining direction) mm
XDB 2. Grooving limit tool (abs) (only for face machining direction) mm
DX Maximum depth infeed - (only for parallel to the contour, as an alternative to D) mm
Do not round contour at end of cut.
Always round contour at end of cut.
Uniform cut segmentation
Round cut segmentation at the edge
Milling

only for align cut segmentation at the edge:
Constant cutting depth
alternating cutting depth
Allowance Allowance for pre-finishing - (only for ) s
Yes
No
allowance
limits
Yes
No
XA 1. Limit XA
ZA 1. Limit ZA
Relief cuts Machine relief cuts
Yes
No
FR Insertion feedrate, relief cuts *
8.5.9 Grooving (CYCLE952)
Function
The "Grooving" function is used to machine grooves of any shape.
Before you program the groove, you must define the groove contour.
If a groove is wider than the active tool, it is machined in several cuts. The tool is moved by a
maximum of 80% of the tool width for each groove.
Blank
When grooving, the cycle takes into account a blank that can consist of a cylinder, an
allowance on the finished-part contour or any other blank contour.
Milling
Precondition

you have selected.
feedrate interruption.
Machining type
You can freely select the machining type (roughing or finishing).
For more detailed information, please refer to section "Stock removal".
Procedure
editor.
3. Press the "Grooving" softkey.

The "Grooving" input window opens.
Milling

PL Machining plane
F Feedrate *
material
Yes
No

(finishing)
Machining Face
direction
Longitudinal
Position front
back
internal
external
Milling

Version, absolute:
Version, absolute:
Allowance Allowance for pre-finishing - (only for ) mm
Yes
No
allowance
limits
Yes
No
XA 1. Limit XA
ZA 1. Limit ZA
N Number of grooves
Milling
8.5.10 Grooving residual material (CYCLE952)
Function
The "Grooving residual material" function is used when you want to machine the material
that remained after grooving along the contour.
For a G code program, first select the "Grooving residual material" function. Material that
remains as part of the finishing allowance is not residual material. The "Grooving residual
material" function allows you to remove unwanted material with a suitable tool.
The "Grooving residual material" function is a software option.
Procedure
editor.
3. Press the "Grooving residual material" softkey.

The "Grooving residual material" input window is opened.

PL Machining plane
longitudinal machining
direction)
F Feedrate *
CON Name of the updated blank contour for
residual material machining (without the
attached character "_C" and double-digit
number)
material
Yes
No
Milling

(finishing)
Machining Face
direction
Longitudinal
Position front
back
internal
external
Yes
No
allowance
limits
Yes
No
XA 1. Limit XA
ZA 1. Limit ZA
N Number of grooves
Milling
8.5.11 Plunge turning (CYCLE952)
Function
Using the "Plunge turning" function, you can machine any shape of groove.
Contrary to grooving, the plunge turning function removes material on the sides after the
groove has been machined in order to reduce machining time. Contrary to stock removal, the
plunge turning function allows you to machine contours that the tool must enter vertically.
You will need a special tool for plunge turning. Before you program the "Plunge turning"
cycle, you must define the contour.
Precondition

you have selected.
feedrate interruption.
Machining type
You can freely select the machining type (roughing or finishing).
For more detailed information, please refer to section "Stock removal".
Milling
Procedure
editor.
3. Press the "Plunge turning" softkey.

The "Plunge turning" input window opens.

PL Machining plane
direction)
material
Yes
No


FX Feedrate in X direction *
FZ Feedrate in Z direction *
(finishing)
Machining Face
direction
Longitudinal
Position front
back
internal
external
Milling

Version, absolute:
Version, absolute:
Yes
No
allowance
Milling

limits
Yes
No
XA 1. Limit XA
ZA 1. Limit ZA
N Number of grooves
DP Distance between grooves mm
8.5.12 Plunge turning residual material (CYCLE952)
Function
The "Plunge turning residual material" function is used when you want to machine the
material that remained after plunge turning.
For a G code program, select the function in the screen. Material that remains as part of the
finishing allowance is not residual material. The "Plunge turning residual material" function
allows you to remove unwanted material with a suitable tool.
The "Plunge turning residual material" function is a software option.
Procedure
editor.
3. Press the "Plunge turning residual material" softkey.

The "Plunge turning residual material" input window opens.
Milling

PL Machining plane
direction)
material
Yes
No

FX Feedrate in X direction *
FZ Feedrate in Z direction *
(finishing)
Machining Face
direction
Longitudinal
Position front
back
internal
external
XDA 1. Grooving limit tool (abs) (end face or rear face only) mm
XDB 2. Grooving limit tool (abs) (end face or rear face only) mm
Allowance Allowance for prefinishing
Yes
No
Milling

XD - (only for unmachined part description, cylinder and allowance) mm
Allowance or cylinder dimension (abs)
Allowance or cylinder dimension (inc)
Allowance on the contour (abs)
Allowance on the contour (inc)
ZD - (only for unmachined part description, cylinder and allowance) mm
Allowance or cylinder dimension (abs or inc)

Allowance on the contour (abs or inc)

allowance
limits
Yes
No
XA 1. Limit XA
ZA 1. Limit ZA
N Number of grooves
Milling
8.6 Further cycles and functions
8.6.1 Swiveling plane/tool (CYCLE800)

The CYCLE800 swivel cycle is used to swivel to any surface in order to either machine or
measure it. In this cycle, the active workpiece zeros and the work offsets are converted to
the inclined surface taking into account the kinematic chain of the machine by calling the
appropriate NC functions - and rotary axes (optionally) are positioned.
Swiveling can be realized:
axis by axis
via solid angle
via projection angle
directly
Before the rotary axes are positioned, the linear axes can be retracted if desired.
Swiveling always means three geometry axes.
In the basic version, the following functions
3 + 2 axes, inclined machining and
toolholder with orientation capability
are available.
Setting/aligning tools for a G code program

The swivel function also includes the "Setting tool" and "Aligning milling tool" functions.
Contrary to swiveling, when setting and aligning, the coordinate system (WCS) is not rotated
at the same time.
Prerequisites before calling the swivel cycle

A tool (tool cutting edge D > 0) and the work offset (WO), with which the workpiece was
scratched or measured, must be programmed before the swivel cycle is first called in the
main program.
Milling
Example:
N1 T1D1
N2 M6
N3 G17 G54
N4 CYCLE800(1,"",0,57,0,0,0,0,0,0,0,0,0,1,0,1)) ;swivel ZERO to
;initial position of the
;machine kinematics
N5 WORKPIECE(,,,,"BOX",0,0,50,0,0,0,100,100) ;blank agreement for
;simulation and
;recording
For machines where swivel is set-up, each main program with a swivel should start in the
basic setting of the machine.
The definition of the blank (WORKPIECE) always refers to the currently effective work offset.
For programs that use "swivel", a swivel to zero must be made before the blank is defined.
For ShopMill programs, the blank in the program header is automatically referred to the
unswiveled state.
In the swivel cycle, the work offset (WO) as well as the shifts and rotations of the parameters
of the CYCLE800 are converted to the corresponding machining plane. The work offset is
kept. Shifts and rotations are saved in system frames - the swivel frames - (displayed under
parameter/work offsets):
Tool reference ($P_TOOLFRAME)
Rotary table reference ($P_PARTFRAME)
Workpiece reference ($P_WPFRAME)
The swivel cycle takes into account the actual machining plane (G17, G18, G19).
Swiveling on a machining or auxiliary surface always involves 3 steps:
Shifting the WCS before rotation
Rotating the WCS (axis-by-axis, ...)
Shifting the WCS after rotation
The shifts and rotations refer to the coordinate system X, Y, Z of the workpiece and are
therefore independent of the machine (with the exception of swivel "rotary axis direct").
No programmable frames are used in the swivel cycle. The frames programmed by the user
are taken into account for additive swiveling.
On the other hand, when swiveling to a new swivel plane the programmable frames are
deleted. Any type of machining operation can be performed on the swivel plane, e.g. by
calling standard or measuring cycles.
The last swivel plane remains active after a program reset or when the power fails. The
behavior at reset and power on can be set using machine data.
Milling
Block search when swiveling the plane / swiveling the tool

For block search with calculation, after NC start, initially, the automatic rotary axes of the
active swivel data set are pre-positioned and then the remaining machine axes are
positioned. This does not apply if a type TRACYL or TRANSMIT transformation is active
after the block search. In this case, all axes simultaneously move to the accumulated
positions.
Aligning tools
In contrast to "Swivel plane", no rotation is operative in the active frame chain (WCS) in the
case of "Swivel tool" or "Align milling tool". Only the offsets calculated by the NC and the
corresponding tool orientation are effective.
The maximum angular range for "Align milling tool" is limited by the traversing range of the
participating rotary axes.
Name of the swivel data set

Selecting the swivel data set or deselecting the swivel data set.
The selection can be hidden by the machine data.
Approaching a machining operation

When approaching the programmed machining operation in the swiveled plane, under worst
case conditions, the software limit switches could be violated. In this case, the system travels
along the software limit switches above the retraction plane. In the event of violation below
the retraction plane, for safety reasons, the program is interrupted with an alarm. To avoid
this, before swiveling, e.g. move the tool in the X/Y plane and position it as close as possible
to the starting point of the machining operation or define the retraction plane closer to the
workpiece.
Retraction
Before swiveling the axes you can move the tool to a safe retraction position. The retraction
versions available are defined when starting up the system (commissioning).
The retraction mode is modal. When a tool is changed or after a block search, the retraction
mode last set is used.
Milling
WARNING
Risk of collision
You must select a retraction position that avoids a collision between the tool and workpiece
when swiveling.
Swivel plane (only for G code programming)

New
Previous swivel frames and programmed frames are deleted and a new swivel frame is
formed according to the values specified in the input screen.
Every main program must begin with a swivel cycle with the new swivel plane, in order to
ensure that a swivel frame from another program is not active.
Additive
The swivel frame is added to the swivel frame from the last swivel cycle.
If several swivel cycles are programmed in a program and programmable frames are also
active between them (e.g., AROT ATRANS), these are taken into account in the swivel
frame.
If the currently active WO contains rotations, e.g., due to previous workpiece measuring
operations, they will be taken into account in the swivel cycle.
Swivel mode
Swiveling can either be realized axis-by-axis, using the angle in space, using the projection
angle or directly. The machine manufacturer determines when setting up the "Swivel
plane/swivel tool" function which swivel methods are available.
Milling
Axis by axis
In the case of axis-by-axis swiveling, the coordinate system is rotated about each axis in
turn, with each rotation starting from the previous rotation. The axis sequence can be
freely selected.
Solid angle
With the solid angle swiveling option, the tool is first rotated about the Z axis and then
about the Y axis. The second rotation starts from the first.
Projection angle
When swiveling using the projection angle, the angle value of the swiveled surface is
projected onto the first two axes of the right-angle coordinate system. The user can freely
select the axis rotation sequence.
The 3rd rotation is based on the previous rotation. The active plane and the tool
orientation must be taken into consideration when the projection angle is used:
For G17 projection angle XY, 3rd rotation around Z
For G18 projection angle ZX, 3rd rotation around Y
For G19 projection angle YZ, 3rd rotation around X
When projection angles around XY and YX are programmed, the new X-axis of the swiveled
coordinate system lies in the old ZX plane.
When projection angles around XZ and ZX are programmed, the new Z-axis of the swiveled
coordinate system lies in the old Y-Z plane.
When projection angles around YZ and ZY are programmed, the new Y-axis of the swiveled
coordinate system lies in the old X-Y plane.
directly
For direct swiveling, the required positions of the rotary axes are specified. The HMI
calculates a suitable new coordinate system based on these values. The tool axis is
aligned in the Z direction. You can derive the resulting direction of the X and Y axis by
traversing the axes.
Note
Direction of rotation
The positive direction of each rotation for the different swivel versions is shown in the
help displays.
Axis sequence
Sequence of the axes which are rotated around:
XYZ or XZY or YXZ or YZX or ZXY or ZYX
Milling
Direction (minus/plus)
Direction reference of traversing direction of rotary axis 1 or 2 of the active swivel data set
(machine kinematics). The NC calculates two possible solutions of the rotation / offset
programmed in CYCLE800 using the angle traversing range of the rotary axes of the
machine kinematics. Usually, only one of these solutions is technologically suitable. The
solutions differ by 180 degrees in each case. Selecting the "minus" or "plus" direction
determines which of the two possible solutions is to be applied.
"Minus" Lower rotary axis value
"Plus" Higher rotary axis value
Also in the basic setting (pole setting) of the machine kinematics, the NC calculates two
solutions and these are approached by CYCLE800. The reference is the rotary axis that was
set as direction reference when commissioning the "swivel" function.
If one of the two positions cannot be reached for mechanical reasons, the alternative position
is automatically selected irrespective of the setting of the "Direction" parameter.
Example:
Machine kinematics with swivel head and swivel table.
Swivel head with rotary axis 1 (B) rotates around machine axis Y.
Angular traversing range of rotary axis B from -90 to +90 degrees.
Swivel table with rotary axis 2 (C) rotates around machine axis Z.
Angle traversing range of rotary axis 2 (C) from 0 to 360 degrees (modulo 360).
Machine manufacturer has set the direction reference to rotary axis 1 (B) when he
commissioned the swivel function.
A rotation around X (WCS) of 10 degrees is programmed in the swivel cycle.
The machine in the basic setting (pole setting) of the kinematics (B = 0 C = 0) is shown in the
following diagram.
Milling
Direction "-" (minus)

Rotary axis B moves to -10 degrees in the negative direction (red arrow).
Rotary axis C moves to 90 degrees (rotation around X!).
Direction "+" (plus)
Rotary axis B moves to +10 degrees in the positive direction (red arrow).
Rotary axis C moves to 270 degrees.
The two "Minus" or "Plus" direction settings enable a workpiece to be machined with
swiveled planes. The two solutions calculated by the NC differ by 180 degrees (see rotary
axis C).
Tool
To avoid collisions, you can use the 5-axis transformation (software option) to define the
position of the tool tip during swiveling.
Correct
The position of the tool tip is corrected during swiveling (tracking function).
No correction
The position of the tool tip is not corrected during swiveling.
Procedure

3. Press the "Swivel plane" softkey.

The "Swivel plane" input window opens.
4. Press the "Basic setting" softkey if you wish to reestablish the initial
state, i.e. you wish to set the values back to 0.
You use this,for example, to swivel the coordinate system back into its
original orientation.
Milling


F Feedrate mm/min
mm/rev

cutting rate m/min

Z: Retraction in the direction of machine axis Z
Z, X, Y: Move machining axis to retraction position before swiveling
Tool direction, max.: Maximum retraction (up to the software end position) in the
tool direction
Tool direction, inc.: Retraction, incremental (up to the software end position) in the
tool direction
When retracting in the tool direction, in the swiveled machine state, several axes
can move (travel).
ZR Retraction path - (only for incremental retraction in the tool direction)
Swivel plane New: New swivel plane
Additive: Additive swivel plane
X0 Reference point for rotation X
Y0 Reference point for rotation Y
Z0 Reference point for rotation Z
Swivel mode Axis by axis: Rotate coordinate system axis-by-axis
Solid angle: Swivel via solid angle
Proj. angle: Swiveling via projection angle
Direct: Directly position rotary axes
Axis sequence Sequence of the axes which are rotated around: - (only for axis-by-axis swivel mode)
XYZ or XZY or YXZ or YZX or ZXY or ZYX
X Rotation around X - (only for axis sequence) Degrees

Milling

Projection Position of the projection in space - (only for swivel mode, projection angle)
position X, Y, Z or Y, Z, Z or Z, X, Z
X Projection angle - (only for projection position) Degrees

Y Projection angle Degrees
Z Angle of rotation in the plane Degrees
Name of rotary Angle of rotation of rotary axis - (only for direct swivel mode) Degrees
axis 1 1
Name of rotary Angle of rotation of rotary axis Degrees
axis 2 2
Z Angle of rotation in the plane Degrees
X1 Zero point of rotated surface X
Y1 Zero point of rotated surface Y
Z1 Zero point of rotated surface Z
Direction Direction reference of traversing direction of rotary axis 1 or 2
- (not for direct swivel mode)
+
-
Tool Tool tip when swiveling
Correct
The position of the tool tip is maintained during swiveling.

No correction
The position of the tool tip is not maintained during swiveling.
Call of an orientation transformation (TRAORI) after swiveling

If a program activating the orientation transformation (TRAORI) is to be executed on the
swiveled machining plane, the system frames tool reference and rotary table reference
for the swivel head or swivel table must be deactivated before TRAORI is called (see
example). The workpiece reference (WPFRAME) is retained.
Milling
Example (machine with swivel table)
N1 G54
N2 T="MILL_10mm"
N3 M6
N4 CYCLE800(1,"",0,57,0,40,0,-45,0,0,0,0,0,-1) ;Swivel cycle
N5 CYCLE71(50,24,2,0,0,0,80,60,0,4,10,5,0,2000,31,5) ;Face milling
N6 TCARR=0 ;Swivel data set
;deselection
N7 PAROTOF ;Deactivate ;rotary
table reference
N8 TOROTOF ;Deactivate ;tool
reference
;(only for ;swivel head
and ;mixed ;kinematics)
N9 TRAORI ;Activate the
;orientation
;transformation
N10 G54 ;Activate ;work offset
N11 EXTCALL "ROLL" ;Call 5-;axis machining
;program with ;direction
vectors ;(A3, B3, C3)
N12 M2
Milling
8.6.2 Swiveling tool (CYCLE800)
8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800)
After "Swivel plane", the tool orientation is always perpendicular on the machining plane.
When milling with radial cutters, it can make technological sense to set the tool at an angle
to the normal surface vector. In the swivel cycle, the setting angle is generated by an axis
rotation (max. +/- 90 degrees) to the active swivel plane. When setting, the swivel plane is
always additive. With "Setting tool", only rotations are displayed on the swivel cycle input
screen form. The user can freely select the rotation sequence.
7RROOHQJWK
7&3
5 7&3
Figure 8-1 The length up to the TCP (Tool Center Point) must be entered as tool length of the radial
cutter.
Procedure
editor.
3. Press the "Swivel tool" and "Setting milling tool" softkeys.

The "Setting tool" input window opens.
Milling

Z, X, Y: Move machining axis to retraction position before swiveling
Tool direction, max.: Maximum retraction in tool direction
Tool direction, inc.: Incremental retraction in tool direction
Axis sequence Sequence of the axes which are rotated around
XY or XZ or YX or YZ or ZX or ZY
Correct

No correction
8.6.2.2 Swiveling aligning tool - only for G code program (CYCLE800)
Function
The purpose of the "Align milling tool" or "Align turning tool" function is to support combined
milling machines - lathes with a B axis that can be swiveled.
This functionality is specifically addressing certain configurations of milling machines, which
have been expanded by turning functionality. Tool orientation in the turning mode is realized
using a swivel axis B (swiveling around Y) with an associated milling spindle (e.g. C1). It is
designed to be compatible with both turning and milling tools.
In contrast to "Swivel plane", no rotation is operative in the active work offsets in the
workpiece coordinate system in the case of "Align tool". Only the offsets calculated by the
NC and the corresponding tool orientation are effective.
The maximum angular range for "Align tool" is + 360 degrees or it is limited by the traversing
range of the participating rotary axes. Technological limits are also placed on the angular
range depending on the tool used. When aligning the tool, the data of the tool is calculated
based on the tool orientation using the CUTMOD NC command. For a turning tool, this
involves the cutting edge position, the holder angle and the cut direction.
The use of the "Align milling tool" function is restricted to milling operations in parallel with
the axis (face, peripheral machining) at a machine with a B axis that can be swiveled. If
milling is to be possible on any swiveled machining plane, then the "swivel plane" function
must be used.
Milling
Procedure
editor.
3. Press the "Swivel tool" and "Align milling tool" softkeys.

The "Align milling tool" input window opens.

Retract No: No retraction before swiveling
Tool direction, max.: Maximum retraction in tool direction
Tool direction, inc.: Incremental retraction in tool direction
Rotation around the 3rd geometry axis (for G18 Y) Degrees
Correct
No correction
Milling
8.6.3 High-speed settings (CYCLE832)
Function
Machining of free-form surfaces involves high requirements regarding velocity, precision and
surface quality.
You can achieve optimum velocity control depending on the type of processing (roughing,
rough-finishing, finishing) very simply with the "High Speed Settings" cycle.
Program the cycle in the technology program before the geometry program is called.
The "High Speed Settings" cycle is also in conjunction with the "Advanced Surface" function.
Software option
You require the software option in order to use this function:
"Advanced Surface"
Machining methods
With the "High Speed Settings" function, you can select between four technological
machining types:
"Finishing"
"Rough-finishing"
"Roughing"
"Deselected" (default setting)
For CAM programs in the HSC range, the four machining types directly relate to the
accuracy and speed of the path contour (see help screen).
The operator/programmer uses the tolerance value to give a corresponding weighting.
Corresponding to the appropriate G commands, the four machining types are assigned to
technology G group 59:
Machining type Technology G group 59

Deselection DYNNORM
Finishing DYNFINISH
Rough-finishing DYNSEMIFIN
Roughing DYNROUGH
Additional G commands that are available in conjunction with machining free-form surfaces,
are also activated in the High Speed Settings cycle.
When deselecting CYCLE832, the G groups are programmed to the settings - during the
program run time - that are declared in the machine data for the reset state.
Milling
References
Procedure

3. Press the "High Speed Settings" softkey.

The "High Speed Settings" input window is opened.

Tolerance Tolerance of the machining axis
(pre-finishing)
(finishing)
Deselection
Milling
8.6.4 Subroutines
If you require the same machining steps when programming different workpieces, you can
define these machining steps in a separate subprogram. You can then call this subprogram
in any programs.
Identical machining steps therefore only have to be programmed once.
ShopMill does not differentiate between main programs and subprograms. This means that
you can call a "standard" machining step or G code program as subprogram in another
machining step program.
You can also call another subprogram in the subprogram. The maximum nesting depth is 8
subprograms.
You cannot insert subprograms into linked blocks.
If you want to call machining step program as subprogram, the program must already have
been calculated once (load or simulate program in Machine Auto mode). This is not
necessary for G code subprograms.
The subprogram must always be stored in the NCK work memory (in a separate directory
"XYZ" or in the "ShopMill", "Part programs", "Subprograms" directories).
If you want to call a subprogram located on another drive, you can use G code command
"EXTCALL".
Please note that, when a subprogram is called, ShopMill evaluates the settings in the
program header of the subprogram. These settings also remain active even after the
subprogram has ended.
If you wish to activate the settings from the program header for the main program again, you
can make the settings again in the main program after calling the subprogram.
Procedure
1. Generate a ShopMill or G code program that you wish to call as a

subprogram in another program.
2. Position the cursor in the work plan or in the program view of the main
program on the program block after which you wish to call the
subprogram.
3. Press the "Various" and "Subroutine" softkeys.
4. Enter the path of the subprogram if the desired subprogram is not

stored in the same directory as the main program.
The subprogram is thus executed in the position pattern.
5. Press the "Accept softkey.
The subprogram call is inserted in the main program.
Milling
Parameter Description
Path/workpiece Path of the subprogram if the desired subprogram is not stored in the same
directory as the main program.
Program name Name of the subprogram that is to be inserted.
Programming example
N10 T1 D1 ;Load tool

N11 M6
N20 G54 G710 ;Select work offset
N30 M3 S12000 ;Switch-on spindle
N40 CYCLE832(0.05,3,1) ;Tolerance value 0.05 mm, machining type,
roughing
N50 EXTCALL"CAM_SCHRUPP" Externally call subprogram CAM_SCHRUPP
N60 T2 D1 ;Load tool
N61 M6
N70 CYCLE832(0.005,1,1) ;Tolerance value 0.005 mm, machining
type, finishing
N80 EXTCALL"CAM_SCHLICHT" ;Call subprogram CAM_SCHLICHT
N90 M30 ;End of program
The subprograms CAM_SCHRUPP.SPF, CAM_SCHLICHT.SPF contain the workpiece

geometry and the technological values (feedrates). These are externally called due to the
program size.
Milling
8.7 Further cycles and functions ShopMill
8.7.1 Transformations
To make programming easier, you can transform the coordinate system. Use this possibility,
for example, to rotate the coordinate system.
Coordinate transformations only apply in the actual program. You can define shift, rotation,
scaling or mirroring. You can select between a new or an additive coordinate transformation.
In the case of a new coordinate transformation, all previously defined coordinate
transformations are deselected. An additive coordinate transformation acts in addition to the
currently selected coordinate transformations.
Note
Transformations with virtual axes
Please note that when selecting TRANSMIT or TRACYL offsets, scaling and mirroring, the
real Y axis is not transferred into the virtual Y axis.
Offsets, scalings and mirroring of the virtual Y axis are deleted for TRAFOOF.
Procedure for work offset, offset, rotation, scaling or mirroring
1. The ShopMill program has been created and you are in the editor.
2. Press the "Various" and "Transformation" softkeys.
3. Press the "Work offsets softkey.

The "Work offsets" input window opens.
- OR -
Press the "Offset" softkey.
The "Offset" input window opens.
- OR -
Press the "Rotation" softkey.
The "Rotate" input window opens.
- OR -
Press the "Scaling" softkey.
The "Scaling" input window opens.
Milling
- OR -
Press the "Mirroring" softkey.
The "Mirroring" input window opens.
8.7.2 Translation
For each axis, you can program an offset of the zero point.
New offset Additive offset

Offset New
New offset
Additive
Additive offset
X Offset X mm
Y Offset Y mm
Z Offset Z mm
Milling
8.7.3 Rotation
You can rotate every axis through a specific angle. A positive angle corresponds to
counterclockwise rotation.
New rotation Additive rotation

Rotation New
New rotation
Additive
Additive rotation
Milling
8.7.4 Scaling
You can specify a scale factor for the active machining plane as well as for the tool axis. The
programmed coordinates are then multiplied by this factor.
New scaling Additive scaling

Scaling New
New scaling
Additive
Additive scaling
XY Scale factor XY
Z Scale factor Z
Milling
8.7.5 Mirroring
Furthermore, you can mirror all axes. Enter the axis to be mirrored in each case.
Note
Travel direction of the milling cutter
Note that with mirroring, the travel direction of the cutting tool (conventional/climbing) is also
mirrored.
New mirroring Additive mirroring

Mirroring New
New mirroring
Additive
Additive mirroring
X Mirroring of the X axis, on/off
Y Mirroring of the Y axis, on/off
Z Mirroring of the Z axis, on/off
Milling
8.7.6 Cylinder surface transformation

You require the cylinder surface transformation to machine
Longitudinal grooves on cylindrical bodies,
Transverse grooves on cylindrical objects
grooves with any path on cylindrical bodies.
The path of the grooves is programmed with reference to the unwrapped, level surface of the
cylinder. The groove can be programmed using line/circle, drilling or milling cycles or with
contour milling (free contour programming).
<
Supporting several data sets

If several Tracyl data sets have been set up, then the corresponding rotary axes can be
selected.
If several Tracyl data sets have been set up around a rotary axis, then the corresponding
numbers of the data sets can be selected.
Milling
Slot side compensation

Cylinder surface transformation is available in the following versions:
Slot side compensation off
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Slot side compensation on (path milling only)
Longitudinal slot with

parallel limit, slot side
compensation on
Slot side compensation off

When slot side compensation is deactivated, any type of slot with parallel sides can be
machined if the tool diameter is equal to the slot width.
The slot sides are not parallel if the slot width is larger than the tool diameter.
The slot contour is programmed for machining purposes.
Slot side compensation on

When slot side compensation is on, slots with parallel sides are machined even if the slot
width is larger than the tool diameter.
The slot contour must not be programmed for machining purposes, but the imaginary center-
point path of a bolt guided in the slot; whereby the bolt must move along every side. The slot
width is determined by parameter D.
Note
Selecting slot side compensation
The slot side compensation selection depends on the transformation type.
Milling
8.7.6.1 General programming

The basic programming procedure is as follows:
1. Select work offset for cylinder surface transformation (e.g. offset the zero point on the
center point of the cylinder end face)
2. Position the Y axis (Y axis must be positioned prior to cylinder surface transformation
because it is defined differently after transformation)
3. Activate cylinder surface transformation
4. Select work offset for machining on the developed cylinder surface (e.g. shift zero point to
the zero point on the workpiece drawing)
5. Program machining operation (e.g. enter contour and path milling)
6. Deactivate cylinder surface transformation
The programmed cylinder surface transformation is simulated only as developed peripheral
surface.
Note
The work offsets active prior to selection of cylinder surface transformation are no longer
active after the function has been deselected.
editor.
3. Press the "Transformations" and "Cylinder surface" softkeys.

Cylinder surface trans. Yes
Activates the cylinder surface transformation for programming.
For several rotary axes, instead of "yes", the name of the rotary axis (A or B) is
displayed.
No
Deactivates cylinder surface transformation after programming.

Transformation number Selects the Tracyl data set, if there are several Tracyl data sets.
Cylinder diameter - only for "Cylinder surface transformation yes"
Milling

Slot side compensation on - only for "Cylinder surface transformation yes"
Activates slot side compensation.

off - only for "Cylinder surface transformation yes"
Deactivates slot side compensation.
The selection for "slot side compensation" depends on the transformation type.
D Offset to programmed path - only for "slot side compensation on"
8.7.7 Straight or circular machining

When you want to perform straight or circular path movements or machining without defining
a complete contour, you can use the functions "Straight line" or "Circle" respectively.
General sequence
To program simple machining operations, proceed as follows:
Specify the tool and the spindle speed
Program the machining operation
Machining options
The following machining options are available:
Straight line
Circle with known center point
Circle with known radius
Helix
Straight line with polar coordinates
Circle with polar coordinates
If you want to program a straight line or a circle using polar coordinates, you must define the
pole first.
CAUTION
If you use a straight or circular path movement to move the tool into the retraction zone
specified in the program header, you must also move the tool out again. Otherwise a
collision could occur as a result of the traversing movements in a subsequently
programmed cycle.
Milling
Before you can program a straight line or circle, you have to select the tool, spindle speed
and machining plane.
If you program a sequence of different straight or circular path movements, the settings for
the tool and spindle speed remain active until you change these again.
Procedure
editor.
3. Press the "Tool" softkey.

The parameter screen "Tool" is opened.
4. Enter a tool in parameter field "T".
- OR -
Press the "Select tool softkey.
Position the cursor on the tool that you wish to use for machining and
press the "To program" softkey.
The tool is copied into the "T" parameter field.
- OR -
Press the "Tool list" and "New tool" softkeys.
Using the softkeys on the vertical softkey bar, select the required tool
and press the "To program" softkey.
The tool is copied into the "T" parameter field.
5. Select the tool cutting edge number D if the tool has several cutting
edges.
6. Enter the spindle speed or cutting rate.
7. Enter an allowance in the "DR" field.
The values are saved and the parameterization screen form is closed.
The process plan is displayed and the newly generated program block
is marked.
Milling

T Tool name
S/V Spindle speed or rev/min
Constant cutting rate m/min
DR Allowance, tool radius mm
8.7.8 Programming a straight line

The tool moves at the programmed feedrate or with rapid traverse from its actual position to
the programmed end position.
Radius compensation
Alternatively, you can implement the straight line with radius compensation. The radius
compensation acts modally, therefore you must deactivate the radius compensation again
when you want to traverse without radius compensation. Where several straight line blocks
with radius compensation are programmed sequentially, you may only select radius
compensation in the first program block.
When executing the first path motion with radius compensation, the tool traverses without
compensation at the starting point and with compensation at the end point. This means that
if a vertical path is programmed, the tool traverses an oblique path. The compensation is not
applied over the entire traversing path until the second programmed path motion with radius
compensation is executed. The reverse effect occurs when radius compensation is
deactivated.
Procedure
editor.
3. Press the "Straight line" softkey.

traverse.
Milling

X Target position X (abs) or target position X referred to the last programmed mm
position (inc)
Y Target position Y (abs) or target position Y referred to the last programmed mm
position (inc)
Z Target position Z (abs) or target position Z referred to the last programmed mm
position (inc)
Note
F Machining feedrate mm/rev
mm/min
mm/tooth
Radius compensation Input defining which side of the contour the cutter travels in the programmed
direction:
The previously programmed setting for radius compensation is used.
8.7.9 Programming a circle with known center point

The tool travels along a circular path from its actual position to the programmed circle end
point. You must know the position of the circle center point. The control calculates the radius
of the circle/arc on the basis of your interpolation parameter settings.
The circle can only be traversed at machining feedrate. You must program a tool before the
circle can be traversed.
Procedure
editor.
3. Press the "Circle center point" softkey.
Milling

Direction of rotation The tool travels in the programmed direction from the circle starting point to its end
point. You can program this direction as clockwise or counterclockwise.

position (inc)
position (inc)
I Distance between circle starting point and center point in X direction (inc.) mm
J Distance between circle starting point and center point in Y direction (inc.) mm
mm/min
mm/tooth
PL Plane: The circle is traversed in the set plane with the relevant interpolation
parameters:
XYIJ: XY plane with interpolation parameters I and J mm
ZXKI: ZX plane with interpolation parameters K and I mm
YZJK: YZ plane with interpolation parameters J and K mm
8.7.10 Programming a circle with known radius

The tool traverses a circular path with the programmed radius from its actual position to the
programmed circle end point. The control system calculates the circle center point. You do
not need to program interpolation parameters.
The circle can only be traversed at machining feedrate.
Procedure
editor.
3. Press the "Circle radius" softkey.
Milling


position (inc)
position (inc)
R Radius of arc. mm
You can select the arc of your choice by entering a positive or a negative sign.
mm/min
mm/tooth
8.7.11 Helix
With helical interpolation, a circular movement is overlaid in the plane with a linear motion in
the tool axis, i.e. a spiral is created.
Procedure
editor.
3. Press the "Helix" softkey.

I Center point of the helix in the X direction (abs or inc) mm

J Center point of the helix in the Y direction (abs or inc) mm
Milling

P Helix pitch The pitch is programmed in mm per revolution. mm/rev
Z Target position of the helical end point (abs or inc) mm

mm/min
mm/tooth
8.7.12 Polar coordinates

If a workpiece has been dimensioned from a central point (pole) with radius and angles, you
will find it helpful to program these as polar coordinates.
You can program straight lines and circles as polar coordinates.
Defining a pole
You must define the pole before you can program a straight line or circle in polar
coordinates. This pole acts as the reference point of the polar coordinate system.
The angle for the first line or circle then needs to be programmed in absolute coordinates.
You can program the angles for any additional straight lines and circles as either absolute or
incremental coordinates.
Procedure
editor.
2. Press the menu forward key and the "Polar" softkey.
3. Press the "Pole" softkey.

X Pole X (abs) or pole X referred to the last programmed position (inc) mm
Y Pole Y (abs) or pole Y referred to the last programmed position (inc) mm
Milling
8.7.13 Straight polar

A straight line in the polar coordinate system is defined by a radius (L) and an angle (). The
angle refers to the X axis.
The tool moves from its actual position along a straight line to the programmed end point at
the machining feedrate or in rapid traverse.
The 1st straight line in polar coordinates entered after the pole must be programmed with an
absolute angle. You can program any additional straight lines or circles with incremental
coordinates.
Procedure
editor.
3. Press the "Polar" and "Straight polar" softkeys.

traverse.

L Distance to the pole, end point mm
Polar angle to the pole, end point (abs) or Degrees
change in polar angle to the pole, end point (inc)
mm/min
mm/tooth
Radius compensation Input defining which side of the contour the cutter travels in the programmed
direction:

The set radius compensation remains as previously set
Milling
8.7.14 Circle polar

A circle in the polar coordinate system is defined by an angle (). The angle refers to the X
axis.
The tool moves from its actual position on a circular path to the programmed end point
(angle) at the machining feedrate. The radius corresponds to the distance from the actual
tool position to the defined pole, i.e. the circle starting and end point positions are at the
same distance from the defined pole.
The 1st arc in polar coordinates entered after the pole must be programmed with an absolute
angle. You can program any additional straight lines or circles with incremental coordinates.
Procedure
editor.
3. Press the "Polar" and "Circle polar" softkeys.

point. You can program this direction as clockwise (right) or counterclockwise
(left).
Polar angle to the pole, end point (abs) or Degrees

change in polar angle to the pole, end point (inc)
mm/min
mm/tooth
Milling
8.7.15 Obstacle
Function
If there is an obstacle between 2 position patterns, it can be crossed. The height of the
obstacle can be programmed absolutely or incrementally.
If all positions in the 1st pattern have been machined, the tool axis travels with rapid traverse
to a height corresponding to the obstacle height + safety clearance. The new position is
approached with rapid traverse at this height. The tool axis then approaches a position
according to Z0 of the position pattern + safety clearance with rapid traverse.
Procedure
editor.
3. Press the "Positions" and "Obstacle" softkeys.

The "obstacle" input window opens.
Note
Obstacles are only taken into consideration if they lie between 2 position patterns. If the tool
change point and the programmed retraction plane are positioned below the obstacle, the
tool travels to the retraction plane height and on to the new position without taking the
obstacle into account. The obstacle must not be higher than the retraction plane.

Z0 Obstacle height (abs or inc)
Milling
Multi-channel view 9
9.1 Multi-channel view
The multi-channel view allows you to simultaneously view several channels in the following
operating areas:
"Machine" operating area
"Program" operating area
See also
Editor settings (Page 169)
9.2 Multi-channel view in the "Machine" operating area

When a multi-channel machine, you have the option of simultaneously monitoring and
influencing the execution of several programs.
Displaying the channels in the "Machine" operating area

In the "Machine" operating area, you can display 2 - 4 channels simultaneously.
Using the appropriate settings, you can define the sequence in which channels are
displayed. Here, you can also select if you wish to hide a channel.
Note
The sub operating mode "REF POINT" is only shown in the single channel view.
Multi-channel view
2 - 4 channels are simultaneously displayed in channel columns on the user interface.
2 windows are displayed one above the other for each channel.
The actual value display is always in the upper window.
Milling
Multi-channel view
The same window is displayed for both channels in the lower window.
You can select the display in the lower window using the vertical softkey bar.
The following exceptions apply when making a selection using the vertical softkeys:
The "Actual values Machine" softkey switches over the coordinate systems of both
channels.
The "Zoom actual value" and "All G functions" softkeys switch into the single-channel
view.
Single channel view

If, for your multi-channel machine, you always only wish to monitor one channel, then you
can set a permanent single-channel view.
Horizontal softkeys
Block search
When selecting the block search, the multi-channel view is kept. The block display is
displayed as search window.
Program control
The "Program control" window is displayed for the channels configured in the multi-
channel view. The data entered here apply for these channels together.
If you press an additional horizontal softkey in the "Machine" operating area (e.g.
"Overstore", "Synchronized actions"), then you change into a temporary single-channel
view. If you close the window again, then you return to the multi-channel view.
Switching between single and multi-channel view
Press the <MACHINE> key in order to briefly switch between the single
and multi-channel display in the machine area.
Press the <NEXT WINDOW> key in order to switch between the upper
and lower window within a channel column.
Editing a program in the block display

You can perform simple editing operations as usual in the actual block display.
If there is not sufficient space, you switch over into the single-channel view.
Running-in a program
You select individual channels to run-in the program at the machine.
Milling
Multi-channel view
Precondition
Several channels have been set-up.
The setting "2 channels", "3 channels" or "4 channels" is selected.
Displaying/hiding a multi-channel view
1. Select the "Machine" operating area
2. Select the operating mode "JOG", "MDA" or "AUTO".
...
4. Press the "Multi-channel view" softkey.
5. In the window "Settings for multi-channel view" in the selection

box "View", select the required entry (e.g. "2 channels") and
define the channels as well as the sequence in which they are
displayed.
In the basic screen for the "AUTO", "MDA" and JOG" operating
modes, the upper window of the lefthand and righthand channel
columns are occupied by the actual value window.
6. Press the "T,S,F" softkey if you wish to view the "T,F,S" window.
The "T,F,S" window is displayed in the lower window of the
lefthand and righthand channel column.
Milling
Multi-channel view
9.3 Multi-channel view for large operator panels

For the large OP15, OP019 operator panels as well as at the PC, there is more space in the
"Machine", "Program" and "Parameter" operating areas as well as in all lists to display
NC blocks, tools etc.
Further, you also have the option of simultaneously displaying more than 2 channels.
This makes it easier for you to identify the machine situation for machines with 3 and more
channels. Further, it makes it simpler for you to generate and run-in three or four-channel
programs.
Supplementary conditions
OP15, OP19 or PC with a display of at least 1280x1024 pixels
For operating an OP019, at least one NCU720.2 or 730.2 with 1 GB of RAM or a PCU50
is required
3 / 4-channel view in the "Machine" operating area

If you have selected 3 channels via settings, then 3 or 4 channel columns are displayed next
to one another.
Channel view Display in the "Machine" operating area

3-channel view The following windows are displayed one above the other for each channel:
Actual value window
T,F,S window
Block display window
4-channel view The following windows are displayed one above the other for each channel:
Actual value window
T,S,F window
G functions (the "G functions" softkey is omitted)
Block display window
Displaying functions

Selection using vertical softkeys:
3-channel view The T,F,S window is overlaid by pressing one of the vertical softkeys.
4-channel view The window showing the G codes is overlaid if you press one of the
vertical softkeys.
Selection using horizontal softkeys:
Milling
Multi-channel view

3-channel view / The block display is overlaid if you press the "Overstore" horizontal softkey
4 channel view
If you press the "Block search" softkey, then the block display changes
into the single-channel view.
If you press the "Prog. control" softkey, then the window changes into the
single-channel view.
If you press one of the horizontal softkeys in the "JOG" operating mode
(e.g. "T,S,M", "Meas. tool", "Positions" etc.), then you change into the
single-channel view.
Toggling between the channels
Press the <CHANNEL> key to toggle between the channels.
Press the <NEXT WINDOW> key to toggle within a channel column

between the three or four windows arranged one above the other.
Note
2-channel display
Contrary to the smaller operator panels, in the "Machine" operating area, for a 2-channel
view, the TFS window is visible.
Program operating area

In the editor, just as many programs are displayed next to one another as in the "Machine"
operating area.
Displaying a program
You can define the width of the program in the editor window using the settings in the editor.
This means that you can distribute programs evenly - or you can display the column with the
active program wider.
Channel status
When required, channel messages are displayed in the status display.
Milling
Multi-channel view
9.4 Setting the multi-channel view
Setting Meaning
View Here, you specify how many channels are displayed.
1 channel
2 channels
3 channels
4 channels
Channel selection and You specify which channels in which sequence are displayed in the multi-
sequence channel view.
(for "2 - 4 channels"
view)
Visible Here, you specify which channels are displayed in the multi-channel view.
(for "2 - 4 channels" You can quickly hide channels from the view.
view)
Example
Your machine has 6 channels.
You configure channels 1 - 4 for the multi-channel view and define the display sequence
(e.g. 1,3,4,2).
In the multi-channel view, for a channel switchover, you can only switch between the
channels configured for the multi-channel view; all others are not taken into consideration.
Using the <CHANNEL> key, advance the channel in the "Machine" operating area - you
obtain the following views: Channels "1" and "3", channels "3" and "4", channels "4" and "2".
Channels "5" and "6" are not displayed in the multi-channel view.
In the single-channel view, toggle between all of the channels (1...6) without taking into
account the configured sequence for the multi-channel view.
Using the channel menu, you can always select all channels, also those not configured for
multi-channel view. If you switch to another channel, which is not configured for the
multiview, then the system automatically switches into the single-channel view. There is no
automatic switchback into the multi-channel view, even if a channel is again selected, which
has been configured for multi-channel view.
Milling
Multi-channel view
Procedure
2. Select the operating mode "JOG", "MDA" or "AUTO".
4. Press the "Multi-channel view" softkey.

The "Settings for multi-channel view" window is opened.
5. Set the multi-channel or single-channel view and define which channels
are to be seen in the "Machine" operating area - and in the editor - in
which sequence.
Milling
Multi-channel view
Milling
User variables 10
10.1 Overview
The defined user data may be displayed in lists.
The following variables can be defined:
Data parameters (R parameters)
Global user data (GUD) is valid in all programs
Local user data (LUD) is valid in one program
Program-global user data (PUD) is valid in one program and the called subroutines.
Channel-specific user data can be defined with a different value for each channel.
Entering and displaying parameter values

Up to 15 positions (including decimal places) are evaluated. If you enter a number with more
than 15 places, it will be written in exponential notation (15 places + EXXX).
LUD or PUD
Only local or program-global user data can be displayed at one time.
Whether the user data are available as LUD or PUD depends on the current control
configuration.
Note
Reading and writing variables protected
Reading and writing of user data are protected via a keyswitch and protection levels.
Searching for user data

You may search for user data within the lists using any character string.
Refer to the "Defining and activating user data" section to learn how to edit displayed user
data.
Milling
User variables
10.2 R parameters
10.2 R parameters
R parameters (arithmetic parameters) are channel-specific variables that you can use within
a G code program. G code programs can read and write R parameters.
These values are retained after the control is switched off.
Number of channel-specific R parameters

The number of channel-specific R parameters is defined in a machine data element.
Range: R0-R999 (dependent on machine data).
There are no gaps in the numbering within the range.
Procedure
2. Press the "User variable" softkey.
3. Press the "R variables" softkey.

The "R parameters" window appears.
Delete R variables
1. Press the ">>" and "Delete" softkeys.

The "Delete R parameters" window appears.
2. Enter the R parameter(s) whose channel-specific values you would like

to delete and press the "OK" softkey.
A value of 0 is assigned to the selected R parameters or to all R

parameters.
Milling
User variables
10.3 Global GUD
10.3 Global GUD
Global user data

Global GUDs are NC global user data (Global User Data) that remains available after
switching the machine off.
GUDs apply in all programs.
Definition
A GUD variable is defined with the following:
Keyword DEF
Range of validity NCK
Data type (INT, REAL, .)
Variable names
Value assignment (optional)
Example
DEF NCK INT ZAEHLER1 = 10
GUDs are defined in files with the ending DEF. The following file names are reserved for this
purpose:
File name Meaning

MGUD.DEF Definitions for global machine manufacturer data
UGUD.DEF Definitions for global user data
GUD4.DEF User-definable data
GUD8.DEF, GUD9.DEF User-definable data
Procedure
3. Press the "Global GUD" softkeys.
The "Global user data" window is displayed. A list of the defined UGUD
variables will be displayed.
Milling
User variables
10.4 Channel GUD
- OR -
Press the "GUD selection" softkey and the "SGUD" to "GUD6" softkeys
if you wish to display SGUD, MGUD, UGUD as well as GUD4 to GUD 6
of the global user variables.
- OR -
Press the "GUD selection" and ">>" softkeys as well as the "GUD7" to
"GUD9" softkeys if you want to display GUD 7 to GUD 9 of the global
user data.
Note
After each start-up, a list with the defined UGUD variables is displayed in the "Global user
data" window.
10.4 Channel GUD
Channel-specific user data

Like the GUDs, channel-specific user data are applicable in all programs for each channel.
However, unlike GUDs, they have specific values.
Definition
A channel-specific GUD variable is defined with the following:
Keyword DEF
Range of validity CHAN
Data type
Variable names
Example
DEF CHAN REAL X_POS = 100.5
Milling
User variables
10.5 Local LUD
Procedure
3. Press the "Channel GUD" and "GUD selection" softkeys.

4. Press the "SGUD" ... "GUD6" softkeys if you want to display the SGUD,
MGUD, UGUD as well as GUD4 to GUD 6 of the channel-specific user
variables.
- OR -
Press the "Continue" softkey and the "GUD7" to "GUD9" softkeys if you
want to display GUD 7 to GUD 9 of the channel-specific user data.
10.5 Local LUD
Local user data

LUDs are only valid in the program or subroutine in which they were defined.
The control displays the LUDs after the start of program processing. The display is available
until the end of program processing.
Definition
A local user variable is defined with the following:
Keyword DEF
Data type
Variable names
Milling
User variables
10.6 Program PUD
Proceed as follows
3. Press the "Local LUD" softkey.
10.6 Program PUD
Program-global user data

PUDs are global part program variables (Program User Data). PUDs are valid in all main
programs and subroutines, where they can also be written and read.
Procedure
3. Press the "Program PUD" softkey.
Milling
User variables
10.7 Searching for user data
10.7 Searching for user data

You can search for R parameters and user data.
Procedure
2. Press the "R parameters", "Global GUD", "Channel GUD", "Local GUD"
or "Program PUD" softkeys to select the list in which you would like to
search for user data.

The "Search for R Parameters" or "Search for User Data" window
opens.
4. Enter the desired search term and press "OK".
The cursor is automatically positioned on the the R parameter or user

data you are searching for, if they exist.
10.8 Defining and activating user variables

By editing a DEF/MAC file, you can alter or delete existing definition/macro files or add new
ones.
Proceed as follows
2. Press the "System data" softkey.
3. In the data tree, select the "NC data" folder and then open the
"Definitions" folder.
4. Select the file you want to edit.
5. Double-click the file.
- OR -
Milling
User variables
10.8 Defining and activating user variables
Press the "Open" softkey.
- OR -
- OR -
The selected file is opened in the editor and can be edited there.
6. Define the desired user data.

7. Press the "Exit" softkey to close the editor.
Activating user data
1. Press the "Activate" softkey.
A prompt is displayed.
2. Select whether the current values in the definition files should be
retained
- OR -
Select whether the current values in the definition files should be
deleted.
This will overwrite the definition files with the initial values.
3. Press the "OK" softkey to continue the process.
Milling
Teaching in a program 11
11.1 Overview
The "Teach in" function can be used to edit programs in the "AUTO" and "MDA" modes. You
can create and modify simple traversing blocks.
You traverse the axes manually to specific positions in order to implement simple machining
sequences and make them reproducible. The positions you approach are applied.
In "AUTO" teach-in mode, the selected program is "taught".
In "MDA" teach-in mode, you teach to the MDA buffer.
External programs, which may have been rendered offline, can therefore be adjusted and
modified according to need.
11.2 General sequence
General sequence
Select the desired program block, press the relevant softkey "Teach
position", "Rap. tra. G01", "Straight line G1" or "Circ. interm. pos. CIP",
and "Circ. end pos. CIP" and traverse the axes to change the program
block.
You can only overwrite a block with a block of the same type.
- OR -
Position the cursor at the desired point in the program, press the
relevant softkey "Teach position", "Rap. tra. G01", "Straight line G1" or
"Circ. interp. pos. CIP", and "Circ. end pos. CIP" and traverse the axes
to insert a new program block.
In order for the block to be inserted, the cursor must be positioned in an
empty line using the cursor key and input key.
Press the "Accept" softkey to teach-in the modified or new program
block.
Note
All defined axes are "taught in" in the first teach-in block. In all additional teach-in blocks,
only axes modified by axis traversing or manual input are "taught in".
If you exit teach-in mode, this sequence begins again.
Milling
Teaching in a program
11.3 Inserting a block
Operating mode or operating area switchover

If you switch to another operating mode or operating area in teach-in mode, the position
changes will be canceled and teach-in mode will be cleared.

You have the option of traversing the axes and writing the current actual values directly to a
new position block.
Requirement
"AUTO" mode: The program to be edited is selected.
Proceed as follows
3. Press the <TEACH IN> key.
4. Press the "Teach prog." softkey.
5. Traverse the axes to the relevant position.

6. Press the "Teach position" softkey.
A new program block with the current actual position values will be
created.
Milling
11.3.1 Input parameters for teach-in blocks
Parameters for teach-in of position and teach-in of G0, G1, and circle end position CIP
X Approach position in X direction
Y Approach position in Y direction
Z Approach position in Z direction
F Feedrate (mm/r; mm/min) - only for teach-in of G1 and circle end position CIP
Parameters for teach-in of circle intermediate position CIP
I Coordinate of the circle center point in the X direction
J Coordinate of the circle center point in the Y direction
K Coordinate of the circle center point in the Z direction
Transition types for teach-in of position and teach-in of G0 and G1, and ASPLINE
The following parameters are offered for the transition:
G60 Exact stop
G64 Corner rounding
G641 Programmable corner rounding
G642 Axis-specific corner rounding
G643 Block-internal corner rounding
G644 Axis dynamics corner rounding
Motion types for teach-in of position and teach-in of G0 and G1

The following motion parameters are offered:
CP Path-synchronous
PTP Point-to-point
PTPG0 Only G0 point-to-point
Milling
11.4 Teach-in via window
Transition behavior at the beginning and end of the spline curve

The following motion parameters are offered:
Start
BAUTO Automatic calculation
BNAT Curvature is zero or natural
BTAN Tangential
End
EAUTO Automatic calculation
ENAT Curvature is zero or natural
ETAN Tangential
11.4.1 General
The cursor must be positioned on an empty line.
The windows for pasting program blocks contain input and output fields for the actual values
in the WCS. Depending on the default setting, selection fields with parameters for motion
behavior and motion transition are available.
When first selected, the input fields are empty unless axes were already traversed before the
window was selected.
All data from the input/output fields are transferred to the program via the "Accept" softkey.
Precondition
"AUTO" mode: The program to be edited is selected.
Milling
Procedure
1 Select the "Machine" operating area.
5. Use the cursor and input keys to position the cursor at the desired point
in the program.
If an empty row is not available, insert one.
6. Press the softkeys "Rap. tra. G0", "Straight line G1", or Circ. interm.
pos. CIP" and "Circ. end pos. CIP".
The relevant windows with the input fields are displayed.
7. Traverse the axes to the relevant position.

A new program block will be inserted at the cursor position.
- OR -
Press the "Cancel" softkey to cancel your input.
Milling
11.4.2 Teach in rapid traverse G0

You traverse the axes and teach-in a rapid traverse block with the approached positions.
Note
Selection of axes and parameters for teach-in
You can select the axes to be included in the teach-in block in the "Settings" window.
You also specify here whether motion and transition parameters are offered for teach-in.
11.4.3 Teach in straight G1

You traverse the axes and teach-in a machining block (G1) with the approached positions.
Note
11.4.4 Teaching in circle intermediate and circle end point CIP

Enter the intermediate and end positions for the circle interpolation CIP. You teach-in each of
these separately in a separate block. The order in which you program these two points is not
specified.
Note
Make sure that the cursor position does not change during teach-in of the two positions.
You teach-in the intermediate position in the "Circle intermediate position CIP" window.
You teach-in the end position in the "Circle end position CIP" window.
Milling
The intermediate or interpolation point is only taught-in with geometry axes. For this reason,
at least 2 geometry axes must be set up for the transfer.
Note
Selection of axes for teach in
11.4.5 Teach-in A spline

For Akima-spline interpolation, you enter interpolation points that are connected by a smooth
curve.
Enter a starting point and specify a transition at the beginning and end.
You teach-in each interpolation point via "Teach in of position".
Software option
You require the "Spline-Interpolation" option for A Spline interpolation.
Note
The relevant option bit must be set to enable you to program a spline interpolation.
Procedure
Milling
5. Press the ">>" and "ASPLINE" softkeys.

The "Akima-spline" window opens with the input fields.
6. Traverse the axes to the required position and if necessary, set the
transition type for the starting point and end point.
A new program block will be inserted at the cursor position.
- OR -
Press the "Cancel" softkey to cancel your input.
Note
Milling
11.5 Editing a block
11.5 Editing a block

You can only overwrite a program block with a teach-in block of the same type.
The axis values displayed in the relevant window are actual values, not the values to be
overwritten in the block.
Note
If you wish to change any variable in a block in the program block window other than the
position and its parameters, then we recommend alphanumerical input.
Requirement
The program to be edited is selected.
Proceed as follows
5. Click the program block to be edited.

6. Press the relevant softkey "Teach position, "Rap. tra. G0", "Straight line
G1", or "Circ. interm. pos. CIP", and "Circ. end pos. CIP".
The relevant windows with the input fields are displayed.
7. Traverse the axes to the desired position and press the "Accept"
softkey.
The program block is taught with the modified values.
- OR -
Press the "Cancel" softkey to cancel the changes.
Milling
11.6 Selecting a block
11.6 Selecting a block

You have the option of setting the interrupt pointer to the current cursor position. The next
time the program is started, processing will resume from this point.
With teach-in, you can also change program areas that have already been executed. This
automatically disables program processing.
You must press reset or select a block to resume the program.
Requirement
The program to be processed is selected.
Proceed as follows
5. Place the cursor on the desired program block.

6. Press the "Block selection" softkey.
Milling
11.7 Deleting a block

You have the option of deleting a program block entirely.
Requirement
"AUTO" mode: The program to be processed is selected.
Proceed as follows
5. Click the program block to be deleted.

6. Press the ">>" and "Delete block" softkeys.
The program block on which the cursor is positioned is deleted.
In the "Settings" window, you define which axes are to be included in the teach-in block and
whether motion-type and continuous-path mode parameters are to be provided.
Proceed as follows
Milling
5. Press the ">>" and "Settings" softkeys.

The "Settings" window appears.
6. Under "Axes to be taught" and "Parameters to be taught", select the

check boxes for the relevant settings and press the "Accept" softkey to
confirm the settings.
Milling
Tool management 12
12.1 Lists for the tool management
All tools and also all magazine locations that have been created or configured in the NC are
displayed in the lists in the Tool area.
All lists display the same tools in the same order. When switching between the lists, the
cursor remains on the same tool in the same screen segment.
The lists have different parameters and softkey assignments. Switching between lists is a
specific change from one topic to the next.
Tool list
All parameters and functions required to create and set up tools are displayed.
Tool wear
All parameters and functions that are required during operation, e.g. wear and monitoring
functions, are listed here.
Magazine
You will find the magazine and magazine location-related parameters and functions for
the tools/ magazine locations here.
Tool data OEM
This list can be freely defined by the OEM.
Sorting the lists

You can change the sorting within the lists:
acc. to the magazine
acc. to the name (tool identifier, alphabetic)
according to the tool type
according to the T number (tool identifier, numerical)
Filtering the lists

You can filter the lists according to the following criteria:
only display the first cutting edge
only tools that are ready to use
only tools that have reached the pre-alarm limit
only locked tools
Milling
Tool management
12.2 Magazine management
Search functions
You have the option of searching through the lists according to the following objects:
Tool
Magazine location
Empty location
12.2 Magazine management

Depending on the configuration, the tool lists support a magazine management.
Magazine management functions

Press the "Magazine" horizontal softkey to obtain a list that displays tools with magazine-
related data.
The Magazine / Magazine location column is displayed in the lists.
In the default setting, the lists are displayed sorted according to magazine location.
The magazine selected via the cursor is displayed in the title line of each list.
The "Magazine selection" vertical softkey is displayed in the tool list.
You can load and unload tools to and from a magazine via the tool list.
Milling
Tool management
12.3 Tool types
12.3 Tool types

A number of tool types are available when you create a new tool. The tool type determines
which geometry data is required and how it will be computed.
Tool types
Figure 12-1 Example of Favorites list
Figure 12-2 Available tools in the "New tool - milling cutter" window
Milling
Tool management
12.3 Tool types
Figure 12-3 Available tools in the "New tool - drill" window
Figure 12-4 Available tools in the "New tool - special tools" window
See also
Changing a tool type (Page 536)
Milling
Tool management
12.4 Tool dimensioning

This section provides an overview of the dimensioning of tools.
Tool types
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Figure 12-6 Face mill (Type 140)
Milling
Tool management
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Figure 12-7 Angle head cutter (Type 130)

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Figure 12-8 Drill (Type 200)
Milling
Tool management
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Figure 12-9 Tap (Type 240)

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Figure 12-10 3D tool with an example of a cylindrical die-sinking cutter (Type 110)
Milling
Tool management
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Figure 12-11 3D tool type with an example of a ballhead cutter (Type 111)
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Figure 12-12 3D tool with an example of an end mill with corner rounding (Type 121)
Milling
Tool management
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Figure 12-13 3D tool type with an example of a bevel cutter (Type 155)
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Figure 12-14 3D tool with an example of a bevel cutter with corner rounding (Type 156)
Milling
Tool management
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Figure 12-15 3D tool with an example of a tapered die-sinking cutter (Type 157)
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Figure 12-16 Electronic workpiece probe
Milling
Tool management
The tool length of the workpiece probe is measured to the center of the ball
(length m) or to the ball circumference (length u).
Note
An electronic workpiece probe must be calibrated before use.
Milling
Tool management
12.5 Tool list
12.5 Tool list

All parameters and functions that are required to create and set up the tools are displayed in
the tool list.
Each tool is uniquely identified by the tool identifier and the replacement tool number.
Tool parameters
Column heading Meaning

Location Magazine/location number
The magazine location numbers
The magazine number is specified first, followed by the location

number in the magazine.
If there is only one magazine, only the location number is displayed.

BS Load position in the load magazine
The following icons can also be displayed for other magazine types (e.g.
for a chain):
Spindle location as an icon
Locations for gripper 1 and gripper 2 (applies only when a spindle with
dual gripper is used) as icons.
* If activated in magazine
selection
Type Tool type
Specific tool offset data is displayed depending on the tool type
(represented as an icon).
You have the option of changing the tool type using the<SELECT> key.
Tool name The tool is identified by the name and the replacement tool number. You
may enter the names as text or numbers.
Note: The maximum length of tool names is 31 ASCII characters. The
number of characters is reduced for Asian characters or Unicode
characters. The following special characters are not permitted: | # ".
ST Replacement tool number (for replacement tool strategy)
Length Tool length
Geometry data, length
Radius Tool radius
Tip angle or Tip angle for Type 200 - twist drill and Type 220 - centering tool and Type
Pitch 230 countersink
Pitch for Type 240 - tap
Milling
Tool management
12.5 Tool list

N Number of teeth for Type 100 - milling tool, Type 110 - ball end mill for
cylindrical die-sinking cutter, Type 111 - ball end mill or tapered die-
sinking cutter, Type 120 - end mill, Type 121 - end mill with corner
rounding, Type 130 - angle head cutter, Type 131 - angle head cutter with
corner rounding, Type 140 - facing tool, Type 150 - side mill, Type 155 -
bevel cutter, Type 156 - bevel cutter with corner rounding and Type 157 -
tapered die-sinking cutter.
Direction of spindle rotation
Spindle is not switched on
CW spindle rotation
CCW spindle rotation

Coolant 1 and 2 (e.g. internal and external cooling) can be switched on
and switched off.
The coolant infeed at the machine does not necessarily have to be set-up.
M1 - M4 Other tool-specific functions such as additional coolant infeed, monitoring
functions for speed, tool breakage, etc.
You use the configuration file to specify the selection of parameters in the list.
Software option
In order to be able to manage the parameter spindle direction of rotation,
coolant and tool-specific functions (M1-M4), you require the
"ShopMill/ShopTurn" option.
Icons in the tool list
Icon/ Meaning
Marking
Tool type
Red "X" The tool is disabled.
Yellow triangle pointing The prewarning limit has been reached.

downward
Yellow triangle pointing The tool is in a special state.
upward Place the cursor on the marked tool. A tooltip provides a
short description.
Green border The tool is preselected.
Milling
Tool management
12.5 Tool list
Icon/ Meaning
Marking
Magazine/location number
Green double arrow The magazine location is positioned at the change position.
Gray double arrow The magazine location is positioned at the loading position.
(configurable)
Red "X" The magazine location is disabled.
Procedure
2. Press the "Tool list" softkey.

The "Tool list" window is opened.
See also
Displaying tool details (Page 535)
Milling
Tool management
12.5 Tool list
12.5.1 Additional data

The following tool types require geometry data that is not included in the tool list display.
Tools with additional geometry data
Tool type Additional parameters

111 Conical ballhead cutter Corner radius
121 End mill with corner Corner radius
rounding
130 Angle head cutter Geometry length (length X, length Y, length Z)
Wear length ( length X, length Y, length Z)
Adapter length (length X, length Y, length Z)
V (direction vector 1 - 6)
Vector X, vector Y, vector Z
131 Angle head cutter with Geometry length (length X, length Y, length Z)
corner rounding Corner radius
Wear length ( length X, length Y, length Z)
Adapter length (length X, length Y, length Z)
V (direction vector 1 - 6)
Vector X, vector Y, vector Z
140 Face milling External radius
Tool angle
155 Bevel cutter Taper angle
156 Bevel cutter with corner Corner radius
rounding Taper angle
157 Conical die-milling cutter Taper angle
You can use the configuration file to specify the data to be displayed for specific tool types in
the "Additional Data" window.
Milling
Tool management
12.5 Tool list
Procedure
1. The tool list is opened.
2. In the list, select an appropriate tool, e.g. an angle head cutter.

3. Press the "Additional data" softkey.
The "Additional data - ..." window is opened.
The "Additional data" softkey is only active if a tool for which the
"Additional Data" window is configured is selected.
12.5.2 Creating a new tool

When creating a new tool, the "New tool - favorites" window offers you a number of selected
tool types, known as "favorites".
If you do not find the desired tool type in the favorites list, then select the milling, drilling or
special tool using the corresponding softkeys.
Procedure
2. Place the cursor in the tool list at the position where the new tool
should be stored.
For this, you can select an empty magazine location or the NC tool
memory outside of the magazine.
You may also position the cursor on an existing tool in the area of the
NC tool memory. Data from the displayed tool will not be overwritten.
3. Press the "New tool" softkey.
The "New tool - favorites" window opens.
- OR -
Milling
Tool management
12.5 Tool list
If you want to create a tool that is not in the "Favorites" list, press the
softkey "Cutters 100-199", "Drill 200-299", or "Spec.tool 700-900".
... The "New tool - milling cutter", "New tool - drill", or "New tool - special
tools" window opens.
4. Select the tool by placing the cursor on the corresponding icon.

The tool is added to the tool list with a predefined name. If the cursor
is located on an empty magazine location in the tool list, then the tool
is loaded to this magazine location.
The tool creation sequence can be defined differently.
Multiple load points

If you have configured several loading points for a magazine, then the "Select loading point"
window appears when a tool is created directly in an empty magazine location or when the
"Load" softkey is pressed.
Select the required load point and confirm with the "OK" softkey.
Additional data
If configured accordingly, the "New tool" window opens after the required tool has been
selected and confirmed with "OK".
You can define the following data in this window:
Names
Tool location type
Size of tool
References:
For a description of configuration options, refer to the
Milling
Tool management
12.5 Tool list
12.5.3 Measuring the tool

You can measure the tool offset data for the individual tools directly from the tool list.
Note
Procedure
2. Select the tool that you want to measure in the tool list and press the
"Measure tool" softkey.
You jump to the "JOG" operating area and the tool to be measured is
entered in the "T" field in the "Length Manual" screen.
tool ST of the tool.
4. Approach the workpiece in the Z direction, scratch it with a turning

spindle and enter the set position Z0 of the workpiece edge.
5. Press the "Set length" softkey.
The tool length is calculated automatically and entered in the tool list.
12.5.4 Managing several cutting edges

In the case of tools with more than one cutting edge, a separate set of offset data is
assigned to each cutting edge. The number of possible cutting edges depends on the
controller configuration.
Tool cutting edges that are not required can be deleted.
Procedure
2. Position the cursor on the tool for which you would like to store more
cutting edges.
3. Press the "Edges" softkey in the "Tool list".
Milling
Tool management
12.5 Tool list
4. Press the "New cutting edge" softkey.

A new data set is stored in the list.
The cutting edge number is incremented by one and the offset data is
assigned the values of the cutting edge on which the cursor is
positioned.
5. Enter the offset data for the 2nd cutting edge.
6. Repeat this process if you wish to create more tool edge offset data.
7. Position the cursor on the cutting edge that you want to delete and
press the "Delete cutting edge" softkey.
The data set is deleted from the list. The first tool cutting edge cannot
be deleted.
12.5.5 Delete tool

Tools that are no longer in use can be deleted from the tool list for a clearer overview.
Procedure
2. Place the cursor on the tool that you would like to delete.
3. Press the "Delete tool" softkey.
A safety prompt is displayed.
4. Press the "OK" softkey if you really want to delete the tool.
Use this softkey to delete the tool.

If the tool is in a magazine location, it is unloaded and then deleted.
Multiple load points - tool in magazine location

If you have configured several loading points for a magazine, then the "Loading Point
Selection" window appears after pressing the "Delete tool" softkey.
Select the required load point and press the "OK" softkey to unload and delete the tool.
Milling
Tool management
12.5 Tool list
12.5.6 Loading and unloading tools

You can load and unload tools to and from a magazine via the tool list. When a tool is
loaded, it is taken to a magazine location. When it is unloaded, it is removed from the
magazine and stored in the NC memory.
When you are loading a tool, the application automatically suggests an empty location. You
may also directly specify an empty magazine location.
You can unload tools from the magazine that you are not using at present. HMI then
automatically saves the tool data in the NC memory.
Should you want to use the tool again later, simply load the tool with the tool data into the
corresponding magazine location again. Then the same tool data does not have to be
entered more than once.
Procedure
2. Place the cursor on the tool that you want to load into the magazine (if
the tools are sorted according to magazine location number you will find
it at the end of the tool list).
3. Press the "Load" softkey.
The "Load to " window opens.

The "... location" field is initialized with the number of the first empty
magazine location.
4. Press the "OK" softkey to load the tool into the suggested location.
- OR -
Enter the location number you require and press the "OK" softkey.
- OR -
Press the "Spindle" softkey.
The tool is loaded into the specified magazine location or spindle.
Several magazines
If you have configured several magazines, the "Load to ..." window appears after pressing
the "Load" softkey.
If you do not want to use the suggested empty location, then enter your desired magazine
and magazine location. Confirm your selection with "OK".
Milling
Tool management
12.5 Tool list

Selection" window appears after pressing the "Load" softkey.
Select the required loading point and confirm with "OK".
Unloading tools
1. Place the cursor on the tool that you would like to unload from the
magazine and press the "Unload" softkey.
2. Select the required load point in the "Loading Point Selection" window.
3. Confirm your selection with "OK".
- OR -
Undo your selection with "Cancel".
12.5.7 Selecting a magazine

You can directly select the buffer memory, the magazine, or the NC memory.
Procedure
2. Press the "Magazine selection" softkey.
If there is only one magazine, you will move from one area to the next
(i.e. from the buffer memory to the magazine, from the magazine to the
NC memory, and from the NC memory back to the buffer memory) each
time you press the softkey. The cursor is positioned at the beginning of
the magazine each time.
- OR -
If there is more than one magazine, the "Magazine Selection" window
opens. Position the cursor on the desired magazine in this window and
press the "Go to" softkey.
The cursor jumps directly to the beginning of the specified magazine.
Milling
Tool management
12.5 Tool list
Hiding magazines
Deactivate the checkbox next to the magazines that you do not want to appear in the
magazine list.
The magazine selection behavior with multiple magazines can be configured in different
ways.
References
Milling
Tool management
12.6 Tool wear
12.6 Tool wear

All parameters and functions that are required during operation are contained in the tool
wear list.
Tools that are in use for long periods are subject to wear. You can measure this wear and
enter it in the tool wear list. The control then takes this information into account when
calculating the tool length or radius compensation. This ensures a consistent level of
accuracy during workpiece machining.
You can automatically monitor the tools' working times via the workpiece count, tool life or
wear.
In addition, you can disable tools when you no longer wish to use them.
Tool parameters

for a chain):
Locations for gripper 1 and gripper 2 (applies only when a spindle
with dual gripper is used) as icons.
selection
Type Tool type
Depending on the tool type (represented by an icon), certain tool offset
data is enabled.
can enter the name as text or number.
ST Replacement tool number (for replacement tool strategy).
Length Length wear
Radius Radius wear
Milling
Tool management
12.6 Tool wear

TC Selection of tool monitoring
- by tool life (T)
- by count (C)
- by wear (W)
The wear monitoring is configured via a machine data item.
Please refer to the machine manufacturer's instructions.
Tool life Tool life
Workpiece count Number of workpieces
Wear * Tool wear
*Parameter depends on
selection in TC
Setpoint Setpoint for tool life, workpiece count, or wear
Prewarning limit Specification of the tool life, workpiece count or wear at which a warning
is displayed.
G The tool is disabled when the checkbox is selected.
Icons in the wear list
Icon/ Meaning
Marking
Tool type

downward
upward Place the cursor on the marked tool. A tooltip provides a
short description.
Green double arrow The magazine location is positioned at the change position.
Gray double arrow The magazine location is positioned at the loading position.
(configurable)
Milling
Tool management
12.6 Tool wear
Procedure
2. Press the "Tool wear" softkey.
See also
12.6.1 Reactivating a tool

You can replace disabled tools or make them ready for use again.
Preconditions
In order to reactivate a tool, the monitoring function must be activated and a setpoint must be
stored.
Procedure
1. The tool wear list is opened.
2. Position the cursor on the disabled tool which you would like to reuse.
3. Press the "Reactivate" softkey.
The value entered as the setpoint is entered as the new tool life or
workpiece count.
The disabling of the tool is canceled.
Reactivating and positioning

When the "Reactivate with positioning" function is configured, the selected tool's magazine
location will also be positioned at a loading point. You can exchange the tool.
Reactivation of all monitoring types

When the "Reactivation of all monitoring types" function is configured, all the monitoring
types set in the NC for a tool are reset during reactivation.
Milling
Tool management
12.6 Tool wear
References

Selection" window appears after pressing the "Load" softkey.
Select the required load point and confirm with the "OK" softkey.
Milling
Tool management
12.7 Tool data OEM
12.7 Tool data OEM

You have the option of configuring the list according to your requirements.
Refer to the following document for more information on configuring OEM tool data:
Procedure
2. Press the "OEM tool" softkey.
3. Position the cursor on a grinding tool.
Milling
Tool management
12.8 Magazine
12.8 Magazine
Tools are displayed with their magazine-related data in the magazine list. Here, you can take
specific actions relating to the magazines and the magazine locations.
Individual magazine locations can be location-coded or disabled for existing tools.
Tool parameters

for a chain):
Locations for gripper 1 and gripper 2 (applies only when a spindle
with dual gripper is used) as icons
selection
Type Tool type
Depending on the tool type (represented by an icon), certain tool offset
data is enabled.
can enter the name as text or number.
ST Replacement tool number (for replacement tool strategy).
G Disabling of the magazine location.
Mag.loctype Display of magazine location type.
Tool.loctype Display of tool location type.
Marking of a tool as oversized. The tool occupies two half locations left,
two half locations right, one half location top and one half location bottom
in a magazine.
P Fixed location coding.
The tool is permanently assigned to this magazine location.
Milling
Tool management
12.8 Magazine
Magazine list icons
Icon/ Meaning
Marking
Tool type

downward
upward Place the cursor on the marked tool. A tooltip
provides a short description.
Green double arrow The magazine location is positioned at the change
position.
Gray double arrow The magazine location is positioned at the loading
(configurable) position.
Procedure
2. Press the "Magazine softkey.
See also
Milling
Tool management
12.8 Magazine
12.8.1 Positioning a magazine

You can position magazine locations directly on the loading point.
Procedure
1. The magazine list is opened.
2. Place the cursor on the magazine location that you want to position
onto the load point.
3. Press the "Position magazine" softkey.
The magazine location is positioned on the loading point.

Selection" window appears after pressing the "Position magazine" softkey.
Select the desired loading point in this window and confirm your selection with "OK" to
position the magazine location at the loading point.
12.8.2 Relocating a tool

Tools can be directly relocated within magazines to another magazine location, which means
that you do not have to unload tools from the magazine in order to load them into a different
location.
When you are relocating a tool, the application automatically suggests an empty location.
You may also directly specify an empty magazine location.
Buffer
You have the option of relocating the tool to buffer locations.
Milling
Tool management
12.8 Magazine
Procedure
1. The magazine list is opened.
2. Position the cursor on the tool that you wish to relocate to a different
magazine location.
3. Press the "Relocate" softkey.
The "... relocate from location ... to location ..." window is displayed. The
"Location" field is pre-assigned with the number of the first empty
magazine location.
4. Press the "OK" softkey to relocate the tool to the recommended
magazine location.
- OR -
Enter the required magazine, enter the location number and press the
"OK" softkey.
- OR -
Enter the number "9998" or the number "9999" into the "... magazine"
field in order to select the buffer as well as the required buffer location
in the "Location" field.
- OR -
Press the "Spindle" softkey to load a tool into the spindle and press the
"OK" softkey.
The tool is relocated to the specified magazine location, in the spindle

or in the buffer.
Several magazines
If you have set up several magazines, then the "...relocate from magazine... location... to..."
window appears after pressing the "Relocate" softkey.
Select the desired magazine and location, and confirm your selection with "OK" to load the
tool.
Milling
Tool management
12.9 Sorting tool management lists
12.9 Sorting tool management lists

When you are working with many tools, with large magazines or several magazines, it is
useful to display the tools sorted according to different criteria. Then you will be able to find a
specific tool more quickly in the lists.
Procedure
2. Press the "Tool list", "Tool wear" or "Magazine" softkey.
...
3. Press the ">>" and "Sort" softkeys.
The lists are displayed sorted numerically according to magazine

location.
Tool types are used to sort tools with the same magazine location.
Identical types (e.g. milling cutters), in turn, are sorted according to their
radius value.
4. Press the "Acc. to type" softkey to display the tools arranged by tool
type. Identical types (e.g. milling cutters) are sorted according to their
radius value.
- OR -
Press the "Acc. to name" softkey to display the tool names in
alphabetical order.
The replacement tool numbers are used to sort tools with the same
names.
- OR -
Press the "Acc. to T number" softkey to display the tools names sorted
numerically.
The list is sorted according to the specified criteria.
Milling
Tool management
12.10 Filtering the tool management lists
12.10 Filtering the tool management lists

The filter function allows you to filter-out tools with specific properties in the tool
management lists.
For instance, you have the option of displaying tools during machining that have already
reached the pre-alarm limit in order to prepare the corresponding tools to be loaded.
Filter criteria
only display the first cutting edge
only tools that are ready to use
only tools that have reached the pre-alarm limit
only locked tools
Note
Multiple selection
You have the option of selecting several criteria. You will receive an appropriate message
if conflicting filter options are selected.
Procedure
...
3. Press the ">>" and "Filter" softkeys.

The "Filter" window is opened.
...
4. Activate the required filter criterion and press the "OK" softkey.
The tools that correspond to the selection criteria are displayed in the
list.
The active filter is displayed in the window header.
Milling
Tool management
12.11 Specific search in the tool management lists
12.11 Specific search in the tool management lists

There is a search function in all tool management lists, where you can search for the
following objects:
Tools
You enter a tool name. You can narrow down your search by entering a replacement tool
number.
You have the option of only entering a part of the name as search term.
Magazine locations or magazines
If only one magazine is configured, then the search is only made for the magazine
location.
If several magazines are configured, then it is possible to search a specific magazine
location in a specific magazine or just to search in a specific magazine.
Empty locations
If the lists with the location type are used, then the empty location search is made using
the location type and location size.
Procedure
...
3. Press the ">>" and "Search" softkeys.
...
4. Press the "Tool" softkey if you wish to search for a specific tool.
- OR -
Milling
Tool management
12.12 Displaying tool details
Press the "Magazine location" softkey if you wish to search for a

specific magazine location or a specific magazine.
- OR -
Press the "Empty location" softkey if you wish to search for a specific
empty location.
12.12 Displaying tool details

All of the parameters of the selected tool are listed in the "Tool details - all parameters"
window.
The parameters are displayed, sorted according to the following criteria
Tool data
Cutting edge data
Monitoring data
Protection level
You require access level, keyswitch 3 (protection level 4) in order to edit the parameters in
the detail window.
Procedure
1. The tool list, the wear list, the OEM tool list or the magazine is opened.
...
2. Position the cursor to the desired tool.

3. If you are in the tool list or in the magazine, press the ">>" softkey and
"Details".
- OR -
If you are in the wear list or OEM tool list, press the "Details" softkey.
Milling
Tool management
12.13 Changing a tool type
The "Tool details" window is displayed.

All of the available tool data is displayed in the list.
4. Press the softkey "Cutting edge data", if you wish to display the cutting
edge data.
5. Press the softkey "Monitoring data", if you wish to display the

monitoring data.
6. Press the "Additional details" softkey.

The "Tool details - all parameters" window is opened.
All of the tool parameters are displayed in the list.
12.13 Changing a tool type
Procedure
1. The tool list, the wear list, the OEM tool list or the magazine is opened.
...
2. Position the cursor in the column "Type" of the tool that you wish to
change.
3. Press the <SELECT> key.
The "Tool types - Favorites" window opens.
4. Select the desired tool type in the list of favorites or select using the
softkeys "Cutters 100-199", "Drill 200-299", "Grinders 400-499" or "
Spec.tool 700-900".
Note: A grinding tool can only be changed into another grinding tool
type.
The new tool type is accepted and the corresponding icon is displayed
in the "Type" column.
Milling
Program management 13
13.1 Overview
You can access programs at any time via the Program Manager for execution, editing,
copying, or renaming. Programs that you no longer require can be deleted to release their
storage space.
NOTICE
Execution from USB FlashDrive
Direct execution from a USB FlashDrive is not recommended.
There is no protection against contact problems, falling out, breakage through knocking or
unintentional removal of the USB FlashDrive during operation.
Disconnecting it during operation will result in the stopping of the machining and thus to the
workpiece being damaged.
Storage for programs

Possible storage locations are:
NC
Local drive
Network drives
USB drives
V24
Software options
To display the "Local drive" softkey, you require the option "Additional 256 MB
HMI user memory on CF Card of the NCU" (not for SINUMERIK Operate on
PCU50 or PC/PG).
Data exchange with other workstations

You have the following options for exchanging programs and data with other workstations:
USB drives (e.g. USB FlashDrive)
Network drives
Milling
Program management
13.1 Overview
Choosing storage locations

In the horizontal softkey bar, you can select the storage location that contains the directories
and programs that you want to display. In addition to the "NC" softkey, via which the passive
file system data can be displayed, additional softkeys can be displayed.
The "USB" softkey is only operational when an external storage medium is connected (e.g.
USB FlashDrive on the USB port of the operator panel).
Structure of the directories

In the overview, the symbols in the left-hand column have the following meaning:
Directory
Program
All directories have a plus sign when the program manager is called for the first time.
Figure 13-1 Program directory in the program manager
The plus sign in front of empty directories is removed after they have been read for the first
time.
The directories and programs are always listed complete with the following information:
Name
The name may be a maximum of 24 characters long
Permissible characters include all upper-case letters (without accents), numbers, and
underscores.
Type
Directory: WPD
Program: MPF
Subprogram: SPF
Initialization programs: INI
Job lists: JOB
Tool data: TOA
Milling
Program management
13.1 Overview
Magazine assignment: TMA

Zero points: UFR
R parameters: RPA
Global user data/definitions: GUD
Setting data: SEA
Protection zones: PRO
Sag: CEC
Size (in bytes)
Date/time (of creation or last change)
Active programs
Selected, i.e. active programs are identified using a green symbol.
Figure 13-2 Active program shown in green
Milling
Program management
13.1 Overview
13.1.1 NC memory
The complete NC working memory is displayed along with all tools and the main programs
and subroutines.
You can create further subdirectories here.
Proceed as follows
2. Press the "NC" softkey.
13.1.2 Local drive

Workpieces, main and subprograms that are saved in the user memory of the CF-Card or on
the local hard disk are displayed.
For archiving, you have the option of mapping the structure of the NC memory system or to
create your own archiving system.
You can create any number of subdirectories here, in which to store any files (e.g. text files
with notes).
Software options
PCU50 or PC/PG).
Procedure
2. Press the "Local drive" software key.
On the local drive, you have the option of mapping the directory structure of the NC memory.
This also simplifies the search sequence.
Milling
Program management
13.1 Overview
Procedure
1. The local drive is selected.
2. Position the cursor on the main directory.
3. Press the "New" and "Directory" softkeys.

The "New Directory" window opens.
4. In the "Name" entry field, enter "mpf.dir", "spf.dir" and "wks.dir" and
press the "OK" softkey.
The directories "Part programs", "Subprograms" and "Workpieces" are
created below the main directory.
13.1.3 USB drives

USB drives enable you to exchange data. For example, you can copy to the NC and execute
programs that were created externally.
NOTICE
Direct execution from the USB FlashDrive is not recommended.
Procedure
2. Press the "USB" softkey.
Note
The "USB" softkey can only be operated when a USB FlashDrive is inserted in the front
interface of the operator panel.
Milling
Program management
13.2 Opening and closing the program

To view a program in more detail or modify it, open the program in the editor.
With programs that are in the NCK memory, navigation is already possible when opening.
The program blocks can only be edited when the program has been opened completely. You
can follow the opening of the program in the dialog line.
With programs that are opened via local network, USB FlashDrive or network connections,
navigation is only possible when the program has been opened completely. A progress
message box is displayed when opening the program.
Note
Channel changeover in the editor
When opening the program, the editor is opened for the currently selected channel. This
channel is used to simulate the program.
If you change over a channel in the editor, this does not influence the editor. Only when
closing the editor do you change into the other channel.
Procedure
program that you would like to edit.
3. Press the "Open" softkey.
- OR -
- OR -
- OR -
Double-click the program.
The selected program is opened in the "Editor" operating area.
4. Now make the necessary program changes.
Milling
Program management
5. Press the "NC Select" softkey to switch to the "Machine" operating area
and begin execution.
When the program is running, the softkey is deactivated.
Closing the program
Press the ">>" and "Exit" softkeys to close the program and editor again.
- OR -
If you are at the start of the first line of the program, press the <Cursor left>
key to close the program and the editor.
To reopen a program you have exited with "Close", press the "Program" key.
Note
A program does not have to be closed in order for it to be executed.
Milling
Program management
13.3 Executing a program
13.3 Executing a program

When you select a program for execution, the controller automatically switches to the
Program selection
Select the workpieces (WPD), main programs (MPF) or subprograms (SPF) by placing the
cursor on the desired program or workpiece.
For workpieces, the workpiece directory must contain a program with the same name. This
program is automatically selected for execution (e.g. when you select the workpiece
SHAFT.WPD, the main program SHAFT.MPF is automatically selected).
If an INI file of the same name exists (e.g. SHAFT.INI), it will be executed once at the first
part program start after selection of the part program. Any additional INI files are executed in
accordance with machine data MD11280 $MN_WPD_INI_MODE.
MD11280 $MN_WPD_INI_MODE=0:
The INI file with the same name as the selected workpiece is executed. For example, when
you select SHAFT1.MPF, the SHAFT1.INI file is executed upon <CYCLE START>.
MD11280 $MN_WPD_INI_MODE=1:
All files of type SEA, GUD, RPA, UFR, PRO, TOA, TMA and CEC which have the same
name as the selected main program are executed in the specified sequence. The main
programs stored in a workpiece directory can be selected and processed by several
channels.
Procedure
workpiece/program that you would like to execute.
The controller switches automatically into the "Machine" operating area.

- OR -
Milling
Program management
13.4 Creating a directory/program/job list/program list
If the selected program is already opened in the "Program" operating

area,
Press the "Execute NC" softkey.
Press the <CYCLE START> key.
Execution of the workpiece is started.
Note
Only workpieces/programs that are located in the NCK memory, local drive or USB drive can
be selected for execution.
13.4.1 Creating a new directory

Directory structures help you to manage your program and data transparently. You can
create subdirectories in a directory on the local drive and on USB/network drives.
In a subdirectory, in turn, you can create programs and then create program blocks for them.
Note
Directory names must end in .DIR or .WPD. The maximum name length is 49 characters
including the extension.
All letters (except accented characters), numbers, and underscores are permitted for name
assignment. These names are automatically converted to upper-case letters.
This limitation does not apply for work on USB/network drives.
Milling
Program management
Procedure
2. Select your chosen storage medium, i.e. a local or USB drive.
3. If you want to create a new directory in the local network, place the
cursor on the topmost folder and press the "New" and "Directory"
softkeys.
4. Enter the desired directory name and press the "OK" softkey.
13.4.2 Creating a new workpiece

You can set up various types of files such as main programs, initialization files, tool offsets,
etc. in a workpiece.
Note
Workpiece directories
828D provides you with the option of nesting tool directories. You must note that the length
of the call line is restricted. You will be informed if the maximum number of characters is
reached when entering the workpiece name.
Under a workpiece directory (WPD), 840D sl does not allow any additional workpiece
directories to be created in the NC memory. You can create a free directory structure on the
local drive, USB and network drives; this means that you have the option to create other
workpieces or any number of directories in a workpiece. If you copy this data to the NC
memory then the length of the call line is checked.
Milling
Program management
Procedure
2. Select the desired storage location and position the cursor on the folder,
in which you would like to create a workpiece.
3. Press the "New" softkey.

The "New workpiece" window appears.
4. If necessary, select a template if any are available.
5. Enter the desired workpiece name and press the "OK" softkey.
The name may be a maximum of 24 characters long.

You can use any letters (except umlauts), digits or the underscore
symbol (_).
The directory type (WPD) is set by default.
A new folder with the workpiece name will be created.
The "New G code program" window will open.
6. Press the "OK" softkey again if you want to create the program.
The program will open in the editor.
13.4.3 Creating a new G code program

You can create G code programs and then render G code blocks for them in a
directory/workpiece.
Procedure
in which you would like to store the program.
Milling
Program management
4. If necessary, select a template if any are available.

5. Select the file type (MPF or SPF).
If you are in the NC memory and have selected either the
"Subprograms" or "Part Programs" folder, you can only create one
subprogram (SPF) or one main program (MPF).
6. Enter the desired program name and press the "OK" softkey.
Program names may be a maximum of 24 characters in length.

You can use all letters (with the exception of special characters,
language-specific special characters, Asian or Cyrillic characters),
numbers and underscores (_).
13.4.4 Creating a new ShopMill program

In the part program and workpiece directories, you can create ShopMill programs and then
subsequently generate the machining steps for them.
Procedure
in which you would like to store the program.
4. Press the "ShopMill" softkey.

The "New step sequence program" window opens.
The "ShopMill" type is specified.
5. Enter the desired program name and press the "OK" softkey.
Program names may be a maximum of 24 characters in length.

You can use all letters (with the exception of special characters,
language-specific special characters, Asian or Cyrillic characters),
numbers and underscores (_).
Milling
Program management
13.4.5 Storing any new file

In each directory or subdirectory you can create a file in any format that you specify.
This does not apply to the NC memory. Here you can create the following file types under a
workpiece using the "Any" softkey.
Procedure
in which you would like to create the file.
3. Press the "New" and "Any" softkeys.
The "Any new program" window appears
4. Select a file type from the "Type" selection field (for example,
"Definitions GUD") and enter the name of the file to be created when
you have selected a workpiece directory in the NC memory.
The file automatically has the selected file format.
- OR -
Enter a name and file format for the file to be created (e.g. My_Text.txt).
Milling
Program management
The name may be a maximum of 24 characters long.

You can use any letters (except umlauts), digits or the underscore
symbol (_).
13.4.6 Creating a Joblist

For every workpiece, you can create a job list for extended workpiece selection.
In the job list, you specify instructions for program selection in different channels.
Syntax
The job list contains the SELECT select instructions.
SELECT <program> CH=<channel number> [DISK]
The SELECT instruction selects a program for execution in a specific NC channel. The
selected program must be loaded into the working memory of the NC. The DISK parameter
enables the selection of external execution (CF card, USB data carrier, network drive).
<Program>
Absolute or relative path specification of the program to be selected.
Examples:
//NC/WCS.DIR/SHAFT.WPD/SHAFT1.MPF
SHAFT2.MPF
<Channel number>
Number of the NC channel in which the program is to be selected.
Example:
CH=2
[DISK]
Optional parameter for programs that are not in the NC memory and are to be executed
"externally".
Example:
SELECT //remote/myshare/shaft3.mpf CH=1 DISK
Comment
Comments are identified in the job list by ";" at the start of the line or by round brackets.
Template
You can select a template from Siemens or the machine manufacturer when creating a new
job list.
Milling
Program management
Executing a workpiece
If the "Select" softkey is selected for a workpiece, the syntax of the associated job list is
checked and then executed. The cursor can also be placed on the job list for selection.
Procedure
2. Press the "NC" softkey, and in directory "Workpieces" place the cursor
on the program for which you wish to create a job list.
3. Press the "New" and "Any" softkeys.

The "Any New Program" window opens.
4. Select entry "Job list JOB" from the "Type" selection field and enter a
name and press the "OK" softkey.
13.4.7 Creating a program list

You can also enter programs in a program list that are then selected and executed from the
PLC.
The program list may contain up to 100 entries.
Procedure
2. Press the menu forward key and the "Program list" softkey.
The "Prog.-list" window opens.
3. Place the cursor in the desired line (program number).
Milling
Program management
13.5 Creating templates
4. Press the "Select program" softkey.

The "Programs" window opens. The data tree of the NC memory with
workpiece, part program and subprogram directory is displayed.
5. Place the cursor on the desired program and press the "OK" softkey.
The selected program is inserted in the first line of the list together with
its path.
- OR -
Enter the program name directly in the list.
If you are making entries manually, check that the path is correct (e.g.
//NC/WKS.DIR/MEINPROGRAMM.WPD/MEINPROGRAMM.MPF).
//NC and the extension (.MPF) may be added automatically.
With multi-channel machines, you can specify in which channel the
program is to be selected.
6. To remove a program from the list, place the cursor on the appropriate
line and press the "Delete" softkey.
- OR -
To delete all programs from the program list, press the "Delete all"
softkey.
13.5 Creating templates

You can store your own templates to be used for creating part programs and workpieces.
These templates provide the basic framework for further editing.
You can use them for any part programs or workpieces you have created.
Storage location for templates

The templates used to create part programs or workpieces are stored in the following
directories:
HMI Data/Templates/Manufacturer/Part programs or Workpieces
HMI Data/Templates/User/Part programs or Workpieces
Procedure
Milling
Program management
13.6 Searching directories and files
3. Position the cursor on the file that you wish to store as a template and
press the "Copy" softkey.
4. Select the directory in which you want to store the data - "Part
programs" or "Workpieces" - and press the "Paste" softkey.
Stored templates can be selected when a part program or a workpiece

is being created.
13.6 Searching directories and files

You have the possibility of searching in the Program Manager for certain directories and
files.
Note
Search with place holders
The following place holders simplify the search:
"*": replaces any character string
"?": replaces any character
Search strategy
The search is made in all of the selected directories and their subdirectories.
If the cursor is positioned on a file, then a search is made from the higher-level directory.
Note
Searching in opened directories
Open the closed directories for a successful search.
Procedure
2. Select the storage location in which you wish to perform the search and
then press the ">>" and "Search" softkeys.
The "Find file" window appears.
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Program management
13.7 Displaying the program in the Preview.
3. Enter the desired search term in the "Text" field.

Note: When searching for a file, enter the complete name with
extension (e.g. DRILLING.MPF).
4. When required, activate the checkbox "Observe upper and lower case".
6. If a corresponding directory or file is found, then it is marked.

7. Press the "Continue search" and "OK" softkeys if the directory or the file
does not correspond to the required result.
- OR -
13.7 Displaying the program in the Preview.

You can show the content on a program in a preview before you start editing.
Procedure
2. Select a storage location and place the cursor on the relevant program.
3. Press the ">>" and "Preview window" softkeys.
The "Preview: ..." window opens.
4. Press the "Preview window" softkey again to close the window.
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Program management
13.8 Selecting several directories/programs

You can select several files and directories for further processing. When you select a
directory, all directories and files located beneath it are also selected.
Note
Selected files
If you have selected individual files in a directory, then this selection is canceled when the
directory is closed.
If the complete directory with all of the files included in it are selected, then this selection is
kept when closing the directory.
Procedure
2. Choose the desired storage location and position the cursor on the file
or directory from which you would like your selection to start.
The softkey is active.
4. Select the required directories/programs with the cursor keys or mouse.

5. Press the "Select" softkey again to deactivate the cursor keys.
Canceling a selection
By reselecting an element, the existing selection is canceled.
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Program management
Selecting via keys
Key combination Meaning

Renders or expands a selection.
You can only select individual elements.
Renders a consecutive selection.
A previously existing selection is canceled.
Selecting with the mouse
Key combination Meaning

Left mouse Click on element: The element is selected.
A previously existing selection is canceled.
Left mouse + Expand selection consecutively up to the next click.
Pressed
Left mouse + Expand selection to individual elements by clicking.
An existing selection will expand to include the element you clicked.
Pressed
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Program management
13.9 Copying and pasting a directory/program

To create a new directory or program that is similar to an existing program, you can save
time by copying the old directory or program and only changing selected programs or
program blocks.
The capability of copying and pasting directories and programs can also be used to
exchange data with other systems via USB/network drives (e.g. USB FlashDrive).
Copied files or directories can be pasted in a different location.
Note
You can only paste directories on local drives and on USB or network drives.
Note
Write protection
If the current directory is write-protected for the user, then the function is not offered.
Note
When you copy directories, any missing endings are added automatically.
All letters (except accented characters), numbers, and underscores are permitted for name
assignment. The names are automatically converted to upper-case letters, and extra dots
are converted to underscores.
Example
If the name is not changed during the copy procedure, a copy is created automatically:
MYPROGRAM.MPF is copied to MYPROGRAM__1.MPF. The next time it is copied, it is
changed to MYPROGRAM__2.MPF, etc.
If the files MYPROGRAM.MPF, MYPROGRAM__1.MPF, and MYPROGRAM__3.MPF
already exist in a directory, MYPROGRAM__2.MPF is created as the next copy of
MYPROGRAM.MPF.
Procedure
or directory which you would like to copy.
3. Press the "Copy" softkey.
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Program management
4. Select the directory in which you want to paste your copied

directory/program.
5. Press the "Paste" softkey.
If a directory/program of the same name already exists in this directory,

you are are informed. You are requested to assign a new name,
otherwise the directory/program is assigned a name by the system.
If the name contains illegal characters or is too long, a prompt will
appear for you to enter a permissible name.
6. Press the "OK" or "Overwrite all" softkey if you want to overwrite
existing directories/programs.
- OR -
Press the "No overwriting" softkey if you do not want to overwrite
already existing directories/programs.
- OR -
Press the "Skip" softkey if the copy operation is to be continued with the
next file.
- OR -
Enter another name if you want to paste the directory/program under
another name and press the "OK" softkey.
Note
Copying files in the same directory
You cannot copy files to the same directory. You must copy the file under a new name.
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Program management
13.10 Deleting a program/directory
13.10 Deleting a program/directory
13.10.1 Deleting a program/directory

Delete programs or directories from time to time that you are no longer using to maintain a
clearer overview of your data management. Back up the data beforehand, if necessary, on
an external data medium (e.g. USB FlashDrive) or on a network drive.
Please note that when you delete a directory, all programs, tool data and zero point data and
subdirectories that this directory contains are deleted.
Temp directory for ShopMill

If you want to free up space in the NCK memory, delete the contents of the "TEMP"
directory. ShopMill stores the programs that are created internally for calculating the stock
removal processes in this directory.
Procedure
or directory that you would like to delete.
3. Press the ">>" and "Delete" softkeys.
A prompt appears as to whether you really want to delete the file or
directory.
4. Press the "OK" softkey to delete the program/directory.
- OR -.
Press the "Cancel" softkey to cancel the process.
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Program management
13.11 Renaming file and directory properties

Information on directories and files can be displayed in the "Properties for ..." window.
Information on the creation date is displayed near the file's path and name.
You can change names.
Changing access rights

Access rights for execution, writing, listing and reading are displayed in the "Properties"
window.
Execute: This is used for the selection
Write: Controls the changing and deletion of a file or a directory
You can set the access rights from keyswitch 0 to the current access level. If an access level
is higher than the current access level, it cannot be changed.
Note
Access rights settings
The settings of the access rights for writing or deleting are evaluated in MD 51050.
Changing directories and files

Using the slfsfileattributes.ini configuration file, you have the option of changing or pre-
assigning the access rights of the directories and file types of the NC and user memory (local
drive).
A template is provided under System data in the directory
HMI data/Templates/Examples/Configuration files
After editing the configuration file, save the file in directory HMI data/Settings/Manufacturer
or HMI data/Settings/User.
The new access rights are effective after the machine has been restarted. If, when powering
up, errors are detected in a file, then a corresponding error message
(slfsfileattributesError.txt) is saved under HMI data/Template/Examples/Configuration data.
References
A detailed description can be found in the following documentation:
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Program management
Procedure
1. Select the Program manager.
or directory whose properties you want to display or change.
3. Press the ">>" and "Properties" softkeys.

The "Properties from ..." window appears.
...
4. Enter any necessary changes.

Note: You can save changes via the user interface in the NC memory.
5. Press the "OK" softkey to save the changes.
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Program management
13.12 EXTCALL
13.12 EXTCALL
The EXTCALL command can be used to access files on a local drive, USB data carriers or
network drives from a part program.
The programmer can set the source directory with the setting data SD $SC42700
EXT_PROG_PATH and then specify the file name of the subprogram to be loaded with the
EXTCALL command.
General conditions
The following supplementary conditions must be taken into account with EXTCALL calls:
You can only call files with the MPF or SPF extension via EXTCALL from a network drive.
The files and paths must comply with the NCK naming conventions (max. 25 characters
for the name, 3 characters for the identifier).
A program is found on a network drive with the EXTCALL command if
with SD $SC42700 EXT_PROG_PATH, the search path refers to the network drive or
a directory contained on the network drive. The program must be stored directly on
that level, no subdirectories are searched.
without SD $SC42700: The correct location of the program is specified in the
EXTCALL call itself by means of a fully qualified path that can also point to a
subdirectory of the network drive.
For programs that were generated on external storage media (Windows system) observe
upper and lower case syntax.
Note
Maximum path length for EXTCALL
The path length must not exceed 112 characters. The path comprises the contents of the
setting data (SD $SC42700) and the path data for EXTCALL call from the part program.
Examples of EXTCALL calls

The setting data can be used to perform a targeted search for the program.
Call of USB drive on TCU (USB storage device on interface X203), if SD42700 is empty:
e.g. EXTCALL "//TCU/TCU1 /X203 ,1/TEST.SPF"
- OR -
Call of USB drive on TCU (USB storage device on interface X203), if SD42700
"//TCU/TCU1 /X203 ,1" contains: EXTCALL "TEST.SPF"
Calls the USB front connection (USB FlashDrive), if SD $SC 42700 is empty: e.g.
EXTCALL "//ACTTCU/FRONT,1/TEST.SPF"
- OR -
Call of USB front connection (USB FlashDrive), if SD42700 "//ACTTCU/FRONT,1"
contains: EXTCALL "TEST.SPF"
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Program management
13.12 EXTCALL
Call of network drive, if SD42700 is empty: e.g. EXTCALL "//computer name/enabled

drive/TEST.SPF"
- OR -
Calls the network drive, if SD $SC42700 "//Computer name/enabled drive" contains:
EXTCALL "TEST.SPF"
Use of the HMI user memory (local drive):
On the local drive, you have created the directories part programs (mpf.dir),
subprograms (spf.dir) and workpieces (wks.dir) with the respective workpiece
directories (.wpd):
SD42700 is empty: EXTCALL "TEST.SPF"
The same search sequence is used on the CompactFlash card as in the NCK part
program memory.
On the local drive, you have created your own directory (e.g. my.dir):
Specification of the complete path: e.g. EXTCALL
"/card/user/sinumerik/data/prog/my.dir/TEST.SPF"
A search is performed for the specified file.
Note
Abbreviations for local drive, CompactFlash Card and USB front connection
As abbreviation for the local drive, the CompactFlash Card and the USB front
connection you can use the abbreviation LOCAL_DRIVE:, CF_CARD: and USB: (e.g.
EXTCALL "LOCAL_DRIVE:/spf.dir/TEST.SPF").
Alternatively, you can also use the abbreviations CF_Card and LOCAL_DRIVE.
Software options
PCU50 / PC).
NOTICE
Direct execution from a USB FlashDrive is not recommended.
There is no protection against contact problems, falling out, breakage through knocking or
unintentional removal of the USB FlashDrive during operation.
Disconnecting it during operation will result in immediate stopping of the machining and,
thus, to the workpiece being damaged.
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Program management
13.13 Backing up data
Processing EXTCALL calls can be enabled and disabled.
13.13.1 Generating an archive in the Program Manager

You have the option of archiving individual files from the NC memory and the local drive.
Archive formats
You have the option of saving your archive in the binary and punched tape format.
Save target
The archive folder of the system data in the "Startup" operating area as well as USB and
network drives are available as save target.
Procedure
2. Select the storage location for the file/files to be archived.
3. In the directories, select the required file from which you want to create
an archive.
- OR -
If you want to back up several files or directories, press the "Select"
softkey and, using the cursor keys or the mouse, select the required
directories or files.
4. Press the ">>" and "Archive" softkeys.
5. Press the "Generate archive" softkey.

The "Generate Archive: Select archiving" window opens.
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Program management
6. Position the cursor to the required storage location, press the "Search"
softkey, enter the required search term in the search dialog and press
the "OK" softkey if you wish to search for a specific directory or
subdirectory.
- OR -
Select the required storage location, press the "New directory" softkey,
enter the required name in the "New directory" window and press the
"OK" softkey to create a directory.
7. Press "OK".
The "Generate Archive: Name" window opens.
9. Select the format (e.g. archive ARC (binary format)), enter the desired
name and press the "OK" softkey.
A message informs you if archiving was successful.
13.13.2 Generating an archive via the system data

If you only want to backup specific data, then you can select the desired files directly from
the data tree and generate an archive.
Archive formats
You have the option of saving your archive in the binary and punched tape format.
You can display the contents of the selected files (XML, ini, hsp, syf files, programs) in a
preview.
You can display information about the file, such as path, name, date of creation and change,
in a Properties window.
Precondition
The access rights depend on the relevant areas and range from protection level 7 (key
switch position 0) to protection level 2 (password: Service).
Storage locations
CompactFlash Card under
/user/sinumerik/data/archive, or
/oem/sinumerik/data/archive
All configured logical drives (USB, network drives)
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Program management
Software option
In order to save archives on the CompactFlash Card in the user area you
require the option "Additional HMI user memory on CF card of NCU".
NOTICE
USB FlashDrive
USB FlashDrives are not suitable as persistent memory media.
Procedure
1. Select the "Start-up" operating area.

The data tree opens.
3. In the data tree, select the required files from which you want to
generate an archive.
- OR -
If you want to back up several files or directories, press the "Select"
softkey and, using the cursor keys or the mouse, select the required
directories or files.
4. If you press the ">>" softkey, further softkeys are displayed on the
vertical bar.
5. Press the "Preview window" softkey.

The contents of the selected file are displayed in a small window. Press
the "Preview window" softkey again to close the window.
6. Press the "Properties" softkey.
Information about the selected file is displayed in a small window. Press
the "OK" softkey to close the window.

Enter the required search term in the search dialog and press the "OK"
softkey if you wish to search for a specific directory or subdirectory.
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Program management
8. Press the "Archive" and "Generate archive" softkeys.

The "Generate Archive: Select storage location" window opens.
The "Archive" folder with the subfolders "User" and "Manufacturer" as
well as the storage media (e.g. USB) are displayed.
9. Select the required location for archiving and press the "New directory"
softkey to create a suitable subdirectory.
The directory is created subordinate to the selected folder.
The "Generate Archive: Name" window opens.
12. Select the format (e.g. archive ARC (binary format)), enter the desired
name and press the "OK" softkey to archive the file/files.
A message informs you if archiving was successful.
13. Press the "OK" softkey to confirm the message and end the archiving
operation.
An archive file in .arc format is created in the selected directory.
13.13.3 Reading in an archive in the Program Manager

In the "Program Manager" operating area, you have the option of reading in archives from
the archive folder of the system data as well as from configured USB and network drives.
Software option
In order to read-in user archives in the "Program Manager" operating area,
you require the option "Additional HMI memory on CF Card of NCU" (not for
SINUMERIK Operate on PCU50 / PC).
Procedure
2. Press the "Archive" and "Read in archive" softkeys.

The "Read in archive: Select archive" window opens.
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Program management
3. Select the archive storage location and position the cursor on the
required archive.
Note: When the option is not set, the folder for user archives is
only displayed if the folder contains at least one archive.
- OR -
Press the "Search" softkey and in the search dialog, enter the
name of the archive file with file extension (*.arc) if you wish to
search for a specific archive and press the "OK" softkey.
4. Press the "OK" or "Overwrite all" softkey to overwrite existing files.
...
- OR -
Press the "Do not overwrite" softkey if you do not want to
overwrite already existing files.
- OR -
Press the "Skip" softkey if the read-in operation is to be continued
with the next file.
The "Read In Archive" window opens and a progress message

box appears for the read-in process.
You will then obtain a "Read error log for archive" in which the
skipped or overwritten files are listed.
5. Press the "Cancel" softkey to cancel the read-in process.
See also
Searching directories and files (Page 553)
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Program management
13.13.4 Read in archive from system data

If you want to read in a specific archive, you can select this directly from the data tree.
Procedure
3. In the data tree below the "Archive" directory, in the "User" folder,
select the file that you wish to read in.
4. Press the "Read in" softkey.
5. Press the "OK" or "Overwrite all" softkey to overwrite existing files.
...
- OR -
Press the "Do not overwrite" softkey if you do not want to
overwrite already existing files.
- OR -
Press the "Skip" softkey if the read-in operation is to be continued
with the next file.
The "Read In Archive" window opens and a progress message

box appears for the read-in process.
You will then obtain a "Read error log for archive" in which the
skipped or overwritten files are listed.
6. Press the "Cancel" softkey to cancel the read-in process.
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Program management
13.14 Setup data
13.14 Setup data
13.14.1 Backing up setup data

Apart from programs, you can also save tool data and zero point settings.
You can use this option, for example, to back up tools and zero point data for a specific
machining step program. If you want to execute this program at a later point in time, you will
then have quick access to the relevant settings.
Even tool data that you have measured on an external tool setting station can be copied
easily into the tool management system using this option.
Backing-up job lists

If you wish to backup a job list, which contains ShopMill and G code programs, you obtain
dedicated selection boxes to backup the tool data and zero points.
Note
Backing up setup data from part programs
Setup data from part programs can only be backed up if they have been saved in the
"Workpieces" directory.
For part programs, which are located in the "Part programs" directory, "Save setup data" is
not listed.
Backing up data
Data
Tool data No
All used in the program (only for ShopMill program and job
list with ShopMill programs)
Complete tool list
Tool data for ShopMill programs No
-- only available for job list with
All used in the program
ShopMill and G code programs
Complete tool list
Tool data for G code programs No
Complete tool list
ShopMill and G code programs
Magazine assignment Yes
No
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Program management
13.14 Setup data
Data
Zero points No
The selection box "Basis zero point" is hidden

All used in the program (only for ShopMill program and job
list with ShopMill programs)
All
Zero points for ShopMill programs No
ShopMill and G code programs The selection box "Basis zero point" is hidden
All used in the program
Complete tool list
Zero points for G code programs No
ShopMill and G code programs The selection box "Basis zero point" is hidden
All
Basic zero points No
Yes
Directory The directory is displayed, in which the selected program is
located.
File name Here you have the option of changing the suggested file
names.
Note
Magazine assignment
You can only read out the magazine assignments if your system provides support for loading
and unloading tool data to and from the magazine.
Milling
Program management
13.14 Setup data
Procedure
2. Position the cursor on the program whose tool and zero point
data you wish to back up.
...
4. Press the "Setup data" softkey.

The "Backup setup data" window opens.
5. Select the data you want to back up.
6. When required, change the specified name of the originally
selected program here in the "File name" field.
The setup data will be set up in the same directory in which the
selected program is stored.
The file is automatically saved as INI file.
Note
Program selection
If a main program as well as an INI file with the same name are in a directory, when
selecting the main program, initially, the INI file is automatically started. In this way,
unwanted tool data can be changed.
Milling
Program management
13.14 Setup data
13.14.2 Reading-in set-up data

When reading-in, you can select which of the backed-up data you wish to read-in:
Tool data
Magazine assignment
Zero points
Basic zero point
Tool data
Depending on which data you have selected, the system behaves as follows:
Complete tool list
First, all tool management data are deleted and then the saved data are imported.
All tool data used in the program
If at least one of the tools to be read in already exists in the tool management system,
you can choose between the following options.
Select the "Replace all" softkey to import all tool data. Any existing tools
will now be overwritten without a warning prompt.
- OR -
Press the "Do not overwrite" softkey if existing tools must not be
overwritten.
Already existing tools are skipped, without you receiving any queries.
- OR -
Press the "Skip" softkey if already existing tools are not to be
overwritten.
For an already existing tool, you receive a query.
Selecting loading point

For a magazine, if more than one loading point was set-up, using the "Select loading point"
softkey, you have the option of opening a window in which you can assign a loading point to
a magazine.
Milling
Program management
13.14 Setup data
Procedure
2. Position the cursor on the file with the backed-up tool and zero point
data (*.INI) that you wish to re-import.
3. Press the <Cursor right> key
- OR -
Double-click the file.
The "Read-in setup data" window opens.
4. Select the data (e.g. magazine assignment) that you wish to read-in.
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Program management
13.15 V24
13.15 V24
13.15.1 Reading-in and reading-out archives

You have the option of reading-out and reading-in archives in the "Program Manager"
operating area as well as in the "Start-up" operating area via the serial V24 interface.
Availability of the serial V24 interface

SINUMERIK Operate in the NCU
The softkeys for the V24 interface are available as soon as option module is connected
and the slot is occupied.
SINUMERIK Operate on PCU 50.3
The softkeys for the V24 interface are always available.
Reading-out archives
The files to be sent (directories or individual files) are zipped in an archive (*.ARC).
If you send an archive (*.arc), this is sent directly without being additionally zipped. If you
have selected an archive (*.arc) together with an additional file (e.g. directory), then these
are zipped into a new archive and are then sent.
Reading-in archives
Only archives can be read-in via the V24 interface. These are transferred and then
subsequently unzipped.
Note
Series commissioning archive
If you read-in a series commissioning archive via the V24 interface, then this is immediately
activated.
Externally processing the punched tape format

If you wish to externally process an archive, then generate this in the punch tape format.
Using the SinuCom commissioning and Servicetool SinuCom ARC, you can process the
archive in the binary format and in the series commissioning archive.
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Program management
13.15 V24
Procedure
1. Select the "Program Manager" operating area, and press the

"NC" or "Local drive" softkey
...
- OR -
Select the "Start-up" operating area and press the "System data"
softkey.
Reading-out archives
2. Select the directories or the files that you wish to send to V24.
4. Press the "Send V24" softkey.
- OR -
Reading in an archive
Press the "Receive V24" softkey if you wish to read-in files via
V24.
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Program management
13.15 V24
13.15.2 Setting V24 in the program manager
V24 setting Meaning

Protocol The following protocols are supported for transfer via the V24 interface:
RTS/CTS (default setting)
Xon/Xoff
Transfer It is also possible to use a secure protocol for data transfer (ZMODEM
protocol).
Normal (default setting)
secure
For the selected interface, secure data transfer is set in conjunction

with handshake RTS/CTS.
Baud rate Transfer rate: Transfer rates of up to 115 kbaud can be selected. The
baud rate that can be used depends on the connected device, the
cable length and the general electrical conditions.
110
....
19200 (default)
...
115200
Archive format Punched tape format (default setting)
Binary format (PC format)
V24 settings (details)
Interface COM1
Parity Parity bits are used for error detection: The parity bits are added to the
coded characters to make the number of positions set to "1" an uneven
number (uneven parity) or to an even number (even parity).
None (default setting)
Odd
Even
Stop bits Number of stop bits for asynchronous data transfer.
1 (default)
2
Data bits Number of data bits for asynchronous data transfer.
5 bits
...
-8 bits (default setting)
XON (hex) Only for punched tape format
XOFF (hex) Only for punched tape format
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Program management
13.15 V24
V24 setting Meaning

End of data transfer (hex) Only for punched tape format
Stop with end of data transfer character
The default setting for the end of data transfer character is (HEX) 1A
Time monitoring (sec) Time monitoring
For data transfer problems or at the end of data transfer (without end
of data transfer character) data transfer is interrupted after the
specified number of seconds.
The time monitoring is controlled by a time generator (clock) that is
started with the first character and is reset with each transferred
character.
The time monitoring can be set (seconds).
Procedure
2. Press the "NC" or "Local drive" softkey.
4. Select the "V24 settings" softkey.

The "Interface: V24" window is opened.
5. The interface settings are displayed.
6. Press the "Details" softkey if you wish to view and process
additional settings for the interface.
Milling
Setting up drives 14
14.1 Overview
Set up connections
Up to 8 connections to so-called logical drives (data carriers) can be configured. These
drives can be accessed in the "Program manager" and "Startup" operating areas.
The following logical drives can be set up:
USB interface
CompactFlash Card of the NCU, only for SINUMERIK Operate in the NCU
Network drives
Local hard disk of the PCU 50.3, only for SINUMERIK Operate on the PCU
Software option
In order to use the CompactFlash Card as data carrier, you require the option
"Additional 256 MB HMI user memory on CF card of NCU" (not for SINUMERIK
Operate of PCU50 / PC).
Note
The USB interfaces of the NCU are not available for SINUMERIK Operate and therefore
cannot be configured.
Milling
Setting up drives
14.2 Setting up drives

The "Set-up drives" window is available in the "Startup" operating area for configuration.
File
The created configuration data is stored in the "logdrive.ini" file. This file is located in the
/user/sinumerik/hmi/cfg directory.
General information
Entry Meaning
Type No drive No drive defined.
USB local Access to the USB memory medium is only realized via the
TCU to which it is connected.
USB drives are automatically identified if the memory medium
is inserted when SINUMERIK Operate powers-up.
USB global All of the TCUs in the plant network can access the USB
memory medium.
- USB global is not possible under Windows!
NW Windows Network drive
Local drive Local drive
Hard disk or user memory on the CompactFlash Card
Connection Front USB interface that is located at the front of the operator panel.
X203/X204 USB interface X203/X204 that is located at the rear of the
operator panel.
X204 For SIMATIC Thin Client the USB interface is X204.
Device Names of the TCU to which the USB storage medium is
connected, e.g. tcu1. The NCU must already know the TCU
name.
Partition Partition number on the USB memory medium, e.g. 1.
If a USB hub is used, specify the USB port of the hub.
Path Start direct directory of the data carrier that is connected
via the local drive.
Network path to a directory that has been released in the
network. This path must always start with "//", e.g.
//Server01/share3.
Access level Assign access rights to the connections: From protection level
7 (key switch position 0) to protection level 1 (password:
Manufacturer).
The particular assigned protection level applies to all
operating areas.
Softkey text Two lines are available as labeling text for the softkey. %n is
accepted as a line separator.
If the first line is too long, then it is automatically separated
into several lines.
If a blank is present, then this is used as line separator.
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Setting up drives
Entry Meaning
Softkey icon No icon No icon is displayed on the softkey.
sk_usb_front.png Icon file name. Is displayed on the softkey.
sk_local_drive.png Icon file name. Is displayed on the softkey.
Text file slpmdialog File for softkey dependent on the language. If nothing is
Text context SlPmDialog specified in the input fields, the text appears on the softkey as
was specified in the input field "Softkey text".
If your own text files are saved, then the text ID, which is used
to search for the text file, is specified in the "Softkey text" input
field.
User name Enter the user name and the corresponding password for
Password which the directory is enabled on the server. The password is
displayed in encoded form as as string of "*" characters and is
stored in the "logdrive.ini" file.
Error messages
Error message Meaning

Error occurred when closing a connection An existing drive was not able to be deactivated.
Error occurred when establishing a connection. Drive connection was not able to be established.
Error occurred while establishing a connection: Drive connection was not able to be established.
Incorrect entry or no authorization.
Incorrect data The entered data are either incorrect or
inconsistent.
Function not available The function is not supported with the current
software release.
Unknown error - error code:%1 Error was not able to be assigned.
Procedure
2. Press the "HMI" and "Log. drive" softkeys.

The "Set Up Drives" window opens.
3. Select the data for the corresponding drive or enter the necessary data.
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Setting up drives
4. Press the "Activate drive" softkey.

The drive is activated.
The operating system now checks the entered data and whether the
connection is established. An OK message is output in the dialog line if
an error is not identified.
The drive can be accessed.
- OR -
If the operating system identifies an error, then you receive an error
message.
You then return to the "Configure drives" window. Check and correct
your entries and re-activate the drive.
If you press the "OK" softkey, the modified data are accepted without
any feedback message. You do not receive any message about a
successful or unsuccessful connection.
If you press the "Cancel" softkey, then all of the data that has not been
activated is rejected.
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HT 8 15
15.1 HT 8 overview
The mobile SINUMERIK HT 8 handheld terminal combines the functions of an operator
panel and a machine control panel. It is therefore suitable for visualization, operation, teach
in, and programming at the machine.
1 Customer keys (user-defined)

2 Traversing keys
3 User menu key
4 Handwheel (optional)
Operation
The 7.5 TFT color display provides touch operation.
It also has membrane keys for traversing the axes, for numeric input, for cursor control, and
for machine control panel functions like start and stop.
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HT 8
15.1 HT 8 overview
It is equipped with an emergency stop button and two 3-position enabling buttons. You can
also connect an external keyboard.
References
For more information about connection and startup of the HT 8, see the following references:
Customer keys
The four customer keys are freely assignable and can be set up customer-specifically by the
machine manufacturer.
Integrated machine control panel

The HT 8 has an integrated machine control panel consisting of keys (e.g. start, stop,
traversing keys, etc.), and keys reproduced as softkeys (see machine control panel menu).
See chapter "Controls on the machine control panel" for a description of the individual keys.
Note
PLC interface signals that are triggered via the softkeys of the machine control panel menus
are edge triggered.
Enabling button
The HT 8 has two enabling buttons. Thus, you can initiate enabling functions for operations
that require enabling (e.g. displaying and operating of traversing keys) with either your right
hand or your left hand.
Enabling buttons are available for the following key positions:
Released (no activation)
Enabling (center position) - enabling for channel 1 and 2 is on the same switch.
Panic (completely pushed through)
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HT 8
15.1 HT 8 overview
Traversing keys
To traverse the axes of your machine using the traversing keys of the HT 8, you must select
"JOG" mode or either the "Teach In" or "Ref.Point" submode. Depending on the setting, the
enabling button must be activated.
Virtual keyboard
A virtual keyboard is available for the easy entry of values.
Changing the channel

You are able to switch the channel by touch in the status display:
In the Machine operating area (large status display), by touch operation of the channel
display in the status display.
In the other operating areas (no status display), by touch operation of the channel
display in the screen headers (yellow field).
The "1 n CHANNEL" softkey is available in the machine control panel menu that can be
reached via the user menu key "U".
Operating-area switchover
You can display the operating area menu by touching the display symbol for the active
operating area.
Handwheel
The HT 8 is available with a hand wheel.
References
For information about connecting the hand wheel, refer to:
Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl
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HT 8
15.2 Traversing keys
15.2 Traversing keys

The traversing keys are not labeled. However, you can display a label for the keys in place of
the vertical softkey bar.
Labeling of the traversing keys is displayed for up to six axes on the touch panel by default.
Showing and hiding

You can link the showing and hiding of the label to activation of the enabling button, for
example. In this case, the traversing keys are displayed when you press the enabling button.
If you release the enabling button, the traversing keys are hidden again.
All existing vertical and horizontal softkeys are covered or hidden, i.e.
other softkeys cannot be used.
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HT 8
15.3 Machine control panel menu
15.3 Machine control panel menu

Here you select keys from the machine control panel which are reproduced by the software
by touch operation of the relevant softkeys.
See chapter "Controls on the machine control panel" for a description of the individual keys.
Note
PLC interface signals that are triggered via the softkeys of the machine control panel menus
are edge triggered.
Showing and hiding

The user menu key "U" displays the CPF softkey bar (vertical softkey bar) and the user
softkey bar (horizontal softkey bar).
You can expand the user softkey bar to display eight additional softkeys via
the menu forward key.
You use the "Back" softkey to hide the menu bar again.
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HT 8
15.4 Virtual keyboard
Softkeys on the machine control panel menu

Available softkeys:
"Machine" softkey Select the "Machine" operating area

"[VAR]" softkey Select the axis feedrate in the variable increment
"1 n CHANNEL" Change the channel
softkey
"Single Block" Switch single block execution on/off
softkey
"WCS MCS" softkey Switch between WCS and MCS
"Back" softkey Close the window.
Note
The window will automatically disappear when changing regions areas with the "Menu
Select" key.

The virtual keyboard is used as the input device for touch operator panels.
It opens when you double-click an operator element with input capability (editor, edit field).
The virtual keyboard can be positioned anywhere on the operator interface. In addition, you
can toggle between a full keyboard and a reduced keyboard that only includes the number
block. Moreover, with the full keyboard, you can toggle between English key assignments
and the keyboard assignment for the current language setting.
Procedure
1. Click in the required input field in order to place the cursor there.
2. Click the input field.
The virtual keyboard is displayed.
3 Enter your values via the virtual keyboard.
4. Press the <INPUT> key.
- OR -
Position the cursor on an another operator element.
The value is accepted and the virtual keyboard is closed.
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HT 8
Positioning of the virtual keyboard

You can position the virtual keyboard anywhere in the window by pressing the empty bar
next to the "Close window" icon with your finger or a stylus and moving it back and forth.
Special keys on the virtual keyboard

1 Num:
Reduces the virtual keyboard to the number block.
2 Eng:
Toggles the keyboard assignment between the English keyboard assignment and the
keyboard assignment for the current language setting.
Number block of the virtual keyboard
Use the "Deu" or "Eng" keys to return to the full keyboard with the English keyboard
assignment or the keyboard assignment of the current language setting.
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HT 8
15.5 Calibrating the touch panel
15.5 Calibrating the touch panel

It is necessary to calibrate the touch panel upon first connection to the controller.
Note
Recalibration
If the operation is not exact, then redo the calibration.
Procedure
1. Press the back key and the <MENU SELECT> key at the same time to
start the TCU service screen.
2. Touch the "Calibrate TouchPanel" button.

The calibration process will be started.
3. Follow the instructions on the screen and touch the three calibration
points one after the other.
The calibration process has terminated.
4. Touch the horizontal softkey "1" or the key with the number "1" to close
the TCU service screen.
Milling
Ctrl Energy 16
16.1 Overview
The "Ctrl-Energy" function provides you with the following options to improve the energy
utilization of your machine.
Acquiring the energy consumption

Acquiring the actual energy consumption is the first step to achieving better energy
efficiency. The energy consumption is measured and displayed at the control using the
SENTRON PAC multi-function device.
Depending on the configuration and connection of the SENTRON PAC, you have the
possibility of either measuring the power of the whole machine or only a specific load.
Independent of this, the power is determined directly from the drives and displayed.
Controlling the energy consumption

To optimize the energy consumption, you have the option of defining energy saving profiles
and saving them. For instance, your machine has a basic and a more sophisticated energy-
saving mode - or under certain conditions, automatically switches itself off.
These defined energy states are saved as profiles. At the user interface, you have the
possibility of activating these energy-saving profiles (e.g. the so-called tea break key).
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Ctrl Energy
16.2 Displaying energy consumption
16.2 Displaying energy consumption

You have the option of displaying the actual energy usage values of the individual axes and
the total energy consumption.
Display Meaning
Manual No input
Entering and displaying a fixed value
Displaying a value from a data source
Sentron PAC Displaying an actual value measured by a SENTRON PAC device.
Total of drives Display of the total of all measured drive values.
Total, machine Addition of the values of all axes as well as a fixed value and Sentron
PAC.
The display in the table depends on the configuration.
References
Information on the configuration is provided in the following reference:
System Manual "Ctrl Energy", SINUMERIK 840D sl / 828D
Procedure
1. Select the "Parameter" operating area and press the "Ctrl Energy" softkey.
- OR -
+ Press the <Ctrl> + <E> keys.
2. Press the "Energy analysis" softkey.

The "SINUMERIK Ctrl-Energy analysis" window is opened.
You obtain a display of the actual active power for all of the axes.
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Ctrl Energy
16.3 Measuring and saving the energy consumption
16.3 Measuring and saving the energy consumption

For the currently selected axes, you have the option of measuring and recording the energy
consumption.
Save the measured usage values so that you can subsequently compare the data.
Note
Up to 3 data sets are displayed. The oldest data set is automatically overwritten if there are
more than 3 measurements.
Measurement duration
The measuring time is limited. When the maximum measuring time is reached, the
measurement is terminated and a corresponding message is output in the dialog line.
Reset
Press the "Reset" softkey.

The contents of the Infeed, Energy recovery and Total columns are deleted.
Procedure
1. The "Ctrl-Energy analysis" window is open

2. Press the "Start measurement" softkey.
The selection box "Setting measurement: Select device" window is
opened.
3. Select the required device in the list and press the "OK" softkey.
The trace is started.
4. Press the "Stop measurement" softkey.
The measurement is ended.
5. Press the "Graphic" softkey, to track the measurement characteristic.
5. Press the softkey "Save measurement" to save the usage values of the
actual measurement.
The selection of the axis to be measured depends on the configuration.
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Ctrl Energy
16.4 Displaying measured curves
References
Information on the configuration is provided in the following reference:
16.4 Displaying measured curves
Procedure
1. The "SINUMERIK Ctrl-Energy Analysis" window is opened and you

have already performed measurements.
2. Press the "Graphic" and "Saved measurements" softkeys.
The measurement curves are displayed in the window "SINUMERIK
Ctrl-Energy analysis".
3. Press the softkey "Saved measurements" again if you only want to see
the actual measurement.
16.5 Using the energy-saving profile

In the "SINUMERIK Ctrl-Energy energy-saving profile" window, you can display all of the
defined energy-saving profiles. Here, directly activate the required energy-saving profile - or
inhibit or release profiles.
SINUMERIK Ctrl-Energy energy-saving profiles
Display Meaning
Energy-saving profile All energy-saving profiles are listed.
active in [min] The remaining time up until the defined profile is reached is
displayed.
Note
Disable all energy-saving profiles
For example, in order not to disturb the machine while measurements are being made,
select "Disable all".
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Ctrl Energy
Once the pre-warning time of a profile has been reached, an alarm window that shows the
remaining time is displayed. Once the energy-saving mode has been reached, then an
appropriate message is displayed in the alarm line.
Energy-saving profiles
Energy-saving profile Meaning

Simple energy-saving mode Machine units that are not required are either throttled or shut down.
(machine standby) When required, the machine is immediately ready to operate again
Full energy-saving mode (NC Machine units that are not required are either throttled or shut down.
standby) Wait times are incurred at the transition into the ready to operate
state.
Maximum energy-saving The machine is completely switched-off.
mode (auto shut-off) Longer wait times are incurred at the transition into the ready to
operate state.
The selection and function of the displayed energy-saving profiles can differ.
References
Information on the configuration of the energy-saving profiles is provided in the following
reference:
Procedure
2. Press the menu forward key and then the "Ctrl Energy" softkey.
- OR -
Press the <CTRL> + <E> keys.
+
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Ctrl Energy
The "SINUMERIK Ctrl-Energy energy-saving profiles" window is

opened.
3. Position the cursor on the required energy-saving profile and press the
"Activate immediately" softkey if you wish to directly activate this state.
4. Position the cursor on the required energy-saving profile and press the
"Disable profile" softkey if you wish to disable this state.
The profile is disabled. The energy-saving profile cannot be used, i.e. it
is grayed-out and displayed without any time information.
The labeling of the "Disable profile" softkey changes to "Enable profile".
Press the "Enable profile" softkey in order to withdraw the energy-
saving profile disable.
5. Press the "Disable all" softkey in order to disable all states.

All profiles are then disabled and cannot be used.
The labeling of the "Disable all" softkey changes to "Enable all".
6. Press the "Enable all" softkey to withdraw the disable for all profiles.
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Easy Message (828D only) 17
17.1 Overview
Easy Message enables you to be informed about certain machine states by means of SMS
messages via a connected modem:
For example, you would like to be informed about emergency stop states
You would like to know when a batch has been completed
Control commands
HMI commands are used to activate or deactivate a user.
Syntax: [User ID] deactivate [User ID] activate
A special area is reserved in the PLC to which you can send commands in the form of
PLC bytes using SMS commands.
Syntax: [User ID] PLC DataByte
The user ID is optional and required only if a corresponding ID has been specified in the
user profile. The string PLC indicates that a PLC byte is to be written. It is followed by the
data byte to be written in the following format: Base#Value. Base can take the values 2,
10 and 16 and defines the number base. Then follows the separator # and the value of
the byte. Only positive values are allowed to be sent.
Examples:
2#11101101
10#34
16#AF
Active users
In order to receive an SMS message for certain events, you must be activated as user.
User logon
As registered user, you can log on via SMS to inquire about messages.
Action log
You can obtain precise information about incoming and outgoing messages via SMS logs.
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Easy Message (828D only)
17.2 Activating Easy Message
References
Information on the GSM modem can be found in the
PPU SINUMERIK 828D Manual
Calling the SMS Messenger
1. Select the "Diagnostics" operating area.
2. Press the "Easy Msg." softkey.
17.2 Activating Easy Message

To commission the connection to the modem for the SMS Messenger, activate the SIM card
at the initial start-up.
Requirement
The modem is connected.
Procedure
Activating the SIM card

The "SMS Messenger" window appears.
"Status" shows that the SIM card has not been activated with a PIN.
2. Enter the PIN, repeat the PIN and press the "OK" softkey.
3. If you made an incorrect entry several times, enter the PUK code in the
"PUK Input" window and press the "OK" softkey to activate the PUK
code.
The "PIN input" window is opened and you can enter the PIN number as
usual.
Activating a new SIM card

The "SMS Messenger" window appears.
"Status" shows that the connection to the modem has been activated.
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17.3 Creating/editing a user profile
3. Press the "Delete PIN" softkey to delete the stored PIN.

Enter the new PIN in the "PIN Input" window at the next power up.
17.3 Creating/editing a user profile

User identification
Display Meaning
User name Name of the user to be created or logged on.
Telephone number Telephone number of the user to which the messages are to be sent.
The telephone number must include the country code in order that
control commands can identify the sender (e.g. +491729999999)
User ID The user ID has 5 digits (e.g. 12345)
It is used to activate and deactivate the user via SMS. (e.g.
"12345 activate")
The ID is used to additionally verify the incoming and outgoing
messages and to activate the control commands.
Events that can be selected

You must set-up the events for which you receive notification.
Requirement
The modem is connected.
Procedure
Creating a new user

1. Press the "User profiles softkey.
The "User Profiles" window appears.
3. Enter the name and telephone number of the user.

4. If required, enter the ID number of the user.
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17.4 Setting-up events
5. In the area "send SMS for the following events" area, activate the
appropriate checkbox and when required, enter the desired value (e.g.
the unit quantity, which when it is reached, a notification should be
sent).
- OR -
Press the "Default" softkey.
The appropriate window is opened and displays the default values.
6. Press the "Send test message" softkey.
An SMS message with predefined text is sent to the specified telephone
number.
Editing user data and events

1. Select the user whose data you want to edit and press the "Edit"
softkey.
The input fields can be edited.
2. Enter new data and activate the desired settings.
- OR -
Press the "Default" softkey to accept the default values.

In the "Send SMS for the following events" area, select the events using the check box,
which when they occur, an SMS is sent to the user.
Programmed messages from the part program (MSG)
In the part program, program an MSG command via which you receive an SMS.
Example: MSG ("SMS: An SMS from a part program")
Select the following events using the <SELECT> key
The workpiece counter reaches the following value
An SMS is sent if the workpiece counter reaches the set value.
The following program progress is reached (percent)
An SMS is sent if, when executing a part program, the set progress is reached.
Actual NC program reaches runtime (minutes)
An SMS is sent after the set runtime has been reached when executing an NC
program.
Tool usage time reaches the following value (minutes)
An SMS is sent if the usage time of the tool reaches the set time when executing a
part program (derived from $AC_CUTTING_TIME).
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Messages/alarms from the Tool Manager

An SMS is sent if messages or alarms are output to the Tool Manager.
Measuring cycle messages for tools
An SMS is sent if measuring cycle messages are output that involve tools.
Measuring cycle messages for workpieces
An SMS is sent if measuring cycle messages are output that involve workpieces.
Sinumerik messages/alarms (error when executing)
An SMS is sent if NCK alarms or messages are output that cause the machine to come to
a standstill.
Machine faults
An SMS is sent if PLC alarms or messages are output that cause the machine to come to
a standstill (i.e. PLC alarms with Emergency Off response).
Maintenance intervals
An SMS is sent if the service planner registers pending maintenance work.
Additional alarm numbers:
Here, specify additional alarms where you should be notified if they occur.
You can enter individual alarms, several alarms or alarm number ranges.
Examples:
1234,400
1000-2000
100,200-300
Requirement
The user profile window is opened.
You selected the event "Measuring cycle messages for tools", "Measuring cycle
messages for workpieces", "Sinumerik messages/alarms (errors when executing)",
"Machine faults" or "Maintenance intervals".
Editing events
1. Activate the required check box and press the "Details" softkey.
The appropriate window opens (e.g. "Measuring cycle messages for
workpieces") and shows a list of the defined alarm numbers.
2. Select the corresponding entry and press the "Delete" softkey to
remove the alarm number from the list.
- OR -
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17.5 Logging an active user on and off
Then press the "New" softkey if you wish to create a new entry.
The "Create new entry" window opens.
Enter the data and press the "OK" softkey to add the entry to the list.
Press the "Save" softkey to save the settings for the result.
3. Press the "Standard" softkey to return to the standard settings for the
events.
17.5 Logging an active user on and off

Only active users receive an SMS message for the specified events.
You can activate users, already created for Easy Message, with certain control commands
via the user interface or via SMS.
The connection has been established to the modem.
Procedure
1. Press the "User profiles softkey.
2. Select the desired user in the User name field and press the "User
active softkey
Note
Repeat step 2 to activate further users.
- OR -
Send an SMS with the User ID and the "activate" text to the control (e.g.
"12345 activate")
If the telephone number and the user ID match the stored data, the user
profile is activated.
You receive a message of success or failure per SMS.
3. Press the "User active softkey to log off an activated user.
- OR -
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17.6 Displaying SMS logs
Send an SMS with the "deactivate" text (e.g. "12345 deactivate") to log
off from the Messenger.
An SMS message is not sent to the deactivated user for the events
specified in the user profile.
17.6 Displaying SMS logs

The SMS data traffic is recorded in the "SMS Log" window. In this way, it is possible to see
the chronological sequence of activates when a fault occurs.
Symbols Description
Incoming SMS message for the Messenger.
Message that has reached the Messenger, but which has not been
processed (e.g. incorrect user ID or unknown account).
SMS message sent to a user.
Message that has not reached the user because of an error.
Requirement
Procedure
1. Press the "SMS log" softkey.
The "SMS Log" window appears.

All the messages that have been sent or received by the Messenger are
listed.
Note
Press the "Incoming" or "Outgoing" softkey to restrict the list.
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17.7 Making settings for Easy Message
17.7 Making settings for Easy Message

You can change the following Messenger configuration in the "Settings" window:
Name of the controller that is part of an SMS message
Number of sent messages
The SMS counter provides information on all sent messages.
Limit the number of sent messages in order to receive an overview of the costs
through SMS messages, for example.
Setting the SMS counter to zero
When a set limit is reached, no further SMS messages are sent.

Press the "Reset SMS counter" softkey to reset the counter to zero.
Requirement
Procedure
2. Enter an arbitrary name for the controller in the "Machine name" field.
3. If you want to limit the number of sent SMS messages then select the
"Specify limit for SMS counter" entry and enter the desired number.
When the maximum number of messages is reached, you obtain a
corresponding error message.
Note
Check the SMS log to see the exact time when the limit was reached.
- OR -
3. Press the "Default" softkey.
If you have freely selected a machine name, this is replaced by a
default name (e.g. 828D).
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Easy Extend (828D only) 18
18.1 Overview
Easy Extend enables machines to be retrofitted with additional units, which are controlled by
the PLC or that require additional NC axes (such as bar loaders, swiveling tables or milling
heads), at a later point in time. These additional devices are easily commissioned, activated,
deactivated or tested with Easy Extend.
The communication between the operator component and the PLC is performed via a PLC
user program. The sequences to be executed for the installation, activation, deactivation and
testing of a device are stored in a statement script.
Available devices and device states are displayed in a list. The view of the available devices
can be controlled for users according to their access rights.
The subsequent chapters are selected for example only and are not available in every
statement list.
Up to 64 devices can be managed.
References
SINUMERIK 828D Turning and Milling Commissioning Manual
Milling
Easy Extend (828D only)
18.2 Enabling a device
18.2 Enabling a device

The available device options are protected by a password.
Procedure
2. Press the menu forward key and then the "Easy Extend" softkey.
A list of the connected devices is displayed.
3. Press the "Enable function" softkey.

The "Enabling of the Devices Option" window is opened.
4. Enter the option code and press the "OK" softkey.
A tick appears in the appropriate checkbox in the "Function" column
and the function is enabled.
18.3 Activating and deactivating a device
Status Meaning
Device activated
System waiting for PLC checkback signal
Device faulty
Interface error in the communication module
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18.4 Commissioning Easy Extend
Procedure
1. Easy Extend is opened.
2 You can select the desired device in the list with the <Cursor up> and
<Cursor down> keys.
3. Position the cursor on the device option for which the function has been
unlocked and press the "Activate" softkey.
The device is marked as activated and can now be used.
4. Select the desired activated device and press the "Deactivate" softkey
to switch the device off again.

As a rule, the "Easy Extend" function has already been commissioned by the machine
manufacturer. If a first commissioning has not been performed or if, for example, function
tests are to be performed again (e.g. when retrofitting additional devices), this is possible at
any time.
The "Start-up" softkey has been declared as Manufacturer data class (M).
Procedure
2. Press the menu forward key and then the "Easy Extend" softkey.
3. Press the "Start-up" softkey.

4. Press the "Comm. startup" softkey to start the commissioning.
Before starting, a complete data backup is generated which you can
then use in an emergency.
5. Press the "Cancel" softkey if you want to abort the commissioning
prematurely.
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6. Press the "Restore" softkey to load the original data.
7. Press the "Device function test" softkey to test the machine

manufacturer's intended function.
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Service Planner (828D only) 19
19.1 Performing and monitoring maintenance tasks
With the "Service Planner", maintenance tasks have been set up that have to be performed
at certain intervals (e.g. top up oil, change coolant).
A list is displayed of all the maintenance tasks that have been set up together with the time
remaining until the end of the specified maintenance interval.
The current status can be seen in the status display.
Messages and alarms indicate when a task has to be performed.
Acknowledging a maintenance task

Acknowledge the message when a maintenance task has been completed.
Note
Protection level
You require protection level 2 (service) to acknowledge completed maintenance tasks.
Service Planner
Display Meaning
Pos Position of the maintenance task in the PLC interface.
Maintenance task Name of the maintenance task.
Interval [h] Maximum time until next servicing in hours.
Remaining time [h] Time until the interval expires in hours.
Status Display of the current status of a maintenance task.
The maintenance task has been started.
The maintenance task is completed.
The maintenance task is deactivated.
Milling
Service Planner (828D only)
19.2 Set maintenance tasks
Procedure
2. Press the menu forward key and then the "Service planner" softkey.
The window with the list of all the maintenance tasks that have been set
up appears.
3. Perform the maintenance task when the maintenance interval has

nearly expired or when prompted to do so by alarms or a warning.
4. After you have performed a pending maintenance task and the task is
signaled as "Completed", position the cursor at the appropriate task and
press the "Servicing performed" softkey.
A message is displayed confirming the acknowledgment, and the
maintenance interval is restarted.
Note
You can perform the maintenance tasks before the interval expires. The maintenance
interval is restarted.

You can make the following changes in the list of maintenance tasks in the configuration
mode:
Set up a maximum of 32 maintenance tasks with interval, initial warning and number of
warnings to be acknowledged
Change the interval, time of the initial warning and the number of warnings to be output
Delete a maintenance task
Reset the times of the maintenance tasks
Acknowledging a maintenance task

You can acknowledge the maintenance tasks with the "Servicing performed" softkey.
Note
Protection level
You require protection level 1 (manufacturer) to set up and edit maintenance tasks.
Milling
Service Planner
Display Meaning
Pos Position of the maintenance task in the PLC interface.
Maintenance task Name of the maintenance task.
Interval [h] Maximum time until next servicing in hours.
1. warning [h] Time in hours at which an initial warning is displayed.
Number of warnings Number of warnings that can be acknowledged by the operator before
an alarm message is output for the last time.
Remaining time [h] Time until the interval expires in hours.
The remaining time cannot be edited.
Status Display of the current status of a maintenance task.
The maintenance task has been started.
The maintenance task is completed.
The maintenance task is deactivated, i.e. the time has been

stopped.
The status cannot be edited.
Procedure
2. Press the menu forward key and then the "Service planner" softkey.
The window opens and displays a list of all the tasks that have been set
up.
3. Press the "New maintenance task" softkey to set up a new maintenance

task.
A message informs you that a new maintenance task will be set up at
the next free position. Enter the required data in the columns and press
the "OK" softkey.
- OR -
Position the cursor on the desired maintenance task and press the
"Change task" softkey to change the associated times.
All columns except Remaining time and Status can be edited.
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- OR -
Press the "Reset all" softkey to reset all the times.
- OR -
Position the cursor on the desired maintenance task and press the
"Delete task" softkey to remove the maintenance task from the list.
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Ladder Viewer and Ladder add-on (828D only) 20
20.1 PLC diagnostics
A PLC user program consists to a large degree of logical operations to implement safety
functions and to support process sequences. These logical operations include the linking of
various contacts and relays. These logic operations are displayed in a ladder diagram.
Ladder add-on tool

As a rule, the failure of a single contact or relay results in a failure of the whole system.
Using the Ladder add-on tool, you can perform a PLC diagnosis in order to find fault causes
or program errors.
Editing of interrupt routines

You can edit the following interrupt programs:
INT_100 - interrupt program, (is executed before the main program)
INT_101 - interrupt program, (is executed after the main program)
Marshalling data
Using the Ladder add-on tool, you can "re-wire" inputs (via INT_100) or outputs (via
INT_101) for service purposes.
Generating INT_100 / INT_101 block

If one or several INT_100 or INT_101 blocks are missing, they can be added via the vertical
softkey bar. If these INT blocks exist in a project, they can be deleted via the vertical softkey
bar. You also have the opportunity to change the networks of a program on the control as
well as to save and load these changes.
Note
Saving the PLC project when changing the operating area
If you have created INT_100/INT_101 blocks or inserted, removed or edited networks in an
INT block, you must save the project before you change from the PLC area into another
operating area. Transfer the project into the PLC using the "Download to CPU" softkey. If
this is not done, all of the changes will be lost and must be re-entered.
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Ladder Viewer and Ladder add-on (828D only)
20.2 Structure of the user interface
20.2 Structure of the user interface

Figure 20-1 Screen structure
Table 20- 1 Key to screen layout
Screen element 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 is stopped
Status of the application area
Sym Symbolic representation
Abs Absolute representation
5 Display of the active keys (<INPUT>, <SELECT>)
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20.3 Control options
Screen element Display Meaning

6 Focus
Performs the tasks of the cursor
7 Information line
Displays information, e.g. for searching
20.3 Control options

In addition to the softkeys and the navigation keys, there are further shortcuts in this area.
Shortcuts
The cursor keys move the focus over the PLC user program. When the window borders are
reached, scrolling is performed automatically.
Shortcuts Action
To the first column of the row
To the last column of the row
Up a screen
Down a screen
One field to the left, right, up or down
To the first field of the first network
-or-
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20.4 Displaying PLC properties
Shortcuts Action
To the last field of the last network
-or-
Open the next program block in the same window
Open the previous program block in the same window
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 all operands
If the input focus is positioned on a command, all operands including

the comments are displayed.
20.4 Displaying PLC properties

The following PLC properties can be displayed in the "SIMATIC LAD" window:
Operating mode
Name of the PLC project
PLC system version
Cycle time
Machining time of the PLC user program
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20.5 Displaying and editing NC/PLC variables
Procedure
2. Press the "PLC" softkey.

The ladder diagram display opens and displays the PLC information.
3. Press the "Reset mach.time" softkey.

The data of the machining time is reset.
20.5 Displaying and editing NC/PLC variables

The "NC/PLC Variables" window enables the monitoring and modification of NC system
variables and PLC variables.
You receive the following list in which you enter the desired NC and PLC variables in order
to display the actual values.
Variable
Address for NC/PLC variable.
Faulty variables have a red background and # is displayed in the Value column.
Comment
Arbitrary comment on the variables.
The column can be shown or hidden.
Format
Specification of the format in which the variable is to be displayed.
The format can be permanently defined (e.g. floating-point).
Value
Display of the current value of the NC/PLC variable.
Procedure
1. Ladder add-on tool is opened.
2. Press the "NC/PLC variables" softkey.

The "NC/PLC Variables" window appears.
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20.6 Displaying and editing PLC signals
20.6 Displaying and editing PLC signals

PLC signals are displayed and can be changed here in the "PLC status list" window.
The following lists are shown

Inputs (IB)
Bit memories (MB)
Outputs (QB)
Variables (VB)
Data (DB)
Setting the address

You can go directly to the desired PLC address to monitor the signals.
Editing
You can edit the data.
Procedure
2. Press the "Status list softkey.

The "Status List" window appears.
3. Press the "Set address" softkey.
The "Set Address" window appears.
4. Activate the desired address type (e.g. DB), enter the value and press
the "OK" softkey.
The cursor jumps to the specified address.
5. Press the "Change" softkey.
The "RW" input field can be edited.
6. Enter the desired value and press the "OK" softkey.
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20.7 Displaying information on the program blocks

You can display all the logic and graphic information of a program block.
Display program block

In the "Program block" list, select the program block that you want to display.
Logic information
The following logic information is displayed in a ladder diagram (LAD):
Networks with program parts and current paths
Electrical current flow through a number of logical operations
Further information
Properties
Name of the block, author, number of the subprogram, data class, date it was generated,
date of the last change and comment.
Local variable
Name of the variable, variable type, data type and comment.
Access protection
If a program block is password-protected. The ladder diagram display

can be enabled using the "Protection" softkey.
Displaying the program status
1. Press the "Program stat. OFF" softkey to hide the program status in the
status display.
2. Press the "Program stat. ON" softkey to unhide the program status in
the status display.
Display progress status

If your PLC has the function "Progress status" available, the status values are displayed at
the time of execution of the operations. The status of the local data memory and the
accumulators is also displayed.
1. Press the "Program stat. OFF" softkey to hide the program status in the
status display.
2. Press the "Program stat. ON" softkey to unhide the program status in
the status display.
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Change colors for displaying of progress or program status

In progress status, different colors are used to display information.
Display Color
Signal flow of power rail, when status active Blue
Signal flow in the networks Blue
All operations that are active and that are executed without Blue
error (corresponds to signal flow)
Status of the Boolean operations (corresponds to signal Blue
flow)
Times and counters active Green
Error during execution Red
No signal flow Gray
No network executed Gray
STOP mode Gray
Note
Colored display in program status
In the display of the program status only the color of the signal flow is relevant.
Enlarging/reducing the display of the ladder diagram
1. Press the "Zoom +" softkey to enlarge the section of the ladder
diagram.
After enlarging, the "Zoom -" softkey is available.
2. Press the "Zoom -" softkey to reduce the section of the ladder diagram
again.
Procedure
2. Press the "Window 1" or "Window 2" softkey.
...
3. Press the "Program block" softkey.
The "Program block" list is displayed.
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20.8 Downloading a PLC user program
4. Press the "Properties" softkey if you wish to display additional

information.
- OR -
Press the "Local variables" softkey if you wish to display data of a
variable.
20.8 Downloading a PLC user program

Download the project data into the PLC if some changes have been made to the project data
and a new PLC user program is available.
When the project data is loaded, the data classes are saved and loaded to the PLC.
Requirement
Check whether the PLC is in Stop mode.
Note
PLC in RUN mode
If the PLC is in RUN mode, a corresponding message is displayed and the "Load in Stop"
and "Load in Run" softkeys appear.
With "Load in Stop", the PLC is set to Stop mode and the project is stored and loaded to the
CPU.
With "Load in Run", the loading operation is continued and the PLC project loaded to the
PLC. Only those data classes that have really been changed are loaded, i.e. generally
INDIVIDUAL data classes.
Procedure

You have changed project data.
2. Press the "PLC Stop" softkey if the PLC is in the run mode.
3. Press the "Load to CPU" softkey to start the loading operation.

All data classes are loaded.
4. When the PLC project has been loaded, press the "PLC Start" softkey
to switch the PLC to Run mode.
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20.9 Editing the local variable table
20.9 Editing the local variable table

You have the option of editing the local variable table of an INT block.
Insert local variable

If you have inserted new networks or operands, it may be necessary to insert new variables
in the local variable table of an INT block.
Name Freely assign.

Variable type Selection:
IN
IN_OUT
OUT
TEMP
Data type Selection:
BOOL
BYTE
WORD
INT
DWORD
DINT
REAL
Comment Freely assign.
Procedure
1. The ladder diagram display (LAD) is opened.
...
2. Press the "Program block" softkey.
3. Press the "Local variables" softkey.

The "Local Variables" window appears and lists the created variables.
4. Press the "Edit" softkey.
The fields can be edited.
5. Enter a name, select the variable and data type and, if required, enter a
comment.
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20.10 Creating a new block
6. Press the "Attach line" softkey if you want to add a further variable and
enter the data.
- OR -
Select the relevant variable and press the "Delete line" softkey to
remove the variable from the list.
20.10 Creating a new block

Create INT blocks i you wish to make changes with the PLC user program.
Name INT _100, INT_101

The number from the selection field "Number, interrupt program" is
taken for the name of the INT block.
Author A maximum of 48 characters is permitted.
Number of the 100
interrupt program 101
Data class Individual
Comment A maximum of 100 lines and 4096 characters are permitted.
Note
Access protection
You have the option of protecting blocks that have been newly created against being
accessed.
Procedure
...
2. Press the "Program block" softkey to open the list of program blocks.
3. Press the "Add" softkey.

The "Properties" window appears.
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20.11 Editing block properties
4. Enter the name of the author, number of the INT block and, if required,
a comment.
The data class of the block is specified.
5. Press the "OK" softkey to transfer the block to the list.
20.11 Editing block properties

You can edit the title, author and comments of an INT block.
Note
You cannot edit the block name, interrupt number and data class assignment.
Procedure
1. The ladder diagram display is opened.
2. Select the relevant block and press the "Program block" softkey.
3. Press the "Properties" softkey.

The "Properties" window appears.
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20.12 Inserting and editing networks

You can create a new network and then insert operations (bit operation, assignment, etc.) at
the selected cursor position.
Only empty networks can be edited. Networks, that already include statements, can only be
deleted.
A simple, single line can be edited for each network. You can create a maximum of 3
columns per network.
Column Operation
Column 1 NO contact -| |-
-|/|-
NC contact
Column 2 NOT -|NOT|-
(optional) Rising edge -|P|-
Falling edge -|N|-
Assign -( )
Set -(S)
Reset -(R)
Column 3 Assign -( )
(only possible if no assign, set or reset Set -(S)
operations were specified in the second Reset -(R)
column)
Note
Logical AND (serial contact) and logical OR (parallel contact) are not possible.
The bit combinations comprise one or several logical operations and the assignment to an
output / bit memory.
If the cursor is moved further to the left with the arrow key, the type of assignment or a logic
operation can be selected. A further logic operation cannot be placed to the right of an
assignment. A network must always be terminated with an assignment.
References
For further information about PLC programming, please refer to:
Function Manual Basic Functions, PLC for SINUMERIK 828D (P4)
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Procedure
1. An interrupt routine has been selected.
2. Press the "Edit" softkey.
3. Position the cursor on a network.

4. Press the "Insert network" softkey.
- OR -
If the cursor is positioned on "Network x", a new, empty network is

inserted behind this network.
5. Position the cursor on the desired element below the network title and
press the "Insert operation" softkey.
The "Insert Operation" window appears.
6. Select the desired bit operation (NC contact or NO contact) or
assignment and press the "OK" softkey.
7. Press the "Insert operand" softkey.
8. Enter the logic operation or the command and press the <INPUT> key
to complete the entry.
9. Position the cursor on the operation that you want to delete and press
the "Delete operation" softkey.
- OR -
Position the cursor on the title of the network that you want to delete
and press the "Delete network" softkey.
- OR -
Press the <DEL> key.
The network, including all the logic operations and operands, or the
selected operation is deleted.
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20.13 Editing network properties
20.13 Editing network properties

You can edit the network properties of an INT block.
Network title and network comment

The title can have a maximum of three lines and 128 characters. The comment can have a
maximum of 100 lines and 4096 characters.
Procedure
2. Use the cursor keys to select the network that you want to edit.
3. Press the <SELECT> key.

The "Network title / comment" window opens and shows the title and a
possibly assigned comment for the selected network.
The fields can be edited.
6. Enter the changes and press the "OK" softkey to transfer the data to the
user program.
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20.14 Displaying and editing symbol tables
20.14 Displaying and editing symbol tables

You can display the symbol tables that are used to obtain an overview of the global
operands available in the project - which you can then edit.
The name, address and possibly also a comment is displayed for each entry.
Procedure
2. Press the "Symbol table" softkey.

The list with the symbol table entries is displayed.
3. Press the "Edit" softkey if you want to change entries.

The display fields can be edited.
4. Use the cursor keys to select the desired entry and the field to be
changed.
5. Enter the value to be changed.

- OR -
Press the "Attach line" softkey to insert an empty line after the selected
entry.
- OR -
Press the "Delete line" softkey to remove the selected entry from the
list.
- OR -
Enter a new value in the selected field.
7. Press the "OK" softkey to confirm your action.
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20.15 Inserting/deleting a symbol table
20.15 Inserting/deleting a symbol table

New user symbol tables can be generated and changed. Tables that are no longer used can
be deleted.
Note
Delete symbol table
The "Delete" softkey is only available if a user symbol table has been selected.
Procedure
1. The symbol table is opened.
2. Press the "Select sym. table" softkey.

The "Symbol Table - Selection" window appears.
3. Position the cursor at the desired position and press the "Insert sym.
table" softkey.
The "Create Symbol Table" window appears.
4 Enter a symbolic name and press the "OK" softkey.
The new user symbol table is inserted in the line after the cursor
position.
- OR -
Select a symbol table and press the "Change symbol table" softkey if
you wish to change the properties of the symbol table.
5. Position the cursor on the symbol table that you want to delete and
press the "Delete" softkey.
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20.16 Searching for operands
20.16 Searching for operands

You can use the search function to quickly reach points in very large programs where you
would like, for example, to make changes.
Restricting the search

"Window 1" / "Window 2","Symbol table"
With "Go to", you can jump directly to the desired network.
"Cross references"
With "Go to", you can jump directly to the desired line.
Requirement
Window 1 / window 2, the symbol tables or the list of cross references is opened.
Procedure
1. Press the "Find" softkey.

A new vertical softkey bar appears. The "Find / Go To" window opens at
the same time.
2. Select the "Find operand" entry in the first input field if you are
searching for a specific operand and enter the search term in the "Find"
input field.
3. Select the search range (e.g. Find all).
4. Select the "In this program unit" or "In all program units" entry if you are
in "Window 1" or "Window 2" or in the symbol table in order to restrict
the search.
If the operand you are searching for is found, the corresponding line is
highlighted.
Press the "Continue search" softkey if the operand found during the
search does not correspond to the element you are looking for.
- OR -
Press the "Cancel" softkey if you want to cancel the search.
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20.17 Displaying the network symbol information table
Further search options
1. Press the "Go to start" softkey to jump to the start of the ladder diagram
in window 1 or window 2, or the list (cross references, symbol table).
2. Press the "Go to end" softkey to jump to the end of the ladder diagram
in window 1 or window 2, or the list (cross references, symbol table).
20.17 Displaying the network symbol information table

All of the symbolic identifiers used in the selected network are displayed in the "Network
symbol information table" window.
The following information is listed:
Names
Absolute addresses
Comments
The symbol information table remains empty for networks that do not contain any global
symbols.
Procedure
2. Select the desired network and press the "Symbol info" softkey.
The "Network Symbol Information Table" window appears.
3. Use the cursor keys to move within the table.
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20.18 Displaying/canceling the access protection
20.18 Displaying/canceling the access protection

You can password protect your program organizational units (POUs) in the PLC 828
programming tool. This prevents other users from accessing this part of the program. This
means that it is invisible to other users and is encrypted when it is downloaded.
A lock symbol is used to show a password-protected POU in the block overview and in the
ladder diagram.
Procedure
2 Select the relevant program organizational unit (POU) in the overview

and press the "Program block" softkey.
3. Press the "Protection" softkey.

The "Protection" window appears.
4. Enter your password and press the "Accept" softkey.
20.19 Displaying cross references

You can display all the operands used in the PLC user project and their use in the list of
cross references.
This list indicates in which networks an input, output, bit memory etc. is used.
The list of cross references contains the following information:
Block
Address in the network
Context (command ID)
Symbolic and absolute address

You can choose between specification in absolute or symbolic address.
Elements for which there are no symbolic identifiers are automatically displayed with
absolute identifiers.
Opening program blocks in the ladder diagram

From the cross references, you have the option of going directly to the location in the
program where the operand is used. The corresponding block is opened in window 1 or 2
and the cursor is set to the corresponding element.
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Searching
Using a specific search, you can go directly to the location that you wish to view in more
detail:
Search for operand
Jump to sought line
Procedure
2. Press the "Cross refs." softkey.

The list of cross references appears and the operands are displayed
sorted according to absolute address.
3. Press the "Symbol. address" softkey.
The list of operands is displayed sorted according to symbolic address.
4. Press the "Absolute address" softkey to return to the display showing
the absolute addresses.
5. Select the desired cross reference and press the "Open in window 1" or
"Open in window 2" softkey.
The ladder diagram is opened, and the selected operand is marked.
6. Press the "Find" softkey.

The "Find / Go To" window appears.
7. Select "Find operand" or "Go to" and enter the sought element or the
desired line and select the search order (e.g. search up).
9. If an an element is found that corresponds to the sought element, but is

not at the appropriate position, press the "Continue search" softkey to
find where the search term occurs next.
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Alarms, error messages, and system alarms 21
21.1 Displaying alarms
If faulty conditions are recognized in the operation of the machine, then an alarm will be
generated and, if necessary, the machining will be interrupted.
The error text that is displayed together with the alarm number gives you more detailed
information on the error cause.
WARNING
Please check the situation in the plant on the basis of the description of the active alarm(s).
Eliminate the cause/s of the alarm/s and acknowledge it/them as instructed.
Failure to observe this warning will place your machine, workpiece, stored settings and
possibly even your own safety at risk.
Alarm overview
You can display all upcoming alarms and acknowledge them.
The alarm overview contains the following information:
Date and time
Deletion criterion
specifies the key or softkey used to acknowledge the alarm
Alarm number
Alarm text
Procedure
2. Press the "Alarm list softkey.

The "Alarms" window appears.
All pending alarms are displayed.
The "Hide SI alarms" softkey is displayed if safety alarms are pending.
3. Press the "Hide SI alarms" softkey if you do not wish to display SI
alarms.
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Alarms, error messages, and system alarms
21.1 Displaying alarms
4. Position the cursor on an alarm.
...
5. Press the key that is specified as acknowledgement symbol to delete

the alarm.
- OR -
Press the "Delete HMI alarm" softkey to cancel an HMI alarm.
- OR -
Press the "Acknowledge alarm" softkey to delete a PLC alarm of the SQ
type (alarm number as of 800000).
The softkeys are activated when the cursor is on the corresponding
alarm.
Acknowledgement symbols
Symbol Meaning
Turn the unit off and back on (main switch), or press NCK POWER ON.
Press the <RESET> key.
Press the <ALARM CANCEL> key.

- OR -
Press the "Acknowl. HMI alarm" softkey.
...
Press the key provided by the manufacturer.
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21.2 Displaying an alarm log
21.2 Displaying an alarm log

A list of all the alarms and messages that have occurred so far are listed in the "Alarm Log"
window.
Up to 500 administered, incoming and outgoing events are displayed in chronological order.
Procedure
2. Press the "Alarm log" softkey.
The "Alarm Log" window opens.

All of the coming and going events - that have occurred since the HMI
was started - are listed.
3. Press the "Display new" softkey to update the list of displayed
alarms/messages.
4. Press the "Save Log" softkey.

The log that is currently displayed is stored as text file alarmlog.txt in the
system data in directory card/user/sinumerik/hmi/log/alarm_log.
21.3 Displaying messages

PLC and part program messages may be issued during machining.
These message will not interrupt the program execution. Messages provide information with
regard to a certain behavior of the cycles and with regard to the progress of machining and
are usually kept beyond a machining step or until the end of the cycle.
Overview of messages
You can display all issued messages.
The message overview contains the following information:
Date
Message number
is only displayed for PLC messages
Message text
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21.4 Sorting, alarms, faults and messages
Proceed as follows
1. Select the "Diagnosis" operating area.
2. Press the "Messages" softkey.

The "Messages" window appears.
21.4 Sorting, alarms, faults and messages

If a large number of alarms, messages or alarm logs are displayed, you have the option of
sorting these in an ascending or descending order according to the following criteria:
Date (alarm list, messages, alarm log)
Number (alarm list, messages)
As a consequence, for every extensive lists, you can obtain the required information faster.
Procedure
2. Press the softkey "Alarm list", "Messages" or "Alarm log" to display the
requested messages and alarms.
...
3. Press the "Sort" softkey.

The list of entries is sorted in ascending order according to date, i.e. the
most recent information is at the end of the list.
4. Press the softkey "Descending" to sort the list in a descending order.

The most recent event is shown at the beginning of the list.
5. Press the "Number" softkey if you wish to sort the alarm list or the list
with messages according to numbers.
6. Press the "Ascending" softkey if you wish to display the list in an

ascending order.
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21.5 PLC and NC variables
21.5.1 Displaying and editing PLC and NC variables

The "NC/PLC variables" window allows NC system variables and PLC variables to be
monitored and changed.
You receive the following list in which you can enter the desired NC/PLC variables in order to
display the actual values.
Variable
Address for NC/PLC variable
Incorrect variables have a red background and are displayed with a # character in the
value column.
Comment
Any comment on the variable.
The columns can be displayed and hidden.
Format
Specify the format in which the variable is to be displayed.
The format can be specified (e.g. floating point)
Value
Displays the actual value of the NC/PLC variables
PLC variables
Inputs Input bit (Ex), input byte (EBx), input word (EWx), input double word (EDx)
Outputs Output bit (Ax), output byte (ABx), output word (AWx), output double word
(ADx)
Bit memory Memory bit (Mx), memory byte (MBx), memory word (MWx), memory
double word (MDx)
Times Time (Tx)
Meters Counter (Cx)
Data Data block (DBx): data bit (DBXx), data byte (DBBx), data word (DBWx),
data double word (DBDx)
Formats
B Binary
H Hexadecimal
D Decimal without sign
+/-D Decimal with sign
F Floating point (for double words)
A ASCII character
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Notation for variables

PLC variables
EB2
A1.2
DB2.DBW2
NC variables
NC system variables - notation
$AA_IM[1]
User variables/GUDs - notation
GUD/MyVariable[1,3]
OPI - notation
/CHANNEL/PARAMETER/R[u1,2]
Note
NC system variables and PLC variables
System variables can be dependent on the channel. When the channel is switched over,
the values from the corresponding channel are displayed.
For user variables (GUDs) it is not necessary to make a specification according to global
or channel-specific GUDs. The indices of GUD arrays are, just like NC variables in the
system variable syntax, 0-based; this means that the first element starts with the index 0.
Using the tooltip, for NC system variables, you can display the OPI notation (with the
exception of GUDs).
Changing PLC variables

Changes can only be made to the PLC variables with the appropriate password.
DANGER
Changes in the states of NC/PLC variables have a major impact on the machine. Incorrect
configuration of the parameters can endanger human life and cause damage to the
machine.
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Changing and deleting values
2. Press the "NC/PLC variab." softkey.
The "NC/PLC variables" window opens.

3. Position the cursor in the "Variable" column and enter the required
variable.
4. Press the <INPUT> key.
The operand is displayed with the value.

The "NC/PLC variables: Details" window is opened. The information for
"Variable", "Comment" and "Value" are displayed in the full length.
6. Position the cursor in the "Format" field and choose the required format
with <SELECT>.
7. Press the "Display comments" softkey.

The "Comments" column is displayed. You have the option of creating
comments or editing existing comments.
Press the "Display comments" softkey once again to hide the column
again.
8. Press the "Change" softkey if you would like to edit the value.
The "Value" column can be edited.
9. Press the "Insert variable" softkey if you wish to select a variable from a
list of all of the existing variables and insert this.
The "Select variable" window opens.
10. Press the "Filter/search" softkey to restrict the display of variables (e.g.
to mode groups-variables) using the "Filter" selection box and/or select
the desired variable using the "Search" input box.
Press the "Delete all" softkey if you would like to delete the entries for
the operands.
11. Press the "OK" softkey to confirm the changes or the deletion.
- OR -
Press the "Cancel" softkey to cancel the changes.
Milling
Note
"Filter/Search" when inserting variables
The start value for "Filter/Search" of variables differs.
For example, to insert the variable $R[0], set "Filter/Search":
The start value is 0, if you filter according to "System variables".
The start value is 1, if you filter according to "All (no filter)". In this case, all signals are
displayed and shown in the OPI notation.
Changing operands
Depending on the type of operand, you can increment or decrtement the address by 1 place
at a time using the "Operand +" and "Operand -" softkeys.
Note
Axis names as index
For axis names, the softkeys "Operand +" and "Operand -" do not act as index, e.g. for
$AA_IM[X1].
Examples
DB97.DBX2.5
Result: DB97.DBX2.6
$AA_IM[1]
Result: $AA_IM[2]
MB201
Result: MB200
/Channel/Parameter/R[u1,3]
Result: /Channel/Parameter/R[u1,2]
Milling
21.5.2 Saving and loading screen forms

You have the option of saving the configurations of the variables made in the "NC/PLC
variables" window in a screen form that you reload again when required.
Editing screen forms

If you change a screen form that has been loaded, then this is marked using with * after the
screen form name.
The name of a screen form is kept in the display after switching-off.
Procedure
1. You have entered values for the desired variables in the "NC/PLC
variables" window.
3. Press the "Save screen" softkey.

The "Save screen: Select archiving" window opens.
4. Position the cursor on the template folder for variable screen forms in
which your actual screen form should be saved and press the "OK"
softkey.
The "Save screen: Name" window opens.
5. Enter the name for the file and press the "OK" softkey.
A message in the status line informs you that the screen form was
saved in the specified folder.
If a file with the same name already exists, they you will receive a
prompt.
6. Press the "Load screen" softkey.
The "Load screen" window opens and displays the sample folder for the
variable screen forms.
7. Select the desired file and press the "OK" softkey.
You return to the variable view. The list of all of the predefined NC and
PLC variables is displayed.
Milling
21.5.3 Load symbols

PLC data can also be edited via symbols.
To do this, the symbol tables and texts for the symbols in the PLC project must have been
suitably prepared (STEP7) and made available in SINUMERIK Operate.
Preparing PLC data

Save the generated files in the /oem/sinumerik/plc/symbols directory.
Procedure
1. The variable view is opened.
2. Press the ">>" and "Load icons" softkeys.

The "Import PLC symbols: *.snh" window opens.
3. In the folder "/oem/sinumerik/plc/symbols", select the "PlcSym.snh" file

to import the symbols and then click on "OK".
4. In the folder "/oem/sinumerik/plc/symbols", select the "PlcSym.snt" file

to import the symbols and then press the "OK" softkey.
You will obtain an appropriate note if the tables were successfully

imported.
You return to the "NC/PLC variables" window.
6. Restart the SINUMERIK Operate in order to activate the files.
Milling
21.6 Version
21.6 Version
21.6.1 Displaying version data

The following components with the associated version data are specified in the "Version
data" window:
System software
Basic PLC program
PLC user program
System extensions
OEM applications
Hardware
Information is provided in the "Nominal version" column as to whether the versions of the
components deviate from the version supplied on the CompactFlash Card.
The version displayed in the "Actual version" column matches the version of
the CF card.
The version displayed in the "Actual version" column does not match the
version of the CF card.
You may save the version data. Version displays saved as text files can be further
processed as required or sent to the hotline in the event of an error.
Procedure
1. Select the "Diagnosis" operating area.
2. Press the "Version" softkey.

The "Version Data" window appears.
Data from the available components are displayed.
3. Select the component for which you would like more information.
4. Press the "Details" softkey, in order to receive more exact information

on the components displayed.
Milling
21.6 Version
21.6.2 Save information

All the machine-specific information of the controller is combined in a configuration via the
user interface. You can save machine-specific information on the drives that have been set-
up.
Procedure

It takes some time to call the version display. While the version data is
being determined a progress message box and the appropriate text are
displayed in the dialog line.
3. Press the "Save" softkey.
The "Save version information: select archive" window opens. The
following storage locations are offered depending on the configuration:
Local drive
Network drives
USB
Version data (archive: Data tree in the "HMI data" directory)
4. Then press the "New directory" softkey if you wish to create your own
directory.
5. Press the "OK" softkey. The directory is created.
6. Press the "OK" softkey again to confirm the storage location.
The "Save version information: name" window opens. The following

options are available:
In the "Name:" text field, The file name is pre-assigned with
<Machine name/no.>+<CF-card number>. "_config.xml" or
"_version.txt" is automatically attached to the file names.
In text field "Comment", you can add a comment, which is stored
with the configuration data.
Milling
21.7 Logbook
Select the following via a checkbox:

Version data (.TXT): Output of pure version data in text format.
Configuration data (.XML): Output of configuration data in XML
format. The configuration file contains the data you entered under
Machine identity, the license requirements, the version information
and the logbook entries.
7. Press the "OK" softkey to start the data transfer.
21.7 Logbook
The logbook provides you with the machine history in an electronic form.
If service is carried out on the machine, this can be electronically saved. This means that it is
possible to obtain a picture about the "History" of the control and to optimize service.
Editing the logbook

You can edit the following information:
Editing information on the machine identity
Machine name/No.
Machine type
Address data
Make logbook entries (e.g. "filter replaced")
Output of the logbook

You have the possibility of exporting the logbook by generating a file using the "Save
version" function in which the logbook is contained as section.
Milling
21.7 Logbook
21.7.1 Displaying and editing the logbook
Procedure
3. Press the "Logbook" softkey.

The "Machine logbook" window opens.
Editing end customer data
You have the option of changing the address data of the end customer
using the "Change" softkey.
21.7.2 Making a logbook entry

Using the "New logbook entry" window to make a new entry into the logbook.
Enter your name, company and department and a brief description of the measure taken or a
description of the fault.
Note
If you wish to make line breaks in the "fault diagnostics/measure" field, use the key
combination <ALT> + <INPUT>.
The date and entry number are automatically added.
Sorting the entries

The logbook entries are displayed numbered in the "machine logbook" window.
More recent entries are always added at the top in the display.
Milling
21.7 Logbook
Procedure
1. The logbook is opened.

2. Press the "New entry" softkey.
The "New logbook entry" window opens.
3. Enter the required data and press the "OK" softkey.
You return to the "Machine logbook" window and the entry is displayed
below the machine identity data.
Note
Once you have stored an entry this can no longer be changed or deleted.
Searching for a logbook entry

You have the option for searching for specific entries using the search function.
1. The "Machine logbook" window is opened.

2. Press the "Search..." softkey and enter the desired term in the search
form. You can make a search according to date/time, company
name/department or according to fault diagnostics/measure.
The cursor is positioned on the first entry that corresponds to the search
term.
3. Press the "Continue search" softkey if the entry found is not the one that
you are looking for.
Additional search option
Press the "Go to Beginning" softkey to start the search at the latest
entry.
Press the "Go to End" softkey to start the search at the oldest entry.
Milling
21.8 Creating screenshots
21.8 Creating screenshots

You can create screenshots of the current user interface.
Each screenshot is saved as a file and stored in the following folder:
/user/sinumerik/hmi/log/screenshot
Procedure
Ctrl + P Press the <Ctrl+P> key combination.

A screenshot of the current user interface is created in .png format.
The file names assigned by the system run in ascending order from
"SCR_SAVE_0001.png" to "SCR_SAVE_9999". You can create up to 9,999
screenshots.
Copy file
2. Press the "System data" softkey and open the specified folder.
As you cannot open screenshots in SINUMERIK Operate, you must

copy the files to a Windows PC either via "WinSCP" or via a USB
FlashDrive.
You can open the files using a graphics program, e.g. "Office Picture
Manager".
Milling
21.9 Remote diagnostics
21.9.1 Setting remote access

You can influence the remote access to your control in the "Remote diagnostics (RCS)"
window.
Here, rights for all types of remote control are set. The selected rights are defined from the
PLC and using the setting at the HMI.
The HMI can restrict the rights specified from the PLC, but however, cannot extend the rights
beyond the PLC rights.
If the settings made permit access from outside, then this is still dependent on a manual or
automatic confirmation.
Rights for remote access

The "Specified from PLC" field shows the access rights for remote access or remote
monitoring specified from the PLC.
In the "Selected in the HMI" selection box, you have the possibility of setting rights for
remote control:
Do not permit remote access
Permit remote monitoring
Permit remote control
The combination of the settings in the HMI and in the PLC show the valid status as to
whether access is permitted or not. This is displayed in the "Resulting from" line.
Settings for the confirmation dialog box

If the settings made for "Specified from the PLC" and "Selected in the HMI" permit access
from outside, then this is however, still dependent on either a manual or automatic
confirmation.
As soon as a remote access is permitted, at all of the active operating stations, a query
dialog box is displayed for the operator at the active operating station to either confirm or
reject an access.
For the case that there is no local operation, then the control behavior can be set for this
particular scenario. You define how long this window is displayed and whether, after the
confirmation has expired, the remote access is automatically rejected or accepted.
Milling
Display of the state
Remote monitoring active
Remote control active
If remote access is active, using these icons you will be informed in the status line as to
whether a remote access is presently active or whether only monitoring is permitted.
Procedure
2. Press the "Remote diag." softkey.

The "Remote diagnostics (RCS)" window is opened.
The "Selected in the HMI" is activated.
4. If you desire remote control, select the entry "Permit remote control".
In order that remote control is possible, the entry "Permit remote

control" must be specified in the fields "Specified from the PLC" and
"Selected in the HMI".
5. Enter new values in the group "Behavior for confirming remote access"
if you wish to change the behavior for confirming remote access.
The settings are accepted and saved.
References
Milling
21.9.2 Permit modem

You can permit remote access to your control via a teleservice adapter IE connected at
X127.
Software option
You need the "MC Information System RCS Host" option to display the
"Permit modem" softkey.
Procedure
1. The "Remote diagnostics (RCS)" window is opened.
2. Press the "Permit modem" softkey.

Access to the control via modem is enabled so that a connection can be
established.
3. To block access again, press the "Permit modem" softkey again.
21.9.3 Request remote diagnostics

Using the "Request remote diagnostics" softkey, from your control you have the option of
actively requesting remote diagnostics with your machinery construction OEM.
The access via modem must be enabled if the access is to be made via modem.
When requesting remote diagnostics, you obtain a window with the corresponding pre-
assigned data and values of the ping service. If required, you can ask your machine
manufacturer for this data.
Data Meaning
IP address IP address of the remote PC
Port Standard port that is intended for remote diagnostics
Send duration Duration of the request in minutes
Milling
Data Meaning
Send interval Cycle in which the message is sent to the remote PC in seconds
Ping send Message for the remote PC
data
Procedure
1. The "Remote diagnostics (RCS)" window is opened.
2. Press the "Request remote diagnostics" softkey.

The "Request remote diagnostics" window is displayed.
3. Press the "Change" softkey if you would like to edit the values.

The request is sent to the remote PC.
References
21.9.4 Exit remote diagnostics
Procedure
1. The "Remote diagnostics (RCS)" is opened and it is possible that

remote monitoring or remote access is active.
2. Block modem access if access via modem is to be blocked .

- OR -
In the "Remote diagnostics (RCS)" window, reset the access rights to
"Permit no remote access" .
Milling
Appendix A
A.1 Overview
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Milling
Appendix
A.1 Overview
Milling
Index
Block search, 150

Mode, 156
Program interruption, 119, 153
Search pointer, 119, 151, 153, 154
A
Search target parameters, 155
Actual-value display, 38 Search target specification, 153
Alarm log Boring - CYCLE86
display, 637 Function, 284
Sorting, 638 Parameter, 286
Alarms, 635
Sorting, 638
Align milling tool - CYCLE800 C
Parameter, 450
Calculator, 45
Any file
Centering - CYCLE81
Create, 549
Function, 276
Arbitrary positions - CYCLE802
Parameter, 277
Function, 298
Changing a program block, 248
Parameter, 300
Channel switchover, 63
Archive
Circle
Generate in the program manager, 564
Polar, 471
generating in the system data, 565
Circle position pattern - HOLES2
read in archive from system data, 569
Function, 302
reading-in in the Program Manager, 567
Parameter, 303
Asian characters, 49
Circle with known center point, 466
Auxiliary functions
Circle with known radius, 467
H functions, 180
Circular pocket - POCKET4
M functions, 180
Function, 313
Axes
Parameter, 317
Defined increment, 130
Circular spigot - CYCLE77
Direct positioning, 132
Function, 321
Referencing, 58
Parameter, 323
Repositioning, 149
Circumferential groove - SLOT2
Traversing, 130
Function, 329
Variable increment, 131
Parameter, 332
Coarse and fine offsets, 110
Context-sensitive online help, 53
B
Continuous-path mode, 491
Backing up Contour call - CYCLE62
Data, 564, 565 Function, 361, 418
Setup data, 570 Parameter, 362, 419
Base offset, 109 Contour milling - CYCLE63
Basic blocks, 145 Function, contour pocket, 371
Binary format, 564 Function, contour spigot, 375
Blank input Function, residual material contour pocket, 373
Function, 215 Function, residual material contour spigot, 377
Parameter, 216 Parameter, contour spigot, 377
Block Parameters, contour pocket, 373
Search, 119, 151, 153, 154 Parameters, residual material contour pocket, 375
Milling
Index
Parameters, residual material contour spigot, 379 Function, residual material contour pocket, 373
Contour milling - CYCLE64 Function, residual material contour spigot, 377
Function, predrilling, 368 Parameter, contour spigot, 377
Parameters, centering, 369 Parameters, contour pocket, 373
Contour turning - CYCLE952 Parameters, residual material contour pocket, 375
Function, grooving, 426 Parameters, residual material contour spigot, 379
Function, grooving residual material, 430 CYCLE64 - contour milling
Function, plunge turning, 432 Function, predrilling, 368
Function, plunge turning residual material, 435 Parameters, centering, 369
Function, stock removal, 419 CYCLE70 - engraving
Function, stock removal residual, 424 Function, 344
Parameters, grooving, 429 Parameter, 350
Parameters, grooving residual material, 431 CYCLE70 - thread milling
Parameters, plunge turning, 435 Function, 341
Parameters, plunge turning residual material, 437 Parameter, 344
Parameters, stock removal, 424 CYCLE72 - Path milling
Parameters, stock removal residual material, 426 Function, 362
Coordinate system Parameter, 366
Switching over, 65 CYCLE76 - rectangular spigot
Coordinate transformation, 455 Function, 318
Copying Parameter, 320
Directory, 557 CYCLE77 - circular spigot
Program, 557 Function, 321
Create Parameter, 323
Program block, 167 CYCLE78 - Drilling and thread milling
Workpiece, 546 Function, 291
Creating Parameter, 294
Any file, 549 CYCLE79 - multi-edge
Directory, 545 Function, 323
G Code program, 547 Parameter, 325
Job list, 550 CYCLE801 - grid/frame position pattern
NC directory on the local drive, 540 Function, 300
Program list, 551 Parameter, 301
Ctrl Energy CYCLE802 - arbitrary positions
Energy analysis, 592 Function, 298
Cut-off - CYCLE92 Parameter, 300
Function, 403 CYCLE81 - centering
Parameter, 405 Function, 276
Cutting edge, 240 Parameter, 277
Cutting rated, 241 CYCLE82 - drilling
CYCLE61- face milling Function, 278
Function, 307 Parameter, 279
Parameter, 309 CYCLE83 - deep-hole drilling
CYCLE62 - new contour Function, 281
Function, 353, 408 Parameter, 283
Parameter, 354 CYCLE832 - High Speed Settings
CYCLE62- contour call Function, 451
Function, 361, 418 Parameter, 452
Parameter, 362, 419 CYCLE84 - rigid tapping
CYCLE63 - contour milling Function, 286
Function, contour pocket, 371 Parameter, 290
Function, contour spigot, 375 CYCLE840 - tapping with compensating chuck
Milling
Index
Function, 286 Current levels, 212

Parameter, 290 Hiding cycle parameters, 222
CYCLE85 - reaming Screen forms, 212
Function, 279 Cylinder surface transformation
Parameter, 280 Function, 460
CYCLE86 - boring General programming, 462
Function, 284
Parameter, 286
CYCLE899 - open slot D
Function, 332
Data block (SB2), 143
Parameter, 338
Deep-hole drilling - CYCLE83
CYCLE92 - cut-off
Function, 281
Function, 403
Parameter, 283
Parameter, 405
Deleting
CYCLE930 - groove
Directory, 559
Function, 383383
Program, 559
Parameter, 385385
Device
CYCLE940 - undercut
Activate/deactivate, 606
Function, DIN thread, 388
Enabling, 606
Function, form E, 386
Directory
Function, form F, 386
Copying, 557
Function, thread, 388
Creating, 545
Parameters, DIN thread, 390
Deleting, 559
Parameters, form E, 387
Highlight, 555
Parameters, form F, 388
Pasting, 557
Parameters, thread, 391
Properties, 560
CYCLE951 - stock removal
Selecting, 555
Function, 380
Displaying
Parameter, 383
Energy consumption, 592
CYCLE952 - contour turning
Program level, 146
Function, grooving, 426
DRF (handwheel offset), 158
Function, grooving residual material, 430
Drilling - CYCLE82
Function, plunge turning, 432
Function, 278
Function, plunge turning residual material, 435
Parameter, 279
Function, stock removal, 419
Drilling and thread milling - CYCLE78
Function, stock removal residual, 424
Function, 291
Parameters, grooving, 429
Parameter, 294
Parameters, grooving residual material, 431
Drive
Parameters, plunge turning, 435
Error messages, 581
Parameters, plunge turning residual material, 437
Logical drive, 579
Parameters, stock removal, 424
Setting up, 580
Parameters, stock removal residual material, 426
DRY (dry run feed), 158
CYCLE98 - thread turning
Dual editor, 168
Function, thread chain, 400
Duplo number, 512
Parameters, thread chain, 403
CYCLE99 - thread turning
Function, face thread, 391
E
Function, longitudinal thread, 391
Function, tapered thread, 391 Easy Extend, 606
Parameters, face thread, 397 Activate/deactivate device, 606
Parameters, tapered thread, 400 Enabling a device, 606
Cycles First commissioning, 607
Milling
Index
Easy Message, 597 Parameter, 385

Commissioning, 598
Settings, 604
User log on/off, 602 H
Editor
Handheld terminal 8, 583
Calling, 162
Handwheel
Settings, 169
Assigning, 119
Elongated hole - LONGHOLE
Helix, 468
Function, 339
High Speed Settings - CYCLE832
Parameter, 340
Function, 451
Enabling button, 584
Parameter, 452
Energy consumption
Highlight
displaying, 592
Directory, 555
Engraving - CYCLE60
Program, 555
Function, 344
HOLES1 - line position pattern
Parameter, 350
Function, 300
Executing
Parameter, 301
Program, 544
HOLES2 - circle position pattern
EXTCALL, 562
Function, 302
Parameter, 303
HT 8, 583
F
Enabling button, 584
Face milling Touch Panel, 590
in JOG, 137 Traversing keys, 586
Face milling - CYCLE61 User menu, 587
Function, 307 Virtual keyboard, 588
Parameter, 309
Feed data
Actual value window, 40 I
Feedrate, 241
Interruption point
Function
Approaching, 119, 153
Cylinder surface transformation, 460
Setting milling tool - CYCLE800, 448
Subprograms, 453
J
Job list
G Creating, 550
G code program
Blank input, 215
L
G Code program
Creating, 547 Ladder viewer, 613
G functions Line position pattern - HOLES1
Display all G groups, 179 Function, 300
G Functions Parameter, 301
Displaying selected G groups, 177 Logbook, 647
Global user data, 483 display, 648
Grid/frame position pattern - CYCLE801 Edit the address data, 648
Function, 300 Entry search, 649
Parameter, 301 Making an entry, 648
Groove - CYCLE930 Output, 646
Function, 383 LONGHOLE - elongated hole
Milling
Index
Function, 339 Mold making view, 171

Parameter, 340 Changing a graphic, 175
Longitudinal groove - SLOT1 Changing the section, 176
Function, 326 Editing a program block, 174
Parameter, 329 Searching for program blocks, 174
Starting, 173
Multi-channel view, 473
M "Machine" operating area,
Settings, 478
M functions, 180
Multi-edge - CYCLE79
Machine control panel
Function, 323
Operator controls, 31
Parameter, 325
Machine functions, 242
Machine-specific information
Save, 646
N
Machining
Canceling, 142 NC directory
Starting, 141 creating on local drive, 540
Stopping, 141 NC variables, 639
Machining schedule NC/PLC variables
ShopMill, 228 Changing, 641
Machining step program, 227 Load symbols, 644
Magazine New contour - CYCLE62
Open, 528 Function, 353, 408
Positioning, 530 Parameter, 354
Selecting, 521 Number of teeth, 513
Magazine management, 502
Maintenance tasks
Monitoring/performing, 609 O
Setting up, 610
Obstacle, 472
Manual mode, 125
Offset, 456
Positioning axes, 132
Online help
Settings, 140
Context-sensitive, 53
Spindle, 127
Open
T, S, M windows, 125
Program, 542
Tool, 127
Second program, 168
Traversing axes, 130
Open slot - CYCLE899
Unit of measurement, 125
Function, 332
MDA
Parameter, 338
Deleting a program, 124
Operating area
Executing a program, 124
Changing, 41
MDI
Operating mode
Loading a program, 122
AUTO, 62
Saving a program, 123
Changing, 41
Measuring
JOG, 61, 125
Tool, 69
MDA, 62
Tool automatically, 73
Operator panel fronts, 20
Tool manually, 69
Workpiece zero, 76
Messages, 637
P
Sorting, 638
Mode groups, 63 Parameter
Mold making programs, 171 Align milling tool - CYCLE800, 450
Milling
Index
Calculating, 44 linked, 232

Changing, 44 Numbering, 166
Entering, 43 Repeat, 245
Setting milling tool - CYCLE800, 449 Search, 163
Swivel plane CYCLE800, 445 Selecting, 165
Pasting Program block display, 41, 145
Directories, 557 Program blocks, 167
Program, 557 Program control, 158
Path milling - CYCLE72 activate, 159
Function, 362 Program editing, 148
Parameter, 366 Program header, 237
Pinyin Important parameters, 240
Input editor, 49 Program level
Pitch, 512 Displaying, 146
PLC diagnostics Program list
Ladder add-on tool, 613 Creating, 551
PLC symbols Program Manager, 567
Loading, 644 Searching directories and files, 553
PLC variables, 641 Program runtime, 183
POCKET3 - rectangular pocket Program settings
Function, 310 changing, 249
Parameter, 313 Program views
POCKET4 - circular pocket ShopMill, 228
Function, 313 Programmed stop 1, 158
Parameter, 317 Programmed stop 2, 158
Polar coordinates, 469 Programming graphics
Positions ShopMill, 228
display/hide, 304 Programs
Parameter, obstacle, 472 Correcting, 41, 145, 148
Parameter, repeat, 306 Editing, 162
Preview Managing, 537
Program, 554 Renumbering blocks, 166
Probe, 75 Replacing text, 164
Electronic, 82 Running-in, 143
Program Searching for a program position, 163
Closing, 542 Selecting, 142
Copying, 557 Teach-in, 489
Creating with cycle support, 214 Properties
Deleting, 559 Directory, 560
Executing, 544 Program, 560
Highlight, 555 Protection levels, 51
Open, 542 PRT (no axis motion), 158
Opening a second program, 168 Punched tape format, 564
Pasting, 557
Preview, 554
Properties, 560 Q
Selecting, 555
Quantity, 524
Program block, 167
Changing, 162
Copying and inserting, 165
R
Delete, 165
generating, 239 R parameters, 482
Milling
Index
Radius compensation, 240 Function, 448

Reading in Parameter, 449
Setup data, 573 Settings
Reaming - CYCLE85 Editor, 169
Function, 279 For automatic operation, 185
Parameter, 280 For manual operation, 140
Rectangular pocket - POCKET3 Multi-channel view, 478
Function, 310 Teach-in, 499
Parameter, 313 Setup data
Rectangular spigot - CYCLE76 Backing up, 570
Function, 318 reading in, 573
Parameter, 320 ShopMill program
Reference point approach, 58 creating, 236
Remote access Machine functions, 242
permit, 653 Program blocks, 239
Setting, 651 Program header, 237
Remote diagnostics, 651 Program settings, 249
Exit, 654 Program structure, 232
requesting, 653 Straight line/Circle, 463
Repeat positions ShopTurn program
Function, 305 Mirroring, 459
Replacement tool number, 512 Scaling, 458
Repositioning, 149 Simulation, 187
RG0 (reduced rapid traverse), 158 Alarm display, 206
Rigid tapping - CYCLE84 Blank, 199
Function, 286 Changing a graphic, 202
Parameter, 290 Program control, 200
Rotation, 457 Showing and hiding the path display, 199
Views, 197
Simultaneous recording, 189
S Before machining, 195
Single block
Save
Coarse (SB1), 143
Setup data, 570
Fine (SB3), 143
SB (single blocks), 158
Skip blocks, 159
SB1, 143
SKP (skip blocks), 158
SB2, 143
SLOT1- longitudinal groove
SB3, 143
Function, 326
Screenshots
Parameter, 329
Copy, 650
SLOT2 - circumferential groove
Creating, 650
Function, 329
Open, 650
Parameter, 332
Search
SMS messages, 597
in the Program Manager, 553
Log, 603
Logbook entry, 649
Spindle data
Search mode, 156
Actual value window, 40
Search pointer, 119, 151, 153, 154
Spindle speed, 241
Selecting
Spindle speed limitation, 118
Directory, 555
Status display, 35
Program, 555
Stock removal - CYCLE951
Service Planner, 609
Function, 380
Setting actual values, 67
Parameter, 383
Setting milling tool - CYCLE800
Milling
Index
Straight line, 463 Function, tapered thread, 391

Polar, 470 Parameters, face thread, 397
Straight line/Circle, 463 Parameters, longitudinal thread, 395
Submode Parameters, tapered thread, 400
REF POINT, 61 Tip angle, 512
REPOS, 61 Tool, 127
TEACH IN, 62 Automatic measurement, 73
Subprograms, 453 Change type, 536
Switching off, 57 Create, 516
Switching on, 57 Deleting, 519
Switching over Details, 535
Channel, 63 Dimensioning, 505
Coordinate system, 65 Loading, 520
Unit of measurement, 66 Manual measurement, 69
Swivel plane CYCLE800 Measuring, 69
Parameter, 445 Reactivating, 525
Swiveling Relocating, 530
Parameter, swivel plane, 137 Unloading, 520
Symbol tables, 628 Tool data
Synchronized actions Actual value window, 39
Displaying status, 181 Backing up, 570
reading in, 573
Tool life, 524
T Tool list, 512
Tool management, 501
Tapping with compensating chuck - CYCLE840
List filtering, 533
Function, 286
Sorting lists, 532
Parameter, 290
Tool parameters, 505
Teach-in, 489
Tool probe, 75
Changing blocks, 497
Tool types, 503
Circle intermediate position CIP, 494
Tool wear, 523
Deleting blocks, 499
Tool wear list
General sequence, 489
open, 523
Inserting a position, 490
Touch Panel
Inserting blocks, 492
Calibrating, 590
Motion type, 491
Parameter, 491
Rapid traverse G0, 494
U
Selecting a block, 498
Settings, 499 Undercut - CYCLE940
Traversing block G1, 494 Function, DIN thread, 388
Templates Function, form E, 386
Creating, 552 Function, form F, 386
Storage locations, 552 Function, thread, 388
Thread milling - CYCLE70 Parameters, DIN thread, 390
Function, 341 Parameters, form E, 387
Parameter, 344 Parameters, form F, 388
Thread turning - CYCLE98 Parameters, thread, 391
Function, thread chain, 400 Unit of measurement
Parameters, thread chain, 403 Switching over, 66
Thread turning - CYCLE99 User acknowledgement, 59
Function, face thread, 391 User data, 481
Function, longitudinal thread, 391 Channel GUD, 484
Milling
Index
Definition, 487
Global GUD, 483
Local LUD, 485
Program PUD, 486
R parameters, 482
Search, 487
User variables
Activate, 487
Global GUD, 487
V
Variable screen forms, 643
Virtual keyboard, 588
W
Wear, 524
Work offsets, 109
Active WO, 110
Calling, 244
Delete, 115
Displaying details, 114
Overview, 111
Settable WO, 113
Setting, 67
Working area limitation, 117
Workpiece
Create, 546
Workpiece counter, 183
Workpiece zero
Aligning the edge, 86
Aligning the plane, 104
Automatic measurement, 76
Changing the user interface, 106
Corrections after measurement, 107
Manual measurement, 76
Measuring, 76
Measuring a hole, 92
Measuring a rectangular pocket, 92
Measuring a rectangular spigot, 98
Measuring a right-angled corner, 89
Measuring any corner, 89
Measuring circular spigot, 98
Measuring the distance between two edges, 86
Z
Zero point settings
Backing up, 570
reading in, 573
Milling
Index
Milling

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What is the manual about?

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What are some of the main sections covered in the manual?

 Milling ___________________

Siemens AG order number: 6FC5398-7CP40-2BA0 Copyright Siemens AG 2011.

My Documentation Manager (MDM)

2.5.4 Fixed point calibration ................................................................................................................. 72

3.6 Simple face milling of workpiece................................................................................................137

4.14 Setting for automatic mode ....................................................................................................... 185

6.9.6 Additional functions in the input screens ...................................................................................224

8.1.5.1 Function..................................................................................................................................... 281

8.4.8 Cut-off (CYCLE92).....................................................................................................................403

10.3 Global GUD ............................................................................................................................... 483

12.10 Filtering the tool management lists ............................................................................................533

14.2 Setting up drives ....................................................................................................................... 580

20.6 Displaying and editing PLC signals ...........................................................................................618

1.2 Operator panel fronts

Operator controls and indicators

1 Status LED: POWER

Figure 1-1 View of OP 010 operator panel front

1.2.2 Keys of the operator panel

Keys and key combinations

* on USB keyboards use the <Home> or <Pos 1> key

+ + <NEXT WINDOW> + <CTRL> + <SHIFT>

+ <PAGE UP> + <SHIFT>

+ <PAGE UP> + <CTRL>

+ <PAGE DOWN> + <SHIFT>

+ <PAGE DOWN> + <CTRL>

+ <Cursor left> + <CTRL>

+ <Cursor up> + <CTRL>

+ <Cursor up> + <SHIFT>

+ <Cursor down> + <CTRL>

+ <Cursor down> + <SHIFT>

+ + <END> + <CTRL> + <SHIFT>

+ + <CTRL> + <ALT> + <S>

+ + <CTRL> + <ALT> + <D>

+ + <SHIFT> + <ALT> + <D>

+ + <SHIFT> + <ALT> + <T>

+ + <SHIFT> + <ALT> + <T>

<ALARM> - only OP 010 and OP 010C

<PROGRAM> - only OP 010 and OP 010C

<OFFSET> - only OP 010 and OP 010C

<PROGRAM MANAGER> - only OP 010 and OP 010C

Menu forward key

Menu back key

1.3 Machine control panels

1.3.2 Controls on the machine control panel

(1) EMERGENCY STOP button

Inc <VAR>(Incremental Feed Variable)

Inc (incremental feed)

(9) Feed control with override switch

Figure 1-2 Front view of machine control panel (milling version)

1.4 User interface

1.4.1 Screen layout

1 Active operating area and mode

Figure 1-3 User interface

1.4.2 Status display

Status display of "Machine" operating area

"Parameter" operating area

Milling ___________________