Operating SINUMERIK Operate

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Content Page
Objectives ........................................................................................................................................ 2
Overview of operating areas ............................................................................................................. 3
Screen structure ............................................................................................................................... 4
Machine operating area .................................................................................................................... 5
Machine operating area – JOG mode (user interfaces) .................................................................... 6
T,S,M function .................................................................................................................................. 7
Machine operating area - MDA mode ............................................................................................... 8
Machine operating area - AUTO mode ............................................................................................. 9
Machine operating area - AUTO mode - Program control ................................................................ 10
Simultaneous recording .................................................................................................................... 11
Parameter operating area – Tool Offsets .......................................................................................... 12
Parameter operating area – User variables ...................................................................................... 13
Program operating area ................................................................................................................... 14
Diagnostics operating area ............................................................................................................... 15
Setup operating area ........................................................................................................................ 16
Switch on simulator .......................................................................................................................... 17
Exercise: Operation - HMI Selection on the TCU .............................................................................. 18
Reference point approach ................................................................................................................ 19
Exercise 1: Operator panel keyboard and screen display ................................................................. 20
Exercise 2: Machine operating area .................................................................................................. 21
Exercise 3: Switchover Machine axis/Geometry axis with MCP ....................................................... 22
Exercise 4: Parameter operating area .............................................................................................. 23
Exercise 5: Program operating area ................................................................................................. 24
Exercise 6: Program operating area ................................................................................................. 25

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 Objectives

The participant should ...

... know how to use SINUMERIK Operate

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Notes

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 Overview of operating areas

Operating areas

Execute Tool data Program editors Read in/out Alarm displays, Machine data,
part program, (programGUIDE, data and Alarm log, Setting data
Variables
Manual control, (R-parameters, Shopmill/ programs, NC/PLC variables Start-up
and trace (drives, hmi)
Set-up, GUD) Shopturn) Manage
Data and Version/Logbook System data
T/S/M, Work offsets,
programs, ... Service displays: (CF card, USB,
Simult. Setting data,... network)
Recording … Axes/Drives/
Networks/Safety Optimization
Remote diagnosticsLicensing

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To facilitate operation of SINUMERIK 840D / 810D / FM-NC, important data have

been grouped in various operating areas for users. The user can call up all the
functions via the control system user interface.
The SINUMERIK 840D provides the following operating areas:

Machine In the "Machine" operating area, the operator can perform all the necessary
operations from setting up the machine to automatic execution of part programs.
The "Machine" operating area will display different softkeys with different
functionalities depending on the operating mode.

Parameter The operator or machine setter can enter data for tools, work offsets, R-para-
meters and variables in the Parameter operating area. Here, the machine can be
adapted to the particular workpiece using setting data.

Program The "Program" operating area provides all the necessary help and functions to
easily modify and create programs.

Program Manager Data (programs, tools, etc.) can be handled via the "Program Manager" operating
area.

Diagnostics In case of an error, you can display help for the actual message or alarm in the
"Diagnostics" operating area. The alarm log is also provided here.

Setup The "Setup" operating area is mainly used by commissioning and service
engineers/specialists to access all data areas of the NC.

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 Screen structure

1 2
12
3
4 5

7
6

10

11

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The display of the presented slimline operator panels (OPs) is structured into the
areas shown in the diagram above.
1 Active operating area and mode
2 Alarm/message line
3 Program name
4 Channel status and program control
5 Channel status messages
6 Axis position display in the actual value window
7 Display for
• active tool T
• present feedrate F
• active spindle with present status (S)
8 Operating window with program block display
9 Display of active G functions , all G functions , H functions as well as
Entry field for various functions (e.g. skip blocks, program control )
10 Dialog line to display additional user messages
11 Horizontal softkey bar
12 Vertical softkey bar

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 Machine operating area

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The "Machine" operating area includes all functions and influencing variables
which initiate actions at the machine tool or detect its status.
The "JOG" mode is used for manual operation and for setting up the machine. For
setting up, the functions reference point approach, repositioning, handwheel or
traversing in specified increments and setting new absolute (machine) zero are
available.

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 Machine operating area – JOG mode
(user interfaces)

Universal Turning Milling

 Turning

 Milling

 Universal

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JOG The "JOG" mode is used for manual operation and for setting up the machine. For
setting up, the functions reference point approach, repositioning, handwheel or
traversing in specified increments and setting new absolute (machine) zero
(Preset) are available.

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 T,S,M function

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T, S, M function allows the loading of a tool and the switching of

• Spindle speed
• Direction of rotation
• M functions (auxiliary functions)
• Selection of a work offset for machining
• Selection of the measurement unit (mm / inch)

Procedure: JOG operating mode > T, S, M > Select tool > In Manual (the tool is
now loaded into the spindle)
• Enter the speed, e.g. 2000 rpm
• Select the direction of rotation using the Select key
• Other M functions (auxiliary functions), e.g. enter 7 for M7 coolant on
• If required, select a work offset
• Procedure JOG operating mode > T, S, M > Select WO > e.g. check G54
and switch on in Manual
• Select the measurement units using the Select key if required mm is selected
when switching-on

The set values can now be started using the NC Start button (cycle start – green
button) for manual operation.

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 Machine operating area - MDA mode

e.g.
e.g.
G0 G90 X100 Y100
G0 G90 X100 Y100
M30
M30
or
or
S2000 M3
S2000 M3
or
or
T1 M6
T1 M6
S2500 M3
S2500 M3
G0 G90 Y250 Y150
G0 G90 Y250 Y150
X150 Y100
X150 Y100
X0
X0
Y0
Y0
X150
X150
Y100
Y100
G0 X250 Y150
G0 X250 Y150
M30
M30

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In "MDI" mode (Manual Data Input), you can generate part programs block-by-
block and execute them. To do this, you can use the keyboard to selectively enter
the required motion as individual part program blocks.

The control processes the entered program blocks when you press the "NC Start"
key.

Note You need the same safety interlocks and prerequisites as for fully automatic
operation. In MDI mode, all automatic functions are active.

Notes The Program Control horizontal softkey is explained in detail in the section
"Machine" operating area "AUTO" mode.

MDI buffer Programs generated in the MDI mode can be saved in the program memory using
the SK "Save MDI".

And with Load MDI, they are loaded from the program memory into the MDI buffer.

Note For compatibility, MD 19730 Bit 11 must be set manually,

otherwise there are no Softkeys ‘Save MDI’ and ‘Load MDI’!

Tip If MDI does not function with the message

'Program already opened by another application',
then the reason for this is the active HMI-Embedded, which blocks the HMI-
Advanced of the PCU at this point (e.g. happened in this way for NC SW 1.3.2).
Remedy: Disable HMI-Embedded on the NCU:

-> WinSCP
-> Enter the command:
SC disable HMI
-> Power ON of the NCU

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 Machine operating area - AUTO mode

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In the "AUTO" mode, the part programs are executed fully automatically.
This is the operating mode for normal operation of part machining.

The following conditions must be fulfilled before you can execute part programs:
• You have synchronized the measuring system of the control with the machine
(reference point approach).
• You have already selected the associated part program in the control.
• You have already checked and entered the necessary offset values, e.g. work
offsets, tool offsets.
• The required safety interlocks are activated.

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 Machine operating area - AUTO mode -
Program control

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Program control
In the "AUTO" and "MDI" modes, this function can be used to change the
execution of a program. The following program controls can be activated or
deactivated
• SKP
skip block; up to max. 10 skip levels can be activated. For more than one skip
level, you obtain an additional selection screen
• DRY Dry run feedrate
• ROV Rapid traverse override
• M01 Programmed stop
• DRF DRF selection
• PRT Program test

Single block selection

• SBL1 Single block, coarse
• SBL2 Calculation block
• SBL3 Single block, fine

Display All blocks, e.g. of comments are displayed in operating area

Program > Editor opened> Double expansion key > Settings

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 Simultaneous recording

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Simultaneous recording before machining 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 programming.

Simultaneous recording while machining the workpiece

If the view onto the working area is blocked by coolant, for example, while the
workpiece is being machined, you can also track the program execution on the
screen.

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 Parameter operating area – Tool Offsets

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Tool list This is the list of tools with their geometry data.
The list starts with the spindle and gripper locations, then the magazine locations,
and finally the tools not available yet.
Functions available are>
- create / delete / load / unload tools

Tool wear Here, the wear data of the tools are accessible

Magazine In the magazine list additional properties are available, like

- location disabled
- oversized tool
- fixed location tool
In addition, here we can relocate tools.

Other data in the parameter operating area

Other available data are
- Work offsets Settable Zero offsets, rotation angles etc
- User variables R-parameters and Global user data
- Setting data Working area limitations, Spindle settings
Note: Other Setting data are available under “Machine data”!

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 Parameter operating area – User variables

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R-parameters R-parameters are used as "placeholders" in NC programs. You can use them to
rapidly adapt e.g. drilling depths, lengths and feed values. The name of the
R-parameter comes from "calculation parameter" or from the data type REAL
(i.e. decimal numbers).
R-parameters can be modified manually in this input screen.

The number of available R-parameters is defined in a machine data element.

A maximum of R0 ... R9999 can be created; no gaps occur in the numbering.
The operator can use R-parameters as required without any restrictions.

R-parameters Using the SK "Search" an input window appears for a parameter.

Search Enter the required R-parameter number at the numerical keypad. After pressing
the "Input" key, the system automatically positions to this R-parameter number.

Additional notes R-parameters are channel-specific, i.e. a two-channel machine has

parameter R1 twice. A key-operated switch can be used to prevent parameters
being entered and deleted.

You can see Global GUDs, Channel GUDs and Local LUDs here.
e.g. def Real OTTO=123

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 Program operating area

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Program operating area > NC

The "Program" operating area provides the operator with program storage as well
as the tools for creating or editing programs.
Directories The program memory is subdivided into subdirectories.

- Workpieces You obtain a current workpiece overview. A workpiece directory contains all files
that are necessary to machine a workpiece. The files can include main program
files, subprogram files or any initialization program. It can also contain comment
files for a technological description of the workpiece.

- Part programs Displays an overview of all main programs.

- Subprograms Displays an overview of all subprograms.

Functions Functions available are:

- Execute The program is loaded for execution.
- New Create a new program or workpiece
as well as the file handling functions
- copy / cut / paste

Drives The local and network drives are shown as

- NC NC program memory
- USB USB drive
- Other drives There may be other configured (local or network) drives
- Example: NW_PG as a network drive on a PG

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 Diagnostics operating area

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Diagnostics operating area

This area is used by the manufacturer and end customer service
basically to
- diagnose the startup of the machine
- locate errors
Alarm display Alarms are displayed in the alarm and message line with alarm number and alarm
text. If several errors occur at the same time, all of these alarms are listed in the
"Diagnostics" operating area.
Notes on resolving the error can be called using the Info key.
Alarm list All alarms present are listed (after the cause has been removed alarms must be
acknowledged using the displayed icon).

Acknowledged using the "NC Start" key on the MCP

Acknowledged using the "Acknowledge alarm" key

Acknowledged using the "Reset" key on the MCP

Acknowledged using "POWER ON", i.e. the control is

switched off and on again

Other functions of the „Diagnostic" operating area

Other functions of the “Diagnostic" operating area is described in detail in the
chapters:
- Diagnosis and startup
- PLC interface (alarm texts)

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 Setup operating area

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"Setup" operating area

As the name of this operating area suggests, it is used for setting up the machine.

The functions of the "Setup" operating area is described in detail in the chapters:
- Data backup
- Diagnosis and startup
- Startup general / Startup basics / Startup advanced
- Licensing
- PLC interface (alarm texts)

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 Switch on simulator

2 3 4 5

6
1

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Switching on This page describes how to switch on the simulator rack.

the simulator

1 Release the "Emergency Stop" button.

2 Switch on the main switch.

Press the '24V SINAMICS ON' key to supply the NCU and drives with
3
24V DC voltage.

Press the 'Power ON' key to supply the power section with
4 400 V AC voltage.

5 Activate the first two NC inputs 'NC DI/DO, DI0 + DI1'.

Set the enable signal for spindle and feed axes. Turn both override switches to the
6 position not equal to 0.

Now you can traverse the axes and spindle.

Switching off To switch off the simulator rack, press the "Emergency Stop" button.
the simulator

Additional notes It is advisable to run down the PCU before turning it off.

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 Exercise: Operation - HMI Selection on the TCU

Recall Menu Select

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Steps 1. Press RECALL ('^' key) and MENU SELECT ("=" key) simultaneously.

2. If the HMI you require is already listed, move the cursor to select the
corresponding line and click on "OK".

3. If an IP address is not displayed with the HMI extension, select the

"Select service session" menu. A scan is made for available sessions.

Move the cursor to select a line containing "HMI Running" and confirm
your selection with "OK".

Note The following exercises relate to system operation with HMI-Advanced.

Note Meaning of displays:

192.168.214.241:0: IP address = 192.168.214.241

Port = 0 (standard display)

The IP addresses of the HMI versions are as follows:

IP = 192.168.214.241 => HMI-Advanced (on the PCU)
IP = 192.168.214.1 => HMI operate (on the NCU)

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 Reference point approach

2a 2b

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Referencing the simulator

This section describes how to proceed to reference the simulator rack.
Referencing is necessary to match the actual axis position with the screen display.

Switch on the simulator rack. Activate the "JOG" operating mode and the "REF"
1 machine function (referencing).

The reference cam for the axes is simulated because - unlike the machine tool - it
does not exist as hardware installed on the simulator rack.

Now you can reference all axes with NC Start

2a (channel-specific referencing)

or

select a single axis (X or Z) and only reference this one axis

2b using the direction key + (single axis referencing).

Referenced For each referenced axis, the HMI machine screen displays the

following symbol:

Note Monitoring functions (e.g. working area limitation, protection areas, software limit
switches, etc.) are only recognized by the control and taken into account after the
axes have been referenced.

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Exercise 1: Operator panel keyboard and screen display

Operator panel keys Use the area switchover key to select the different operating areas.

The machine key M always selects the machine basic screen.

If you press the area switchover key twice, you switch immediately from the
machine basic screen to the screen for the preceding operating area.

Press the channel switchover key and check the selected channel in the
screen display.

Use the softkey "Act. val. Machine" to switch between machine coordinate system
and workpiece coordinate system.

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Exercise 2: Machine operating area

Referencing axes Approach the reference point with the X axis. For simulating the reference cam,
use the "Reference point deceleration" switch on the simulator. Use the axis
selector switch to select Axis 1.

Traversing axes/spindle (continuously) in JOG mode

JOG mode

Axis key X ... 4

Travel direction - or + Rapid traverse override

Traversing axes/spindle with fixed travel paths (incremental)

and 1000 Travel 1000 µm

Axis key X ... Z

Travel direction - or +

Using softkey "INC" set any travel path, e.g. 5000, confirm with

and return to the main menu using the " ^ " key.

With [ . ] select the user-specific increments and travel with the

axis keys.

Starting individual part program blocks with MDI mode

MDI mode

Input: G1 X100 Y100 F1000

Program start

Reset and softkey "Delete MDI buffer"

Input: S1000 M3

Program start

The spindle can be stopped by pressing Reset.

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Exercise 3: MCS/WCS switchover with MCP

The MCP can be used to switch between machine coordinate system (MCS) and
workpiece coordinate system (WCS).

Rotation around In MDI mode, program the blocks

the Z axis G1 X1000 F1000
ROT Z45 ;Rotation of Z axis through 450
G1 X0
and start the program. Observe which axes are traversed in the individual blocks.
Then change to JOG mode.

MCS/WCS As standard, the key on the MCP is used for switching between
MCS and WCS.

Traverse the X axis in the plus or minus direction in the different coordinate
systems. Which axes are traversed?

Deselect rotation In MDI mode, program the command

ROT ;Rotation OFF
and start the program (there is no traversing movement).

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Exercise 4: Parameter operating area

Area switchover and softkey "Parameter"

Entering a tool offset

• "Tool list" softkey, select an empty magazine slot
• "New tool" softkey

e.g. Tool name: “M_10”; Tool type: 120 (End mill),

• Enter the cutting edge data for cutting edge D1

• e.g. length 1: 100, radius: 10, and "OK" softkey

• You can enter additional tool offsets by pressing the "New tool" softkey or the
“Edges” -> "New cutting edge" softkeys.

Entering R-parameters
• „User variables“ softkey, "R variables" softkey
• Use the cursor, scroll keys or "Search" softkey to select the R-parameters
• Input: R10=50, R20=120, R30=1.234, ...

Entering setting data

• "Setting data" softkey
• Using the "Spindle data" softkey, change the maximum spindle speed to
1000 rpm
• Traverse the spindle in JOG mode
• What do you observe?

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Exercise 5: Program operating area

Editing a part program

Area switchover and "Program" softkey

Select "Part programs" dirrectory
"New" softkey -> „programGUIDE G Code“ softkey
Name: EXERCISE1, file type: MPF, "OK" softkey
Edit the program

N5 G0 G54 X100 Y100 T=“M_10” D1 S500 M3

N10 G41 G1 X50 Y50 F1000
N15 X=R10 Y=R20
N20 X=R30
N25 G0 G40 X100 Y100
N30 M5
N35 M2
Press the “>>” “Exit" softkey to terminate input
Press the “Execute" softkey (press softkey "<<" first if necessary)

Switch to the Machine area M

Automatic mode

Program start
Observe the actual value display! Check whether the values specified in the
R-parameters are approached in block N15, N20!
Press the "Work offset" softkey in the "Parameter" operating area and enter values
10 for the X axis and 20 for the Y axis. The work offset is activated in the program
using the command G54. Press the "Act. val. Machine" softkey to change over the
actual value display for the axes and start the program again.
What happens to the actual value display?
Change the display of the top right-hand window by pressing the softkeys
"G Functions", "Auxiliary functions"! Start the program again and observe the
display.

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Exercise 6: Program operating area

Enter two part programs which will later serve as test programs.

TEST_SPINDLE ;Program name

N1 ANF: ;Target marker for jump function

N2 S1000 M3 ;Spindle clockwise with 1000 rpm

N3 G4 F5 ;Dwell time 5 sec.

N4 S2000 M4 ;Spindle counterclockwise with 2000 rpm

N5 G4 F3 ;Dwell time 3 sec.

N6 SPOS=0 ;For axis operation and positioning to 0 degrees

N7 M1 ;Optional STOP, new NC Start required

N8 G1 C180 F1000 ;Traverse C axis at 1000 mm/min to 180 degrees

N9 M1 ;New NC Start required (program control)

N10 C270 F500 ;Traverse C axis at 500 mm/min to 270 degrees

N11 G4 F4 ;Dwell time 4 sec.

N12 S500 M3 ;Switch to spindle operation

N13 G4 F2 ;Dwell time 2 sec.

N14 GOTOB ANF ;Jump in direction of program start

N15 M2 ;End of program

TEST_X_AXIS ;Program name

N1 ANF: ;Target marker for jump function

N2 G0 X1000 ;Travel with rapid traverse to position 1000 mm

N3 G4 F4 ;Dwell time 4 sec.

N4 G1 X0 F300 ;Traverse at 300 mm/min to position 0

N5 GOTOB ANF ;Jump in direction of program start

N6 M2 ;End of program

Copy the program TEST_X_AXIS and insert it as TEST_Y_AXIS. Now change the
axis name X in the program to Y.

Select the three programs in succession.

Test the three programs in AUTOMATIC mode.

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