802d BPF 0805 en

Introduction 1
Turning On,
Reference−Point Approach 2
Setting Up 3
SINUMERIK 802D
Manually Controlled Mode 4
Operation and Programming
Milling Automatic Mode 5
Part Programming 6
System 7
Programming 8
Cycles 9
Valid for
Control system Software version

SINUMERIK 802D 2
08/05 Edition
Safety information
This Manual contains information which you should carefully observe to ensure your own personal safety
and the prevention of material damage. The notices are highlighted by a warning triangle and, depending on
the degree of hazard, represented as shown below:
Danger
! indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
! indicates that death or severe personal injury can result if proper precautions are not taken.
Caution
! with a warning triangle indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a warning triangle means that material damage can occur if the appropriate precautions are not
taken.
Attention
indicates that an undesired event or status can occur if the appropriate note is not observed.
If several hazards of different degrees occur, the hazard with the highest degree must always be given prefe-
rence. If a warning note with a warning triangle warns of personal injury, the same warning note can also
contain a warning of material damage.
Qualified personnel
Start−up and operation of the device/equipment/system in question must only be performed using this docu-
mentation. The start−up and operation of a device/system must only be performed by qualified personnel.
Qualified personnel as referred to in the safety guidelines in this documentation are those who are authori-
zed to start up, earth and label units, systems and circuits in accordance with the relevant safety standards.
Proper use
Please note the following:
Warning
! The device may only be used for the applications described in the Catalog and only in combination with the
equipment, components and devices of other manufacturers as far as this is recommended or permitted by
Siemens. It is assumed that this product be transported, stored and installed as intended and maintained
and operated with care to ensure that the product functions correctly and properly.
Trademarks
All designations marked with the copyright notice ® are registered trademarks of Siemens AG. Other names
in this publication might be trademarks whose use by a third party for its own purposes may violate the rights
of the registered holder.
Disclaimer of liability
Although we have checked the contents of this publication for agreement with the hardware and software
described, since differences cannot be totally ruled out. Nonetheless, differences might exist and therefore
we cannot guarantee that they are completely identical. The information given in this publication is reviewed
at regular intervals and any corrections that might be necessary are made in the subsequent editions.
Siemens AG Copyright (E) Siemens AG 2005.

Automation and Drives 6FC5698−2AA10−1BP5
Postfach 4848
90437 NÜRNBERG Siemens AG 2005
GERMANY Subject to change without prior notice.
Preface
SINUMERIK Documentation
The SINUMERIK Documentation is organized in 3 levels:
S General Documentation:
S User Documentation
S Manufacturer/Service Documentation:
For detailed information regarding further publications about SINUMERIK 802D, as well as
for publications that apply for all SINUMERIK control systems (e.g. Universal Interface, Mea-
suring Cycles...), please contact your Siemens branch office.
A monthly overview of publications with specification of the available languages can be found
on the Internet at:
http://www.siemens.com/motioncontrol
Follow the menu items ”Support”/”Technical Documentation”/”Overview of Publications”.
The Internet edition of DOConCD − DOConWEB − can be found at:
http://www.automation.siemens.com/doconweb
Addressees of the documentation

The present documentation is aimed at the machine tool manufacturer. This publication pro-
vides detailed information required for the machine tool manufacturer to start up the SINU-
MERIK 802D control system.
Standard scope
The present Instruction Manual describes the functionality of the standard scope. Any
amendments made by the machine manufacturer are documented by the machine manufac-
turer.
Other functions not described in this documentation can possibly also be performed on the
control system. However, the customer is not entitled to demand these functions when the
new equipment is supplied or servicing is carried out.
Hotline
If you have any questions, do not hesitate to call our hotline:
A&D Technical Support
Tel.: +49 (0) 180 / 5050 − 222
Fax: +49 (0) 180 / 5050 − 223
Internet: http://www.siemens.de/automation/support−request
If you have any questions (suggestions, corrections) regarding the Documentation, please
send a fax to the following number or an e−mail to the following address:
Fax: +49 (0) 9131 / 98 − 63315
E−mail: [email protected]
Fax form: see return fax form at the end of this publication
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition iii
6FC5 698−2AA10−1BP5
Preface
Internet address
http://www.siemens.com/motioncontrol
iv SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition

6FC5 698−2AA10−1BP5
Contents
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.1 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2 Operating areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3 Accessibility options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.3.1 Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.3.2 Editing Chinese characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.3.3 Hotkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.4 The help system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.5 Coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
2 Turning On and Reference Point Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
3 Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.1 Entering tools and tool offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.1.1 Use this softkey to create a new tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.1.2 Determining the tool offsets (manually) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.1.3 Determining tool compensations using a probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.1.4 Probe settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.2 Tool monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.3 Entering/modifying a work offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.3.1 Determining the work offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.4 Programming setting data - ”Parameter” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.5 R parameters − ”Offset/Parameter”operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
4 Manually Controlled Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.1 JOG mode - ”Position” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4.1.1 Assigning handwheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4.2 MDA mode (Manual input) - ”Machine” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4.2.1 Face milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
5 Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.1 Selecting / starting a part program - ”Machine” operating
area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.2 Block search - ”Machine” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.3 Stopping / canceling a part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.4 Reapproach after cancellation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.5 Repositioning after interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.6 Program execution from external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
6 Part Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
6.1 Entering a new program - ”Program” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
6.2 Editing part programs - ”Program” operating area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6.3 Blueprint programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
6.4 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
6.5 Data transfer via the RS232 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
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Contents
7 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
7.1 PLC diagnosis represented as a ladder diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
7.1.1 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
7.1.2 Operating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
7.2 Alarm display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
8 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-129
8.1 Fundamentals of NC programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-129
8.1.1 Program names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-129
8.1.2 Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-129
8.1.3 Word structure and address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-130
8.1.4 Block structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-131
8.1.5 Character set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132
8.1.6 Overview of the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-134
8.2 Positional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148
8.2.1 Plane selection: G17 to G19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148
8.2.2 Absolute / incremental dimensioning: G90, G91, AC, IC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-149
8.2.3 Dimensions in metric units and inches: G71, G70, G710, G700 . . . . . . . . . . . . . . . . . . . . . . 8-150
8.2.4 Polar coordinates, pole definition: G110, G111, G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-151
8.2.5 Programmable work offset: TRANS, ATRANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-153
8.2.6 Programmable rotation: ROT, AROT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-153
8.2.7 Programmable scaling factor: SCALE, ASCALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-155
8.2.8 Programmable mirroring: MIRROR, AMIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-156
8.2.9 Workpiece clamping − settable work offset:
G54 to G59, G500, G53, G153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-157
8.2.10 Programmable working area limitation:
G25, G26, WALIMON, WALIMOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-159
8.3 Axis movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-161
8.3.1 Linear interpolation with rapid traverse: G0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-161
8.3.2 Linear interpolation with feedrate: G1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-162
8.3.3 Circular interpolation: G2, G3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-163
8.3.4 Circular interpolation via intermediate point: CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-168
8.3.5 Circle with tangential transition: CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-168
8.3.6 Helix interpolation: G2/G3, TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-169
8.3.7 Thread cutting with constant lead: G33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-170
8.3.8 Tapping with compensating chuck: G63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-171
8.3.9 Thread Interpolation: G331, G332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-172
8.3.10 Fixed point approach: G75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-174
8.3.11 Reference point approach: G74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-174
8.3.12 Measuring with touch−trigger probe: MEAS, MEAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-174
8.3.13 Feedrate F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-175
8.3.14 Feedrate override for circles: CFTCP, CFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-176
8.3.15 Exact stop / continuous−path control mode: G9, G60, G64 . . . . . . . . . . . . . . . . . . . . . . . . . . 8-177
8.3.16 Acceleration pattern: BRISK, SOFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-180
8.3.17 Percentage acceleration override: ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-181
8.3.18 Traversing with feedforward control: FFWON, FFWOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-182
8.3.19 4th axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-183
8.3.20 Dwell Time: G4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-183
8.3.21 Travel to fixed stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-184
8.4 Spindle movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-188
8.4.1 Spindle speed S, directions of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-188
8.4.2 Spindle speed limitation: G25, G26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-188
8.4.3 Spindle positioning: SPOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-189
8.4.4 Gear stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-190
8.5 Contour programming support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-191
8.5.1 Rounding, chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-191
8.5.2 Blueprint programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-192
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8.6 Tool and tool offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-195

8.6.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-195
8.6.2 Tool T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-196
8.6.3 Tool offset number D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-196
8.6.4 Selecting the tool radius compensation: G41, G42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-200
8.6.5 Corner behavior: G450, G451 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-202
8.6.6 Tool radius compensation OFF: G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-203
8.6.7 Special cases of the tool radius compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-204
8.6.8 Example of tool radius compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-206
8.7 Miscellaneous function (M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-207
8.8 H function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-208
8.9 Arithmetic parameters R, LUD and PLC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-209
8.9.1 Arithmetic parameters R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-209
8.9.2 Local User Data (LUD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-210
8.9.3 Reading and writing PLC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-212
8.10 Program jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-213
8.10.1 Jump destination for program jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-213
8.10.2 Unconditional program jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-213
8.10.3 Conditional program jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-214
8.10.4 Program example for jumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-216
8.11 Subroutine technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-218
8.11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-218
8.11.2 Calling machining cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-221
8.11.3 Modal subroutine call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-221
8.12 Timers and workpiece counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-222
8.12.1 Runtime timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-222
8.12.2 Workpiece counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-223
8.13 Language commands for tool monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-225
8.13.1 Tool monitoring overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-225
8.13.2 Tool life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-226
8.13.3 Workpiece count monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-227
8.14 Smooth approach and retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-230
8.15 Milling of the peripheral surface − TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-235
8.16 G functions equivalent to the SINUMERIK 802S/C − Milling . . . . . . . . . . . . . . . . . . . . . . . . . 8-240
9 Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-241
9.1 Overview of cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-241
9.2 Programming cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-242
9.3 Graphical cycle support in the program editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-244
9.4 Drilling cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-246
9.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-246
9.4.2 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-247
9.4.3 Drilling, centering – CYCLE81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-248
9.4.4 Drilling, counterboring – CYCLE82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-251
9.4.5 Deep hole drilling – CYCLE83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-254
9.4.6 Rigid tapping – CYCLE84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-258
9.4.7 Tapping with compensating chuck – CYCLE840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-261
9.4.8 Reaming 1 (boring 1) – CYCLE85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-266
9.4.9 Boring (boring 2) – CYCLE86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-270
9.4.10 Boring with Stop 1 (boring 3) – CYCLE87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-273
9.4.11 Drilling with stop 2 (boring 4) – CYCLE88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-275
9.4.12 Reaming 2 (boring 5) – CYCLE89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-278
9.5 Drilling pattern cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-281
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Contents
9.5.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-281

9.5.2 Row of holes – HOLES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-282
9.5.3 Circle of holes – HOLES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-286
9.6 Milling cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-289
9.6.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-289
9.6.2 Face milling − CYCLE71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-290
9.6.3 Contour milling − CYCLE72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-296
9.6.4 Rectangular spigot milling − CYCLE76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-305
9.6.5 Circular spigot milling − CYCLE77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-310
9.6.6 Slots on a circle − LONGHOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-314
9.6.7 Slots on a circle − SLOT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-319
9.6.8 Circumferential slot − SLOT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-326
9.6.9 Milling a rectangular pocket − POCKET3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-332
9.6.10 Milling a circular pocket − POCKET4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-341
9.6.11 Thread milling − CYCLE90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-345
9.7 Error messages and error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-352
9.7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-352
9.7.2 Error handling in the cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-352
9.7.3 Overview of cycle alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-352
9.7.4 Messages in the cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-354
viii SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
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SINUMERIK 802D Key Definition
”Recall” key ”Position” operating area key
ETC key ”Program” operating area key
”Acknowledge alarm” key ”Parameter” operating area
without function ”Program Manager” operating area
Info key ”Alarm” / ”System” operating areas

(Shift+key)
Shift key
Controlkey
not assigned
Altkey
PageUp / PageDown keys
SPACE
Backspace
Cursor keys
Clear key
Selection key / toggle key
INSERT key
Tabulator
Alphanumeric keys
Double assignment on the Shift level
ENTER / Input key
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition ix

6FC5 698−2AA10−1BP5
Numeric keys
Double assignment on the Shift level
External Machine Control Panel
%
Spindle override (option)
User−defined key with LED
User−defined key without LED
INCREMENT
80 90
JOG
70
100
60
110 REFERENCE POINT
120
AUTOMATIC
SINGLE BLOCK
60 70
40 80
20
10 90
6 100 MANUAL DATA
2 110
0 120 SPINDLE START LEFT
SPINDLE STOP
SPINDLE START RIGHT
RESET
RAPID TRAVERSE OVERRIDE
NC STOP
X axis
NC START
Z axis
EMERGENCY STOP %
Feedrate override
x SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition

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Introduction 1
1.1 Screen layout
Status area G
function
Applicationarea
Tip
and softkey area
Fig. 1-1 Screen layout
The screen is divided into the following main areas:

S Status area
S Applicationarea
S Tip and softkey area
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition 1-11
6FC5 698−2AA10−1BP5
Introduction
1.1 Screen layout
Status area
Fig. 1-2 Status area
Table 1-1 Explanation of the display elements in the status area
Screen Con- Display Meaning

trol
Active operating area, active mode
Position
JOG; 1 INC, 10 INC, 100 INC, 1000 INC, VAR INC (evaluation by increments in
the JOG mode)
MDA
AUTOMATIC
1
Offset
Program
Program Manager
System
Alarm
Marked as an ”external language” using G291
Alarm and message line
I addition,
In dditi the
th ffollowing
ll i is i displayed:
di l d
2
1. Alarm number with alarm text, or
2. Message text
Program status
RESET Program canceled / default status
3 RUN Program running
STOP Program stopped
4 Program controls in the AUTOMATIC mode
Path N: − NC internal ”drive”

5
D: − CF card
6 NC messages
7 Selected part program (main program)
1-12 SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
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Introduction
1.1 Screen layout
Tip and softkey area
Fig. 1-3 Tip and softkey area
Table 1-2 Explanation of the screen elements in the tip and softkey area

trol
Recall symbol
1
Pressing the Recall key lets you return to the next higher menu level.
Tip line
2
Displays tips for the operator
MMC status information
ETC is possible (Pressing this key displays the horizontal softkey bar
providing further functions.)
Mixed notation active (uppercase/lowercase letters)

3
Data transfer running
Connection to the PLC programming tool active
4 Softkey bar vertical and horizontal
Standard softkeys
Use this softkey to quit the screenform.
Use this softkey to cancel the input; the window is closed.
Selecting this softkey will complete your input and start the calculation.
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Introduction
1.2 Operating areas
Selecting this softkey will complete your input and accept the values you have entered.
1.2 Operating areas

The functions of the control system can be carried out in the following operating areas:
Position Machine operation
Offset/Parameters Input of offset values and setting data
Program Creation of part programs
Program Manager Part program directory
System Diagnosis, start−up
Alarm Alarm and message lists
To switch the operating area, use the relevant key (hard key).
Protection levels
The input and modification of vital data in the control system is protected by passwords.
In the menus listed below the input and modification of data depends on the protection level
set:
S Tool offsets
S Work offsets
S Setting data
S RS232 settings
S Program creation / program correction
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Introduction
1.3 Accessibility options
1.3.1 Calculator
The calculator function can be activated from any operating area using ”SHIFT” and ”=”.
To calculate terms, the four basic arithmetic operations can be used, as well as the functions
”sine”, ”cosine”, ”squaring” and ”square root”. A bracket function is provided to calculate
nested terms. The bracket depth is unlimited.
If the input field is already occupied by a value, the function will accept this value into the input
line of the calculator.
When you press the Input key, the result is calculated and displayed in the calculator.
Selecting the Accept softkey enters the result in the input field at the current cursor position of
the part program editor and closes the calculator automatically.
Note
If an input field is in the editing mode, it is possible to restore the original status using the
”Toggle” key.
Fig. 1-4 Calculator
Characters permitted for input

+, − Basic arithmetic operations
*, /
S Sine function
The X value (in degrees) in front of the input cursor is replaced by the sin(X) value.
O Cosine function
The X value (in degrees) in front of the input cursor is replaced by the cos(X) value.
Q Square function
The X value in front of the input cursor is replaced by the X2 value.
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Introduction
R Square root function

The X value in front of the input cursor is replaced by the √⎮ value.
() Bracket function (X+Y)*Z
Calculation examples
Task Input −> Result

100 + (67*3) 100+67*3 −> 301
sin(45_) 45 S −> 0.707107
cos(45_) 45 O −> 0.707107
42 4 Q −> 16
√4 4 R −> 2
(34+3*2)*10 (34+3*2)*10 −> 400
To calculate auxiliary points on a contour, the calculator offers the following functions:
S Calculating the tangential transition between a circle sector and a straight line
S Moving a point in the plane
S Converting polar coordinates to Cartesian coordinates
S Adding the second end point of a straight line/straight line contour section given from an
angular relation
Softkeys
This function is used to calculate a point on a circle. The point results from the angle of the tangent
created, as well as from the radius and the direction of rotation of the circle.
Fig. 1-5
Enter the circle center, the angle of the tangent and the circle radius.
Use the G2 / G3 softkey to define the direction of rotation of the circle.
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Introduction
Use this softkey to calculate the abscissa and ordinate values. The abscissa is the first axis of the
plane, and the ordinate is the second axis of the plane. The abscissa value is copied into the input
field from which the calculator function has been called, and the value of the ordinate is copied into
the next following input field. If the function has been called from the part program editor, the coordi-
nates are saved with the axis names of the selected basic plane.
Example: If the G18 plane is active, the abscissa is the Z axis and the ordinate the X axis.
Example: Calculate the intersection point between the circle sector and the straight line
.
Given: Radius: 10
Circle center: Z 20 X 20
Connection angle of the straight line: 45°
Direction of rotation: G2
Result: X = 12.928
Y = 27.071
This function calculates the Cartesian coordinates of a point in the plane, which is to be connected
to a point in the plane (PP) on a straight line. For calculation, the distance between the points and
the slope angle (A2) of the new straight line to be created with reference to the slope (A1) of the
given straight line must be known.
Fig. 1-6
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Introduction
Enter the following coordinates or angles:

S the coordinates of the given point (PP)
S the slope angle of the straight line (A1)
S the distance of the new point with reference to PP(offset)
S the slope angle of the connecting straight line (A2) with reference to A1
Use this softkey to calculate the Cartesian coordinates which are subsequently copied into two input
fields following one after another. The abscissa value is copied into the input field from which the
calculator function has been called, and the value of the ordinate is copied into the next following
input field.
If the function has been called from the part program editor, the coordinates are saved with the axis
names of the selected basic plane.
Example
Calculating the end point of the straight line . The straight line stands vertically on the end
point of the straight line (Coordinates: X = 51.981, Y = 43.081) (see example: ”Converting
polar coordinates into Cartesian coordinates”). The length of the straight lines is also given.
Result: X = 68.668
Y = 26.393
This function converts the given polar coordinates into Cartesian coordinates.
Fig. 1-7
Enter the reference point, the vector length and the slope angle.
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Introduction
Use this softkey to calculate the Cartesian coordinates which are subsequently copied into two input
fields following one after another. The abscissa value is copied into the input field from which the
input field.
If the function has been called from the part program editor, the coordinates are saved with the axis
names of the selected basic plane.
Example
Calculating the end point of the straight line . The straight line is determined by the angle
A=45° and its length.
Result: X = 51.981
Y = 43.081
Use this function to calculate the missing end point of the straight line/straight line contour section
whereby the second straight line stands vertically on the first straight line.
The following values of the straight line are known:
Straight line 1:
Starting point and slope angle
Straight line 2:
Length and one end point in the Cartesian coordinate system
Fig. 1-8
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Introduction
This function is used to select the given coordinate of the end point.
The ordinate value or the abscissa value is given.
The second straight line is rotated in the CW direction or in the CCW direction by 90 degrees rela-
tive to the first straight line.
This function will select the relevant end position.
The missing end point is calculated. The abscissa value is copied into the input field from which the
input field.
If the function has been called from the part program editor, the coordinates are saved with
the axis names of the selected basic plane.
Example
Add the present drawing by the values of the center circle to be able to calculate the points of
intersection between the circle sectors. The missing coordinates of the center points are cal-
culated using the calculator function, since the radius in the tangential transition
stands vertically on the straight line.
Calculating M1 in section 1:
In this section, the radius stands in the counterclockwise direction turned on the straight
line section.
Use the softkeys and to select the given configuration.

Enter the coordinates of the pole (PP) P1, the slope angle of the straight line, the given
ordinate value and the circle radius as the length.
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Introduction
Result: X = −19.449
Y = 30
Calculating M2 in section 2:
In this section, the radius stands in the clockwise direction turned on the straight line sec-
tion. Use the softkeys to select the given configuration.

Enter the parameters in the screenform.
Result: X = 21.399
Y = 30
1.3.2 Editing Chinese characters
This function is only available in the Chinese language version.

The control system provides a function for editing Chinese characters in the program editor
and in the PLC alarm text editor. After activation, type the phonetic alphabet of the searched
character in the input field. The editor will then offer various characters for this sound, from
which you can choose the desired one by entering either of the digits 0 to 9.
Fig. 1-9 Chinese editor
Alt S Is used to turn on / turn off the editor
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Introduction
1.3.3 Hotkeys
This operator control can be used to select, copy, cut and delete texts using special key com-
mands. These functions are available both for the part program editor and for input fields.
CTRL C Copy
CTRL B Select
CTRL X Cut
CTRL V Paste
Alt L Switches between uppercase and lowercase letters

Alt H Help system
or Info key
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Introduction
1.4 The help system
1.4 The help system

To activate the help system, use the Info key. It offers a brief description for all important oper-
ating functions.
In addition, the help offers the following topics:
S Overview of the NC commands with a brief description
S Cycle programming
S Explanation of the drive alarms
Fig. 1-10 Table of contents of the help system
Show This function opens the selected topic.
Fig. 1-11 Description for a help topic
Go to Use this function to select cross references. A cross reference is marked by the characters
topic ”>>....<<”. This softkey is only unhidden if a cross reference is displayed in the application area.
Back to If you select a cross reference, in addition, the Back to topic softkey is displayed.
topic This function lets you return to the previous screenform.
6FC5 698−2AA10−1BP5
Introduction
1.4 The help system
Find Use this function to search for a term in the table of contents. Type the term you are looking for and
start the search process.
Help in the ”Program editor” area

The system offers an explanation for each NC instruction. To display the help text directly,
position the cursor after the appropriate instruction and press the Info key. This possibility will
only function if the NC instruction is written using uppercase letters.
6FC5 698−2AA10−1BP5
Introduction
1.5 Coordinate systems

For machine tools, right−handed, right−angled coordinate systems are used.
The movements on the machine are described as a relative movement between tool and
workpiece.
+Z
+Y
+Y
90° 90°
90°
+X
+X
+Z
Fig. 1-12 Definition of the directions of the axes one to another; right−angled
coordinate system
Machine coordinate system (MCS)

How the coordinate system is located with reference to the machine, depends on the machine
type concerned. It can be rotated in different positions.
+Z
+Y
+X
Fig. 1-13 Machine coordinates/machine axes using the example of a milling

machine
The origin of the coordinate system is the machine zero.

All axes have zero position. This point only represents a reference point defined by the ma-
chine manufacturer. It need not be approachable.
The traversing range of the machine axes can by in the negative range.
6FC5 698−2AA10−1BP5
Introduction
Workpiece coordinate system (WCS)

The coordinate system described above (see Fig. 1-12) is also used to describe the geometry
of a workpiece in the workpiece program.
The workpiece zero can be freely selected by the programmer. The programmer need not to
know the real motion relations on the machine, i.e. he need not to know whether the work-
piece or the tool moves. Furthermore, it can be different from axis to axis. The directions are
always defined such if the workpiece would be resting and the tool would move.
ÉÉÉ
Y
W X
W - workpiece zero
Fig. 1-14 Workpiece coordinate system
Relative coordinate system

In addition to the machine and workpiece coordinate systems, the control system provides a
relative coordinate system. This coordinate system is used for setting freely selected refer-
ence points which have no influence on the active workpiece coordinate system. All axis
movements are displayed relative to these reference points.
Clamping the workpiece

For machining, the workpiece is clamped on the machine. The workpiece must be aligned
such that the axes of the workpiece coordinate system run in parallel with those of the ma-
chine. Any resulting offset of the machine zero with reference to the workpiece zero is deter-
mined for each axis individually and entered in the relevant data areas intended for the set-
table work offset. In the NC program, this offset is activated, e.g. using a programmed G54
(see also Section ”Workpiece clamping − settable work offset, ...”).
ZMachine W - workpiece zero

M − machine zero
ZWorkpiece
Y
ÉÉ
e.g.
W X
G54 YMachine
M XMachine
Fig. 1-15 Workpiece on the machine
6FC5 698−2AA10−1BP5
Introduction
Current workpiece coordinate system

The programmed work offset TRANS can be used to generate an offset with reference to the
workpiece coordinate system resulting in the current workpiece coordinate system (see Sec-
tion ”Programmable work offset: TRANS”).
Programmable offset
TRANS
Z current
Z Y
Y
ÉÉÉ X
W X
W - workpiece zero
Fig. 1-16 Coordinates on the workpiece; current workpiece coordinate sy-

stem
6FC5 698−2AA10−1BP5
Introduction
This sheet has been left empty for your notes
6FC5 698−2AA10−1BP5
Turning On and Reference Point Approach 2
Note
When you turn on the SINUMERIK 802D and the machine, please also observe the Machine Docu-
mentation, since turning on and reference point approach are machine−dependent functions.
This documentation assumes an 802D standard machine control panel (MCP). Should you use a
different MCP, the operation may be other than described herein.
Operating sequence
First, turn on the power supply of CNC and machine. After the control system has booted, you
are in the ”Position” operating area, in the Jog mode.
The ”Reference point approach” window is active.
Fig. 2-1 The ”Jog−Ref” start screen
Use the Ref key on the machine control panel to activate ”reference point approach”.
The ”Reference point approach” window (Fig. 2-1) displays whether or not the axes have a
reference point.
Axis must be referenced
Axis has reached its reference point
+X Press a direction key.

...
-Z
6FC5 698−2AA10−1BP5
Turning On and Reference Point Approach
If you select the wrong approach direction, no motion will be carried out.
Approach the reference points for each axis one after the other.
Quit the function by switching the mode (MDA, AUTOMATIC or Jog).
Note
”Reference point approach” is only possible in the Jog mode.
6FC5 698−2AA10−1BP5
Setting Up 3
Preliminary remarks
Before you can work with the CNC, set up the machine, the tools, etc. on the CNC as follows:
S Enter the tools and the tool offsets
S Enter/modify the work offset
S Enter the setting data
3.1 Entering tools and tool offsets
Functionality
The tool offsets consist of several data describing the geometry, the wear and the tool type.
Depending on the tool type, each tool is assigned a defined number of parameters. Tools are
identified by a number (T number).
See also Section 8.6 ”Tool and tool compensation”
Operating sequences
Use this softkey to open the ”Tool offset data” window which contains a list of the tools created. Use
the cursor keys and the PageUp / PageDown keys to navigate in this list.
Tool
List
Fig. 3-1
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Setting Up
Enter the offsets by positioning the

S cursor bar on the input field to be changed,
S enter the value(s)
and either press Input or use a cursor key to confirm.
Extend
For special tools, the softkey function is provided which offers a complete parameter
list which can be filled out.
Softkeys
Tool Use this softkey to determine the tool offset data (only effective in the JOG mode!)
Measur.
Measure Use this softkey to determine the tool compensation data manually.
manually
Measure Use this softkey to determine the tool offset data semi−automatically (only applies in conjunction
auto
with a sensing probe).
Calibrate Use this softkey to calibrate the sensing probe.

probe
Delete Selecting this softkey will delete the tool offset data of all edges of the tool.
tool
Extend Use this function to display all parameters of a tool.
Fig. 3-2 Input screen for special tools
For the meanings of the parameters, please refer to the Section ”Programming”.
Edges Opens a lower−level menu bar offering all functions required to create and display further edges.
D >> Use this softkey to select the next higher edge number.
<< D Use this softkey to select the next lower edge number.
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Setting Up
New Use this softkey to create a new edge.

tool edge
Reset Use this softkey to reset all compensation values of the edge to zero.
edge
Change This function is intended to change the tool type. select the tool type using the appropriate softkey.
type
Find tool number

Find
Type the number of the tool you are looking for and select the OK softkey to start searching. If the
tool you are looking for exists, the cursor is positioned on the appropriate line.
New Use this softkey to create tool offset data for a new tool.
tool
3.1.1 Use this softkey to create a new tool.
Operating sequence
New This function offers another two softkey functions to select the tool type. After selecting the tool type,
tool type the desired tool number in the input field.
Fig. 3-3 The ”New tool” window Input of the tool number
Select OK to confirm your input. A data record loaded with zero will be included in the tool list.
OK
3.1.2 Determining the tool offsets (manually)
Functionality
This function can be used to determine the unknown geometry of a tool T.
6FC5 698−2AA10−1BP5
Setting Up
Prerequisite
The relevant tool is loaded. In the JOG mode, you will approach the edge of the tool to a ma-
chine point whose machine coordinate values are known. This can be a workpiece with a
known position.
Procedure
Enter the reference point in the appropriate field X0, Y0 or Z0.
Please observe: For milling tools, length 1 and the radius must be determined, and for drilling
tools only length 1.
By using the actual position of point F (machine coordinate) and the reference point, the con-
trol system can calculate the offset value assigned to length 1 or the radius for the selected
axis.
Note: You can also use a zero already determined (e.g value of G54). In this case, use the
edge of the tool to approach the workpiece zero point. If the edge is positioned directly at
workpiece zero, the reference point is zero.
F − toolholder reference point

M − machine zero F
Zactual position
W - workpiece zero
Length 1=?
Z Machine
Intermediate position
Known machine
coordinate value Z
Workpiece W Offset
M Gxx, e.g. G54
XMachine
Fig. 3-4 Determination of the length offset using the example of a drill: Length 1 / Z axis
Operating sequence
Tool Select this softkey. The Measure tool window is opened. You will automatically get to the ”Position”
Measur. operating area.
6FC5 698−2AA10−1BP5
Setting Up
Fig. 3-5 Selecting manual or semiautomatic measuring
Measure The Measure tool window is opened.

manually
Fig. 3-6 ”Offset values” window; measuring the length and the tool diameter
S Enter the reference point in the field X0, Y0 or Z0. This can be either the current machine
coordinate (absolute) or a value from the work offsets (base, G54 − G59). If any other val-
ues are used, the offset value will refer to the specified position.
S After selecting the Set length or Set diameter softkey, the control system will calculate
the searched geometry length 1 or the diameter according to the preselected axis. The
offset value determined will be stored.
S If a spacer is inserted between the tool and the workpiece, its thickness can be entered in
the ”Clearance” field.
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Setting Up
3.1.3 Determining tool compensations using a probe
Operating sequence
Tool Measure
Measur. auto
Use this softkey to open the Measure tool window.

After the screenform has appeared, the input fields are loaded with the tool currently working,
and the plane in which the measurements are to be performed are displayed.
This setting can be changed in the Probe data settings screenform (Section 3.1.4).
Note
To create the measuring program, the ”Safety clearance” parameters from the ”Settings” screenform
and the feedrate from the ”Probe data” screenform are used.
If several axes are moved simultaneously, no probe position data can be calculated.
Measuring the tool length
Fig. 3-7 The ”Offset values” window; measuring the tool length
Use the feed axis to traverse to the probe.
After the ”Probe triggered” has appeared, release the traversing key and wait until the
measuring process is completed. A dial gauge symbolizing the active measuring process
is displayed on the animated screen during the automatic measurement.
6FC5 698−2AA10−1BP5
Setting Up
Measuring the tool diameter

The diameter can only be determined with the spindle rotating. To this end, enter the speed
and the direction of rotation of the spindle in the Sensing probe data screen.
Fig. 3-8 The ”Offset values” window; measuring the diameter
Use any axis from the plane to traverse to the probe. Depending on the axis selected, traverse
either to point P1 or P3, or P2 or P4.
After the ”Probe triggered” has appeared, release the traversing key and wait until the
measuring process is completed. A dial gauge symbolizing the active measuring process
is displayed on the animated screen during the automatic measurement.
Warning
! The spindle will rotate at the speed defined in the probe data!
3.1.4 Probe settings
Data
Settings
probe
The screenform below is used to store the coordinates of the probe and to set the following
parameters for the automatic measuring process:
S Plane of the probe
S Axis feedrate
S Speed and direction of rotation of the spindle
The direction of rotation of the spindle must be opposite to the cutting direction of the cut-
ter.
6FC5 698−2AA10−1BP5
Setting Up
All position values refer to the machine coordinate system.
Fig. 3-9 The ”Probe data” interactive screenform
Table 3-1 Meaning of the input fields
Parameter Meaning
abs. position P5 Absolute position of the probe in the Z− direction
Center point: X Calculated center point of the probe (machine coordinates)
Center point: Y
Diameter Diameter of the probe disk (after calibration, the calculated diam-
eter is displayed)
Thickness Thickness of the probe disk
Calibrating the probe
Calibrate The calibration of the probe can be carried out either in the Settings menu or in the Tool measure
probe
menu.
Fig. 3-10 Calibrating the probe (length) (diameter)
6FC5 698−2AA10−1BP5
Setting Up
After the screenform has appeared, an animation signaling the step to be executed is dis-
played next to the current positions of the probe. This point must be approached with the ap-
propriate axis. If the probe is triggered, the control system will take over the measuring pro-
cess by switching to the AUTOMATIC mode, activating the measuring program and starting it
automatically. The operator will see an axis movement in the opposite direction for a short
time.
During the automatic measurement, a dial appears symbolizing that the NC is active.
The positions delivered by the measuring program serve to calculate the real probe position.
Note
To create the measuring program, the parameters ”Safety clearance” from the ”Settings” screenform
and feedrate from the ”Probe data” screenform are used.
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Setting Up
3.2 Tool monitoring
3.2 Tool monitoring
Tool- Each monitoring type is represented in 4 columns.

life
S Setpoint
S Prewarning limit
S Residual value
S active
Use the checkbox element in the 4th column to enable / disable the monitoring type.
Fig. 3-11 Tool monitoring
Symbols in the T column provide information on the tool status.
Prewarning limit reached
Tool disabled
Tool is monitored
Reset Use this softkey to reset the monitoring values of the selected tool.
monitor
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Setting Up
3.2 Tool monitoring
Fig. 3-12
After Use this softkey to change the enable of the selected tool.
enable
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Setting Up
3.3 Entering/modifying a work offset
Functionality
After the reference point approach, the actual−value memory and thus also the actual−value
display are referred to the machine zero. A machining program, however, is always referred to
the workpiece zero. This offset must be entered as the work offset.
Operating sequences
Use Offset Parameter and Work Offset to select the work offset.
An overview of all settable work offsets will appear on the screen. The screenform additionally
Work contains the values of the programmed work offset, of the active scaling factors, the status
offset
display and the total of all active work offsets.
Fig. 3-13 The ”Work offset” window
Position the cursor bar on the input field to be changed
and enter the value(s). Either move the cursor a press the Input key to accept the values from the
input fields into the work offsets.
Change The compensation values of the cutting edge come into effect immediately.
activated
6FC5 698−2AA10−1BP5
Setting Up
3.3.1 Determining the work offset
Prerequisite
You have select the window with the relevant work offset (e.g. G54) and the axis you want to
determine for the offset.
Fig. 3-14 Determining the work offset
Procedure
Measure Select the ”Measure workpiece” softkey. The control system will switch to the ”Position” operating
workpiece area and will open the dialog box for measuring the work offsets. The selected axis will appear as a
softkey with a black background.
Then scratch the workpiece with the tool.
If scratching is not possible or if the desired point cannot be reached with the tool (for exam-
ple, when using a spacer), the clearance between the tool and the workpiece surface must be
entered in the ”Clearance” field.
To determine the offset, the direction of movement of the tool must be taken into account for
the active tool. If no tool is active, the ”Radius” field is hidden.
Fig. 3-15 The Determine work offset in X” screenform

The ”Determine work offset in Y” screenform
6FC5 698−2AA10−1BP5
Setting Up
Fig. 3-16 The Determine work offset in Zscreen
Set work Selecting this softkey will calculate the offset and display the result in the ”Offset” field.
offset
6FC5 698−2AA10−1BP5
Setting Up
3.4 Programming setting data - ”Parameter” operating area
Functionality
The setting data are used to define the settings for the operating states. These can be
changed as necessary.
Operating sequences
Select Setting data using the Offset/Param and the Setting data keys.
The Setting data softkey branches to another menu level where various control options can
Setting be set.
data
Fig. 3-17 The Setting datastart screen
JOG feedrate
Feedrate in the Jog mode
If the feedrate value is zero, the control system will use the value stored in the machine
data.
Spindle
Spindle speed
Minimum / maximum
A limitation of the spindle speed in the ”Max.” (G26) / ”Min.” (G25) fields can only be per-
formed within the limit values defined in the machine data.
Programmed (limitation)
Programmable upper speed limitation (LIMS) at constant cutting rate (G96).
Dry run feed (DRY)
The feedrate which can be entered here will be used instead of the programmed feedrate
in the AUTOMATIC mode if the ”Dry run feed” function is selected.
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Setting Up
Start angle for thread cutting (SF)

For thread cutting, a start position for the spindle is displayed as the start angle. If the
thread cutting operation is repeated, a multiple thread can be cut by modifying the angle.
Position the cursor bar on the input field you want to change and enter the value(s).
Either press the Input key or move the cursor to confirm.
Softkeys
Work area The working area limitation is active with geometry and additional axes. Enter the values for the
limit. work area limitation. Selecting the Set Active softkey will activate / deactivate the values for the axis
highlighted by the cursor.
Fig. 3-18
Time Timers Counters

counter
Fig. 3-19
6FC5 698−2AA10−1BP5
Setting Up
Meaning:
S Parts required: Number of workpieces required ( require number of workpieces )
S Parts total: Number of workpieces produced in total ( actual total )
S Part count: This counter registers the number of all workpieces produced since the starting
time.
S Run time: Total runtime of NC programs in the AUTOMATIC mode(in seconds)
In the AUTOMATIC mode, the runtimes of all programs between NC START and end of
program / RESET are summed up. The timer is zeroed with each power−up of the control
system. Runtime of the selected NC program (in seconds)
S Cycle time: Tool action time (in seconds)
The runtime between NC START and end of program / RESET is measured in the se-
lected NC program. The timer is reset with starting a new NC program.
S Cutting time
The runtime of the path axes is measured in all NC programs between NC START and end
of program / RESET without rapid traverse active and with the tool active. The measure-
ment is interrupted when a dwell time is active.
The timer is automatically reset to zero in the case of a ”Control power−up with default val-
ues”.
Use this function to display all setting data for the control system in the form of a list. The data are
Misc
divided into
S general
S axis−specific and
S channel setting data.
Fig. 3-20
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Setting Up
3.5 R parameters − ”Offset/Parameter”operating area
3.5 R parameters − ”Offset/Parameter”operating area
Functionality
The R parameters start screen displays all R parameters existing in the control system in the
form of a list (see also Section 8.9 ”R parameters”).
These can be changed as necessary.
Fig. 3-21 The ”R parameters” window
Operating sequence
Use the variable and the R variablesoftkeys
R vari−
able
to position the cursor bar on the input field you want to change and enter the values.
Either press the Input key or move the cursor to confirm.
6FC5 698−2AA10−1BP5
Manually Controlled Mode 4
Preliminary remark
The manually controlled mode is possible in the Jog and MDA modes.
Set Measure Tool

base workpiece measure Settings
x=0 Measure Data

manual probe
Work Measure
y=0
offset auto
z=0 X
Add. Y
axes
Set rel Switch

Z mm>inch.
Delete Calibrate
base W0 probe
All Set work

to zero offset
Back << Back << Back << Back <<
Fig. 4-1 Menu tree for the JOG mode, ”Position” operating area
Set
base Face Settings
x=0
y=o
z=0
Add.
axes
Set rel
Delete
base Z0
All
to zero Abort
Back << OK
Fig. 4-2 Menu tree for the MDA mode, ”Machine” operating area
6FC5 698−2AA10−1BP5
Manually Controlled Mode
4.1 JOG mode - ”Position” operating area
Operating sequences
Use the Jog key on the machine control panel to select the Jog mode.
+X -Z
...
To traverse the axes, press the appropriate key of the X, Y or Z axis.

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

%
If you press additionally the Rapid traverse override key, the selected axis will be traversed at
rapid traverse speed until both keys are released.
In the Jog mode, you can traverse the axes by adjustable increments using the same operating
sequence. The set number of increments is visualized in the display area. To deselect the Jog
mode, press Jog once more.
The Jog start screen displays the position, feedrate and spindle values, as well as the current
tool.
Fig. 4-3 The ”Jog” start screen
6FC5 698−2AA10−1BP5
Parameters
Table 4-1 Description of the parameters in the JOG start screen
Parameter Explanation
MCS Displays the address of the axes existing in the machine coordinate system (MCS)
X
Y
Z
+X If you traverse an axis in the positive (+) or negative (-) direction, a plus or minus sign will ap-
.... pear in the relevant field.
−Z If the axis is already in the required position, no sign is displayed.
Position These fields display the current position of the axes in the MCS or WCS.
mm
REPOS offset If the axes are traversed in the ”Program interrupted” condition in the Jog mode, the distance
traversed by each axis is displayed referred to the interruption point.
G function Displays important G functions
Spindle S Displays the actual value and the setpoint of the spindle speed
r.p.m.
Feed F Displays the path feedrate actual value and setpoint
mm/min
Tool Displays the currently active tool with the current edge number
Note
If a second spindle is integrated into the system, the workspindle will be displayed using a smaller
font. The window will always display the data of only one spindle.
The control system displays the spindle data according to the following aspects:
The master spindle is displayed:
− in the idle condition;
− when starting the spindle;
− if both spindles are active.
The workspindle is displayed:
− when starting the workspindle.
The power bar applies to the spindle currently active.
Softkeys
Set This softkey is used to set the base work offset or a temporary reference point in the relative coordi-
base nate system. After opening, this function can be used to set the base work offset.
6FC5 698−2AA10−1BP5
The following subfunctions are provided:

S Direct input of the desired axis position
In the input window, position the input cursor on the desired axis; thereafter, enter the new
position. Then, press Input or move the cursor to confirm your input.
S Setting of all axes to zero
The X=Y=Z=0 softkey function overwrites the current position of the appropriate axis with
zero.
S Setting of individual axes to zero
Use the X=0 Y=0 or Z=0 softkey to overwrite the current position with zero.
Any additional axes must only be set to zero if the X, YX and Z geometry axes required for
milling have been configured.
Use the Set rel softkey to switch the display to the relative coordinate system. Any subse-
quent inputs will change the reference point in this coordinate system.
Note
A changed base work offset acts independently of any other work offsets.
Measure Use this softkey to determine the work offset (cf. Chapter 3)
workpiece
Tool Use this softkey to measure the tool offsets (cf. Chapter 3)
measure
The interactive screenform shown below is intended to set the retraction plane, the safety clearance
Settings
and the direction of rotation of the spindle for automatically generated part programs in the MDA
mode (see Section4.2.1). Furthermore, the values for the JOG feedrate and the variable size of in-
crements can be set.
Fig. 4-4
6FC5 698−2AA10−1BP5
Retract plane: The Face function retracts the tool to the specified position (Z position) after
the function has been executed.
Safety distance: Safety clearance to the workpiece surface
This value defines the minimum distance between the workpiece surface and the workpiece. It
is used by the ”Face” and ”Automatic tool gauging” functions.
JOG feedrate: Feedrate value in the JOG mode
Dir. of rot.: Direction of rotation of the spindle for automatically generated programs in the
JOG and MDA modes.
Switch Use this softkey to switch between the metric and the inch system.
mm > inch
4.1.1 Assigning handwheels
Operating sequence
Hand
wheel
Use this softkey to display the handwheel window in the Jog mode.
After the window has been opened, all axis identifiers are displayed in the ”Axis” column,
which simultaneously appear in the softkey bar. Depending on the number of handwheels
connected, you can switch from handwheel 1 to handwheel 2 or 3.
Select the desired handwheel using the cursor. Thereafter, select the relevant axis softkey for the
required axis for assignment or deselection.
The .
Fig. 4-5 The Handwheel menu screen
Use the MCS softkey to select the axes from the machine or workpiece coordinate system for hand-
MCS
wheel assignment. The current setting is displayed in the window.
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4.2 MDA mode (Manual input) - ”Machine” operating area
Functionality
In the MDA mode, you can create or execute a part program.
Caution
! The Manual mode is subject to the same safety interlocks as the fully automatic mode.
Furthermore, the same prerequisites are required as in the fully automatic mode.
Operating sequences
Use the MDA key on the machine control panel to select the MDA mode.
Fig. 4-6 The ”MDA” start screen
Enter one or several blocks using the keyboard.
Press NC START to start machining. During machining, editing of the blocks is no longer possible.
After machining, the contents is preserved so that the machining can be repeated by pressing
NC START once more.
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Parameters
Table 4-2 Description of the parameters in the MDAworking window
MCS Displays the existing axes in the MCS or WCS
X
Y
Z
... pear in the relevant field.
−Z If the axis is already in the required position, no sign is displayed.
mm
Distance to This field displays the distance to go of the axes in the MCS or WCS.
go
r.p.m.
Feed F Displays the path feedrate actual value and setpoint in mm/min or mm/rev.
Tool Displays the currently active tool with the current edge number (T..., D...).
Editing win- In the ”Reset” program state, an editing window serves to input a part program block.
dow
Note
6FC5 698−2AA10−1BP5
Softkeys
Set Use this softkey to set the base work offset (see Section 4.1).
base
Face milling (see also Section 4.2.1)

Face
see Section 4.1

Settings
G The G function window displays G functions whereby each G function is assigned to a group and
function has a fixed position in the window.
Use the PageDown and PageUp keys to display further G functions. Selecting the softkey repeat-
edly will close the window.
Auxiliary This window displays the auxiliary and M functions currently active. Selecting the softkey repeatedly
function will close the window.
Axis Use this softkey to display the Axis feedrate window.

feedrate Selecting the softkey repeatedly will close the window.
Delete Use this function to delete blocks from the program window.
MDI prog.
Save Enter a name in the input field with which you wish the MDA program to be saved in the program
MDI prog. directory. Alternatively, you can select an existing program from the list.
To switch between the input field and the program list, use the TAB key.
Fig. 4-7
MCS/WCS The actual values for the MDA mode are displayed depending on the selected coordinate system.
REL Use this softkey to switch between the two coordinate systems.
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4.2.1 Face milling
Functionality
Use this function to prepare a blank for the subsequent machining without creating a special
part program.
Operating sequence
Face
In the MDA mode, select the Face softkey to open the interactive screenform.
S Position the axes on the start point.
S Enter the values in the screenform.
After you have filled out the screenform completely, the function will create a part program which can
be started with NC START. The interactive screenform will be closed, and ”Machine” start screen will
appear. Here you can observe the program progress.
Important
The retraction plane and the safety clearance must be defined beforehand in the ”Settings” menu.
Fig. 4-8 Face milling
6FC5 698−2AA10−1BP5
Table 4-3 Description of the parameters in the Face milling working window
Tool Input of the tool to be used
The tool is loaded prior to machining. To this end, the function calls a working cycle performing
all steps required. This cycle (LL6) is provided by the machine manufacturer.
Work offset Work offset (formerly called ”zero offset” − transl.) to be selected in the program
Feed F Input of the path feedrate, in mm/min or mm/rev.
Spindle S Input of the spindle speed
r.p.m.
Direction Use this softkey to select the direction of rotation of the spindle.
Mach. Definition of the surface quality
You can select between roughing and finishing.
X0, Y0, Z0, Use this softkey to enter the geometry of the workpiece.
X1, Y1
Blank dimen-
sions
Z1 Finished dimension in Z
Finished di-
mension
DXY Input field for the amount of the infeed motion (X, Y)
Max. infeed
DZ Input field for the amount of the infeed motion (Z)
Max. infeed
UZ Input field for the stock allowance when roughing
Softkeys for specifying the stock removal strategy (opposite / synchronous run)
Machining parallel to the abscissa, with changing direction
Machining parallel to the ordinate, with changing direction
Machining parallel to the abscissa, in one direction
Machining parallel to the ordinate, in one direction
6FC5 698−2AA10−1BP5
Automatic Mode 5
Prerequisite
The machine is set up for the AUTOMATIC mode according to the specifications of the
machine manufacturer.
Operating sequence
Select the AUTOMATIC mode using the AUTOMATIC key on the machine control panel.
The AUTOMATIC start screen appears, displaying the position, feedrate, spindle, and tool
values, as well as the block currently active.
Fig. 5-1 The AUTOMATICstart screen
6FC5 698−2AA10−1BP5
Automatic Mode
Program Block Real−time Correct

control search simulat. progr.
Program To Zoom
test contour Auto
Dry run To To
feedrate endpoint origin
Condit. Without Show

stop calculate ...
Skip Interr. Zoom +

point
SBL fine Find Zoom −
Delete
ROV active window
Cursor
coarse / fine
Back << Back << Back << Back <<
Fig. 5-2 Menu tree of the AUTOMATIC mode
Parameters
Table 5-1 Description of the parameters in the working window
MCS Displays the existing axes in the MCS or WCS
X
Z
- Z pear in the relevant field.
If the axis is already in the required position, no sign is displayed.
mm
Distance to These fields display the current position of the axes in the MCS or WCS.
go
r.p.m.
Feed F Displays the path feedrate actual value and setpoint
mm/min or
mm/rev.
Tool Displays the currently active tool with the current edge number (T..., D...).
Current block The block display displays seven subsequent blocks of the currently active part program. The
display of one block is limited to the width of the window. If several blocks are executed quickly
one after the other, it is recommended to switch to the ”Program progress” window. To switch
back to the seven−block display, use the ”Program sequence” softkey.
6FC5 698−2AA10−1BP5
Automatic Mode
Note
Softkeys
Program The program control softkeys are displayed (e.g. ”Skip block”, ”Program test”).
control
Program If ”Program test” (PRT) is selected, the output of setpoints to axes and spindles is disabled. The
test setpoint display will ”simulate” the traversing motion.
Dry run If you select this softkey, all traversing motions will be performed with the feedrate setpoint specified
feedrate via the ”Dry run feed” setting data. In other words: Instead of the programmed motion commands,
the dry run feedrate will act.
Condit If this function is active, the program execution is stopped at the blocks in which the miscellaneous
stop function M01 is programmed.
Program blocks marked with a slash in front of the block number are skipped during the program
Skip
execution (e.g. ”/N100”).
If this function is enabled, the part program blocks are executed separately as follows: Each block is
SBL fine
decoded separately, and a stop is performed at each block; an exception are only the thread blocks
without dry run feedrate. In such blocks, a stop is only performed at the end of the current thread
block. ”Single Block fine” can only be selected in the RESET status.
The feedrate override switch will also act on the rapid traverse override.
ROV active
Use this softkey to quit the screenform.

Back <<
Block Use the block search function to go to the desired place in the program.
Search
To Forward block search forward to the block start point with calculation
contour During the block search, the same calculations are carried out as during normal program operation,
but the axes do not move.
6FC5 698−2AA10−1BP5
Automatic Mode
To Forward block search with calculation to the block end point

endpoint During the block search, the same calculations are carried out as during normal program operation,
but the axes do not move.
Without Block search without calculation

calculate During the block search, no calculation is carried out.
Interr. The cursor is positioned on the interruption point.

point
The ”Find” softkey provides the functions ”Find line”, ”Find text” etc.
Find
Real−time Broken−line graphics are displayed to trace the programmed tool path while the workpiece is being
simulat. machined on the machine (see also Section 6.4)
Note: Whether or not this function is implemented is decided by the machine manufacturer and per-
formed via parameterization.
Correct Use this softkey to correct a fault program passage. Any changes will be stored immediately.
progr.
Opens the G functions window to display all G functions currently active.

G funct
The G functions window displays all G functions currently active whereby each G function is
assigned to a group and has a fixed position in the window.
Use the PageDown and PageUp keys to display further G functions.
Fig. 5-3 The Active G functionswindow
Auxiliary This window displays the auxiliary and M functions currently active.
function Selecting the softkey repeatedly will close the window.
Axis Use this softkey to display the Axis feedrate window.

feedrate Selecting the softkey repeatedly will close the window.
Program Use this softkey to switch from the seven−block to the three−block display.
sequence
6FC5 698−2AA10−1BP5
Automatic Mode
MCS/WCS Use this softkey to select the machine coordinate system, the workpiece or the relative coordinate
REL system.
External Use this softkey to transmit an external program to the control system via the RS232 interface; to
programs execute this program, press NC START.
6FC5 698−2AA10−1BP5
Automatic Mode
5.1 Selecting
area / starting a part program - ”Machine” operating
5.1 Selecting / starting a part program - ”Machine” operating

area
Functionality
Before starting the program, make sure that both the control system and the machine are set
up. Observe the relevant safety notes of the machine manufacturer.
Operating sequence
Select the AUTOMATIC mode using the AUTOMATIC key on the machine control panel.
An overview of all programs stored in the control system is displayed.
Position the cursor bar on the desired program.
Execute
To select the program for execution, use the Execute softkey. The name of the selected program
will appear in the ”Program name” screen line.
Progr. If desired, here you can specify how you want the program to be executed.
control
Fig. 5-4 Program control
Press NC START to start the part program execution.
6FC5 698−2AA10−1BP5
Automatic Mode
5.2 Block search - ”Machine” operating area
5.2 Block search - ”Machine” operating area
Operating sequence
Prerequisite: The required program has already been selected (cf. Section 5.1) and the control
system is in the RESET condition.
Block The block search function provides advance of the program to the required block in the part pro-
Search gram. The search target is set by positioning the cursor bar directly on the required block in the part
program.
Fig. 5-5 Block search
To Block search to the block start

contour
To Block search to the end of the block

end point
Without Block search without calculation

calculate
Interr. The interruption point is loaded.

point
Find Selecting this softkey opens a dialog box will where you can enter a line number or terms you are
looking for.
6FC5 698−2AA10−1BP5
Automatic Mode
5.3 Stopping / canceling a part program
Fig. 5-6 Entering the searched term
A toggle field is provided to define from which position you will search for the term.
Search result
The required block is displayed in the Current blockwindow.
5.3 Stopping / canceling a part program
Operating sequence
Press NC STOP to cancel a part program.

Press NC START to continue the program execution.
Use RESET to interrupt the program currently running.

Pressing NC START again will restart the program you have interrupted and execute the program
from the beginning.
6FC5 698−2AA10−1BP5
Automatic Mode
5.4 Reapproach after cancellation
5.4 Reapproach after cancellation

After a program cancellation (NC STOP), you can retract the tool from the contour in the
Manual mode (Jog).
Operating sequence
Select the AUTOMATIC mode.
BlockSearc Use this softkey to open the Block search window for loading the interruption point.
h
Interr. The interruption point is loaded.

Point
To Selecting this softkey will start the block search to the interruption point. An adjustment to the start
contour position of the interrupted block will be carried out.
5.5 Repositioning after interruption

After a program interruption (NC STOP), you can retract the tool from the contour in the
Manual mode (Jog); the coordinates of the interruption point are stored by the control system.
The path differences traversed by the axes are displayed.
Operating sequence
Select the AUTOMATIC mode.
Caution
When reapproaching the interruption point, all axes will traverse at the same time. Make
sure that the traversing area is not obstructed.
6FC5 698−2AA10−1BP5
Automatic Mode
5.6 Program execution from external
5.6 Program execution from external
Functionality
Use this softkey to transmit an external program to the control system via the RS232 inter-
face; to execute this program, press NC START.
While the contents of the buffer memory are being processed, the blocks are reloaded auto-
matically. For example, a PC with the PCIN tool installed for data transfer can be used as the
external device.
Operating sequence
Prerequisite: The control system is in the RESET condition.
The RS232 interface is parameterized correctly (for the relevant text format, see also Chapter
7) and not occupied by any other application (DataIn, DatatOut, STEP7).
External Select the softkey.

programs
On the external device (PC), activate the relevant program for data output via the PCIN tool.
The program is transmitted into the buffer memory and selected and displayed in the Program
Selection automatically.
Advantageous for the program execution: Wait until the buffer memory is filled.
Press NC START to start the program execution. The program is reloaded continuously.
At the end of the program or in case of RESET, the program is automatically removed from
the control system.
Note
Any transmission errors are displayed in the System / Data I/O area if you select the Error
log softkey.
Block search is not possible for programs read in from an external source.
6FC5 698−2AA10−1BP5
Part Programming 6
Operating sequence
Press the Program Manager key to call the Program Manager.
Fig. 6-1 The ”Program Manager” start screen
Use the cursor keys to navigate in the program directory. To quickly find the required program,
type the 1st letter of the program name you are looking for. The control system will automati-
cally position the cursor on a program with matching characters.
6FC5 698−2AA10−1BP5
Part Programming
Softkeys
Use this softkey to display all files contained in the part program directory.
Programs
Use this softkey to select the program on which the cursor is positioned for execution. The control
Execute
system will switch to the position display. With the next NC START, the program is started.
Use the New softkey to create a new program.

New
Use the Copy softkey to copy the selected program into another program with a new name.
Copy
Use the ”Open” softkey to open the file highlighted by the cursor for processing.
Open
Use this softkey to delete either only the program highlighted by the cursor or all part programs; first,
Delete
however, a warning confirmation is displayed.
Use the OK softkey to execute the deletion order and Abort to discard.
Selecting the Rename softkey opens a window where you can rename the program you have se-
Rename lected beforehand using the cursor.
After you have entered the new name, either press OK to confirm or Abort to cancel.
Use this softkey to saved files via the RS232 interface.

Read out
Use this softkey to load part programs files via the RS232 interface.
Read in
For the settings of the interface, please refer to the System operating area (Chapter 7). The
part programs must be transmitted using the text format.
Use the User cycles softkey to display the ”Standard cycles” directory. This softkey will only appear
Cycles unhidden if you have the relevant access right.
Use this softkey to delete the cycle highlighted by the cursor; first, a confirmation warning will ap-
Delete
pear.
User Use the User cycles softkey to display the ”User cycles” directory.
cycles With the appropriate access right, the softkeys New, Copy, Open, Delete, Rename, Read out and
Read in are displayed.
6FC5 698−2AA10−1BP5
Part Programming
Fig. 6-2
Save Save data

data This function is used to save the contents of the volatile memory into a non−volatile memory area.
Prerequisite: There is no program currently executed.
Do not carry out any operator actions while the data backup is running!
6FC5 698−2AA10−1BP5
Part Programming
6.1 Entering a new program - ”Program” operating area
6.1 Entering a new program - ”Program” operating area
Operating sequences
Programs
You have selected the Program Manager operating area and you are in the overview of the NC
programs already created.
Select the New softkey; a dialog box will appear where you can enter the name of the new main
New
program or subroutine. The extension for main programs ”.MPF” is entered automatically; the exten-
sion for subroutines ”.SPF” must be entered together with the program name.
Fig. 6-3 The New program interactive screenform
Enter the name for the new program.
Use the OK softkey to confirm your input. The new part program file will be created, and the editor
window is opened automatically.
Use Abort to cancel the creation of the program; the window will be closed.
6FC5 698−2AA10−1BP5
Part Programming
6.2 Editing part programs - ”Program” operating area
Functionality
A part program or sections of a part program can only be edited if it is currently not being
executed.
Any modifications to the part program are stored immediately.
Fig. 6-4 The ”Program editor” start screen
Menu tree
Edit Contour Drilling Milling Simulation Recompile
Drilling Zoom
Execute Auto
centering
Mark Center Face To

block drilling milling origin
Copy Deep hole Contour Show

block drilling milling ...
Insert
block Boring Zoom +
Delete Standard Zoom −

Tapping
block pockets
Delete
Find Deselect Grooves window
modal
Hole Thread Cursor

Renumber crs./fine
pattern milling
Fig. 6-5 The ”Program” menu tree
6FC5 698−2AA10−1BP5
Part Programming
Softkeys
Use this function to edit text segments.

Edit
Use this softkey to execute the selected file.

Execute
Mark Use this function to highlight a text section from the current cursor position. When doing so, use the
block arrow keys.
Copy Use this softkey to copy a selected block to the clipboard

block
Insert Use this softkey to paste a text from the clipboard at the current cursor position
block
Delete Use this softkey to delete a selected text

block
Use the Find softkey to search for a string in the program file displayed.
Find
Type the term you are looking for in the input line and use the OK softkey to start the search.
Use ”Abort” to close the dialog box without starting the search process.
Use this softkey to replace the block numbers from the current cursor position up to the program
Renumber
end.
Contour For programming the contour (”blueprint programming”), see Section 6.3
see Section ”Cycles”

Drilling
see Section ”Cycles”

Milling
The simulation is described in Section 6.4.

Simulation
For recompilation, position the cursor on the cycle calling line in the program. This function decodes
Recompile
the cycle name and prepares the screenform with the relevant parameters. If there are any parame-
ters beyond the range of validity, the function will automatically use the default values. After closing
the screenform, the original parameter block is replaced by the corrected block.
Please note: Only automatically generated blocks can be recompiled.
6FC5 698−2AA10−1BP5
Part Programming
6.3 Blueprint programming
Functionality
The control system offers various contour screenforms for the fast and reliable creation of part
programs. Fill out the relevant parameters in the interactive screenforms.
The following contour elements or contour sections can be programmed using the contour
screenforms:
S Straight line section with specification of end point or angle
S Contour section straight line − straight line with specification of angle and end point
S Circle sector with specification of center point / end point / radius
S Contour section straight line − circle with tangential transition; calculated on the basis of
angle, radius and end point
S Contour section straight line − circle with any transition; calculated on the basis of angle,
center point and end point
S Contour section circle − straight line with tangential transition; calculated on the basis of
angle, radius and end point
S Contour section circle − straight line circle with any transition; calculated on the basis of
angle, center point and end point
S Contour section circle − straight line − circle with tangential transitions
S Contour section circle − circle with tangential transition; calculated on the basis of center
point, radius and end point
S Contour section circle − circle with any transition; calculated on the basis of center point
and end point
S Contour section circle − circle − circle with tangential transitions
S Contour section straight line − circle − straight line − circle with tangential transitions
Fig. 6-6 Softkey functions
The coordinates can be input either as an absolute, incremental or polar value. Input is
switched using the Toggle key.
6FC5 698−2AA10−1BP5
Part Programming
Softkeys
Use these softkey functions to branch into the individual contour elements.
If a contour screenform is opened for the first time, the starting point of the contour section
must be reported to the control system. All subsequent motions will refer to this point. If you
move the input bar using the cursor, all values must be reentered.
Fig. 6-7 Setting the starting point
The Approach start point softkey function will generate an NC block approaching the en-
tered coordinates.
Programming aid for the programming of straight line sections
Fig. 6-8
Enter the end point of the straight line in absolute dimensions (ABS), in incremental dimen-
sions (INC) (with reference to the starting point), or in polar coordinates (POL). The current
settings are displayed in the interactive screenform.
The end point can also be defined by a coordinate and the angle between an axis and the
straight line.
6FC5 698−2AA10−1BP5
Part Programming
If you are using polar coordinates to determine the end point, it is imperative to specify the length of
the vector between the pole and the end point (in field 1), as well as the angle of the vector referred
to the pole (to be entered in field 2).
The prerequisite is that a pole was set beforehand. This pole will be applicable until a new pole is
set.
Set A dialog box will appear where the coordinates of the pole point must be entered. The pole point will
Pole refer to the selected plane.
Fig. 6-9
If this function is selected, the selected block is traversed at rapid traverse or with the programmed
G0/G1
path feedrate.
Add. If necessary you can enter additional functions in the fields. The commands can be separated from
functions each other by spaces, commas or semicolons.
Fig. 6-10
This interactive screenform is provided for all contour elements.
Use this softkey to select the relevant plane G17 (X−Y), G18 (Z−X) or G19 (Y−Z). The designations
G17/18/19
of the axes in the screenform will change according to the selection.
This interactive screenform is provided for all contour elements.
6FC5 698−2AA10−1BP5
Part Programming
Pressing the OK softkey will accept all commands into the part program.
OK
Select Abort to quit the interactive screenform without saving the values.
This function is intended to calculate the point of intersection between two straight lines.
Specify the coordinates of the end point of the second straight line and the angles of the
straight lines.
Fig. 6-11
Table 6-1 Input in the interactive screenform
End point of straight E Enter the end point of the straight line.
line 2
Angle of straight line 1 A1 The angle is specified in the counterclockwise direction from 0 to
360 degrees.
Angle of straight line 2 A2 The angle is specified in the counterclockwise direction from 0 to
360 degrees.
Feedrate F Feedrate
Use this interactive screenform to create a circular block using the coordinates end point and center
point.
6FC5 698−2AA10−1BP5
Part Programming
Fig. 6-12
Enter the end point and center point coordinates in the input fields. Input fields no longer
needed are hidden.
Use this softkey to switch the direction of rotation from G2 to G3. G3 will appear on the display.
G2/G3
Pressing this softkey again will switch back the display to G2.
Pressing the OK softkey will accept the block into the part program.
OK
This function will calculate the tangential transition between a contour and a circle sector. The
straight line must be described by the starting point and the angle. The circle must be described by
the radius and the end point.
For calculating the points of intersection with any transition angles, the POI softkey function
will display the center point coordinates.
Fig. 6-13 Straight line − circle with tangential transition
End point of the circle E Enter the end point of the circle.
Angle of straight line A The angle is specified in the counterclockwise direction from 0 to
360 degrees.
6FC5 698−2AA10−1BP5
Part Programming
Table 6-2 , cont’dInput in the interactive screenform
Radius of the circle R Input field for the circle radius

Feedrate F Input field for the interpolation feedrate
Center point of the M If there is no tangential transition between the straight line and the
circle circle, the circle center point must be known. The specification is
performed depending on the type of calculation (absolute, incre-
mental or polar coordinates) selected in the previous block.
G2/G3
Pressing this softkey again will switch back the display to G2. The display changes to G2.
You can choose between tangential or any transition.

POI
The screenform generates a straight line and a circle block from the data you have entered.
If several points of intersection exist, the desired point of intersection must be selected from a
dialog box.
If one coordinate was not entered, the program tries to calculate it from the existing specifica-
tions. If there are several possibilities, the coordinate must be selected from an appropriate
dialog box.
This function will calculate the tangential transition between a contour and a straight line. The circle
sector must be described by the parameters starting point and radius, and the straight line must be
described by the parameters end point and angle.
Fig. 6-14 Tangential transition
End point of straight E Enter the end point of the straight line in absolute, incremental or
line polar coordinates.
Center point M Enter the center point of the circle in absolute, incremental or po-
lar coordinates.
Radius of the circle R Input field for the circle radius
6FC5 698−2AA10−1BP5
Part Programming
Table 6-3 , cont’dInput in the interactive screenform
Angle of straight line 1 A The angle is specified in the counterclockwise direction from 0 to
360 degrees and with reference to the point of intersection.
G2/G3

POI
The screenform generates a straight line and a circle block from the data you have entered.
dialog box.
This function will insert a straight line tangentially between two circle sectors. The sectors are deter-
mined by their center points and their radii. Depending on the direction of rotation selected, different
tangential points of intersection result.
Use the displayed screenform to enter the parameters center point and radius for the sector 1
and the parameters end point, center point and radius for the sector 2. Furthermore, the direc-
tion of rotation of the circles must be selected. A help screen is provided to display the current
settings.
Pressing OK calculates three blocks from the entered values and inserts them into the part
program.
Fig. 6-15
End point E 1. and 2nd geometry axes of the plane

If no coordinates are entered, this function provides the
point of intersection between the straight line you have
inserted and sector 2.
Center point of the circle 1 M1 1st and 2nd geometry axes of the plane(absolute coordi-
nates)
Radius of circle 1 R1 Input field for radius 1
6FC5 698−2AA10−1BP5
Part Programming
Center point of circle 2 M2 1st and 2nd geometry axes of the plane(absolute coordi-
nates)
The screenform generates one straight line and two circle blocks from the data you have en-
tered.
Use this softkey to define the direction of rotation of the two circle sectors. Possible combinations
G2/G3 are:
Sector 1 Sector 2
G2 G3,
G3 G2
G2 G2
G3 G3
The end point and the center point coordinates can be entered either in absolute or incremental
dimensions or as polar coordinates. The current settings are displayed in the interactive screenform.
Example
Given: R1 18 mm
R2 15 mm
R3 15 mm
M1 X 20 Y 30
M2 X 50 Y 75
M3 X 75 Y 20
Starting point: The point X = 2 and Y = 30 mm is supposed as the starting point.
6FC5 698−2AA10−1BP5
Part Programming
Procedure:
In the Contour menu, select . A screenform will appear where you can enter the start-
ing point.
Fig. 6-16 Setting the starting point
Press OK to confirm your input; the screenform for entering the values for the contour section
− − will appear.
Use the G2/G3 softkey to select the direction of rotation for the two circle sectors (G2|G3) and
fill out the parameter list.
The field for the end point can either be left open, or you can enter the points X 50 Y 90 ( 75 +
R 15).
Fig. 6-17 Calling the screenform
After you have filled out the interactive screenform, click on OK to quit the screenform. The
points of intersection are calculated and the two blocks are generated.
6FC5 698−2AA10−1BP5
Part Programming
Fig. 6-18 Result of step 1
Since the end point has been left open, the point of intersection of the straight line and the
circle sector will be used as the starting point for the next contour definition.
Now, call the interactive screenform for calculating the contour section − again.
The end point of step 2 is the point of intersection of the straight line with the circle sector
. Subsequently, calculate the contour section ’starting point 2 − circle sector’.
6FC5 698−2AA10−1BP5
Part Programming
Subsequently, connect the new end point with the starting point. To do so, you can use the
softkey.
Fig. 6-23 Step 4
6FC5 698−2AA10−1BP5
Part Programming
The function calculates the tangential transition between two circle sectors. Circle sector 1 must be
described by the parameters starting point, center point and radius, and the circle sector 2 be de-
scribed by the parameters end point and radius.
Fig. 6-25 Tangential transition
End point of circle 2 E 1st and 2nd geometry axes of the plane
Center point of the M1 1st and 2nd geometry axes of the plane
circle 1
Radius of circle 1 R1 Input field for the radius
Center point of circle 2 M2 1st and 2nd geometry axes of the plane
Radius of circle 1 R2 Input field for the radius
The specification of the points is performed depending on the type of calculation (absolute or
incremental dimension or polar coordinates) selected beforehand. Input fields no longer
needed are hidden. If any value is omitted when specifying the center point coordinates, the
radius must be entered.
G2/G3

POI
The screenform generates two circle blocks from the data you have entered.
Selecting the point of intersection

dialog box.
6FC5 698−2AA10−1BP5
Part Programming
Fig. 6-26 Selecting the point of intersection
The contour will be drawn using the point of intersection 1.

POI 1
Fig. 6-27
The contour will be drawn using the point of intersection 2.

POI 2
Fig. 6-28
6FC5 698−2AA10−1BP5
Part Programming
Pressing OK accepts the point of intersection of the displayed contour into the part program.
OK
This function will insert a circle sector between two adjacent circle sectors. The circle sectors are
described by their center points and circle radii, and the inserted sector is described only be its ra-
dius.
The operator is offered a screenform where he will enter the parameters center point, radius
for circle sector 1 and the parameters end point, center point and radius for the circle sector 2.
Furthermore, the radius for the inserted circle sector 3 must be entered and the direction of
rotation be defined.
A help screen is provided to display the selected settings.
Pressing OK calculates three blocks from the entered values and inserts them into the part
program.
Fig. 6-29 Screenform for calculating the contour section circle−circle−circle
End point E 1st and 2nd geometry axes of the plane

If no coordinates are entered, this function provides the
point of intersection between the circle sector you have
inserted and sector 2.
Center point of the circle 1 M1 1st and 2nd geometry axes of the plane
Center point of circle 2 M2 1st and 2nd geometry axes of the plane
If it is not possible to determine the starting point from the previous blocks, use the ”Starting
point” screenform to enter the appropriate coordinates.
Use this softkey to define the direction of rotation of the two circles. You can choose between
G2/G3
Sector 1 Inserted sector Sector 2

G2 G3 G2,
6FC5 698−2AA10−1BP5
Part Programming
G2 G2 G2,
G2 G2 G3,
G2 G3 G3,
G3 G2 G2,
G3 G3 G2,
G3 G2 G3,
G3 G3 G3
Center and end points can be acquired either in absolute dimensions, incremental dimensions or
using polar coordinates. The current settings are displayed in the interactive screenform.
The function inserts a circle sector (with tangential transitions) between two straight lines. The circle
sector is described by the center point and the radius. Specify the coordinates of the end point of
the second straight line and, optionally, the angle A2. The first straight line is described by the start-
ing point and the angle A1.
The screenform can be used if the following conditions are fulfilled:
Point Given coordinates

Starting point S Both coordinates in a Cartesian coordinate system
S Starting point as a polar coordinate
Circle sector S Both coordinates in the Cartesian coordinate system and the radius
S Center point as a polar coordinate
End point S Both coordinates in a Cartesian coordinate system
S End point as a polar coordinate
Point Given coordinates

Starting point S Both coordinates in a Cartesian coordinate system
S Starting point as a polar coordinate
Circle sector S One coordinate in the Cartesian coordinate system and the radius
S Angle A1 or A2
End point S Both coordinates in a Cartesian coordinate system
S End point as a polar coordinate
If it is not possible to determine the starting point from the previous blocks, the starting point
must be set by the operator.
6FC5 698−2AA10−1BP5
Part Programming
Fig. 6-30 Straight line − circle − straight line
End point of straight line 2 E Enter the end point of the straight line.
Center point of the circle M 1st and 2nd axes of the plane
Angle of straight line 1 A1 The angle is specified in the counterclockwise direction.
Angle of straight line 2 A2 The angle is specified in the counterclockwise direction.
Feedrate F Input field for the feedrate
End and center points can be specified either absolute, incremental or polar coordinates. The
screenform generates one circle and two straight line blocks from the data you have entered.
G2/G3 Pressing this softkey again will switch back the display to G2. The display changes to G2.
6FC5 698−2AA10−1BP5
Part Programming
6.4 Simulation
6.4 Simulation
Functionality
By using broken−line graphics, the programmed tool path can be traced. No compensating
movement is executed.
Note: Whether or not this function is implemented is decided by the machine manufacturer
and performed via parameterization.
Operating sequence
You are in the AUTOMATIC mode and have selected a program for execution (cf. Section
5.1).
Simulation
The start screen will appear.
Fig. 6-31 The ”Simulation” start screen
Press NC START to start the simulation for the selected part program.
Softkeys
Zoom If you select this softkey, the recorded tool path is scaled automatically.
Auto
To
If you select this softkey, the default setting is used for the scaling.
origin
Show
Various display options are offered here:
...
All G17 Displays the traversing motion of the specified plane.

blocks

blocks
6FC5 698−2AA10−1BP5
Part Programming
6.5 Data transfer via the RS232 interface

blocks
Display Select this softkey to display the whole workpiece.

All
Use this softkey to enlarge the displayed section.

Zoom +
Use this softkey to reduce the displayed section.

Zoom −
Delete Use this softkey to delete the visible image.

window
Cursor Use this softkey to change the cursor increment.

crs./fine
Functionality
The RS232 interface of the control system can be used to output data (e.g. part programs) to
an external data backup device or to read in data from there. The RS232 interface and your
data backup device must be matched with each other.
File types
S Main programs
− Part programs
− Subroutines
S Cycles
− Standard cycles
− User cycles
Operating sequence
Programs
You have selected the Program Manager operating area and you are in the overview of the NC
programs already created.
Use this softkey to saved files via the RS232 interface.

Read out
6FC5 698−2AA10−1BP5
Part Programming
Start
19200
None, 8, 1
RTS−CTS
TAPE
<<
Back
User
cycle
Fig. 6-32 Reading out a program
Use this softkey to select all files.

All files
Selecting this softkey selects all files from the part program directory and starts the data transfer.
Use this softkey to start the output.

Start
Selecting this softkey starts the output of one or several files from the part program directory. To
cancel the transfer, use the STOP key.
Use this softkey to load part programs files via the RS232 interface.
Read in
Error Transfer log

log This log contains all transmitted files with a status information:
S For files to be output:
- the name of the file
- an error acknowledgment
S For files to be input:
- the name of the file and the path
- an error acknowledgment
Transmission messages:
OK Transmission completed successfully

ERR EOF End−of−text character received, but archive file incomplete
Time Out The time monitoring is reporting an interruption of the data transfer
User Abort Data transfer aborted by the Stop softkey
Error Com Error at the COM 1 port
NC / PLC Error Error message from the NC
Error Data Data error
1. Files read in with / without header
or
2. Files transmitted without file names in the punched−tape format
Error File Name The file name does not correspond to the name convention of the NC.
6FC5 698−2AA10−1BP5
Part Programming
6FC5 698−2AA10−1BP5
System 7
Functionality
The ”System” operating area provides all functions required for parameterizing and analyzing
the NCK and the PLC.
Fig. 7-1 The ”System” start screen
Depending on the function selected, the horizontal and the vertical softkey bars change. The
menu tree shown below only shows the horizontal softkeys.
Start up Machine Service PLC Data I/O

data display
General Service STEP 7 Data

NC MD Axes connect selection
Axis Service PLC RS232

PLC MD settings
drives status
Channel Service Status

MD profibus list
Drive PLC
MD lprogram
Program
list
Display
MD
Servo Servo
trace trace
Edit PLC
Version alarm txt
Fig. 7-2 The ”System” menu tree (only horizontal level)
6FC5 698−2AA10−1BP5
System
Softkey
Set Setting the password

password
Three password levels are distinguished in the control system, which provide different access
rights:
S System password
S Manufacturer password
S User password
Depending on the access levels (see also ”Technical Manual”), certain data can be changed.
If you do not know the password, access will be denied.
Fig. 7-3 Entering the password
After you have selected the OK softkey, the password is set.

Use ABORT to return without any action to the System main screen.
Change Changing the password

password
Fig. 7-4 Changing the password
6FC5 698−2AA10−1BP5
System
Depending on the access right, various possibilities are offered in the softkey bar to change
the password.
Select the password level using the appropriate softkeys. Enter the new password and press
OK to complete your input.
You will be prompted to enter the new password once more for confirmation.
Press OK to complete the password change.
Use ABORT to return without any action to the Start−up main screen.
Delete Resetting the access right

password
Change Change language

language
Use the Change language softkey to switch between foreground and background language.
Save Saving data

data
This function will save the contents of the volatile memory into a nonvolatile memory area.
Prerequisite: There is no program currently executed.
Do not carry out any operator actions while the data backup is running!
Start−up
Start up
Use this softkey to select the power−up mode of the NC.

NC
Select the desired mode using the cursor.
S Normal power−up
The system will be restarted.
S Power−up with default data
Cold restart with the default values (will restore the default data as on delivery)
S Power−up with saved data
Cold restart with the data saved last (see ”Data backup”)
The PLC can be started in the following modes:

PLC
S Restart Cold restart
S Overall reset Overall reset
Furthermore, it is possible to link the start with a subsequent debugging mode.
Use OK to RESET the control system and to carry out a restart in the mode selected.
OK
Use RECALL to return without any action to the System start screen.
Machine Machine data

data
Any changes in the machine data have a substantial influence on the machine.
6FC5 698−2AA10−1BP5
System
MD number Name Value Unit Effect
Fig. 7-5 Structure of a machine data line
Activation so immediately effective

cf with confirmation
re Reset
po Power on
Caution
! Faulty parameterization may result in destruction of the machine.
The machine data are divided into the groups described in the following.
General General machine data

MD
Open the General machine data window. Use the PageUp / PageDown keys to browse for-
ward / backward.
Fig. 7-6 The ”Machine data” start screen
Axis Axis−specific machine data

MD
Open the Axis−specific machine data window. The softkey bar will be added by the softkeys
Axis + and Axis -.
6FC5 698−2AA10−1BP5
System
Fig. 7-7 Axis−specific machine data
The data of axis 1 are displayed.
Axis +
Use Axis + or Axis - to switch to the machine area of the next or previous axis.
Axis−
Find
Find
Type the number or the name (or a part of the name) of the machine data you are looking for
and press OK.
The cursor will jump to the data searched.
Continue Use this softkey to continue searching for the next match.
find
Select This function provides various display filters for the active machine data group. Further softkeys are
group provided:
Softkey Expert: Use this softkey to select all data groups of the Expert mode for display.
Softkey Filter active: Use this softkey to activate all data groups selected. After you have quit
the window, you will only see the selected data on the machine data display.
Select all softkey: Use this softkey to select all data groups of the Expert mode for display.
Deselect all softkey: Selecting this softkey deselects all data groups.
6FC5 698−2AA10−1BP5
System
Fig. 7-8 Display filter
Channel Channel−specific machine data

MD
Open the Axis−specific machine data window. Use the PageUp / PageDown keys to browse
forward / backward.
Drive Drive machine data

MD
Open the Drive machine data window. Use the PageUp / PageDown keys to browse forward /
backward.
Display Display machine data

MD
Open the Display machine data window. Use the PageUp / PageDown keys to browse for-
ward / backward.
Note for the reader

For a description of the machine data, please refer to the Manufacturer’s Documentation:
”SINUMERIK 802D Instruction Manual”
”SINUMERIK 802D, Description of Functions”.
Service Selecting this softkey displays the Service axes window.

display
Service This window displays information in respect of the axis.

Axes
Use the Axis+ or Axis- softkeys to display the values for the next or previous axis.
Service This window displays information in respect of the digital drive.

drive
Service This window displays information in respect of the PROFIBUS settings.

profibus
6FC5 698−2AA10−1BP5
System
Servo To optimize the drives, an oscilloscope function is provided for graphical representation
trace
S of the velocity setpoint
S of the contour violation
S of the following error
S of the actual position value
S of the position setpoint
S of exact stop coarse / fine
The start of tracing can be linked to various criteria allowing a synchronous tracing of internal
control states. This setting must be made using the ”Select signal” function.
To analyze the result, the following functions are provided:
S Changing and scaling of abscissa and ordinate;
S Measuring of a value using the horizontal or vertical marker;
S Measuring of abscissa and ordinate values as a difference between two marker positions;
S Storing of the result as a file in the part program directory. Thereafter, it is possible to ex-
port the file using WINPCIN and to process the data in MS Excel.
Fig. 7-9 The Servo trace start screen
The header of the diagram contains the current scaling of the abscissa and the difference
value of the markers.
The diagram shown above can be moved within the visible screen area using the cursor keys.
6FC5 698−2AA10−1BP5
System
Fig. 7-10 Meaning of the fields
Select Use this menu to parameterize the measuring channel.

signal
Fig. 7-11
S Selecting the axis: To select the axis, use the ”Axis” toggle field.
S Signal type: Following error
Servo difference
Contour violation
Actual position value
Velocity actual value
Velocity setpoint
Compensation value
Parameter set
Position setpoint at controller input
Velocity setpoint at controller input
Acceleration setpoint at controller input
Velocity feedforward control value
Exact stop fine signal
exact stop coarse signal
S Status: On The tracing is carried out in this channel

Off The channel is inactive.
The parameters for the measuring time and for the trigger type for channel 1 can be set in the
lower screen half. The remaining channels will accept this setting.
S Determining the measuring time: The measuring time in ms is entered directly in the
”Measuring time” input field. It applies to all trace channels.
6FC5 698−2AA10−1BP5
System
S Selecting the trigger condition: Position the cursor on the ”Trigger condition” field and
select the relevant condition using the toggle key.
− No trigger, i.e. the measurement starts directly after selecting the ”Start” softkey;
− Positive edge;
− Negative edge;
− Exact stop fine reached;
− Exact stop coarse reached
V−Mark Use the Marker on / Marker off softkeys to hide / unhide the gridlines.
OFF
T−Mark
OFF
FIX Use the markers to determine the differences in the horizontal or vertical direction. To this end, posi-
V−Mark tion the marker on the starting point and select either the ”Fix H − Mark.” or the ”Fix T− Mark.” soft-
FIX key. The difference between the starting point and the current marker position is now displayed in
T−Mark the status bar. The softkey designations will change to ”Free H − Mark.” or ”Free T − Mark.”.
Show This function opens another menu level offering softkeys for hiding / unhiding the diagrams. If a soft-
trace key is displayed on a black background, the diagrams are displayed for the selected trace channel.
Time Use this function to zoom in / zoom out the time basis.
scale +
Time
scale −
Vertical Use this function to increase / reduce the resolution (amplitude).

scale +
vertical
scale −
Marker Use these softkeys to define the step sizes of the markers.
steps
Fig. 7-12
The markers are moved using the cursor keys at a step size of one increment. larger step
sizes can be set using the input fields. The value specifies how many grid units must be
moved per <SHIFT cursor movement.If a marker reaches the margin of the diagram, the grid
automatically appears in the horizontal or vertical direction.
6FC5 698−2AA10−1BP5
System
File Use this softkey to save or load trace data.

service
Fig. 7-13
Type the desired file name without extension in the ”File name” field.
Use the Save softkey to save the data with the specified name in the part program directory.
Thereafter, the file can be exported, and the data can be processed in MS Excel.
Use the Load softkey to load the specified file and to display the data graphically.
Version
This window displays the version numbers and the date of creation of the individual CNC compo-
nents.
HMI The menu HMI details is intended for servicing and can only be accessed via the user password
details level. All programs provided by the operator unit are displayed with their version numbers. By re-
loading software components, the version numbers can be differ from each other.
Fig. 7-14 The ”HMI version” menu area
6FC5 698−2AA10−1BP5
System
registry This function displays the assignment of the hardkeys (function keys ”Machine”, ”Offset”, ”Program”,
details ...) for the programs to be started in the form of a list. For the meanings of the individual columns,
please refer to the table below.
Fig. 7-15
Table 7-1 Meanings of the entries under [DLL arrangement]
Designation Meaning
Softkey SK1 to SK7 Hardkey assignment 1 to 7
DLL name Name of the program to be executed
Class name The identifier for receiving messages is defined in this column.
Start method Number of the function executed after starting the program
Execute flag 0 - The program is managed via the basic system.
(kind of execution) 1 - The basic system starts the program and transfers the control to the
loaded program.
Text file name Name of the text file (without extension)
Softkey text ID Reserved
(SK ID)
Password level The execution of the program depends on the password level.
Class SK Reserved
SK file Reserved
6FC5 698−2AA10−1BP5
System
Font This function displays the data of the loaded character sets in the form of a list.
details
Fig. 7-16
Change Defining the start program

Start DLL
After the system has booted, the control system automatically starts the ”Machine” operating
area (SK 1). If a different starting behavior is desired, you can use this function to define a
different starting behavior.
Type the number of the program (”Softkey” column) to be started after the system has booted
here.
Fig. 7-17 Modifying the start-up DLL
6FC5 698−2AA10−1BP5
System
This softkey offers further functions for diagnostics and start−up of the PLC.
PLC
STEP 7 This softkey opens the configuration dialog for the interface parameters for the connection to STEP
connect 7 (see also description of the Programming Tool, Section ”Communications”).
If the RS232 interface is already occupied by the data transfer, you can connect the control
system to the Programming Tool only if the transmission is completed.
The RS232 interface is initialized with activation of the connection.
Fig. 7-18 Activating/deactivating RS232 for the Programming Tool
The baud rate is set using the toggle field. The following values are possible: 9600 / 19200 /
38400 / 57600 / 115200.
Fig. 7-19 Settings with the modem active
With the modem active (”ON”), you can additionally choose between the data formats 10 or
11−bit.
S Parity: ”None” with 10−bit format
”Even” with 11−bit format
S Stop bits: 1 (set by default; active with initialization of the control system)
S Data bits: 8 (set by default; active with initialization of the control system)
6FC5 698−2AA10−1BP5
System
Connect Use this softkey to activate the connection between the control system and the PC/PG. It is waited
on for the call of the Programming Tool. No modifications to the settings are possible in this state.
Connect The softkey designations will change to Connect off.
off
You can cancel the transmission from the control system at any time by pressing Connect off. Now
it is possible again to make changes in the settings.
The active or inactive state is kept even after Power On (except power−up with the default
data). An active connection is displayed by a symbol in the status bar (cf. Table 1−2).
Press Back to quit the menu.
Modem In this area, the modem settings are made.

settings
Possible modem types are: Analog Modem
ISDN Box
Mobile Phone.
The types of both communication partners must match with each other.
Fig. 7-20 Settings for an analog modem
When specifying several AT strings, AT must merely be written once; the remaining com-
mands can simply be attached, e.g. AT&FS0=1E1X0&W. For the individual commands and
their parameters, please refer to the manuals of the appropriate manufacturers. The default
values of the control system are therefore only a real minimum and should be verified very
exactly in any case before they are used for the first time. To be on the safe side, it is recom-
mended to connect the devices first to a PC/PG and then to test and optimize the establish-
ment of the connection.
6FC5 698−2AA10−1BP5
System
Fig. 7-21 Settings for an ISDN box
PLC Use this function to display and change the current states of the memory areas listed in Table 7-2.
status
It is possible to display 16 operands at the same time.
Table 7-2 Memory areas
Inputs I Input byte (IBx), input word (Iwx), input double−word (IDx)
Outputs Q Output byte (Qbx), output word (Qwx), output double−word (QDx)
Flags M Flag byte (Mx), flag word (Mw), flag double−word (MDx)
Timers T Timer (Tx)
Counter C Counter (Zx)
Data V Data byte (Vbx), data word (Vwx), data double−word (VDx)
Format B binary
H hexadecimal
D decimal
The binary representation is not possible with double words. Counters and
timers are represented decimally.
Fig. 7-22 PLC status display
6FC5 698−2AA10−1BP5
System
Operand Each time if you select this softkey the operand address is incremented by 1.
+
Operand The operand address displays the value decremented by 1.

−
Delete
Use this softkey to delete all operands.
Change
This softkey will cancel the cyclic update of the values. Then you can change the values of the op-
erands.
Status Use the PLC status list function to display and modify PLC signals.
list
There are 3 lists to choose from:
S Inputs (default setting) left list
S Flags (default setting) central list
S Outputs (default setting) right list
S Variable
Fig. 7-23 The PLC status liststart screen
Use the Edit pad function to change the settings.
Change
Use this softkey to change the value of the selected variable. Select the Accept softkey to con-
firm your changes.
Edit Use this softkey to assign the active column a new area. To this end, the interactive screenform of-
pad fers four areas to choose from. For each column, a start address can be assigned which must be
entered in the relevant input field. When you quit the interactive screenform, the control system will
save your settings.
6FC5 698−2AA10−1BP5
System
Fig. 7-24 The ”Data type” selection screen
Use the cursor keys and the PageUp / PageDownkeys to navigate in and between the col-
umns.
PLC PLC diagnosis using a ladder diagram (see Section 7.1)

program
Program Using the PLC, you may select part programs and run them via the PLC. To this end, the PLC user
list program writes a program number to the PLC interface, which is then converted to a program name
using a reference list. It is possible to manage max. 255 programs.
Fig. 7-25
This dialog displays all files of the CUS directory and their assignment in the reference list
(PLCPROG.LST) in the form of a list. You can use the TAB key to switch between the two columns.
The softkey functions Copy, Insert and Delete are displayed with reference to a specific context. If
the cursor is positioned on the left−hand side, only the Copy function is available. On the right−hand
side, the functions Insert and Delete are offered to modify the reference list.
Copy
... writes the selected file name to the clipboard
Insert
... pastes the file name at the current cursor position
6FC5 698−2AA10−1BP5
System
Delete
... deletes the selected file name from the assignment list
Structure of the reference list (file PLCPROG.LST)
It is divided into 3 areas:
Number Area Protection level

1 ... 100 User area User
101 ... 200 Machine manufacturer Machine manufacturer
201 ... 255 Siemens Siemens
The notation is carried out for each program by lines. Two columns are intended per line,
which must be separated from each other by TAB, space or the ”|” character. In the first col-
umn, the PLC reference number must be specified, and in the second column, the file name.
Example: 1 | shaft.mpf
2 | taper.mpf
Edit PLC This function can be used to insert or modify PLC user alarm texts. Select the desired alarm number
alarm txt using the cursor. At the same time, the text currently valid is displayed in the input line.
Fig. 7-26 Editing the PLC alarm text
Enter the new text in the input line. Press the Input key to complete your input and select
Save to save it.
For the notation of the texts, please refer to the Start−Up Guide.
6FC5 698−2AA10−1BP5
System
Data I/O The window is divided into two columns. The left column is used to select the data group, and the
right−hand column is used to select individual data for transfer. If the cursor is positioned in the left−
hand column, the whole data group is output when Read out is selected. If it is positioned in the
right−hand column, only the selected file is transferred. You can use the TAB key to switch between
the two columns.
Fig. 7-27
In the NC Card selection area, the set interface parameters are ineffective. When reading in
data from NC Card, first the desired area must be selected.
If when reading in one of the areas
S PLC Sel. or
S Alarm texts PC is selected when reading in
S Start−up data PC, PLC−Application PC or Display machine data PC
S Alarm texts PC
the settings of the column special functions are internally switched to Binary format.
Note
The menu item ”Part programs to NC −> NC_Card” or . “Part programs from NC_Card −> NC”
will overwrite the existing files without confirmation warning.
Data Select the data to be transferred. To start the transfer of the data to an external device, use the
selection Read out softkey function.
To read in data from an external device, use the Read in function. For reading in, it is not
necessary to select the data group, since the target is determined by the data flow.
RS232 Use this function to display and change the interface parameters. The type of data to be transferred
settings can be selected using the Text Format and Binary Format softkey functions.
6FC5 698−2AA10−1BP5
System
Fig. 7-28
Any changes in the settings come into effect immediately.

Pressing the Save softkey will save the selected settings even beyond switching off.
The Default Settings softkey will reset all settings to their default settings.
Interface parameters
Table 7-3 Interfac e parameters
Parameter Description
Device type RTS/CTS
The signal RTS (Request to Send) controls the Send mode of the data transfer de-
vice.
Active: Data are to be sent.
Passive: The Send mode is only quitted after all data have been transmitted.
The CTS signal indicates the readiness to transmit data as the acknowledgment
signal for RTS.
Baud rate ... used to set the interface transmission rate.
300 Baud
600 Baud
1200 Baud
2400 Baud
4800 Baud
9600 Baud
19200 Baud
38400 Baud
57600 Baud
115200 Baud
Stop bits Number of stop bits with asynchronous transmission
Input:
1 stop bit (default setting)
2 stop bits
6FC5 698−2AA10−1BP5
System
Table 7-3 Interfac e parameters, cont’d
Parameter Description
Parity Parity bits are used for error detection. These are added to the coded character to
convert the number of digits set to ”1” into an odd or even number.
Input:
No parity (default setting)
Parity even
Parity odd
Data bits Number of data bits with asynchronous transmission
Input:
7 data bits
8 data bits (default setting)
Overwriting Y: When reading in, it is checked whether the file already exists in the NC.
with con- N: The files are overwritten without confirmation warning.
firmation
6FC5 698−2AA10−1BP5
System
7.1 PLC diagnosis represented as a ladder diagram
Functionality
A PLC user program consists to a large degree of logical operations to realize safety functions
and to support process sequences. These logical operations include the linking of various
contacts and relays. As a rule, the failure of a single contact or relay results in a failure of the
whole system/installation.
To locate causes of faults/failures or of a program error, various diagnostic functions are of-
fered in the ”System” operating area.
Note
It is not possible here to edit the program.
Operating sequence
PLC
Select the PLC softkey which is to be found in the ”System” operating area.
PLC The project stored in the permanent memory is opened.

program
7.1.1 Screen layout
The screen layout with its division into the main areas corresponds to the layout already de-
scribed in Section 1.1. Any deviations and amendments pertaining to the PLC diagnosis are
shown below.
Fig. 7-29 Screen layout
6FC5 698−2AA10−1BP5
System

trol
1
A li ti
Applicationarea
2 Supported PLC program language
Name of the active program block

3
Representation: Symbolic name (absolute name)
Program status
RUN Program running
STOP Program stopped
4
Status of the applicationarea
Sym Symbolic representation
abs Absolute representation
5 Display of the active keys
Focus
6
performs the tasks of the cursor
Tip line
7
contains notes for searching
7.1.2 Operating options
In addition to the softkeys and the navigation keys, this area provides still further key com-
binations.
Key combinations
The cursor keys move the focus over the PLC user program. When reaching the window bor-
ders, it is scrolled automatically.
Table 7-4 Key combinations
Key combination Action

to the first line of the row
or
to the last line of the row
or
up a screen
down a screen
one field to the left
one field to the right
6FC5 698−2AA10−1BP5
System
Table 7-4 Key combinations, cont’d
Key combination Action

up a field
down a field
to the first field of the first network

or
to the last field of the first network

or
opens the next program block in the same window
opens the previous program block in the same window
The function of the Select key depends on the position of the

input focus.
S Table line: Displays the complete text line
S Network title: Displays the network comment
S Command: Displays the complete operands
If the input focus is positioned on a command, all operands in-
cluding the comments are displayed.
6FC5 698−2AA10−1BP5
System
Softkeys
PLC The ”PLC Info” menu (normally called ”About ... − transl.) displays the PLC model, the PLC system
info version, cycle time and PLC user program runtime.
Fig. 7-30 PLCinfo
Reset Use this softkey to refresh the data in the window.

pro. time
PLC Use ”PLC status” for monitoring and changing during the program execution.
status
Fig. 7-31 PLC status display
Status Use the PLC status list function to display and modify PLC signals.
list
6FC5 698−2AA10−1BP5
System
Fig. 7-32 Status list
Window 1 This window displays all logical and graphical information of the PLC program running in the ap-
xxxx propriate program block. The logic in the LAD (ladder diagram) is divided into clearly structured pro-
gram parts and current paths, called networks. Generally, programs written in LADs represent the
Window 2
electrical current flow using various logical operations.
xxxx
Fig. 7-33 Window 1
In this menu, you can switch between symbolic and absolute representation of the operand.
Program sections can be displayed using various zoom factors; a search function is provided
to find operands quickly.
Program This softkey can be used to display the list of the PLC program blocks. Use the Cursor Up/Cursor
block
Down and Page Up/Page Down keys to select the PLC program block to be opened. The current
program block is displayed in the Info line of the list box.
6FC5 698−2AA10−1BP5
System
Fig. 7-34 PLC block selection
Proper− Selecting this softkey displays the description of the selected program block which was stored when
ties
the PLC project was created.
Fig. 7-35 Properties of the selected PLC program block
Local Pressing this softkey displays the table of local variables of the selected program block.
variables
There are two types of program blocks.
S OB1 only temporary local variable
S SBRxx temporary local variable
A table of variables exists for each program block.
6FC5 698−2AA10−1BP5
System
Fig. 7-36 Table of local variables for the selected program block
Texts which are longer than the column width are cut in all tables and the ”~” character is at-
tached. For such a case, a higher−level text field exists in such tables in which the text of the
current cursor position is displayed. If the text is cut with a ”~”, it is displayed in the same color
as that of the cursor in the higher−level text field. With longer texts, it is possible to display the
whole text by pressing the SELECT key.
Open
Selecting this softkey opens the selected program block; its name (absolute) is displayed on the
”Window 1/2” softkey.
Program Use this softkey to activate/deactivate the display of the program status. It is possible here to ob-
stat. ON
serve the current network states beginning from the end of the PLC cycle. The states of all oper-
Program ands are displayed in the ”Program status” ladder diagram. This LAD acquires the values for the
stat. OFF
status display in several PLC cycles and then refreshes the status display.
Fig. 7-37 ”Program status” ON – symbolic representation
6FC5 698−2AA10−1BP5
System
Fig. 7-38 ”Program status” ON – absolute representation
Symbolic Use this softkey to switch between the absolute and symbolic representation of the operands. De-
address
pending on the selected type of representation, the operands are displayed either with absolute or
Absolute symbolic identifiers.
address
If no symbol exists for a variable, this is automatically displayed absolutely.
Zoom The representation in the application area can be zoomed in or zoomed out step by step. The fol-
+
lowing zoom stages are provided:
Zoom
− 20% (default), 60%, 100% and 300%
can be used to search for operands in the symbolic or absolute representation

Find
A dialog box is displayed from which various search criteria can be selected. Using the ”Ab-
solute/Symbolic address” softkey, you can search for a certain operand matching this crite-
rion in both PLC windows. When searching, uppercase and lowercase letters are ignored.
Selection in the upper toggle field:
S Search for absolute and symbolic operands
S Go to network number
S Find SBR command
Further search criteria:
S Search direction down (from the current cursor position)
S Whole program block (from the beginning)
S In one program block
S Over all program blocks
You can search for the operands and constants as whole words (identifiers).
Depending on the display settings, you can search for symbolic or absolute operands.
Press the OK softkey to start the search. The found search element is highlighted by the fo-
cus. If nothing is found, an appropriate error message will appear in the notes line.
Use the Abort softkey to quit the dialog box; no search is carried out.
6FC5 698−2AA10−1BP5
System
Fig. 7-39 Searching for symbolic operands Searching for absolute operands
If the search object is found, use the Continue search softkey to continue the search.
Symbol Selecting this softkey displays all symbolic identifiers used in the highlighted network.
info
Fig. 7-40 Network symbolic
Cross Use this softkey to display the list of cross references. All operands used in the PLC project are dis-
refs. played.
This list indicates in which networks an input, output, flag etc. is used.
Fig. 7-41 The ”Cross references” main menu (absolute)

(symbolic)
6FC5 698−2AA10−1BP5
System
You can open the appropriate program segment directly in the 1/2 window using the Open in
Window 1/2 function.
Symbolic Depending on the active type of representation, the elements are displayed either with absolute or
address
symbolic identifiers.
Absolute
address If no symbol exists for an identifier, the description is automatically absolute.
The type of representation of identifiers is displayed in the status bar. The absolute represen-
tation of identifiers is set by default.
Open in The operand selected from the list of cross references is opened in the appropriate window.
window 1
Open in
Example:
window 2
You want to view the logic interrelation of the absolute operand M251.0 in network 1 in pro-
gram block OB1.
After the operand has been selected from the cross−reference list and the Open in Window 1
softkey has been actuated, the appropriate program section is displayed in window 1.
Fig. 7-42 Cursor ”M251.0 in OB1 network 2) M251.0 in OB1 network 2 in window 1
... is used to search for operands in the list of cross references

Find
You can search for the operands as whole words (identifiers). When searching, uppercase
and lowercase letters are ignored.
Search options:
S Search for absolute and symbolic operands
S Go to line
Search criteria:
S Down (from the current cursor position)
S Whole program block (from the beginning)
6FC5 698−2AA10−1BP5
System
Fig. 7-43 Searching for operands in cross references
The text you are looking for is displayed in the notes line. If the text is not found, an appropri-
ate error message is displayed which must be confirmed with OK.
If the search object is found, use the ”Continue search” softkey to continue the search.
6FC5 698−2AA10−1BP5
System
7.2 Alarm display
7.2 Alarm display
Operating sequence
The alarm window is opened. You can sort the NC alarms using softkeys; PLC alarms will not
be sorted.
Fig. 7-44 Alarm window
Softkeys
Highest Use this softkey to display all alarms sorted by their priority. The alarm with the highest priority
priority
stands at the beginning of the list.
Most rec. Use this softkey to display the alarms sorted by the time of their occurrence. The most recent alarm
alarm
Oldest Use this softkey to display the alarms sorted by the time of their occurrence. The oldest alarm
alarm
6FC5 698−2AA10−1BP5
System
7.2 Alarm display
6FC5 698−2AA10−1BP5
Programming 8
8.1 Fundamentals of NC programming
8.1.1 Program names
Each program has its own program name. When creating a program, the program name can
be freely selected, observing the following rules:
S The first two characters must be letters;
S Only use letters, digits or underscore.
S Do not use delimiters (see Section ”Character set”)
S The decimal point must only be used for separation of the file extension.
S Do not use more than 16 characters.
Example: FRAME52
8.1.2 Program structure
Structure and contents

The NC program consists of a sequence of blocks (see Table 8-1).
Each block represents a machining step.
Instructions in a block are written in the form of words.
The last block in the order of execution of the blocks contains a special word for the program
end: M2.
Table 8-1 NC program structure
Block Word Word Word ... ; Comment

Block N10 G0 X20 ... ; 1st block
Block N20 G2 Z37 ... ; 2nd block
Block N30 G91 ... ... ; ...
Block N40 ... ... ...
Block N50 M2 ; End of program
6FC5 698−2AA10−1BP5
Programming
8.1.3 Word structure and address
Functionality/structure
A word is a block element and mainly constitutes a control command. The word consists of
S address character: generally a letter
S and a numerical value: a sequence of digits which with certain addresses can be added
by a sign put in front of the address, and a decimal point.
A positive sign (+) can be omitted.
Word Word Word
Address Value Address Value Address Value
Example: G1 X-20.1 F300

Explanation: Traverse with Travel or end posi-
Feedrate:
linear interpolation for the
300 mm/min
tion X axis: −20.1mm
Fig. 8-1 Word structure (example)
Several address characters

A word can also contain several address letters. In this case, however, the numerical value
must be assigned via the intermediate character ”=” .
Example: CR=5.23
Additionally, it is also possible to call G functions using a symbolic name (see also Section
”List of instructions”).
Example: SCALE ; Enable scaling factor
Extended address
For the addresses
R Arithmetic parameter
H H function
I, J, K Interpolation parameter/intermediate point,
the addresses are extended by 1 to 4 digits to obtain more addresses. In this case, the value
must be assigned using an equality sign ”=” (see also Section ”List of instructions”).
Example: R10=6.234 H5=12.1 I1=32.67
6FC5 698−2AA10−1BP5
Programming
8.1.4 Block structure
Functionality
A block should contain all data required to execute a machining step.
Generally, a block consists of several words and is always completed with the
end−of−block character ” LF ” (LineFeed). This character is automatically generated when
pressing the line feed key or the Input key.
/N... Word1 Word2 ... Wordn ;Comment LF
Space Space Space Space

End−of−block
(BLANK) character
only if necessary;
Block instructions stands at the end separated from the rest of the block with ”
Block number − stands in front of the instruc-

tions;
only if necessary; instead of ”N”, a colon ” ”
is used in main blocks
Skip block;
only if necessary; stands in the
Total number of characters in a block: 200 characters
beginning
Fig. 8-2 Block structure diagram
Word order
If a block contains several instructions, the following order is recommended:
N... G... X... Y... Z... F... S... T... D... M... H...
Note regarding block numbers

First select the block numbers in steps of 5 or 10. Thus, you can later insert blocks and never-
theless observe the ascending order of block numbers.
Block skip
Blocks of a program, which are to be executed not with each program run, can be marked by
a slash ”\” in front of the block number. The block skip operation itself is activated either via
operation (Program control: ”SKP”) or via the PLC (signal). It is also possible to skip a whole
program section by skipping several blocks using the ” / ”.
If block skip is active during the program execution, all blocks marked with ” / ” are skipped. All
instructions contained in the blocks concerned will not be considered. The program is contin-
ued with the next block without marking.
6FC5 698−2AA10−1BP5
Programming
Comment, remark
The instructions in the blocks of a program can be explained using comments (remarks). A
comment starts with the character ” ; ” and ends with block end.
Comments are displayed in the current block display, together with the remaining contents of
the block.
Messages
Messages are programmed in a separate block. A message is displayed in a special field and
remains active until a block with a new message is executed or until the end of the program is
reached. Max. 65 characters of a text message can be displayed.
A message without message text will delete any previous message.
MSG (”THIS IS THE MESSAGE TEXT”)
Programming example
N10 ; Company G&S, order no. 12A71
N20 ; Pump part 17, drawing no.: 123 677
N30 ; Program created by H. Adam, Dept. TV 4
N40 MSG(”ROUGHING BLANK”)
:50 G17 G54 G94 F470 S20 D2 M3 ;Main block
N60 G0 G90 X100 Y200
N70 G1 Y185.6
N80 X112
/N90 X118 Y180 ;Block can be skipped
N100 X118 Y120
N110 G0 G90 X200
N120 M2 ;End of program
8.1.5 Character set
The following characters are used for programming; they are interpreted in accordance with
the relevant definitions.
Letters, digits
A, B, C, D, E, F, G, H, I, J, K, L, M, N,O, P, Q, R, S, T, U, V, W X, Y, Z
0, 1, 2, 3, 4, 5, 6, 7, 8, 9
No distinction is made between lowercase and uppercase letters.
Printable special characters

( Left round bracket ” Inverted commas
) Right round bracket _ Underscore (belonging to a letter)
[ Left square bracket . Decimal point
] Right square bracket , comma, delimiter
< Less than ; Start of a comment
> Greater than % Reserved; do not use
6FC5 698−2AA10−1BP5
Programming
: Main block, completion of label & reserved; do not use

= Assignment; part of equality ’ Reserved; do not use
/ Division; block skip $ System−internal variable identifier
* Multiplication ? Reserved; do not use
+ Addition; positive sign ! Reserved; do not use
− Subtraction; negative sign
Non−printable special characters

LF End−of−block character
Blank Delimiter between the words; blank
Tabulator Reserved; do not use
6FC5 698−2AA10−1BP5
Programming
Programming
8-134
8.1.6 Overview of the instructions
Valid as of software version 2.0.
Address Meaning Value Assignment Information Programming

D Tool offset number 0 ... 9, only integer, no Contains offset data for a certain tool T... ; D0−> offset D...
sign values= 0,
max. 9 D numbers per tool
F Feedrate 0.001 ... 99 999.999 Path velocity of a tool/workpiece; F...
unit: mm/min or mm/revolution
depending on G94 or G95
F Dwell time 0.001 ... 99 999.999 Dwell time in seconds G4 F... ;separate block
in block with G4
G G function Only integer, specified va- The G functions are divided into G groups. Only one G G...
(preparatory function) lues function of a group can be programmed in a block. or symbolic name, e.g.:
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
A G function can be either modal (until it is canceled CIP

by another function of the same group) or only effec-
tive for the block in which it is programmed non−mo-
dal.
G group:
G0 Linear interpolation at rapid traverse rate 1: Motion commands G0 X... Y... Z... ; Cartesian
using polar coordinates:
G0 AP=... RP=...
or with additional axis:
G0 AP=... RP=... Z... ; e.g.: with G17, Z axis
G1 * Linear interpolation at feedrate (type of interpolation) G1 X... Y... Z... F...
With polar coordinates:
G1 AP=... RP=... F...
G1 AP=... RP=... Z... F... ; e.g.: with G17, Z axis
G2 Circular interpolation CW modally effective G2 X... Y... I... J... F... ; Center and end points
G2 X... Y... CR=... F... ; Radius and end point
6FC5 698−2AA10−1BP5
(in conjunction with a 3rd axis and TURN=... also helix G2 AR=... I... J... F... ; Aperture angle and center
interpolation −>see also TURN ) point
G2 AR=... X... Y... F... ; Aperture angle and end point
in polar coordinates:
G2 AP=... RP=... F...
G2 AP=... RP=... Z... F... ; e.g.: with G17, Z axis
6FC5 698−2AA10−1BP5
G3 Circular interpolation CCW G3 .... ;otherwise, as with G2
(in conjunction with a 3rd axis and TURN=... also helix

interpolation −>see also TURN )
CIP Circular interpolation via intermediate point CIP X... Y... Z... I1=... J1=... K1=... F...
CT Circular interpolation; tangential transition N10 ...

N20 CT X... Y... F... ;Circle, tangential transition to the
previous path segment
G33 Thread cutting, tapping with constant lead S... M... ;spindle speed, direction
G33 Z... K... ;Tapping with compensation
chuck, e.g. in the Z axis
G331 Thread interpolation N10 SPOS=... ;Position−controlled spindle

N20 G331 Z... K... S... ;Tapping without compensation
chuck, e.g. in the Z axis
;RH or LH thread is specified via the arithmetic sign of the
lead (e.g. K+): + : as with M3
− : as with M4
G332 Thread interpolation − retraction G332 Z... K... ;rigid tapping (without compen−
sation chuck, e.g. along the Z axis,
retraction motion
; Sign of the lead as with G331
G4 Dwell time 2: Special motions, G4 F... ;separate block, F: Time in seconds

non−modal or
G4 S.... ;separate block, S: in spindle re-
volutions
G63 Tapping with compensation chuck G63 Z... F... S... M...
G74 Reference point approach G74 X1=0 Y1=0 Z1=0 ;separate block
(machine axis identifier!)
G75 Fixed−point approach G75 X1=0 Y1=0 Z1=0 ;separate block

(machine axis identifier!)
G147 SAR −approach along a straight line G147 G41 DISR=... DISCL=... FAD=... F... X... Y... Z...
G148 SAR −retraction along a straight line G148 G40 DISR=... DISCL=... FAD=... F... X... Y... Z...
G247 SAR −approach along a quadrant G247 G41 DISR=... DISCL=... FAD=... F... X... Y... Z...
Programming
G248 SAR −retraction along a quadrant G248 G40 DISR=... DISCL=... FAD=... F... X... Y... Z...
G347 SAR −approach along a semicircle G347 G41 DISR=... DISCL=... FAD=... F... X... Y... Z...
8-135
G348 SAR −retraction along a semicircle G348 G40 DISR=... DISCL=... FAD=... F... X... Y... Z...
Programming
TRANS Programmable offset 3: Write memory TRANS X... Y... Z... ;separate block
8-136
ROT programmable rotation ROT RPL=... ;rotation in the current plane

non−modal G17 ... G19, separate block
SCALE Programmable scaling factor SCALE X... Y... Z... ;scaling factor in the direction of
the
specified axis,
separate block
MIRROR programmable mirroring MIRROR X0 ; coordinate axis whose

direction is changed;
separate block
ATRANS Additive programmable offset ATRANS X... Y... Z... ;separate block
AROT additive programmable rotation AROT RPL=... ; Add. rotation in the current
plane G17 ... G19,
separate block
ASCALE Additive programmable scaling factor ASCALE X... Y... Z... ; scaling factor in the direction
of the specified axis,

separate block
AMIRROR additive programmable mirroring AMIRROR X0 ; coordinate axis whose

direction is changed;
separate block
G25 Lower spindle speed limitation G25 S... ;separate block

or
lower working area limitation G25 X... Y ... Z... ;separate block
G26 Upper spindle speed limitation G26 S... ;separate block

or
upper working area limitation G26 X... Y ... Z... ;separate block
G110 Pole specification, G110 X... Y... ; Pole specification, Cartesian,

relative to the last programmed set position e.g.: With G17
G110 RP=... AP=... ;pole specification, polar
separate block

6FC5 698−2AA10−1BP5
relative to the origin of the current workpiece coordi- e.g.: With G17
nate system G111 RP=... AP=... ;pole specification, polar
separate block

relative to the POLElast valid e.g.: With G17
G112 RP=... AP=... ;pole specification, polar
separate block
6FC5 698−2AA10−1BP5
G17 * X/Y plane 6: Plane selection G17 .... ;vertical axis on this
G18 Z/X plane modally effective Plane is tool length
G19 Y/Z plane offset axis
G40 * Tool radius compensation OFF 7: Tool radius compensation

modally effective
ff
G41 Tool radius compensation left of the contour
G42 Tool radius compensation right of the contour
G500 * Settable work offset OFF 8: Settable work offset

modally effective
ff
G54 1st settable work offset
G55 2nd settable work offset
G56 3rd settable work offset
G57 4th settable work offset
G53 Non−modal skipping of the settable work offset 9: Skipping of the settable work offset
non−modal
G153 Non−modal skipping of the settable work offset inclu-

ding base frame
G60 * Exact stop 10: Approach behavior

modally
d ll effective
ff i
G64 Continuous−path control mode
G9 Non−modal exact stop 11: Non−modal exact stop

non−modal
G601 * Exact stop window, fine, with G60, G9 12: Exact stop window
modally effective
ff
G602 Exact stop window, coarse, with G60, G9
G70 Inch dimension input 13: Inch / metr.dimension input

modally effective
ff
G71 * Metric dimension data input
G700 Inch dimension data input; also for feedrate F
Programming
G710 Metric dimension data input; also for feedrate F
8-137
Programming
G90 * Absolute dimension data input 14: Absolute / incremental dimension
8-138
modally effective
ff
G91 Incremental dimension data input
G94 * Feed F in mm/min 15: Feedrate / spindle

modally effective
ff
G95 Feedrate F in mm/spindle revolutions
CFC * Feedrate with circle ON 16: Feedrate override

modally effective
ff
CFTCP Feedrate override OFF
G450 * Transition circle 18: Behavior at corners when working with tool radius
compensation
G451 Point of intersection modally effective
BRISK * Jerking path acceleration 21: Acceleration profile

modally effective
ff
SOFT Jerk−limited path acceleration
FFWOF * Feedforward control OFF 24: Feedforward control

modally effective
ff
FFWON Feedforward control ON
WALIMON Working area limitation ON 28: Working area limitation ; applies to all axes activated via setting data;
* modallyy effective values set via G25, G26
WALIMOF Working area limitation OFF
G340 * Approach and retraction in the space (SAR = smooth 44: Path distribution with smooth approach and retrac-
approach and retraction) tion
modally
d ll effective
ff ti
G341 Approach and retraction in the plane (SAR)
G290 * SIEMENS mode 47: External NC languages

modally effective
ff
G291 External mode
The functions marked with an asterisk (*) act when starting the program (in the default condition of the control system, unless
otherwise programmed and if the machine manufacturer has preserved the default settings for the milling technology).
6FC5 698−2AA10−1BP5
6FC5 698−2AA10−1BP5

H H function 0.0000001 ... Value transfer to the PLC; H0=... H9999=...
9999 9999 meaning defined by the machine manufacturer
H0= (8 decimals) or with e. g.: H7=23.456
through specification of an
H9999= exponent:
(10−300 ... 10+300 )
I Interpolation parameters 0.001 ... 99 999.999 Belongs to the X axis; meaning dependent on G2,G3 See G2, G3, G33, G331 and G332
Thread: −> circle center or
0.001 ... 2000.000 G33, G331, G332 −> thread lead
J Interpolation parameters 0.001 ... 99 999.999 Belongs to the Y axis; otherwise, as with I See G2, G3, G33, G331 and G332
Thread:
0.001 ... 2000.000
K Interpolation parameters 0.001 ... 99 999.999 Belongs to the Z axis; otherwise, as with I See G2, G3, G33, G331 and G332
Thread:
0.001 ... 2000.000
I1= Intermediate point for cir- 0.001 ... 99 999.999 Belongs to the X axis; specification for circular interpo- See CIP
cular interpolation lation with CIP
J1= Intermediate point for cir- 0.001 ... 99 999.999 Belongs to the Y axis; specification for circular interpo- See CIP
K1= Intermediate point for cir- 0.001 ... 99 999.999 Belongs to the Z axis; specification for circular interpo- See CIP
L Subroutine; name and call 7 decimals; It is also possible to use L1 ...L9999999, Instead of a L781 ;separate block
integer only, no sign free name;
thus, the subroutine will be called in a separate block.
Please observe: L0001 is not always equal to L1.
The name ”LL6” is reserved for the tool change sub-
routine.
M Miscellaneous function 0 ... 99 For example, for initiating switching actions, M...
integer only, no sign such as ”Coolant ON”; max. 5 M functions per block
M0 Programmed stop The machining is stopped at the end of a block contai-

ning M0; to continue, press NC START.
M1 Optional stop As with M0, but the stop is only performed if a special
signal (Program control: ”M01”) is present.
Programming
M2 End of program Can be found in the last block of the processing se-
quence
8-139
M30 − Reserved; do not use

Programming
8-140
M17 − Reserved; do not use
M3 Spindle CW rotation
M4 Spindle CCW rotation
M5 Spindle stop
M6 Tool change Only if activated with M6 via the machine control pa-
nel; otherwise, change directly using the T command
M40 Automatic gear stage switching
M41 to Gear stages 1 to

M45 5
M70, M19 − Reserved; do not use
M... Remaining M functions Functionality is not defined by the control system and
can therefore be used freely by the machine manufac-
turer
N Block number of an auxi- 0 ... 9999 9999 Can be used to identify blocks with a number; N20 ...
liary block integer only, no sign is written in the beginning of a block
: Block number of a main 0 ... 9999 9999 Special block identification, used instead of N... ; such :20 ...
block integer only, no sign a block should contain all instructions for a complete
subsequent machining step.
P Number of subroutine 1 ... 9999 Is used if the subroutine is run several times and is N10 L781 P... ; separate block
passes integer only, no sign contained in the same block as the call
N10 L871 P3 ; passed three times
R0 Arithmetic parameters 0.0000001 ... R1=7.9431 R2=4

through 9999 9999
R299 (8 decimals) or with
specification of an With specification of an exponent:
exponent: R1=−1.9876EX9 ; R1=−1 987 600 000
(10−300 ... 10+300 )
Arithmetic functions In addition to the 4 basic arithmetic functions using the

6FC5 698−2AA10−1BP5
operands + − * /, there are the following

arithmetic functions:
SIN( ) Sine Degrees R1=SIN(17.35)
COS( ) Cosine Degrees R2=COS(R3)
TAN( ) Tangent Degrees R4=TAN(R5)

6FC5 698−2AA10−1BP5

ASIN( ) Arc sine R10=ASIN(0.35) ; R10: 20.487 degrees
ACOS( ) Arc cosine R20=ACOS(R2) ; R20: ... degrees
ATAN2( , ) Arc tangent2 The angle of the sum vector is calculated from 2 vec- R40=ATAN2(30.5,80.1) ; R40: 20.8455 degrees
tors standing vertically one on another. The 2nd vector
specified is always used for angle reference.
Result in the range: −180 to +180 degrees
SQRT( ) Square root R6=SQRT(R7)
POT( ) Square R12=POT(R13)
ABS( ) Amount R8=ABS(R9)
TRUNC( ) Integer portion R10=TRUNC(R11)
LN( ) Natural logarithm R12=LN(R9)
EXP( ) Exponential function R13=EXP(R1)
RET End of subroutine Used instead of M2 − to maintain the continuous−path RET ;separate block
control mode
S Spindle speed 0.001 ... 99 999.999 Unit of measurement of the spindle r.p.m. S...
S Dwell time 0.001 ... 99 999.999 Dwell time in spindle revolutions G4 S... ;separate block
in block with G4
T Tool number 1 ... 32 000 The tool change can be performed either directly using T...
integer only, no sign the T command or only with M6. This can be set in the
machine data.
X Axis 0.001 ... 99 999.999 G command X...
Y Axis 0.001 ... 99 999.999 G command Y...
Z Axis 0.001 ... 99 999.999 G command Z...
AC Absolute coordinate − The dimension can be specified for the end or center N10 G91 X10 Z=AC(20) ; X − incremental dimension,
point of a certain axis, irrespective of G91. Z − absolute
ACC[axis] Percentage path accele- 1 ... 200, integer Acceleration override for an axis or spindle; specified N10 ACC[X]=80 ;for the X axis: 80%
ration override as a percentage N20 ACC[S]=50 ;for the spindle: 50%
Programming
ACP Absolute coordinate; ap- − It is also possible to specify the dimensions for the end N10 A=ACP(45.3) ;Approach absolute position of the
proach position in the po- point of a rotary axis with ACP(...) irrespective of A axis in
sitive direction G90/G91; also applies to spindle positioning the positive direction
8-141
(for rotary axis, spindle) N20 SPOS=ACP(33.1) ;Position spindle

Programming
8-142
ACN Absolute coordinate; ap- − It is also possible to specify the dimensions for the end N10 A=ACN(45.3) ;Approach absolute position of the
proach position in the ne- point of a rotary axis with ACN(...) irrespective of A axis in
gative direction G90/G91; also applies to spindle positioning the negative direction
(for rotary axis, spindle) N20 SPOS=ACP(33.1) ;Position spindle
ANG Angle for the specification 0.00001 ... 359.99999 Specified in degrees; N10 G1 G17 X... Y....
of a straight line for the one possibility of specifying a straight line when using N11 X... ANG=...
contour definition G0 or G1 if only one end−point coordinate of the plane or contour over several blocks:
is known or N10 G1 G17 X... Y....
if the complete end point is known with contour ranging N11 ANG=...
over several blocks N12 X... Y... ANG=...
AP Polar angle 0 ... 359.99999 Specified in degrees, traversing in polar coordinates, see G0, G1, G2, G3
definition of the pole; in addition: RP − polar radius G110, G111, G112
AR Aperture angle for circular 0.00001 ... 359.99999 Specified in degrees; one possibility of defining the See G2, G3
interpolation circle when using G2/G3
CALL Indirect cycle call − Special form of the cycle call; no parameter transfer; N10 CALL VARNAME ; variable name
the name of the cycle is stored in a variable;

only intended for cycle−internal use
CHF Chamfer; 0.001 ... 99 999.999 Inserts a chamfer of the specified chamfer length N10 X... Y.... CHF=...
general use between two contour blocks N11 X... Y...
CHR Chamfer; 0.001 ... 99 999.999 Inserts a chamfer of the specified leg length between N10 X... Y.... CHR=...
in the contour definition two contour blocks N11 X... Y...
CR Radius for circular inter- 0.010 ... 99 999.999 One possibility of defining a circle when using G2/G3 See G2, G3
polation Negative sign − for
selecting the circle:
greater than semicircle
CYCLE... Machining cycle Only specified values The call of the machining cycles requires a separate
HOLES... block; the appropriate transfer parameters must be
POCKET.. loaded with values.
SLOT... Special cycle calls are also possible with an additional
MCALL or CALL.
CYCLE81 Drilling, centering N5 RTP=110 RFP=100 .... ;assign values

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N10 CYCLE81(RTP, RFP, ...) ;separate block
CYCLE82 Drilling, counterboring N5 RTP=110 RFP=100 .... ;assign values

N10 CYCLE82(RTP, RFP, ...) ;separate block
CYCLE83 Deep−hole drilling N10 CYCLE83(110, 100, ...) ;or transfer values
directly; separate block
6FC5 698−2AA10−1BP5

CYCLE84 Rigid tapping N10 CYCLE84(...) ;separate block
CYCLE840 Tapping with compensation chuck N10 CYCLE840(...) ;separate block
CYCLE85 Reaming N10 CYCLE85(...) ;separate block
CYCLE86 Boring N10 CYCLE86(...) ;separate block
CYCLE87 Boring 3 N10 CYCLE87(...) ;separate block
CYCLE88 Boring with stop N10 CYCLE88(...) ;separate block
CYCLE89 Boring 5 N10 CYCLE89(...) ;separate block
CYCLE90 Thread milling N10 CYCLE90(...) ;separate block
HOLES1 Row of holes N10 HOLES1(...) ;separate block
HOLES2 Circle of holes N10 HOLES2(...) ;separate block
SLOT1 Milling a slot N10 SLOT1(...) ;separate block
SLOT2 Milling a circumferential slot N10 SLOT2(...) ;separate block
POCKET3 Square pocket N10 POCKET3(...) separate block
POCKET4 Circular pocket N10 POCKET4(...) separate block
CYCLE71 Face milling N10 CYCLE71(...) separate block
CYCLE72 Contour milling N10 CYCLE72(...) separate block
LONG- Elongated hole N10 LONGHOLE(...) separate block

HOLE
DC Absolute coordinate; − It is also possible to specify the dimensions for the end N10 A=DC(45.3) ;Approach absolute position of the
approach position directly point of a rotary axis with DC(...) irrespective of A axis directly
(for rotary axis, spindle) G90/G91; also applies to spindle positioning N20 SPOS=DC(33.1) ;Position spindle
DEF Definition instruction Defining a local user variable of the type DEF INT VARI1=24, VARI2 ; 2 variables of the type INT
BOOL, CHAR, INT, REAL, directly at the beginning of ; the name is defined by the
the program user
DISCL Approach / retraction di- − Safety clearance for switching the velocity du- See with G147, G148 , G247, G248 , G347, G348
stance of the infeed mo- ring the infeed motion;
Programming
vement to the machining Observe: G340, G341
plane (SAR)
8-143
Programming
8-144
DISR Approach/retraction di- − G147/G148: Distance of the cutter edge from See with G147, G148 , G247, G248 , G347, G348
stance or approach/re- the starting or end point of the contour
traction radius (SAR) G247, G347/G248, G348:
Radius of the tool center point path
FAD Infeed speed − The velocity acts after reaching the safety clea- See with G147, G148 , G247, G248 , G347, G348
(SAR) rance when infeeding;
Observe: G340, G341
FXS Travel to fixed stop =1: Selection Axis: Use the machine identifier N20 G1 X10 Z25 FXS[Z1]=1 FXST[Z1]=12.3 FXSW[Z1]=2
[axis] =0: Deselection F...
FXST Clamping torque, > 0.0 ... 100.0 in %, max. 100% from the max. torque of the drive, N30 FXST[Z1]=12.3
[axis] travel to fixed stop axis: Use the machine identifier
FXSW Monitoring window, > 0.0 Unit of measurement mm or degrees, axis−specific, N40 FXSW[Z1]=2.4
[axis] travel to fixed stop axis: Use the machine identifier
GOTOB GoBack instruction − A GoTo operation is performed to a block marked by a N10 LABEL1: ...
label; the jump destination is in the direction of the pro- ...

gram start. N100 GOTOB LABEL1
GOTOF GoForward instruction − A GoTo operation is performed to a block marked by a N10 GOTOF LABEL2
label; the jump destination is in the direction of the end ...
of the program. N130 LABEL2: ...
IC Coordinate specified − The dimension can be specified for the end or center N10 G90 X10 Z=IC(20) ;Z − incremental dimension, X
using incremental dimen- point of a certain axis irrespective of G90. − absolute dimension
sions
IF Jump condition − If the jump condition is fulfilled, the jump to the next N10 IF R1>5 GOTOF LABEL3
block marked with the label: is executed; otherwise, ...
the next instruction/block is executed. N80 LABEL3: ...
Several IF instructions in a block are possible.
Comparison operands:
== equal to, <> not equal
> greater than, < less than
>= greater than or equal to
<= less than or equal to
6FC5 698−2AA10−1BP5
MEAS Measuring with deletion +1 =+1: Measuring input 1, rising edge N10 MEAS=−1 G1 X... Y... Z... F...
of the distance to go −1 =−1: Measuring input1, falling edge
MEAW Measuring without dele- +1 =+1: Measuring input 1, rising edge N10 MEAW=−1 G1 X... Y... Z... F...
tion of the distance to go −1 =−1: Measuring input1, falling edge
6FC5 698−2AA10−1BP5

$A_DBB[n] Data byte Reading and writing PLC variables N10 $A_DBR[5]=16.3 ; write real variables
$A_DBW[n] Data word ; with offset position 5
$A_DBD[n] Data double word ; (position, type and meaning are agreed between NC and
$A_DBR[n] Real data PLC)
$A_MONI- Factor for tool life monito- > 0.0 Initialization value: 1.0 N10 $A_MONIFACT=5.0 ; tool life elapsed
FACT ring 5 times faster
$AA_FXS Status, − Values: 0 ... 5 N10 IF $AA_FXS[X1]==1 GOTOF ....

[axis] travel to fixed stop axis: machine axis identifier
$AA_MM[ Measurement result for an − Axis: Identifier of an axis (X, Y, Z, ...) traversing when N10 R1=$AA_MM[X]
axis] axis in the machine coor- measuring
dinate system
$AA_MW[ Measurement result for an − Axis: Identifier of an axis (X, Y, Z, ...) traversing when N10 R2=$AA_MW[X]
axis] axis in the workpiece measuring
coordinate system
Timer for runtime: 0.0 ... 10+300 System variable:

$A..._..._ $AN_SETUP_TIME min (read−only value) Time since the control has last booted
TIME $AN_POWERON_TIME min (read−only value) Time since the control has last booted normally
$AC_OPERATING_TIME s Total runtime of all NC programs
$AC_CYCLE_TIME s Runtime of NC program (only of selected program) N10 IF $AC_CYCLE_TIME==50.5 ....
$AC_CUTTING_TIME s Tool action time
Workpiece counter: 0 ... 999 999 999, System variable:

$AC_..._ $AC_TOTAL_PARTS integer Total actual count
PARTS $AC_REQUIRED Set number of workpiece
_PARTS
$AC_ACTUAL_PARTS Current actual count N10 IF $AC_ACTUAL_PARTS==15 ....
$AC_SPECIAL_PARTS Count of workpieces − specified by the user
$AC_MEA Measurement task status − Default condition: N10 IF $AC_MEAS[1]==1 GOTOF .... ; if the probe has
[1] 0: Default condition, probe did not switch switched
1: Probe switched ; continue the program ...
$P_ Number of the active tool − read−only N10 IF $P_TOOLNO==12 GOTOF ....
TOOLNO T
$P_TOOL Active D number of the − read−only N10 IF $P_TOOL==1 GOTOF ....

active tool
Programming
$TC_MOP Tool life prewarning limit 0.0 ... in minutes, writing or reading values N10 IF $TC_MOP1[13,1]<15.8 GOTOF ....
1[t,d] for tool t, D number d
$TC_MOP Residual tool life 0.0 ... in minutes, writing or reading values N10 IF $TC_MOP2[13,1]<15.8 GOTOF ....
8-145

Programming
8-146
$TC_MOP Count prewarning limit 0 ... 999 999 999, writing or reading values N10 IF $TC_MOP3[13,1]<15 GOTOF ....
3[t,d] integer for tool t, D number d
$TC_MOP Residual count 0 ... 999 999 999, writing or reading values N10 IF $TC_MOP4[13,1]<8 GOTOF ....
$TC_MOP Set tool life 0.0 ... in minutes, writing or reading values N10 $TC_MOP11[13,1]=247.5
$TC_MOP Required count 0 ... 999 999 999, writing or reading values N10 $TC_MOP13[13,1]=715
$TC_TP8[t] Status of the tool − default status − coding by bits N10 IF $TC_TP8[1]==1 GOTOF ....
for tool t, (bit 0 to bit 4)
$TC_TP9[t] Type of monitoring of the 0 ... 2 Monitoring type for tool t, writing or reading N10 $TC_TP9[1]=2 ; Select count monitoring
tool 0: No monitoring, 1: Tool life, 2: Count
MCALL Modal subroutine call − The subroutine in the block containing MCALL is cal- N10 MCALL CYCLE82(...) ;Separate block, drilling
led automatically after each successive block contai- cycle
ning a path motion. The call acts until the next MCALL N20 HOLES1(...) ;Row of holes
is called. N30 MCALL ;separate block, modal call
Application example: Drilling a hole pattern of CYCLE82(...) completed
MSG( ) Message max. 65 characters Message text in inverted commas N10 MSG(”MESSAGE TEXT”) ; separate block
...
N150 MSG() ; cancels the previous message
OFFN Groove width with TRA- − Only effective with the tool radius compensation G41, N10 OFFN=12.4
CYL, otherwise specifica- G42 active
tion of stock allowance
RND Rounding 0.010 ... 99 999.999 Inserts a rounding with the specified radius value tan- N10 X... Y.... RND=...
gentially between two contour blocks N11 X... Y...
RP Polar radius 0.001 ... 99 999.999 Traversing in polar coordinates, definition of the pole; see G0, G1, G2; G3
in addition: AP − polar angle G110, G111, G112
RPL Angle of rotation with 0.00001 ... 359.9999 Specification in degrees; angle for a programmable see ROT, AROT
ROT, AROT rotation in the current plane G17 to G19
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SET( , , , ) Set values for the SET: Various values, from the specified element
variable fields up to: according to the number of values DEF REAL VAR2[12]=REP(4.5) ; all elements value 4.5
REP() REP: the same value, from the specified element up to N10 R10=SET(1.1,2.3,4.4) ; R10=1.1, R11=2.3, R4=4.4
the
end of the field
6FC5 698−2AA10−1BP5

SF Thread starting point 0.001 ... 359.999 Specified in degrees; the thread commencement point See G33
when using G33 with G33 is offset by the specified value (not relevant
for tapping)
SPI(n) converts the spindle num- n= 1 or n= 2

ber n into the axis identi- axis identifier: e.g. ”SP1” or ”C”
fier
SPOS Spindle position 0.0000 ... 359.9999 specified in degrees; the spindle stops at the specified N10 SPOS=....
position (to achieve this, the spindle must provide the N10 SPOS=ACP(...)
If specified incrementally appropriate technical prerequisites: position control) N10 SPOS=ACN(...)
(IC): N10 SPOS=IC(...)
0.001 ... 99 999.999 N10 SPOS=DC(...)
STOPRE Preprocessing stop − Special function; the next block is only decoded if the STOPRE ;separate block
block before STOPRE is completed.
TRACYL(d) Milling of the peripheral d: 1.000 ... 99 999.999 kinematic transformation TRACYL(20.4) ; separate block
(only available if the relevant option exists; to be confi- ; Cylinder diameter: 20.4 mm
gured) TRACYL(20.4,1) ; also possible
TRAFOOF Deactivate TRACYL − Disables all kinematic transformations TRAFOOF ; separate block
TURN Number of additional 0 ... 999 in conjunction with circular interpolation G2/G3 in a N10 G0 G17 X20 Y5 Z3
circle passes with helix in- plane G17 to G19 and infeed motion of the axis stan- N20 G1 Z−5 F50
terpolation ding vertically on the plane N30 G3 X20 Y5 Z−20 I0 J7.5 TURN=2
; in total, 3 full circles
Programming
8-147
Programming
8.2 Positional data
Programming
8.2 Positional data
8.2.1 Plane selection: G17 to G19
Functionality
To assign, for example, tool radius and tool length compensations, a plane with two axes
is selected from the three axes X, Y and Z. In this plane, you can activate a tool radius com-
pensation.
For drill and cutter, the length compensation (length1) is assigned to the axis standing verti-
cally on the selected plane (see Section 8.6 ”Tool and tool offsets”). It is also possible to use a
3−dimensional length compensation for special cases.
Another influence of plane selection is described with the appropriate functions (e.g. Section
8.5 ”Rounding, chamfer”).
The individual planes are also used to define the direction of rotation of the circle for the
circular interpolation CW or CCW. In the plane in which the circle is traversed, the abscissa
and the ordinate are designed and thus also the direction of rotation of the circle. Circles can
also be traversed in a plane other than that of the currently active G17 to G19 plane (see Sec-
tion 8.3 ”Axis movements”).
The following plane and axis assignments are possible:
Table 8-2 Plane and axis assignments
Plane Axis standing vertically on the plane

G function
(abscissa/ordinate) (length compensation axis when drilling / milling)
G17 X/Y Z
G18 Z/X Y
G19 Y/Z X
X Y
Fig. 8-3 Planes and axes when drilling/milling
Programming example
N10 G17 T... D... M... ; X/Y plane selected
N20 ... X... Y... Z... ;Tool length compensation (length1) in the Z axis
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Programming
8.2 Positional data
8.2.2 Absolute / incremental dimensioning: G90, G91, AC, IC
Functionality
By using the instructions G90/G91, the written positional data for X,Y, Z,.. are interpreted ei-
ther as a coordinate target point (G90) or as an axis path to be traversed (G91). G90/G91 ap-
plies to all axes.
Irrespective of G90/G91, certain positional data can be specified for certain blocks in absolute/
incremental dimensions using AC/IC.
These instructions do not determine the path by which the end points are reached; this is
provided by a G group (G0,G1,G2, and G3... see Section 8.3 ”Axis movements”).
Programming
G90 ; Absolute dimensioning
G91 ; Incremental dimensioning
X=AC(..) ; Absolute dimensioning for a certain axis (here: X axis), non−modal
X=IC(..) ; Incremental dimensioning for a certain axis (here: X axis), non−modal
Y Absolute dimension Y Incremental dimension
P2 P2
P3 P3
P1 P1
X X
Fig. 8-4 Different dimensioning types in the drawing
Absolute dimensioning G90

With absolute dimensioning, the dimensioning data refers to the zero point of the currently
active coordinate system (workpiece or current workpiece coordinate system or machine
coordinate system). This is dependent on which offsets are currently active: programmable,
settable, or no offsets.
Upon program start, G90 is active for all axes and remains active until it is deselected in a
subsequent block by G91 (incremental dimensioning data) (modally active).
Incremental dimensioning G91

With incremental dimensioning, the numerical value of the path information corresponds to the
axis path to be traversed. The leading sign indicates the traversing direction.
G91 applies to all axes and can be deselected in a subsequent block by G90 (absolute dimen-
sioning).
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Programming
8.2 Positional data
Specification with =AC(...), =IC(...)

After the end point coordinate, write an equality sign. The value must be specified in paren-
theses (round brackets).
Absolute dimensions are also possible for circle center points using =AC(...). Otherwise, the
reference point for the circle center is the circle starting point.
Programming example
N10 G90 X20 Z90 ;Absolute dimensioning
N20 X75 Z=IC(−32) ;X dimensioning still absolute, Z incremental dimensioning
...
N180 G91 X40 Z20 ;Switching to incremental dimensioning
N190 X−12 Z=AC(17) ;X still incremental dimensioning, Z absolute
8.2.3 Dimensions in metric units and inches: G71, G70, G710, G700
Functionality
If workpiece dimensions that deviate from the base system settings of the control are present
(inch or mm), the dimensions can be entered directly in the program. The required conversion
into the base system will then be performed by the control system.
Programming
G70 ;Inch dimensional notation
G71 ;Metric dimensional notation
G700 ;Inch dimensional notation, also for feed F
G710 ;Metric dimensional notation, also for feed F
Programming example
N10 G70 X10 Z30 ;Inch dimensional notation
N20 X40 Z50 ;G70 continues to be active
...
N80 G71 X19 Z17.3 ;Metric dimensional notation from here ...
Information
Depending on the default setting you choose, the control interprets all geometric values as
either metric or inch dimensions. Tool offsets and settable zero offsets including their displays
are also to be understood as geometrical values; this also applies to the feedrate F in mm/min
or inch/min. The default setting can be changed via machine data.
All examples listed in this Manual are based on a metric default setting.
6FC5 698−2AA10−1BP5
Programming
8.2 Positional data
G70 or G71 evaluates all geometric parameters that directly refer to the workpiece, either as
inches or metric units, for example:
S Positional data X, Y, Z, ... for G0,G1,G2,G3,G33, CIP, CT
S Interpolation parameters I, J, K (also thread pitch)
S Circle radius CR
S Programmable work offset (TRANS, ATRANS)
S Polar radius RP
All remaining geometric parameters that are not direct workpiece parameters, such as fee-
drates, tool offsets, and settable work point offsets, are not affected by G70/G71.
G700/G710 however, also affects the feedrate F (inch/min, inch/rotation or mm/min, mm/rota-
tion).
8.2.4 Polar coordinates, pole definition: G110, G111, G112
Functionality
In addition to the common specification in Cartesian coordinates (X, Y, Z), the points of a
workpiece can also be specified using polar coordinates.
Polar coordinates are also helpful if a workpiece or a part of it is dimensioned from a central
point (pole) with specification of the radius and the angle.
Plane
The polar coordinates refer to the plane activated with G17 to G19.
The 3rd axis standing vertically on this plane can additionally be specified. When doing so,
spatial specifications can be programmed as cylinder coordinates.
Polar radius RP=...

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

The angle is always referred to the horizontal axis (abscissa) of the plane (for example, with
G17: X axis). Positive or negative angle specifications are possible.
The polar angle remains stored and must only be written in blocks in which it changes, after
changing the pole or when switching the plane.
6FC5 698−2AA10−1BP5
Programming
8.2 Positional data
Point Point
Y defined by RP, AP X defined by RP, AP
RP=... RP=...
+ +
AP=... AP=...
Pole Pole
X Z
Example G17: X/Y plane Example G18: Z/X plane
Fig. 8-5 Polar radius and polar angle with definition of the positive direction in different planes
Pole definition, programming

G110 ;Pole specification, relative to the last programmed set position
(in the plane, for example, with G17: X/Y)
G111 ;Pole specification, relative to the zero point of the current
workpiece coordinate system (in the plane, for example, with G17: X/Y)
G112 ;Pole specification, relative to the last valid pole; preserve plane
Notes
S Pole definitions can also be performed using polar coordinates. This makes sense if a pole
already exists.
S If no pole is defined, the zero point of the current workpiece coordinate system will act as
the pole.
Programming example
N10 G17 ; X/Y plane
N20 G111 X17 Y36 ; Pole coordinates in the current workpiece coordinate sys-
tem
...
N80 G112 AP=45 RP=27.8 ; New pole, relative to the last pole, as a polar coordinate
N90 ... AP=12.5 RP=47.679 ; Polar coordinate
N100 ... AP=26.3 RP=7.344 Z4 ; Polar coordinate and Z axis (= cylinder coordinate)
Traversing with polar coordinates

The positions programmed using polar coordinates can also be traversed as positions speci-
fied with Cartesian coordinates as follows:
S G0 − linear interpolation with rapid traverse
S G1 − linear interpolation with feedrate
S G2 − circular interpolation CW
S G3 − circular interpolation CCW.
(see also section 8.3 ”Axis movements”)
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Programming
8.2 Positional data
8.2.5 Programmable work offset: TRANS, ATRANS
Functionality
The programmable work offset can be used for recurring forms/arrangements in various positions
on a workpiece or simply for the selection of a new reference point for the dimensional infor-
mation or as an allowance for roughing. This results in the current workpiece coordinate
system. The rewritten dimensions use this as a reference.
The offset is possible in all axes.
Programming
TRANS X... Y... Z... ;Programmable offset; clears old instructions for
offset, rotation, scaling factor, mirroring
ATRANS X... Y... Z... ;Programmable offset
additively to existing instructions
TRANS ;No values: clears old instructions for offset,
rotation, scale factor, mirroring
The instructions with TRANS/ATRANS always requires a separate block.
Y
Y
L10
X
TRANS Y...
W TRANS X... X
Fig. 8-6 Programmable offset (example)
Programming example
N20 TRANS X20 Y15 ;Programmable offset
N30 L10 ;Subroutine call, contains the geometry to be offset
...
N70 TRANS ;Offset cleared
Subroutine call − see Section 8.11 ”Subroutine technique ”
8.2.6 Programmable rotation: ROT, AROT
Functionality
The rotation is performed in the current plane G17 or G18 or G19 using the value of RPL=...
specified in degrees.
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Programming
8.2 Positional data
Programming
ROT RPL=... ;Programmable rotation, clears old instructions for offset,
AROT RPL=... ;Programmable offset, cumulative with existing ROT
instructions
;without values: clears old instructions for offset,
The instruction with ROT, AROT always requires a separate block.
Y X Z
G17 G18 G19
Rotated system
+ + +
RPL= RPL= RPL=
X Z Y
Fig. 8-7 Definition of the positive direction of the angle of rotation in the individual planes
Y L10
(N60)
45o
Y
L10
26
(N30)
X
10
20
W 30
X
Fig. 8-8 Programming example for programmable offset and programmable rotation
Programming example
N10 G17 ... ;X/Y plane
N20 TRANS X20 Y10 ;Programmable offset
N30 L10 ;Subroutine call, contains the geometry to be offset
N40 TRANS X30 Y26 ;New offset
N50 AROT RPL=45 ;Additive rotation by 45 degrees
N60 L10 ;Subroutine call
N70 TRANS ;Offset and rotation deleted
...
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Programming
8.2 Positional data
8.2.7 Programmable scaling factor: SCALE, ASCALE
Functionality
With SCALE, ASCALE, a scaling factor used to zoom in or zoom out the relevant axis can be
used for all axes.
The currently set coordinate system is used as the reference for the scale change.
Programming
SCALE X... Y... Z... ;Programmable scaling factor; clears old instructions for
offset, rotation, scaling factor, mirroring
ASCALE X... Y... Z... ; Programmable scaling factor; additively to existing instructions
SCALE ; No values: clears old instructions for offset, rotation, scaling factor,
mirroring
The instruction with SCALE, ASCALE always requires a separate block.
Notes
S For circles, the same factor should be used in both axes.
S If ATRANS is programmed with SCALE/ASCALE active, these offset values are also
scaled.
Y
Workpiece
36 N60
ATRANS X... Y...
SCALE X2 Y2
W
Original N40
5 X
Workpiece
Fig. 8-9 Example for scaling and offset
Programming example
N10 G17 ; X/Y plane
N20 L10 ; Programmed contour original
N30 SCALE X2 Y2 ; Contour twice enlarged in X and Y
N40 L10
N50 ATRANS X2.5 Y18 ; The values are also scaled!
N60 L10 ; Contour enlarged and offset
For calling a subroutine, see section 8.11 ”Subroutine technique”
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Programming
8.2 Positional data
8.2.8 Programmable mirroring: MIRROR, AMIRROR
Functionality
MIRROR and AMIRROR can be used to mirror workpiece forms on coordinate axes. All tra-
versing motions of axes for which mirroring is programmed are reversed in their direction.
Programming
MIRROR X0 Y0 Z0 ;Programmable mirroring, clears old instructions for offset, rotation, scal-
ing factor, mirroring
AMIRROR X0 Y0 Z0 ;Programmable mirroring, additive to existing instructions
MIRROR ;No values: clears old instructions for offset,
rotation, scaling factor, mirroring
The instruction with MIRROR, AMIRROR always requires a separate block. The axis value has
no influence. A value, however, must be specified.
Notes
− Any active tool radius compensation (G41/G42) is reversed automatically when mirroring.
− The direction of rotation of the circle G2/G3 is also reversed automatically when mirroring.
Y
Workpiece
mirrored in X Original
G42 G41
G2 G3
N40 N20
mirrored in Y and X X
mirrored in Y Workpiece
N80 N60
G3 G2
G41 G42
Fig. 8-10 Example for mirroring with the tool position shown
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Programming
8.2 Positional data
Programming example
Mirroring in different coordinate axes with influence on an active tool radius compensation and
G2/G3:
...
N10 G17 ; X/Y plane with Z standing vertically on it
N20 L10 ; Programmed contour with G41
N30 MIRROR X0 ; The direction is changed in X
N40 L10 ; Mirrored contour
N50 MIRROR Y0 ; The direction is changed in Y
N60 L10
N70 AMIRROR X0 ; Repeated mirroring, now in X
N80 L10 ; Contour mirrored twice
N90 MIRROR ; Mirroring OFF
...
8.2.9 Workpiece clamping − settable work offset:

G54 to G59, G500, G53, G153
Functionality
The settable work offset specifies the position of the workpiece zero point on the machine (off-
set of the workpiece zero point with respect to the machine zero point). This offset is deter-
mined upon clamping of the workpiece into the machine and must be entered in the corre-
sponding data field by the operator. The value is activated by the program by selection from
six possible groupings: G54 to G59.
Note: An inclined workpiece clamping is possible by entering the angles of rotation around the
machine axes. These rotation portions are activated with the offset G54 to G59.
For information on operation, see Section ”Setting/changing the work offset”
Programming
G54 ;1st settable work offset
G55 ;2nd settable work offset
G56 ;3rd settable work offset
G57 ;4th settable work offset
G500 ;Settable work offset OFF − modal
G53 ;Settable work offset OFF − non−modal;

also suppresses the programmable offset
G153 ;As with G53, but additionally suppresses base frame
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Programming
8.2 Positional data
Z1 (Machine) W - workpiece zero

M − machine zero
ZWorkpiece
Y Workpiece
W X
X Workpiece
ÉÉ
e.g.
G54 Y1 (Machine)
M X1(Machine)
Fig. 8-11 Settable work offset
ÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊ
Y1 (Machine)
ÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊ Y Workpiece 2
Y Workpiece 1
X Workpiece 2
G54 X Workpiece 1
G55
Y Workpiece 3 Y Workpiece 4
G56
X Workpiece 3
G57
X Workpiece 4
X1
(Machine)
Fig. 8-12 Various workpiece clamping positions when drilling/milling
Programming example
N10 G54 ... ; Call of the first settable work offset
N20 L47 ; Machining of workpiece 1, here as L47
N30 G55 ... ; Call of the second settable work offset
N50 G56 ... ; Call of the third settable work offset
N70 G57 ... ; Call of the fourth settable work offset
N90 G500 G0 X... ; Deactivating the settable work offset
6FC5 698−2AA10−1BP5
Programming
8.2 Positional data
8.2.10 Programmable working area limitation:

G25, G26, WALIMON, WALIMOF
Functionality
With G25, G26, a working area can be defined for all axes in which it is possible to traverse,
with no traversing allowed outside this area. With the tool length compensation active, the tool
tip is decisive; otherwise, the toolholder reference point. The coordinate parameters are ma-
chine−based.
In order to use the working area limitation, it must be activated in the setting data (under Off-
set/Setting data/Work area limit) for the respective axis. In this dialog, the values for the work-
ing area limitation can be also be preset. This makes them effective in the JOG mode. In the
part program, the values for the individual axes can be changed with G25/G26, whereby the
values of the working area limitation in the setting data are overwritten. The working area limi-
tation is enabled/disabled in the program by WALIMON/WALIMOF.
Programming
G25 X... Y... Z... ; Lower working area limitation
G26 X... Y... Z... ; Upper working area limitation
WALIMON ; Working area limitation ON

WALIMOF ; Working area limitation OFF
WZL = active tool length compensation

Z1
(Machine)
F
Z G26
Working
area
M Tool tip
X1
Z (Machine)
G25
X G25 X G26
Fig. 8-13 Programmable working area limitation (example: 2−dimensional)
Notes
S For G25, G26, the channel axis identifier consisting of machine data 20080: AX-
CONF_CHANAX_NAME_TAB is to be used. These can be other than the geometry axis
identifiers in MD 20060: AXCONF_GEOAX_NAME_TAB.
S G25 / G26 is also used in connection with the address S for the spindle speed limitation
(see also Section ”Spindle speed limitation”).
S A working area limitation can only be activated if the reference point for the relevant axes
has been approached.
6FC5 698−2AA10−1BP5
Programming
8.2 Positional data
Programming example
N10 G25 X10 Y−20 Z30 ; Lower working area limitation values
N20 G26 X100 Y110 Z300 ; Upper working area limitation values
N30 T1 M6
N40 G0 X90 Y100 Z180
N50 WALIMON ; Working area limitation ON
... ; Work only within the limitation
N90 WALIMOF ; Working area limitation OFF
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
8.3 Axis movements
8.3.1 Linear interpolation with rapid traverse: G0
Functionality
The rapid traverse movement G0 is used for rapid positioning of the tool, but not for direct
workpiece machining.
All axes can be traversed simultaneously. This results in a straight path.
For each axis, the maximum speed (rapid traverse) is defined in machine data. If only one
axis traverses, it uses its rapid traverse. If two or three axes are traversed simultaneously, the
path velocity (e.g. the resulting velocity at the tool tip) must be selected such that the maxi-
mum possible path velocity with consideration of all axes involved results.
A programmed feedrate (F word) has no meaning for G0.
G2/G3 remains active until canceled by another instruction from this G group (G0, G1, ...).
Programming
G0 X... Y... Z... ; Cartesian coordinates
G0 AP=... RP=... ; Polar coordinates
G0 AP=... RP=... Z... ; Cylinder coordinates (3−dimensional)
Note: Another option for linear programming is available with the angle specification ANG=...
(see Section 8.5.2 ”Blueprint programming”).
Z Y
P1
Straight path P2
X
Fig. 8-14 Linear interpolation with rapid traverse from point P1 to P2
Programming example
N10 G0 X100 Y150 Z65 ; Cartesian coordinate
...
N50 G0 RP=16.78 AP=45 ; Polar coordinate
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Information
Another group of G functions exists for movement to the position (see Section 8.3.15 ”Exact
stop / continuous−path control mode: G60, G64”).
For G60 exact stop, a window with various precision values can be selected with another G
group. For exact stop, an alternative instruction with non−modal effectiveness exists: G9.
You should consider these options for adaptation to your positioning tasks.
8.3.2 Linear interpolation with feedrate: G1
Functionality
The tool moves from the starting point to the end point along a straight path. The pro-
grammed F word is decisive for the path velocity.
All axes can be traversed simultaneously.
G1 remains active until canceled by another instruction from this G group (G0, G2, G3, ...).
Programming
G1 X... Y... Z... F... ; Cartesian coordinates
G1 AP=... RP=... F... ; Polar coordinates
G1 AP=... RP=... Z... F... ; Cylinder coordinates (3−dimensional)
Note: Another option for linear programming is available with the angle specification ANG=...
(see Section 8.5.2 ”Blueprint programming”).
Y 12
P1
48
18
P2
20 X 10 Z
40 15
Fig. 8-15 Linear interpolation in three axes using the example of a slot
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example
N05 G0 G90 X40 Y48 Z2 S500 M3 ;Tool traverses to P1 at rapid traverse,
3 axes simultaneously,
spindle speed = 500 rpm, CW rotation
N10 G1 Z−12 F100 ;Infeed to Z−12, feedrate 100 mm/min
N15 X20 Y18 Z−10 ;Tool traverses along a straight line in the space to P2
N20 G0 Z100 ;Retraction at rapid traverse
N25 X−20 Y80
To machine a workpiece, spindle speed S ... and direction M3/M4 are required (see Section
”Spindle movement”).
8.3.3 Circular interpolation: G2, G3
Functionality
The tool moves from the starting point to the end point along a circular path. The direction is
determined by the G function:
G2 ; CW
G3 ; CCW
Y X Z
G2 G2 G2
G3 G3 G3
X Z Y
Fig. 8-16 Definition of the direction of rotation of the circle G2/G3 in the 3 possible planes
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
The description of the desired circle can be given in various ways:

G2/G3 and center point parameter (+end point): G2/G3 and radius parameter (+end point):
Y End point X, Y Y End point X, Y
e.g. G2 X... Y... I... J... e.g. G2 X... Y...CR=...
Circle radiusCR
Center point I, J
Starting point X, Y Starting point X, Y
X X
G2/G3 and aperture angle parameter G2/G3 and aperture angle parameter (+end point):
Y (+center point): Y
End point X, Y
e.g. G2 AR=... I... J... e.g. G2 AR=... X...Y...
Angle AR Angle AR
Center point I, J
Starting point X, Y Starting point X, Y
X X
Fig. 8-17 Possibilities of circle programming with G2/G3 using the example of the axes X/Y
G2/G3 acts until it is canceled by another instruction from this G group (G0, G1, ...).
For the path velocity, the programmed F word is decisive.
Programming
G2/G3 X... Y... I... J... ; Center and end points
G2/G3 CR=... X... Y... ; Circle radius and end point
G2/G3 AR=... I... J... ; Aperture angle and center point
G2/G3 AR=... X... Y... ; Aperture angle and end point
G2/G3 AP=... RP=... ; Polar coordinates, circle around the pole
Note
Additional options for circular path programming are available with
CT − circle with tangential connection and
CIP − circle via intermediate point (see next sections).
Input tolerances for the circle

Circles are only accepted by the control system with a certain dimensional tolerance. The
circle radius at the starting and end points are compared here. If the difference is within the
tolerance, the center point is exactly set internally. Otherwise, an alarm message is issued.
The tolerance value can be set via machine data.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Information
Full circles in a block are only possible if the center point and the end point are specified!
For circles with radius specification, the arithmetic sign of CR=... is used to select the correct
circle. It is possible to program 2 circles with the same starting and end points, as well as with
the same radius and the same direction. The negative sign with CR=−... defines the circle
whose circle segment is larger than a semicircle; otherwise, the circle with the circle segment
smaller or larger than the semicircle is defined as follows:
Y Circle larger than semicircle

G2
MP1 − center point of the circle 1
MP2 − center point of the circle 2
MP1
G2 End point
Circle smaller than or equal to semicircle

Starting point
MP2
X
Fig. 8-18 Selection of the circle from two possible circles with radius specification via the sign of
CR=
Programming example for center point and end point specification:
Y
Starting point
End point
J
Center point
40
33
KI
X
30
40
50
Fig. 8-19 Example for center point and end point specification
N5 G90 X30 Y40 ;Circle starting point for N10

N10 G2 X50 Y40 I10 J−7 ;End point and center point
Note: Center point values refer to the circle starting point!
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example for end point and radius specification:
Y
Starting point
End point
Center point ?
40
X
30
50
Fig. 8-20 Example for end point and radius specification

N10 G2 X50 Y40 CR=12.207 ;End point and radius
Note: With a negative leading sign for the value with CR=−..., a circular segment larger than a
semicircle is selected.
Programming example for end point and aperture angle:
Y
Starting point
End point
1050
Center point ?
40
X
30
50
Fig. 8-21 Example for end point and aperture angle specification

N10 G2 X50 Y40 AR=105 ;End point and aperture angle
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example for center point and aperture angle:
Y
Starting point
End point ?
J 1050
40 Center point
33
X
30
40
Fig. 8-22 Example for center point and aperture angle specification

N10 G2 I10 J−7 AR=105 ;Center point and aperture angle
Note: Center point values refer to the circle starting point!
Programming example for polar coordinates:
Y
Starting point
AP=
Center point = pole

40
33
X
30
40
Fig. 8-23 Example for circle with polar coordinates
N1 G17 ;X/Y plane

N5 G90 G0 X30 Y40 ;Circle starting point for N10
N10 G111 X40 Y33 ;Pole = circle center point
N20 G2 RP=12.207 AP=21 ;Polar specifications
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
8.3.4 Circular interpolation via intermediate point: CIP
Functionality
If you know three contour points of the circle, instead of center point or radius or aperture
angle, then it as advantageous to use the CIP function.
The direction of the circle results here from the position of the intermediate point (between
starting and end points). The intermediate point is written according to the axis assignment as
follows:
I1=... for the X axis, J1=... for the Y axis, K1=... for the Z axis.
CIP remains active until canceled by another instruction from this G group (G0, G1, G2, ...).
Note: The configured dimensional data G90 or G91 applies to the end point and the inter-
mediate point.
Y Intermediate point
I1=... J1=...
Starting point End point

45
40
X
30
40
50
Fig. 8-24 Circle with end point and intermediate point specification using the example of G90
Programming example
N10 CIP X50 Y40 I1=40 J1=45 ;End point and intermediate point
8.3.5 Circle with tangential transition: CT
Functionality
With CT and the programmed end point in the current plane G17 through G19, a circle is gen-
erated which is connected tangentially to the previous path segment (circle or straight line) in
this plane.
This defines the radius and center point of the circle from the geometric relationships of the
previous path section and the programmed circle end point.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
N10 G1 ...
N20 CT...
End point of the circle

e.g.: G17
Y
X
Fig. 8-25 Circle with tangential transition to the previous path section
Programming example
N10 G1 X20 F300 ; Straight line
N20 CT X... Y... ; Circle with tangential connection
8.3.6 Helix interpolation: G2/G3, TURN
Functionality
With helix interpolation, two movements are overlaid:
− the circular movement in plane G17 or G18 or G19, and
− the linear movement of the axis standing vertically on this plane.
The number of additional full−circle passes is programmed with TURN=. These are added to
the actual circle programming.
The helix interpolation can preferably be used for the milling of threads or of lubricating
grooves in cylinders.
Programming
G2/G3 X... Y... I... J... TURN=... ; Center and end points
G2/G3 CR=... X... Y... TURN=... ; Circle radius and end point
G2/G3 AR=... I... J... TURN=
; Aperture angle and center point
G2/G3 AR=... X... Y... TURN... ; Aperture angle and end point
G2/G3 AP=... RP=... TURN=
; Polar coordinates, circle around the pole
Fig. 8-26 Helix interpolation:
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example
N10 G17 ;X/Y plane, Z standing vertically on it
N20 ... Z...
N30 G1 X0 Y50 F300 ;Approach starting point
N40 G3 X0 Y0 Z33 I0 J−25 TURN= 3 ;Helix
...
8.3.7 Thread cutting with constant lead: G33
Functionality
This requires a spindle with position measuring system.
The function G33 can be used to machine threads with constant lead of the following type: If
an appropriate tool is used, tapping with compensating chuck is possible.
The compensating chuck compensates the resulting path differences to a certain limited de-
gree.
The drilling depth is specified via one of the axes X, Y or Z; the thread lead is specified via the
relevant I, J or K.
G33 remains active until canceled by another instruction from this G group (G0, G1, G2, G3,
...).
Right−hand or left−hand threads

Right−hand or left−hand threads are set with the rotation direction of the spindle (M3 right
(CW), M4 left (CCW) − see Section 8.4 ”Spindle movement”). To do this, the rotation value
must be programmed under address S or a rotation speed set.
Remark:
A complete cycle of tapping with compensating chuck is provided by the standard cycle
CYCLE84.
Fig. 8-27 Tapping using G33
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example
Metric thread 5 ,
lead as per table: 0.8 mm/rev., tap hole already premachined:
N10 G54 G0 G90 X10 Y10 Z5 S600 M3 ; Approach starting point, CW spindle rotation
N20 G33 Z−25 K0.8 ; Tapping, end point −25 mm
N40 Z5 K0.8 M4 ; Retraction, CCW spindle rotation
N50 G0 X... Y... Z...
Axis velocity
With G33 threads, the velocity of the axis for the thread lengths is determined on the basis of
the spindle speed and the thread lead. The feedrate F is not relevant. It is, however, stored.
However, the maximum axis velocity (rapid traverse) defined in the machine data can not be
exceeded. This will result in an alarm.
Information
Important
S The spindle speed override switch should remain unchanged for thread machining.
S The feedrate override switch has no meaning in this block.
8.3.8 Tapping with compensating chuck: G63
Functionality
G63 can be used for tapping with compensating chuck. The programmed feedrate F must
match with the spindle speed S (programmed under the address ”S” or specified speed) and
with the thread lead of the drill:
F [mm/min] = S [rpm] x thread lead [mm/rev.]
The compensating chuck compensates the resulting path differences to a certain limited de-
gree.
The drill is retracted using G63, too, but with the spindle rotating in the opposite direction M3
<−> M4.
G63 is non−modal. In the block after G63, the previous G command of the ”Interpolation type”
group (G0, G1,G2, ...) is active again.

Right−hand or left−hand threads are set with the rotation direction of the spindle (M3 right
(CW), M4 left (CCW) − see Section 8.4 ”Spindle movement”).
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Remark:
The standard cycle CYCLE840 provides a complete tapping cycle with compensating chuck
(but with G33 and the relevant prerequisites).
Fig. 8-28 Tapping using G63
Programming example
Metric thread 5 ,
N10 G54 G0 G90 X10 Y10 Z5 S600 M3 ; Approach starting point, CW spindle rotation
N20 G63 Z−25 F480 ; Tapping, end point −25 mm
N40 G63 Z5M4 ; Retraction, CCW spindle rotation
N50 X... Y... Z...
8.3.9 Thread Interpolation: G331, G332
Functionality
This function requires a position−controlled spindle with position measuring system.
By using G331/G332, threads can be tapped without compensating chuck, if the dynamics of
the spindle and the axis allow it.
If, however, a compensating chuck is used, the path differences to be compensated by the
compensating chuck are reduced. This allows tapping at higher spindle speeds.
Drilling is done using G331, retraction is done using G332.
The drilling depth is specified via one of the axes X, Y or Z; the thread lead is specified via the
relevant I, J or K.
For G332, the same lead is programmed as for G331. Reversal of the spindle’s direction of
rotation occurs automatically.
The spindle speed is programmed with S, and without M3/M4.
Before tapping the thread with G331/G332, the spindle must be switched to the position con-
trolled mode with SPOS=... (see also Section 8.4.3 ”Spindle positioning”).
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements

The leading sign of the thread lead determines the direction of spindle rotation:
Positive: Right−hand (as with M3)
Negative: Left−hand (as with M4)
Remark:
A complete thread tapping cycle with thread interpolation is provided with the standard cycle
CYCLE84.
Fig. 8-29 Tapping using G331/G332
Axis velocity
For G331/G332, the speed of the axis for the thread length results from the spindle speed and
the thread lead. The feedrate F is not relevant. It is, however, stored. However, the maxi-
mum axis velocity (rapid traverse) defined in the machine data can not be exceeded. This will
result in an alarm.
Programming example
Metric thread 5 ,
N5 G54 G0 G90 Y10 Z5 ;Approach starting point
N10 SPOS=0 ;Spindle in position control mode
N20 G331 Z−25mm K0.8 S600 ;Thread tapping, K positive = clockwise
rotation of the spindle, end point −25 mm
N40 G332 Z5 K0.8 ;Retraction
N50 G0 X...Y... Z...
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
8.3.10 Fixed point approach: G75
Functionality
By using G75, a fixed point on the machine, e.g. tool change point, can be approached. The
position is stored permanently in the machine data for all axes. No offset is effective. The
speed of each axis is its rapid traverse.
G75 requires a separate block and is non−modal. The machine axis identifier must be pro-
grammed!
In the block after G75, the previous G command of the ”Interpolation type” group (G0, G1,G2,
...) is active again.
Programming example
N10 G75 X1=0 Y1=0 Z1=0
Remark: The programmed position values for X1, Y1 (any value, here = 0) are ignored, but
must still be written.
8.3.11 Reference point approach: G74
Functionality
The reference point can be approached in the NC program with G74. The direction and speed
of each axis are stored in machine data.
G74 requires a separate block and is non−modal. The machine axis identifier must be pro-
grammed!
In the block after G74, the previous G command of the group ”interpolation type” (G0, G1, G2,
...) is active again.
Programming example
N10 G74 X1=0 Y1=0 Z1=0
Remark: The programmed position values for X1, Y1 (any value, here = 0) are ignored, but
must still be written.
8.3.12 Measuring with touch−trigger probe: MEAS, MEAW
Functionality
If the instruction MEAS=... or MEAW=... is in a block with traversing movements of axes, the
positions of the traversed axes for the switching flank of a connected measuring probe are
registered and stored. The measurement result can be read for each axis in the program.
For MEAS, the movement of the axes is halted when the selected switching flank of the probe
appears and the remaining distance to go is deleted.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming
MEAS=1 G1 X... Y... Z... F... ; Measuring with rising edge of the probe,
delete distance−to−go
MEAS=−1 G1 X... Y... Z... F... ; Measuring with falling edge of the probe,
delete distance−to−go
MEAS=1 G1 X... Y... Z... F... ; Measuring with rising edge of the probe,
without deletion of the distance−to−go
MEAS=−1 G1 X... Y... Z... F... ; Measuring with falling edge of the probe,
without deletion of the distance−to−go
Caution
For MEAW: Measuring probe travels to the programmed position even after is has triggered.
Risk of destruction!
Measurement task status

If the probe has switched, the variable $AC_MEA[1] after the measuring block has the value
=1; otherwise, the value =0.
At the start of a measuring block, the variable is set to the value=0.
Measurement result
When the measuring probe is successfully activated, the result of the measurement is avail-
able after the measuring block with the following variables for the axes traversed in the mea-
suring block:
in the machine coordinate system:
$AA_MM[axis]
in the workpiece coordinate system:
$AA_MW[ axis]
Programming example
N10 MEAS=1 G1 X300 Z−40 F4000 ; Measuring with deletion of the distance−
to−go, rising edge
N20 IF $AC_MEA[1]==0 GOTOF MEASERR ; Measuring error ?
N30 R5=$AA_MW[X] R6=$AA_MW[Z] ; Process measured values
..
N100 MEASERR: M0 ; Measuring error
Note: IF instruction − see Section ”Conditional program jumps”
8.3.13 Feedrate F
Functionality
The feed F is the path velocity and represents the value of the geometric sum of the velocity
components of all involved axes. The individual axis velocities therefore result from the portion
of the axis path in the overall distance to be traversed.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
The feedrate F is effective for the interpolation types G1, G2, G3, CIP, and CT and is retained
until a new F word is written.
Programming
F...
Remark:
For integer values, the decimal point is not required, e.g. F300.
Unit of measure for F with G94, G95

The dimension unit for the F word is determined by G functions:
S G94 F as the feedrate in mm/min
S G95 F as feed in mm/rev. of the spindle
(only meaningful if the spindle is turning!)
Remark:
This unit of measure applies to metric dimensions. According to Section ”Metric and inch di-
mensioning”, settings with inch dimensioning are also possible.
Programming example
N10 G94 F310 ;Feedrate in mm/min
...
N110 S200 M3 ;Spindle rotation
N120 G95 F15.5 ;Feedrate in mm/rev.
Remark: Write a new F word if you change G94 − G95!
8.3.14 Feedrate override for circles: CFTCP, CFC
Functionality
With the tool radius compensation activated (G41/G42, see Section 8.6.4) and circle pro-
gramming, it is imperative to correct the feedrate at the cutter center point if the pro-
grammed F value is to act at the circle contour.
Internal and external machining of a circle and the current tool radius are taken into account
automatically if the tool radius compensation is enabled.
This feedrate correction (override) is not necessary for linear paths; the path velocities at the
cutter center point and at the programmed contour are identical.
If you wish the programmed feedrate always to act at the cutter center point path, then disable
the feedrate override. The modally acting G group that contains CFTCP/CFC (G functions) is
provided for switching.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming
CFTCP ;Feedrate override OFF (programmed feedrate acts at the cutter center point)
CFC ;Feedrate override with circle ON
Fprogr.
M
Fcorr.
M
Fprogr.
Fprogr. −Programmed feedrate value F

Fcorr. − Corrected feedrate at the cutter center point
Fig. 8-30 Feedrate override G901 with internal / external machining
Corrected feedrate
S External circle machining: Fcorr. = Fprogr. (rcont + rtool) / rcont
S Internal circle machining: Fcorr. = Fprogr. (rcont − rtool) / rcont
rcont : Radius of the circle contour
rtool: Tool radius
Programming example
N10 G42 ... ;Tool radius compensation ON
N20 CFC ... ;Feedrate override for circle ON
N30 G2 X... Y... I... J... F350 ;Feedrate value acts at the contour
N40 G3 X... Y... I... J... ;Feedrate value acts at the contour
...
N70 CFTCP ;Feedrate override OFF, programmed
feedrate value acts at the cutter center point
8.3.15 Exact stop / continuous−path control mode: G9, G60, G64
Functionality
To set the movement behavior at the block limits and to continue with the next block, G func-
tions are provided for optimum adaptation to different requirements. Example: For example,
you would like to quickly position with the axes or you would like to machine path contours
over multiple blocks.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming
G60 ;Exact stop − modally effective
G64 ;Continuous−path−control mode
G9 ;Exact stop − non−modal
G601 ;Exact stop fine window

G602 ;Exact stop coarse window
Exact stop G60, G9

If the exact stop function (G60 or G9) is active, the velocity for reaching the exact end position
at the end of a block is decelerated to zero.
Another modal G group can be used here to set when the traversing movement of this block is
considered ended and the next block is started.
S G601 Exact stop window fine
Block advance takes place when all axes have reached the ”Exact stop window fine”
(value in the machine data).
S G602 Exact stop window coarse
Block advance takes place when all axes have reached the ”Exact stop window coarse”
(value in the machine data).
The selection of the exact stop window has a significant influence on the total time if many
positioning operations are executed. Fine adjustments require more time.
Y Block change enable

for ”coarse” / for ”fine”
G602 (coarse)
G601
(fine)
Fig. 8-31 Exact stop window coarse or fine, in effect for G60/G9; enlarged display of the windows
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming example
N5 G602 ;Exact stop window coarse
N10 G0 G60 X... ;Exact stop modal
N20 X... Y... ;G60 is still effective
...
N50 G1 G601 ... ;Exact stop window fine
N80 G64 Z... ;Switching to continuous−path control mode
...
N100 G0 G9 Z... ;Exact stop is only effective for this block
N111 ... ;Continuous−path control mode again
Remark: The command G9 only creates exact stop for the block in which it is programmed;
G60, however, is active until it is canceled by G64.
Continuous−path control mode G64

The objective of the continuous−path control mode is to avoid deceleration at the block bound-
aries and to switch to the next block with the most constant path velocity possible (during
tangential transitions). The function works with look−ahead velocity control via several
blocks.
For non−tangential transitions (corners), the velocity can reduced rapidly enough so that the
axes are subject to a relatively high velocity change over a short time. This may lead to a sig-
nificant jerk (acceleration change). The magnitude of the jerk can be limited by activating the
SOFT function.
Programming example
N10 G64 G1 X... F... ;Continuous−path control mode
N20 Y.. ;Continuous−path control mode continued
...
N180 G60 ... ;Switching to exact stop
Look−ahead velocity control
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Programming
8.3 Axis movements
In the continuous−path control mode with G64, the control system automatically determines
the velocity control for several NC block in advance. This enables acceleration and decelera-
tion across multiple blocks with almost tangential transitions. For paths that consist of short
sections in the NC blocks, higher velocities can be achieved than without look ahead.
Feedrate
G64 − Continuous−path mode with LookAhead
Programmed feed F
F1
G60 − exact stop
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 Block path
Fig. 8-32 Comparison of the G60 and G64 velocity behavior with short paths in the blocks
8.3.16 Acceleration pattern: BRISK, SOFT
BRISK
The axes of the machine change their speeds using the maximum allowable acceleration
value until reaching the final speed. BRISK allows time−optimized working. The set velocity is
reached in a short time. However, jumps are present in the acceleration pattern.
SOFT
The axes of the machine accelerate along a nonlinear, constant characteristic until reaching
the final velocity. With this jerk−free acceleration, SOFT allows for reduced machine load. The
same behavior can also be applied to braking procedures.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Velocity
(path) BRISK SOFT
(time−optimized) (spares the mechanical parts)
Setpoint
t1 t2 Time
Fig. 8-33 Principle course of the path speed when using BRISK/SOFT
Programming
BRISK ;Stepped path acceleration
SOFT ;Path acceleration with jerk limitation
Programming example
N10 SOFT G1 X30 Z84 F650 ;Path acceleration with jerk limitation
...
N90 BRISK X87 Z104 ;Continue with stepped path acceleration
...
8.3.17 Percentage acceleration override: ACC
Functionality
In certain program sections, it can be necessary to change the axis or spindle acceleration set
via machine data via the program. This programmable acceleration is a percentage
acceleration correction.
For each axis (e.g.: X) or spindle (S), a percentage value 0% and v 200% can be
programmed. The axis interpolation is then carried out with this proportional acceleration. The
reference value (100%) is the valid machine data value for the acceleration (depending on
whether it is the axis or spindle; for the spindle it depends further on the gear step and
whether it is positioning mode or speed mode).
Programming
ACC[axis name]= percentage value ;for the axis
ACC[S]= percentage value ;for the spindle
Programming example
N10 ACC[X]=80 ; 80% acceleration for the X axis
N20 ACC[S]=50 ; 50% acceleration for the spindle
...
N100 ACC[X]=100 ; Deactivate override for the X axis
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Activation
The limitation is effective in all interpolation types of the AUTOMATIC and MDA modes. The
limitation is not active in the JOG mode and during reference point approach.
The override is disabled by assigning the value ACC[...] = 100; this can also be achieved
using RESET and end of program.
The programmed override value is also active with dry run feedrate.
Caution
A value greater than 100% may only be programmed if this load is permissible for the
machine mechanics and the drives have the corresponding reserves. Failure to adhere to the
limits can lead to damage to the mechanical parts and/or error messages.
8.3.18 Traversing with feedforward control: FFWON, FFWOF
Functionality
The feedforward control reduces the following error approximately to zero.
Traversing with feedforward control permits higher path accuracy and thus improved machin-
ing results.
Programming
FFWON ; Feedforward control ON
FFWOF ; Feedforward control OFF
Programming example
N10 FFWON ; Feedforward control ON
N20 G1 X... Y... F900
...
N80 FFWOF ; Feedforward control OFF
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
8.3.19 4th axis
Functionality
Depending on the machine design, a 4th axis could be necessary, for example, if the machine
possesses a rotary table, a swing table or the like. The 4th axis can be designed either as a
linear or as a rotary axis. Accordingly, the identifier for this axis can be configured, e.g.: U, C,
or A etc. For rotary axes, the traversing range can be configured between 0 ...< 360 degrees
(modulo−behavior).
The 4th axis can be linear traversed with the remaining axes at the same time with a corre-
sponding machine design. If the axis is traversed in a block with G1 or G2/G3 with the remain-
ing axes (X, Y, Z), it is not assigned a component of the feedrate F; its velocity will depend on
the path time of the X, Y and Z axes. Its ”linear” movement starts and ends with the remaining
path axes. The velocity, however, must not be greater than the defined limiting value.
If only this 4th axis is programmed in a block, with G1, the axis will traverse with the active
feedrate F. If it is a rotary axis, the unit of measurement for F is correspondingly degrees/min
(with G94) or degrees/revolution of the spindle (with G95).
For this axis, it is also possible to specify (G54 ... G57) and program (TRANS, ATRANS) off-
sets.
Programming example
Assumed the 4th axis is swivel table (rotary axis) and has the axis identifier A:
N5 G94 ; F in mm/min or degrees/min
N10 G0 X10 Y20 Z30 A45 ; Traverse X−Y−Z path with rapid traverse, A simultaneously
N20 G1 X12 Y21 Z33 A60 F400 ; X−Y−Z path at 400 mm/min, A − simultaneously
N30 G1 A90 F3000 ; A axis traverses alone to 90 deg. position
at a velocity of 3,000 degrees/min
Special instructions for rotary axes: DC, ACP, ACN

e.g. for rotary axis A:
A=DC(...) ; Absolute dimensions, approach position directly (along shortest
path) Absolute dimensions, approach position in positive direction Absolute dimensions, ap-
proach position in negative direction
Example:
N10 A=ACP(55.7) ; Absolute position 55.7 degrees; approach position in positive direc-
tion
8.3.20 Dwell Time: G4
Functionality
Between two NC blocks, you can interrupt the machining for a defined time by inserting a sep-
arate block with G4, for example, for relief cutting.
The words with F... or S... are only used for this block for the specified time. Any previously
programmed feedrate F and a spindle speed S remain valid.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Programming
G4 F... ;Dwell time in seconds
G4 S... ;Dwell time in spindle rev.’s
Programming example
N5 G1 F200 Z−50 S300 M3 ;Feedrate F, spindle speed S
N10 G4 F2.5 ;Dwell time 2.5 s
N20 Z70
N30 G4 S30 ;Dwell for 30 spindle revolutions, with S=300 rpm and
a speed override of 100 %, this corresponds to: t=0.1 min
N40 X... ;Feedrate and spindle speed continue to be effective
Remark
G4 S.. is only possible if a controlled spindle is available (if the speed preset is also pro-
grammed via S...).
8.3.21 Travel to fixed stop
Functionality
This function is an option and available as of SW 2.0.
The travel to fixed stop (FXS = Fixed Stop) function can be used to establish defined forces
for clamping workpieces, such as those required for sleeves and grippers. This function can
also be used for approaching mechanical reference points. With sufficiently reduced torque, it
is also possible to perform simple measurement operations without connecting a probe.
Programming
FXS[axis]=1 ; Select ”Travel to fixed stop”
FXS[axis]=0 ; Deselect ”Travel to fixed stop”
FXST[axis]=... ; Clamping torque, specified in % of the max. torque of the drive
FXSW[axis]=... ; Width of the window for fixed−stop monitoring in mm/degrees
Remark: The machine axis identifier, e.g: X1, should be used as the axis identifier. X1. The
channel axis identifier (e.g.: X) is only permitted, if e.g. no coordinate rotation is active and this
axis is directly assigned to a machine axis.
The commands are modal. The traversing path and the selection of the function FXS[axis]=1
must be programmed in a separate block.
Programming example − selection

N10 G1 G94 ...
N100 X250 Z100 F100 FXS[Z1]=1 FXST[Z1]=12.3 FXSW[Z1]=2
; For the Z1 machine axis FXS function selected,
; Clamping torque 12.3%,
; Window width 2 mm
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Notes
S When selected, the fixed stop must be located between the start and end positions.
S Torque (FXST[ ]= ) and window width (FXSW[ ]= ) may be specified optionally. If they are
not written, the value of the existing setting data are used. Programmed values are im-
ported into the setting data. At the start, the setting data are loaded with values from ma-
chine data. FXST[ ]=... or FXSW[ ]=... can be changed at any time in the program. The
changes are active before traversing movements in the block.
Actual position after

”Travel to fixed stop”
Fixed stop
Start position
(tool tip)
Programmed end position Fixed−stop

monitoring window
Fig. 8-34 Example of travel to fixed stop: The tool is approached against a
stop
Further programming examples

N10 G1 G94 ...
N20 X250 Z100 F100 FXS[X1]=1 ; FXS selected for machine axis X1
Clamping torque and window width as
specified in the SDs
N20 Y250 Z100 F100 FXS[X1]=1 FXST[X1]=12.3 ; FXS selected for machine axis X1
Clamping torque 12.3 %, window width as
specified in the SDs
N20 X250 Y100 F100 FXS[X1]=1 FXST[X1]=2 ; FXS selected for machine axis X1 FXS
Clamping torque 12.3%,

window width 12,3 mm
N20 X250 Z100 F100 FXS[X1]=1 FXSW[X1]=2 ; FXS selected for machine axis
X1, clamping torque as
specified in the SD, window
width 2 mm
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
Fixed stop reached

After the fixed stop has been reached:
S The distance to go is deleted and the position setpoint is followed up.
S The drive torque increases to the programmed limit value FXST[ ]=... or the value from SD
and then remains constant.
S The monitoring of the fixed stop is active within the specified window width
(FXSW[ ]=... or value from SD ).
Deselecting the function

Deselecting the function results in a preprocessing stop. In the block with FXS[X1]=0, travers-
ing movements should stop.
Example:
N200 G1 G94 X200 Y400 F200 FXS[X1] = 0 ;The X1 axis is retracted to the position
X= 200 mm.
Important
The traversing motion to the retraction position must lead away from the fixed stop; otherwise, the
fixed stop or the machine may be damaged.
The block change takes place when the retraction position has been reached. If no retraction
position is specified, the block change takes place immediately after the torque limit has been
deactivated.
Further information
S ”Measure and delete distance−to−go” (MEAS command) and ”Travel to fixed stop” cannot
be programmed in the same block.
S Contour monitoring is not performed while ”Travel to fixed stop” is active.
S If the torque limit is reduced too far, the axis will not be able to follow the specified setpoint;
the position controller then goes to the limit and the contour deviation increases. In this
operating state, an increase in the torque limit may result in sudden, jerky movements. To
make sure that the axis may still follow, make sure that the contour deviation is not greater
than with unlimited torque.
S A rate of rise ramp for the new torque limit can be defined in MD to prevent any abrupt
changes to the torque limit setting (e.g. insertion of a spindle sleeve or quill).
System variable for status: $AA_FXS[axis]

This system variable provides the ”Travel to fixed stop” status for the axis specified:
Value = 0: Axis not at stop
1. Stop was approached successfully
(axis is within fixed−stop monitoring window)
2: Approach to fixed stop has failed (axis is not at fixed stop)
Travel to fixed stop activated
4: Fixed stop was detected
5: Travel to fixed stop is deselected. The deselection is not yet completed.
The interrogation of the system variable in the part program triggers a preprocessing stop.
6FC5 698−2AA10−1BP5
Programming
8.3 Axis movements
With the SINUMERIK 802D, only the static states before selection/deselection may be ac-
quired.
Alarm suppression
The issuing of the following alarms can be suppressed with machine data:
S 20091 ”Fixed stop not reached”
S 20094 ”Fixed stop aborted”
References: ”Description of Functions”, Section ”Travel to fixed stop”
6FC5 698−2AA10−1BP5
Programming
8.4 Spindle movements
8.4.1 Spindle speed S, directions of rotation
Functionality
The spindle speed is programmed under the address S in RPM, if the machine has a con-
trolled spindle.
The direction of rotation and the start or end of the movement are specified via M commands
(also see Section 8.7 ”Miscellaneous function M”).
M3 Spindle CW
M4 Spindle CCW
M5 Spindle STOP
Remark: For integer S values, the decimal point can be omitted, e.g. S270
Information
If you write M3 or M4 in a block with axis movements, the M commands become active be-
fore the axis movements.
Default setting: The axis movements will only start once the spindle has accelerated to
speed (M3, M4). M5 is also issued before the axis movement. However, it does not wait for
the spindle to stop. The axis movements begin before the spindle stops.
The spindle is stopped using program end or RESET.
At program start, spindle speed zero (S0) is in effect.
Remark: Other settings can be configured via machine data.
Programming example
N10 G1 X70 Z20 F300 S270 M3 ;prior to traversing of the X, Z axes, the spindle
accelerates to 270 r.p.m.
...
N80 S450 ... ;Speed change
...
N170 G0 Z180 M5 ;Z motion in the block; Spindle STOP
8.4.2 Spindle speed limitation: G25, G26
Functionality
In the program, you can limit the limit values that would otherwise apply for a controlled
spindle by writing G25 or G26 and the spindle address S with the speed limit value. This over-
writes the values entered in the setting data at the same time.
G25 or G26 each requires a separate block. A previously programmed speed S is maintained.
6FC5 698−2AA10−1BP5
Programming
Programming
G25 S... ;Lower spindle speed limitation
G26 S... ;Upper spindle speed limitation
Information
The outmost limits of the spindle speed are set in machine data. By making inputs via the op-
erator panel, setting data can be active for further limiting.
Programming example
N10 G25 S12 ;Lower spindle speed : 12 rpm
N20 G26 S700 ;Upper spindle speed : 700 rpm
Note
G25/G26 are used in conjunction with axis addresses for a working area limitation (see Sec-
tion ”Working area limitation”).
8.4.3 Spindle positioning: SPOS
Functionality
Prerequisite: The spindle must be technically designed for position control.
With the function SPOS= you can position the spindle in a specific angular position. The
spindle is held in the position by position control.
The speed of the positioning procedure is defined in machine data.
With SPOS=value from the M3/M4 movement, the respective direction of rotation is main-
tained until the end of the positioning. When positioning from standstill, the position is ap-
proached via the shortest path. The direction results from the respective starting and end posi-
tion.
Exception: The spindle movement is completed first, when the measurement system is not yet
synchronized. In this case, the direction is specified in machine data.
Other movement specifications for the spindle are possible with SPOS=ACP(...),
SPOS=ACN(...), ... as for rotary axes (see Section ”3rd and 4th axes”).
The spindle movement takes place parallel to any other axis movements in the same block.
This block is ended when both movements are finished.
6FC5 698−2AA10−1BP5
Programming
Programming
SPOS =..... ; absolute position: 0 ... <360 degrees
SPOS=ACP(...) ; Absolute dimensions, approach position in positive direction
SPOS=ACN(...) ; Absolute dimensions, approach position in negative direction
SPOS=IC(...) ; Incremental dimensions, leading sign determines the traversal direction
SPOS=DC(...) ; Absolute dimensions, approach position directly (on the shortest path)
Programming example
N10 SPOS=14.3 ;Spindle position 14.3 degrees
...
N80 G0 X89 Z300 SPOS=25.6 ;Positioning of the spindle with axis motions
This block is ended when both movements are finished.
N81 X200 Z300 ;The N81 block will only start if the spindle position from
N80.
;is reached.
8.4.4 Gear stages
Function
Up to 5 gear stages can be configured for a spindle for speed / torque adaptation. The gear
stage is selected in the program via M commands
(see Section 8.7 ”Miscellaneous function M”):
S M40 ; Automatic gear stage selection
S M41 to M45 ; Gear stages 1 to 5
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Programming
8.5 Contour programming support
8.5.1 Rounding, chamfer
Functionality
In a contour corner, you can insert the elements chamfer or rounding.
The respective instruction CHF= ... or RND=... is written in the block, which leads to the cor-
ner.
Programming
CHF=... ;insert chamfer, value: Length Side length of the chamfer
RND=... ;Insert rounding, value: Radius of the rounding
Information
The chamfer/rounding functions are executed in the current plane G17 to G19.
Note:
The programmed value for chamfer and rounding is automatically reduced if the contour
length of an involved block is insufficient.
No chamfer/rounding is inserted, if
S more than three blocks in the connection are programmed that do not contain any informa-
tion for traversing in the plane
S or a plane change is carried out.
Chamfer CHF=
A linear contour element is inserted between linear and circle contours in any combination.
The edge is broken.
N10 G1 ... CHF=...
Chamfer
N20 G1 ...
Y Angle bisector
e.g.: G17 X
Fig. 8-35 Inserting a chamfer CHF between to straight lines (example)
6FC5 698−2AA10−1BP5
Programming
Programming example for a chamfer

N10 G1 X... CHF=5 ;Insert 5 mm chamfer
N20 X... Y...
Rounding RND=
A circle contour element can be inserted with tangential link between the linear and circle
contours in any combination.
Straight line/straight line: Straight line/circle:

Rounding
N10 G1 ...RND=... N50 G1 ...RND=...
Rounding
N20 G1 ... RND=... N60 G3 ...

e.g.: G17 RND=... e.g.: G17
Y Y
X X
Fig. 8-36 Inserting roundings as examples
Programming example for a rounding

N10 G1 X... RND=8 ;Insert rounding with 8 mm radius
N20 X... Y...
...
N50 G1 X... RND=7.3 ;Insert rounding with 7.3 mm radius
N60 G3 X... Y...
8.5.2 Blueprint programming
Functionality
If direct end point values for the contour are not visible in a machining drawing, angle values
can also be used for straight line determination. In a contour corner, you can insert the ele-
ments chamfer or rounding. The respective instruction CHR= ... or RND=... is written in the
block, which leads to the corner.
The contour definition programming can be used in blocks with G0 or G1.
Theoretically, any number of straight line blocks can be linked and a rounding or a chamfer
can be inserted between them. Every straight line must be clearly identified by point values
and/or angle values.
Programming
ANG=... ;Angle value for defining a straight line
RND=... ;Insert rounding, value: Radius of the rounding
CHR=... ;Insert chamfer, value: Side length of the chamfer
6FC5 698−2AA10−1BP5
Programming
Angle ANG=
If only one end point coordinate of the plane is known for a straight line, or for contours across
multiple blocks the cumulative end point, an angle parameter can be used for unique definition
of the straight line path. The angle is always referred to the abscissa of the current plane G17
to G19; e.g.: with G17 to the X axis. Positive angles are aligned counterclockwise.
Contour Programming
Y End point in N20 not comple-
(X2,?)
or tely known
(?, Y2) N10 G1 X1 Y1
N20 X2 ANG=...
ANG=...
+ N10 or:
N20 N10 G1 X1 Y1
(X1,Y1) N20 Y2 ANG=...
The values are only examples.
X
Fig. 8-37 Specification of an angle for determination of a straight line using the example of the G17 plane
Rounding RND=
A contour element is inserted into the corner of two linear blocks with tangential corner (see
also Fig. 8-36).
Chamfer CHR=
Another linear contour element (chamfer) is inserted into the corner of two linear blocks. The
programmed value is the side length of the chamfer.
Contour Programming
CHR= Insert a chamfer with side

N10 G1 ... length
e.g. 5 mm:
N10 G1 X... CHR=5
Chamfer N20 X... Y..
Y
N20 ...
Angle bisector
Fig. 8-38 Inserting a chamfer using CHR
6FC5 698−2AA10−1BP5
Programming
Contour Programming
Y (X3,Y3) End point in N20 unknown
ANG=...2 N10 G1 X1 Y1
N30 N20 ANG=...1
ANG=...1 N30 X3 Y3 ANG=...2
(?, ?)
N10
N20
(X1,Y1)
The values are only examples.
X
Y (X3,Y3) ANG=...2 End point in N20 unknown;

insert chamfer:
N10 G1 X1 Y1
N30 N20 ANG=...1 RND=...
N30 X3 Y3 ANG=...2
ANG=...1 analogously
(?, ?) N10 Insert chamfer:
N10 G1 X1 Y1
N20 (X1,Y1) N20 ANG=...1 CHR=...
N30 X3 Y3 ANG=...2
X
Y
(X3,Y3) End point in N20 known;
insert rounding:
N10 G1 X1 Y1
N30 N20 X2 Y2 RND=...
N30 X3 Y3
analogously
(X2,Y2) N10 Insert chamfer:
N10 G1 X1 Y1
N20 (X1,Y1) N20 X2 Y2 CHR=...
N30 X3 Y3
X
End point in N20 unknown;

Y (X3,Y3) insert roundings:
ANG=...2
N40 N10 G1 X1 Y1
N20 ANG=...1 RND=...1
N30 X3 Y3 ANG=...2 RND=...2
(X4,Y4)
N40 X4 Y4
N30 ANG=...1
analogously
(?, ?) N10 Insert chamfer:
N10 G1 X1 Y1
N20 (X1,Y1) N20 ANG=...1 CHR=...1
X N30 X3 Y3 ANG=...2 CHR=...2
N40 X4 Y4
Fig. 8-39 Multiple block contours using the example of the G17 plane
Information
The blueprint programming function is executed in the current plane G17 to G19. It is not pos-
sible to change the plane during blueprint programming.
Notes:
S If radius and chamfer are programmed in one block, only the radius is inserted regardless
of the programming sequence.
S In fields other than blueprint programming, you will also find specification of a chamfer in
the form CHF=. In such cases, the value after CHF= is the chamfer length, instead of
CHR=.
6FC5 698−2AA10−1BP5
Programming
8.6 Tool and tool offset
8.6.1 General notes
Functionality
When creating programs for machining workpieces, it is not necessary to take into account
the tool length or the tool radius. You can program workpiece dimensions directly, e.g. as spe-
cified in the drawing.
You enter the tool data separately in a special data section.
You will simply call the required tool with its offset data in the program and enable the tool ra-
dius compensation if necessary. The control executes the required path corrections based on
this data to create the described workpiece.
T1
Workpiece contour
T2
T1 − tool 1
T2 − tool 2
Fig. 8-40 Machining of a workpiece with different tool
radii

Z T1 − tool 1
F T2 − tool 2
F T0 − no tool
Length
Length
F
0
X
Fig. 8-41 Approaching the workpiece position Z0 − different length compensations
6FC5 698−2AA10−1BP5
Programming
8.6.2 Tool T
Functionality
The tool selection takes place when the T word is programmed. Whether this is a tool change
or only a preselection, is defined in the machine data:
S The tool change (tool call) is performed either directly using the T word or
S the change takes place after the preselection with the T word by an additional instruction
M6 (see also Section 8.7 ”Miscellaneous functions M”).
Please note:
If a certain tool was activated, it remains stored as an active tool even beyond the end of the
program and after turning off / turning on the control system.
If you change a tool manually, input the change also in the control system so that the control
system ’knows’ the correct tool. For example, you can start a block with the new T word in the
MDA mode.
Programming
T... ;Tool number: 1 ... 32 000, T0 − no tool
Note
Max. 48 tools can be stored in the control system at a time.
Programming example
;Tool change without M6:
N10 T1 ;Tool 1
...
N70 T588 ;Tool 588
;Tool change using M6:

N10 T14 ... ;Preselect tool 14
...
N15 M6 ;Execute tool change, thereafter, T14 is active
8.6.3 Tool offset number D
Functionality
It is possible to assign between 1 to 9 (12) data fields with different tool offset blocks (for multi-
ple cutting edges) to a specific tool. If a special cutting tool is required, it can be programmed
with D and the corresponding number.
If no D word is written, D1 is automatically in effect.
If D0 is programmed, the offsets for the tool are ineffective.
6FC5 698−2AA10−1BP5
Programming
Note
Max. 96 data fields (D numbers) with tool offset blocks can be stored in the control system at
a time.
Programming
D... ;Tool offset number: 1 ... 9,
D0: no offsets active!
T1 D1 D2 D3 D9
T2 D1
T3 D1
T6 D1 D2 D3
T8 D1 D2
Each tool has separate offset blocks − a maximum of 9.
Fig. 8-42 Examples for assigning tool offset numbers / tool
Information
Tool length offsets are active immediately if the tool is active; if no D numbers have been
programmed, the values of D1 will be used.
The offset is applied with the first programmed traverse of the respective length compensation
axis. Observe any active G17 to G19.
A tool radius compensation must also be activated by G41/G42.
Programming example
Tool change without M6 command (only with T):
N5 G17 ;Defines the axis assignment for corrections
N10 T1 ;Tool 1 with the relevant D1 is activated
N11 G0 Z... ;With G17, Z is the length compensation axis; the length
compensation is overlaid here
N50 T4 D2 ;Load tool 4, D2 of T4 is active
...
N70 G0 Z... D1 ;D1 is active for tool 4, only edge changed
6FC5 698−2AA10−1BP5
Programming
Tool change using the M6 command:

N5 G17 ;Defines the axis assignment for compensations
N10 T1 ;Tool preselection
...
N15 M6 ;Tool change, T1 with appropriate D1 is active
N16 G0 Z... ;With G17, Z is the length compensation axis; the
length compensation is overlaid here
...
N20 G0 Z... D2 ;D2 is active for tool 1; with G17, Z is the length compensation axis; the
difference of the length compensation D1−>D2 is overlaid here
N50 T4 ;Tool preselection T4, please note: T1 with D2 is still active !
...
N55 D3 M6 ;Tool change, T4 with the appropriate D3 is active
...
Contents of an offset memory

Enter the following in the offset memory:
S Geometric quantities: Length, radius
These consist of several components (geometry, wear). The control computes the compo-
nents to a certain dimension (e.g. overall length 1, total radius). The respective overall di-
mension becomes effective when the offset memory is activated.
How these values are calculated in the axes is determined by the tool type and the com-
mands G17, G18, G19 (see following illustrations).
S Tool type
The tool type (drill, cutter) defines which geometry data are necessary and how they are
taken into account.
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Programming
Tool special cases

For the tool types ’cutter’ and ’drill’, the parameters for length 2 and length 3 are only required
for special cases (e.g.: multidimensional length compensation when using an angular head
attachment).
Activa- Length
tion 3
Length 1 in Z Z
G17:
Length 2 in Y Length
Length 3 in X 2 F
X
Radius in X/Y Y
G18: Length 1 in Y Y
Length 2 in X
Length 3 in Z Z
X
Radius in Z/X
Length 1 in X X
G19:
Length 2 in Z
Length 3 in Y Y
Z
Radius in Y/Z
The radius is not taken into account for the drill type.

Length
1
Fig. 8-43 Effect of the tool length compensation − 3D (special case)
Activation F − toolholder reference point

G17: Length 1 in Z
G18: Length 1 in Y
G19: Length 1 in X F
Length 1
Fig. 8-44 Effect of the offsets with the tool type ’drill’
Activation F − toolholder reference point
G17: Length 1 in Z
Radius in X/Y
Radius F
G18: Length 1 in Y
Radius in Z/X
G19: Length 1 in X
Radius in Y/Z
Length 1
Fig. 8-45 Effect of the offsets with the tool type ’cutter’
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Programming
8.6.4 Selecting the tool radius compensation: G41, G42
Functionality
The control system is working with tool radius compensation in the selected plane G17 to
G19.
A tool with a corresponding D number must be active. The tool radius compensation is acti-
vated by G41/G42. The controller automatically calculates the required equidistant tool paths
for the programmed contour for the respective current tool radius.
Milling tool
Workpiece con-
tour
Path of the
tool center point
at the same distance
to the contour (equidistant)
Fig. 8-46 Tool radius compensation
Programming
G41 X... Y... ;Tool radius compensation left of the contour
G42 X... Y... ;Tool radius compensation right of the contour
Remark: The selection can only be made for linear interpolation (G0, G1).
Program both axes of the plane (e.g. with G17: X, Y). If you only specify one axis, the second
axis is automatically completed with the last programmed value.
G42 G41
Workpiece con-
tour
Fig. 8-47 Compensation to the right/left of the contour
6FC5 698−2AA10−1BP5
Programming
Starting the compensation

The tool travels directly to the contour along a straight line and is positioned perpendicular to
the path tangent at the starting point of the contour.
Select the starting point such that a collision−free travel is ensured.
P1 − starting point of the contour

Contour: Straight line Contour: Circle
MP Circle radius
P1 Tangent P1
Tool radius
uncorrected uncorrected
G42 G42
Corrected Corrected
tool path tool path
P0 − starting point P0 − starting point
Fig. 8-48 Start of the tool radius compensation with G42 as example
Information
As a rule, the block with G41/G42 is followed by the block with the workpiece contour. The
contour description, however, may be interrupted by 5 blocks which lie between them and do
not contain any specifications for the contour path in the plane, e.g. only an M command or
infeed motions.
Programming example
N10 T...
N20 G17 D2 F300 ;Compensation no. 2, feedrate 300 mm/min
N25 X... Y... ;P0 − starting point
N30 G1 G42 X... Y... ;Selection right of the contour, P1
N31 X... Y... ;Starting contour, circle or straight line
After selection, it is also possible to execute blocks with infeed movements or M outputs:
N20 G1 G41 X... Y... ;Selection left of the contour
N21 Z... ;Infeed motion
N22 X... Y... ;Starting contour, circle or straight line
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Programming
8.6.5 Corner behavior: G450, G451
Functionality
Using the functions G450 and G451, you can set the behavior for non−continuous transition
from one contour element to another contour element (corner behavior) when G41/G42 is ac-
tive.
Internal and external corners are detected by the control system itself. For inside corners, the
intersection of the equidistant paths is always approached.
Programming
G450 ;Transition circle
G451 ;Point of intersection
Transition circle
External corner (radius = tool radius) External corner
Point of in-
P* tersection
G450 G451
P* − it is possible to execute an
intermediate block without plane
information here
Fig. 8-49 Corner behavior at an external corner
Inside corner
Point of intersection
Fig. 8-50 Corner behavior at an internal corner
Transition circle G450

The tool center point travels around the workpiece external corner in an arc with the tool ra-
dius.
In view of the data, for example, as far as the feedrate value is concerned, the transition circle
belongs to the next block containing traversing movements, for example, with reference to the
feedrate value.
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Programming
Point of intersection G451

For a G451 intersection of the equidistant paths, the point (intersection) that results from the
center point paths of the tool (circle or straight line) is approached.
With acute contour angles and active point of intersection, depending on the tool radius, un-
necessary idle motions could result for the tool.
In this case, the control automatically switches to transition circle for this block if a certain set
angle value (100°) is reached.
External corner
Transition circle
R = tool radius
Fig. 8-51 Acute contour angle and switching to transition circle
8.6.6 Tool radius compensation OFF: G40
Functionality
The compensation mode (G41/G42) is deselected with G40. G40 is also the activation posi-
tion at the beginning of the program.
The tool ends the block before G40 in the normal position (compensation vector vertically to
the tangent at the end point); irrespective of the approach angle.
If G40 is active, the reference point is the tool center point. The tool tip then travels to the pro-
grammed point upon deselection.
Always select the end point of the G40 block such that collision−free traversing is guaranteed!
Programming
G40 X... Y... ;Tool radius compensation OFF
Remark: The compensation mode can only be deselected with linear interpolation (G0, G1).
6FC5 698−2AA10−1BP5
Programming
Program both axes of the plane (e.g. with G17: X, Y). If you only specify one axis, the second
axis is automatically completed with the last programmed value.
Contour: Straight line Contour: Circle
P1
Tangent
P1
R = tool radius
G40
G40 P2
P2 P1 − end point, e.g. last block with G41
P2 − end point, block with G40
Fig. 8-52 Quitting the tool radius compensation
Programming example
...
N100 X... Y... ;Last block at the contour; circle or straight line, P1
N110 G40 G1 X... Y.. ;Deactivate tool radius compensation, P2
8.6.7 Special cases of the tool radius compensation
Repetition of the compensation

The same compensation (e.g. G41 −> G41) can be programmed once more without writing
G40 between these commands.
The last block in front of the new compensation call ends with the normal position of the com-
pensation vector at the end point. The new compensation is carried out as a compensation
start (behavior as described for change in compensation direction).
Changing the offset number

The offset number D can be changed in compensation mode. A modified tool radius is active
with effect from the block in which the new D number is programmed. Its complete modifica-
tion is only achieved at the end of the block. In other words: The modification is traversed con-
tinuously over the entire block; this also applies to circular interpolation.
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Programming
Change of the compensation direction

The compensation direction G41 <−> G42 can be changed without writing G40.
The last block with the old compensation direction ends with the normal position of the com-
pensation vector at the end point. The new compensation direction is executed as a com-
pensation start (normal position at starting point).
N22
N20
N21 G41 N25
N24 N23
Y
N21 N22
X N20
e.g.: e.g.:
N10 G42 ... N20 G42 G1 X... Y...
... N21 X... Y
N20 G1 X... N22 G41 Y...
N21 G41 X... Y... N23 X...
N22 X... N24 G42 Y...
... N25 X... X
...
Fig. 8-53 Change of the compensation direction
Cancellation of compensation by M2
If the compensation mode is canceled using M2 (end of program) without writing the com-
mand G40, the last block with coordinates of the plane (G17 to G19) will end in the normal
position of the compensation vector. No compensating movement is executed. The program
ends with this tool position.
Critical machining cases

When programming, pay special attention to cases where the contour travel is smaller than
the tool radius; in case of two successive internal corners, this is smaller than the diameter.
Such cases should be avoided.
Also check over multiple blocks that the contour contains no ”bottlenecks”.
When carrying out a test/dry run, use the largest tool radius you are offered.
6FC5 698−2AA10−1BP5
Programming
Acute contour angles

If very sharp outside corners occur in the contour with active G451 intersection, the control
system automatically switches to transition circle. This helps avoid long idle motions (see Fig.
8-51).
8.6.8 Example of tool radius compensation
Y
100
90
80
70
N20 N30
N50
60
N110 N40 N60

50
40
N80 N70
N100
30
N90
20
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 X
Fig. 8-54 Example of tool radius compensation
Programming example
N1 T1 Tool 1 with compensation D1
N5 G0 G17 G90 X5 Y55 Z50 ;Approach starting point
N6 G1 Z0 F200 S80 M3
N10 G41 G450 X30 Y60 F400 ;Compensation left of the contour, transition circle
N20 X40 Y80
N30 G2 X65 Y55 I0 J−25
N40 G1 X95
N50 G2 X110 Y70 I15 J0
N60 G1 X105 Y45
N70 X110 Y35
N80 X90
N90 X65 Y15
N100 X40 Y40
N110 X30 Y60
N120 G40 X5 Y60 ;Quit compensation mode
N130 G0 Z50 M2
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Programming
8.7 Miscellaneous function (M)
8.7 Miscellaneous function (M)
Functionality
The special function M initiates switching operations, such as ”Coolant ON/OFF” and other
functions.
Permanent functions have already been assigned to some of the M functions by the control
manufacturer. The machine manufacturer can freely dispose of the other functions.
Note:
An overview of the M special functions used and reserved in the control can be found in Sec-
tion 8.1.6 ”Overview of the instructions”.
Programming
M... ; a maximum of 5 M functions per block,
Activation
Activation in blocks with axis movements:
If the functions M0, M1, M2 are contained in a block with traversing movements of the axes,
then these M functions become effective after the traversing movements.
The functions M3, M4, M5 are output to the internal PLC prior to the traversing movements.
The axis movements only begin once the controlled spindle has ramped up for M3, M4. For
M5, however, the spindle standstill is not waited for. The axis movements already begin before
the spindle stops (default setting).
The remaining M functions are output to the PLC with the traversing movements.
If you would like to program an M function directly before or after an axis movement, then in-
sert a separate block with this M function. Please note: This block interrupts G64 continuous
path mode and generates exact stop!
Programming example
N10 S...
N20 X... M3 ;M function in a block with axis motion
Spindle ramps up prior to the X axis motion
N180 M78 M67 M10 M12 M37 ;Max. 5 M functions in the block
Note
In addition to M and H functions, T, D, and S functions can also be transferred to the PLC
(programmable logic controller). In all, a maximum of 10 such function outputs are possible in
a block.
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Programming
8.8 H function
8.8 H function
Functionality
With H functions, floating point data (REAL data type − as with arithmetic parameters, see
Section ”Arithmetic Parameters R”) can be transferred from the program to the PLC.
The meaning of the values for a given H function is defined by the machine manufacturer.
Programming
H0=... to H9999=... ; max. 3 H functions per block
Programming example
N10 H1=1.987 H2=978.123 H3=4; 3 H functions in the block
N20 G0 X71.3 H99=−8978.234 ; with axis movements in the block
N30 H5 ; corresponds to: H0=5.0
Note
In addition to M and H functions, T, D, and S functions can also be transferred to the PLC
(programmable logic controller). In all, a maximum of 10 such function outputs are possible in
a block.
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Programming
8.9 Arithmetic parameters R, LUD and PLC variables
8.9.1 Arithmetic parameters R
Functionality
The arithmetic parameters are used if an NC program is not only to be valid for values as-
signed once, or if you must calculate values. The required values can be set or calculated by
the control during program execution.
The arithmetic parameter values can also be set by operator inputs. If values have been as-
signed to the arithmetic parameters, they can be assigned to other variable−setting NC ad-
dresses in the program.
Programming
R0=... to R299=...
Value assignment
You can assign values in the following range to the arithmetic parameters:
(0.000 0001 ... 9999 9999)
(8 decimal places and leading sign and decimal point).
The decimal point can be omitted for integer values. A plus sign can always be omitted.
Example:
R0=3.5678 R1=−37.3 R2=2 R3=−7 R4=−45678.123
Use the exponential notation to assign an extended range of numbers:
( 10−300 ... 10+300 ).
The exponent value is written after the EX characters; max. number of characters: 10
(including the leading sign and decimal point)
Value range of EX: −300 to +300
Example:
R0=−0.1EX−5 ;Meaning: R0 = −0,000 001
R1=1.874EX8 ;Meaning: R1 = 187 400 000
Remark: Several assignments can be provided per block; this also applies to the assignment
of arithmetic expressions.
Assignments to other addresses

The flexibility of an NC program lies in assigning these arithmetic parameters or expressions
with arithmetic parameters to other NC addresses. Values, arithmetic expressions and arith-
metic parameters can be assigned to all addresses; Exception: addresses N, G, and L.
When assigning, write the ” = ” sign after the address character. It is also possible to have an
assignment with a minus sign.
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Programming
A separate block is required for assignments to axis addresses (traversing instructions).

Example:
N10 G0 X=R2 ;Assignment to the X axis
Arithmetic operations/arithmetic functions

When operators/arithmetic functions are used, it is necessary to use conventional mathemati-
cal notation. Machining priorities are set by parentheses. Otherwise, multiplication and divi-
sion take precedence over addition and subtraction.
Degrees are used for the trigonometrical functions.
Permitted arithmetic functions: see Section ”Overview of the instructions”
Programming example: R parameters

N10 R1= R1+1 ;The new R1 results from the old R1 plus 1
N20 R1=R2+R3 R4=R5−R6 R7=R8* R9 R10=R11/R12
N30 R13=SIN(25.3) ;R13 yields the sine of 25.3 degrees
N40 R14=R1*R2+R3 ;Multiplication before addition R14=(R1*R2)+R3
N50 R14=R3+R2*R1 ;Result as block N40
N60 R15=SQRT(R1*R1+R2*R2) ; Meaning: R15 = R12 + R22
Programming example: Assignment to the axes

N10 G1 G91 X=R1 Z=R2 F300
N20 Z=R3
N30 X=−R4
N40 Z=−R5
...
8.9.2 Local User Data (LUD)
Functionality
The operator/programmer (user) can define his/her own variable in the program from various
data types (LUD = Local User Data). These variables are only available in the program in
which they were defined. The definition takes place immediately at the start of the program
and can also be associated with a value assignment at the same time. Otherwise the starting
value is zero.
The name of a variable can be defined by the programmer. The naming is subject to the fol-
lowing rules:
S maximum length 32 characters
S The first two characters must be letters. Only use letters, digits, or underscore.
S Do not use a name that is already being used in the controller (NC addresses, keywords,
names of programs, subroutines, etc.)
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Programming
Programming
DEF BOOL varname1 ; Bool type, values: TRUE (=1), FALSE (=0)
DEF CHAR varname2 ; Char type, 1 character in the ASCII code: ”a”, ”b”, ...
; Code numerical value: 0 ... 255
DEF INT varname3 ; Integer type, integer values, 32−bit value range:
; −2 147 483 648 to +2 147 483 648 (decimal)
DEF REAL varname4 ; Real type, natural number (such as arithmetic parameters R),
; Range of values: (0.000 0001 ... 9999 9999)
; (8 decimal places, arithmetic sign and decimal point) or
; exponential notation: ( 10−300 ... 10+300 ).
Each type requires a separate program line. It is, however, possible to define several vari-
ables of the same type in a line.
Example:
DEF INT PVAR1, PVAR2, PVAR3=12, PVAR4 ; 4 variables of the INTtype
Fields
In addition to the individual variables, one or two−dimensional fields of variables of these data
types can also be defined:
DEF INT PVAR5[n] ; One−dimensional field of the INT type, n: integer
DEF INT PVAR6[n,m] ; Two−dimensional field of the INT type, n, m: integer
Example:
DEF INT PVAR7[3] ; Field with 3 elements of the INTtype
Access to the individual field elements is granted in the program via the field index; each indi-
vidual field element can be handled as an individual variable. The field index ranges from 0 to
”less number of elements”.
Example:
N10 PVAR7[2]=24 ; The third field element (with index 2) is assigned the value 24.
Value assignment for field with SET instruction:
N20 PVAR5[2]=SET(1,2,3) ; Beginning with the 3rd field element, different values are as-
signed.
Value assignment for field with REP instruction:
N20 PVAR7[4]=REP(2) ; As of field element [4], all elements is assigned the same value,
here 2.
Number of LUDs
With the SINUMERIK 802D, max. 200 LUDs may be defined. However, please note: The
standard cycles of SIEMENS also use LUDs and they share this quantity with the user. Al-
ways keep a sufficient reserve if you are working with these cycles.
6FC5 698−2AA10−1BP5
Programming
Note for display

There is no special display for LUDs. They would only be visible during execution of the pro-
gram anyway.
For testing purposes, when creating the program, the LUDs may be assigned to the arithmetic
parameters R and are thus visible via the arithmetic parameter display, but are converted into
the REAL type.
Another possibility of displaying is offered in the STOP condition of the program via a mes-
sage output:
MSG(” VAR1 value: ”<<PVAR1<<” VAR2 value: ”: ”<<PVAR2) ;Values of PVAR1, PVAR2
M0
8.9.3 Reading and writing PLC variables
Functionality
To allow rapid data exchange between NC and PLC, a special data area exists in the PLC
user interface with a length of 512 bytes. In this area, PLC data are compatible in data type
and position offset. In the NC program, these compatible PLC variables can be read or writ-
ten.
Special system variables are provided here:
$A_DBB[n] ; Data byte (8−bit value)
$A_DBW[n] ; Data word (16−bit value)
$A_DBD[n] ; Data double−word (32−bit value)
$A_DBR[n] ; REAL data (32−bit value)
n stands here for the position offset (between the data area start and the variable start)
in bytes
Example:
R1=$A_DBR[5] ; Reading of a REAL value, offset 5 (starts at byte 5 of this range)
Notes
S When reading variables, a preprocessing stop is generated (internal STOPRE).
S A maximum of 3 variables can be written simultaneously (in a block).
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Programming
8.10 Program jumps
8.10 Program jumps
8.10.1 Jump destination for program jumps
Functionality
A label or a block number serve to mark blocks as jump destinations for program jumps.
Program jumps can be used to branch to the program sequence.
Labels can be freely selected, but must contain a minimum of 2 and a maximum of 8 letters or
numbers, and the first two characters must be letters or underscores.
Labels that are in the block that serves as the jump destination are ended by a colon. They
are always at the start of a block. If a block number is also present, the label is located after
the block number.
Labels must be unique within a program.
Programming example
N10 LABEL1: G1 X20 ; LABEL1 is the label, jump destination
...
TR789: G0 X10 Z20 ; TR789 is the label, jump destination
− no block number exists
N100 ... ; A block number can be a jump destination
...
8.10.2 Unconditional program jumps
Functionality
NC programs process their blocks in the sequence in which they were arranged when they
were written.
The processing sequence can be changed by introducing program jumps.
The jump destination can be a block with a label or with a block number. This block must be
located within the program.
The unconditional jump instruction requires a separate block.
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Programming
8.10 Program jumps
Programming
GOTOF Label ;Jump forward (towards the last block of the program)
GOTOB Label ;Jump backward (towards the first block of the program)
Label ;Selected character string for the label (jump mark) or block number
Program
N10 G0 X... Z...
execution
...
...
N20 GOTOF LABEL0 ; Jump to label LABEL0
...
...
...
...
...
N50 LABEL0: R1 = R2+R3
N51 GOTOF LABEL1 ; Jump to label LABEL1
...
...
LABEL2: X... Z...
LABEL1: X... Z...
...
N150 GOTOB LABEL2; Jump to label LABEL2
Fig. 8-55 Unconditional jumps using an example
8.10.3 Conditional program jumps
Functionality
Jump conditions are formulated after the IF instruction. If the jump condition (value not
zero) is satisfied, the jump takes place.
The jump destination can be a block with a label or with a block number. This block must be
located within the program.
Conditional jump instructions require a separate block. Several conditional jump instructions
can be located in the same block.
By using conditional program jumps, you can also considerably shorten the program, if neces-
sary.
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Programming
8.10 Program jumps
Programming
IF condition GOTOF label ;Jump forward
IF condition GOTOB label ;Jump backward
GOTOF ;Jump direction forward (in the direction of the last block of the program)
GOTOB ;Jump direction backward (in the direction of the first block of the program)
Label ;Selected string for the label (jump label) or block number
IF ;Starting of the jump condition
condition ;Arithmetic parameter, arithmetic expression for formulating the condition
Comparative operations
Operators Meaning
== Equal to
<> Not equal to
> Greater than
< Less than
>= Greater than or equal to
<= Less than or equal to
The comparative operations support the formulating of a jump condition. Arithmetic expres-
sions can also be compared.
The result of comparing operations is ”satisfied” or ”not satisfied.” ”Not satisfied” sets the value
equal to zero.
Programming example for comparing operators

R1>1 ;R1 greater than 1
1 < R1 ;1 less than R1
R1<R2+R3 ;R1 less than R2 plus R3
R6>=SIN( R7*R7) ;R6 greater than or equal to SIN (R7)2
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Programming
8.10 Program jumps
Programming example
N10 IF R1 GOTOF LABEL1 ; If R1 is not zero, go to block with LABEL1
...
N90 LABEL1: ...
N100 IF R1>1 GOTOF LABEL2 ; If R1 is greater than 1, go to the block with LABEL2
...
N150 LABEL2: ...
...
N800 LABEL3: ...
...
N1000 IF R45==R7+1 GOTOB LABEL3; If R45 is equal to R7 plus 1, go to the
block with LABEL3
...
Several conditional jumps in the block:
N10 MA1: ...
...
N20 IF R1==1 GOTOB MA1 IF R1==2 GOTOF MA2 ...
...
N50 MA2: ...
Remark: The jump is executed for the first fulfilled condition.
8.10.4 Program example for jumps
Task
Approaching points on a circular section:
Given: Starting angle: 30° in R1
Circle radius: 32 mm in R2
Distance of the positions: 10° in R3
Number of points: 11 in R4
position of the circle center point
in Z: 50 mm in R5
Position of the circle center point
in X: 20 mm in R6
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Programming
8.10 Program jumps
X
R4 = 11 (number of points)
Point 3
Point 10
Point 2
Point 11 R3
R3 R3
Point 1
R1
20
R6
Z
R5 50
Fig. 8-56 Approaching points on a circular section
Programming example
N10 R1=30 R2=32 R3=10 R4=11 R5=50 R6=20 ; Assignment of the initial values
N20 MA1: G0 Z=R2 *COS (R1)+R5 X=R2*SIN(R1)+R6
; Computation and assignment to axis addresses
N30 R1=R1+R3 R4= R4−1
N40 IF R4 > 0 GOTOB MA1
N50 M2
Explanation
In block N10, the starting conditions are assigned to the corresponding arithmetic parameters.
The calculation of the coordinates in X and Z and the processing takes place in N20.
In block N30, R1 is incremented by the clearance angle R3; R4 is decremented by 1.
If R4 > 0, N20 is executed again; otherwise, N50 with end of program.
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Programming
8.11 Subroutine technique
8.11.1 General
Use
Basically, there is no difference between a main program and a subroutine.
Frequently recurring machining sequences are stored in subroutines, e.g certain contour
shapes. These subroutines are called at the appropriate locations in the main program and
then executed.
One form of subroutine is the machining cycle. Machining cycles contain universally valid
machining scenarios (e.g.: Drilling, tapping, groove milling, etc.). By assigning values via in-
cluded transfer parameters, you can adapt the subroutine to your specific application.
Subroutine
Fig. 8-57 Example for using a subroutine for a workpiece four times
Structure
The structure of a subroutine is identical to that of a main program (see Section 8.1.2 ”Pro-
gram structure”). Like main programs, subroutines contain
M2 program end in the last block of the program sequence. This means a return to the pro-
gram level where the subroutine was called from.
End of program
The end instruction RET can also be used instead of the M2 program end in the subroutine.
RET requires a separate block.
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Programming
The RET instruction is used when G64 continuous−path mode is not to be interrupted by a
return. With M2, G64 is interrupted and exact stop is initiated.
Main program Sequence

MAIN123
...
... Subroutine
N20 L10 ;Call
L10
N21 ... Return
... N10 R1=34 ...
... N20 X...Z...
... ...
...
N80 L10 ;Call ...
... M2
Return
...
...
M2
Fig. 8-58 Example of sequence when calling a subroutine twice
Subroutine name
The subprogram is given a unique name allowing it to be selected from among the others.
When you create the program, the program name may be freely selected provided the follow-
ing conventions are observed:
The same rules apply as for the names of main programs.
Example: LRAHMEN7
It is also possible to use the address word L... in subroutines. The value can have 7 decimal
places (integers only).
Note: With address L, leading zeros are meaningful for differentiation.
Example: L128 is not L0128 or L00128 !
These are three different subroutines.
Note: The subroutine name LL6 is reserved for tool change.
Subroutine call
Subroutines are called in a program (main or subprogram) with their names. To do this, a sep-
arate block is required.
Example:
N10 L785 ; Call of the subroutine L785
N20 LRAHMEN7 ; Call of the subroutine LRAHMEN7
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Programming
Program repetition P...

If a subroutine is to be executed several times in succession, write the number of times it is to
be executed in the block of the call after the subroutine name under the address P. A maxi-
mum of 9999 passes are possible (P1 ... P9999).
Example:
N10 L785 P3 ; Call of the subroutine L785, 3 passes
Nesting depth
Subroutines can also be called from a subroutine, not only from a main program. Totally, 8
program levels, including the main program level are available for such a nested call.
1st level 2nd level 3rd level ... 8th level
ÊÊÊÊ
Main program
ÊÊÊÊ ÊÊÊÊ
Subroutine
ÊÊÊÊ ÊÊÊÊ ÊÊÊÊ

Subroutine
...
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
Subroutine
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
ÊÊÊÊ
Fig. 8-59 Execution with 8 program levels
ÊÊÊÊ
Information
Modal G functions can be changed in the subroutine, e.g. G90 −> G91. When returning to the
calling program, ensure that all modal functions are set the way you need them to be.
This also applies to the arithmetic parameters R. Please make sure that the values of your
arithmetic parameters used in upper program levels are not inadvertently changed in lower
program levels.
When working with SIEMENS cycles, up to 4 program levels are needed.
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Programming
8.11.2 Calling machining cycles
Functionality
Cycle are technology subroutines that realize a certain machining process, such as drilling or
thread cutting, generally. Adaptation to the concrete problem is done directly via supply pa-
rameters/values when calling the respective cycle.
Programming example
N10 CYCLE83(110, 90, ...) ; Call of cycle 83, transfer values directly, separate block
...
N40 RTP=100 RFP= 95.5 ... ; Set transfer parameters for cycle 82
N50 CYCLE82(RTP, RFP, ...) ; Call of cycle 82, separate block
8.11.3 Modal subroutine call
Functionality
The subroutine in the block containing MCALL is called automatically after each successive
block containing a path motion. The call acts until the next MCALL is called.
The modal call of the subroutine which contains MCALL or quitting of the call requires a sepa-
rate block.
MCALL is advantageous, for example, when producing drill patterns.
Programming example
Application example: Drilling a row of holes
N10 MCALL CYCLE82(...) ; Drilling cycle 82
N20 HOLES1(...) ; Cycle for the row of holes, CYCLE82 is executed with the trans-
fer parameters N30 MCALL each time after
approaching the hole position (...)
; Modal call of CYCLE82(...) completed
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Programming
8.12 Timers and workpiece counters
8.12.1 Runtime timer
Functionality
The timers are prepared as system variables ($A...) that can be used for monitoring the tech-
nological processes in the program or only in the display.
These timers can only be read. There are timers that are always active. Others can be deacti-
vated via machine data.
Timers − always active

S Time since the last ”Control power−up with default values” ( in minutes ):
$AN_SETUP_TIME (read−only)
”Power−up of the control system with default values” will reset it to zero automatically.
S Time since the last ”Power−up of the control system” ( in minutes ):
$AN_POWERON_TIME (read−only)
”It is reset to zero automatically with each power−up of the control system.
Timers that can be deactivated

The following timers are activated via machine data (default setting).
The start is timer−specific. Each active run−time measurement is automatically interrupted in
the stopped program state or for feedrate−override−zero.
The behavior of the activated timers for active dry run feedrate and program testing can be
specified using machine data.
S Total runtime of NC programs in the AUTOMATIC mode(in seconds)
$AC_OPERATING_TIME
In the AUTOMATIC mode, the runtimes of all programs between NC START and end of
program / RESET are summed up. The timer is zeroed with each power−up of the control
system.
S Runtime of the selected NC program (in seconds):
$AC_CYCLE_TIME
The runtime between NC START and end of program / RESET is measured in the se-
lected NC program. The timer is reset with the start of a new NC program.
S Tool action time ( in seconds ):
$AC_CUTTING_TIME
The runtime of the path axes is measured in all NC programs between NC START and end
of program / RESET without rapid traverse active and with the tool active.
The measurement is also interrupted if a dwell time is active.
The timer is automatically reset to zero with each ”Control power−up with default values”.
Programming example
N10 IF $AC_CUTTING_TIME>=R10 GOTOF WZZEIT ;Tool action time limit value?
...
N80 WZZEIT:
N90 MSG(”Tool action time: Limit value reached”)
N100 M0
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Programming
Display
The contents of the active system variables is displayed on the screen in the
”OFFSET/PARAM” operating area −> ”Setting data” softkey (2nd page):
Run time = $AC_OPERATING_TIME
Cycle time = $AC_CYCLE_TIME
Cutting time = $AC_CUTTING_TIME
Setup time = $AN_SETUP_TIME
Power on time = $AN_POWERON_TIME
”Cycle time” is also displayed in the AUTOMATIC mode in the ”Position” operating area in the
information line.
8.12.2 Workpiece counter
Functionality
The ”Workpiece counter” function provides counters for counting workpieces.
These counters exist as system variables with write and read access from the program or via
operator input (observe the protection level for writing!).
Machine data can be used to control counter activation, counter reset timing and the counting
algorithm.
Counter
S Number of workpieces required ( required number of workpieces ):
$AC_REQUIRED_PARTS
The number of workpieces at which the number of current workpieces $AC_AC-
TUAL_PARTS is set to zero can be defined in this counter.
The generation of the display alarm 21800 ”Workpiece setpoint reached” can be activated
via machine data.
S Number of workpieces produced in total ( actual total ):
$AC_TOTAL_PARTS
The counter specifies the number of all workpieces manufactured from the time of starting.
The counter is automatically set to zero upon every booting of the control system.
S Number of current workpieces ( actual total ):
$AC_ACTUAL_PARTS
This counter registers the number of all workpieces produced since the starting time.
When the workpiece setpoint is reached ( $AC_REQUIRED_PARTS, value greater than
zero), the counter is automatically zeroed.
S Number of workpieces specified by the user:
$AC_SPECIAL_PARTS
This counter allows user−defined workpiece counting. Alarm output can be defined for the
case of identity with
$AC_REQUIRED_PARTS (workpiece target). The user must reset the counter himself.
6FC5 698−2AA10−1BP5
Programming
Programming example
N10 IF $AC_TOTAL_PARTS==R15 GOTOF SIST ;Count reached?
...
N80 SIST:
N90 MSG(”Workpiece setpoint reached”)
N100 M0
Display
The contents of the active system variables is displayed on the screen in the
”OFFSET/PARAM” operating area −> ”Setting data” softkey (2nd page):
Part total = $AC_TOTAL_PARTS
Part required = $AC_REQUIRED_PARTS
Part count = $AC_ACTUAL_PARTS
$AC_SPECIAL_PARTS (not displayed)
”Part count” is also displayed in the AUTOMATIC mode in the ”Position” operating area in the
information line.
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Programming
8.13 Language commands for tool monitoring
8.13.1 Tool monitoring overview
Functionality
This function is an option and available as of SW 2.0.
The tool monitoring is activated via machine data.
The following types of active cutting edge monitoring for the active tool are possible:
S Monitoring of the tool life
S Monitoring of the workpiece count
For a tool, the above−mentioned types of monitoring can be activated simultaneously.
The control / data input of tool monitoring is preferably done by operator input. In addition,
functions are programmable.
Monitoring counter
Monitoring counters exist for each monitoring type. The monitoring counters count from a set
value > 0 down to zero. When a counter has decremented to a value of <=0, the limit value is
reached. A corresponding alarm message is issued.
System variable for type and condition of the monitoring

S $TC_TP8[t] − status of the tool with number t:
Bit 0 =1: Tool is active
=0: Tool not active
Bit 1 =1: Tool is enabled
=0: not enabled
Bit 2 =1: Tool is disabled
=0: not disabled
Bit 3 : Reserved
Bit 4 =1: Prewarning limit reached
=0: Not reached
S $TC_TP9[t] − type of the monitoring function for the tool with number t :
= 0: No monitoring
= 1: (Tool monitored for the tool life
= 2: Count−monitored tool
These system variables can be read/written in the NC program.
System variables for tool monitoring data
Table 8-3 Tool monitoring data
Identifier Description Data type Default setting

$TC_MOP1[t,d] Prewarning limit for tool life in minutes REAL 0.0
$TC_MOP2[t,d] Residual tool life in minutes REAL 0.0
$TC_MOP3[t,d] Count prewarning limit INT 0
6FC5 698−2AA10−1BP5
Programming
Table 8-3 Tool monitoring data, cont’d
Identifier Description Data type Default setting

$TC_MOP4[t,d] Remaining part quantity INT 0
... ...
$TC_MOP11[t,d] Tool life setpoint REAL 0.0
$TC_MOP13[t,d] Required count INT 0
t for tool number T, d for D number
System variables for active tool

The following can be read in the NC program via system variables:
S $P_TOOLNO − number of the active tool T
S $P_TOOL − active D number of the active tool
8.13.2 Tool life monitoring
Tool life monitoring is done for the tool cutting edge that is currently in use (active cutting edge
D of the active tool T).
As soon as the path axes traverse (G1, G2, G3, ... but not for G0), the residual tool life
($T C_MOP2[t,d] ) of this tool cutting edge is updated. If the residual tool life of a tool’s cutting
edge runs below the value of ”Prewarning limit for tool life" ($TC_MOP1[t,d] ), it is reported
via an interface signal ” to the PLC.
If the residual tool life <=0 , an alarm is issued and an additional interface signal is set. The
tool changes to the ”disabled” condition and cannot be programmed again until this condition
changes. The operator must intervene: The operator must change the tool or ensure that he
has an operational tool for machining.
$A_MONIFACT system variable

The $A_MONIFACT system variable (REAL data type) allows the monitoring clock to be run
slower or faster. This factor can be set before using the tool, in order to take the different kinds
of wear into consideration according to the workpiece material used, for example.
After booting of the control, reset / program end, the factor $A_MONIFACT has the value 1.0.
Real time is in effect.
Examples for accounting:
$A_MONIFACT=1 1 minute realtime = 1 minute tool life which is decremented
$A_MONIFACT=0.1 1
minute realtime = 0.1 minute tool life which is decremented
$A_MONIFACT=5 1 minute real time = 5 minutes tool life which are decremented
Setpoint update with RESETMON( )

The RESETMON(state, t, d, mon) function sets the actual value to the set-
point:
− either for all cutting edges or only for a certain cutting edge of a certain tool
− either for all monitoring type or only for a certain monitoring type.
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Programming
Transfer parameters:
INT state Status of executing the command :
= 0 Command executed successfully
= −1 The edge with the specified D number d does not exist.
= −2 The tool with the specified T number t does not exist.
= −3 The specified tool t does not have a defined monitoring function.
= −4 The monitoring function is not activated, i.e. the command is not executed.
INT t Internal T number :

=0 For all tools
<> 0 For this tool ( t < 0 : Absolute value formation |t|)
INT d optional: D number of the tool with the number t:

>0 for this D number
without d / = 0 all cutting edges of tool t
INT mon optional: bit−coded parameter for the monitoring type (values analogously to
$TC_TP9):
= 1: Tool life
= 2: Count
without monitoring or = 0:
All actual values of the monitoring functions active for tool t are
set to the setpoints.
Notes:
− RESETMON( ) has no effect during active ”Program test.”
− The variable for the state status feedback must be defined at the beginning of the pro-
gram using a DEF instruction: DEF INT state
You can also define a different name for the variable (instead of state, with a maximum
of 15 characters, beginning with 2 letters). The variable is only available in the program
in which it was defined.
The same applies to the monitoring type variable mon. If an entry is required for this,
it may also be passed directly as a number (1 or 2).
8.13.3 Workpiece count monitoring
The workpiece count of the active cutting edge of the active tool is monitored.
Monitoring of the unit quantity covers all tool cutting edges, which are used to manufacture a
workpiece. If the count is changed by new parameters, the monitoring data are adapted to all
of the tool cutting edges that became active since the last unit count.
Updating the workpiece count by operator input or SETPIECE( )

The workpiece count can be updated by an operator input (HMI) or in the NC program through
the SETPIECE( ) language command.
By using the SETPIECE function, the programmer can update the count monitoring data of
the tools involved in the machining process. All tools that became active since the last activa-
tion of SETPIECE are acquired with their D numbers. If a tool is active at the time when
SETPIECE( ) is called, it is also counted.
If a block containing path axis motions is programmed after SETPIECE( ), the appropriate tool
is also taken into account in the next SETPIECE call.
6FC5 698−2AA10−1BP5
Programming
SETPIECE(x ) ;
x : = 1... 32000 Number of workpieces produced since the last execution of the SETPIECE
function. The counter status for the remaining part quantity ($TC_MOP4[t,d] )
is reduced by this value.
x:=0 Deletion of all counters for the residual count ($TC_MOP4[t,d] ) for the
tools/D number involved in machining since then.
Alternatively, the deletion via operation is recommended (HMI).
Programming example
N10 G0 X100
N20 ...
N30 T1
N40 M6
N50 D1
N60 SETPIECE(2) ;$TC_MOP4[1,1 ] (T1,D2) is decremented by ”2”
N70 T2
N80 M6
N90 SETPIECE(0) ;Deletion command for the tools stored
N91 D2
N100 SETPIECE(1) ;$TC_MOP4[2,2 ] (T2,D2) is decremented by ”1”
N110 SETPIECE(0) ;Deletion command for the tools stored

N120 M30
Notes:
S The SETPIECE( ) command is not active in the block search.
S Direct writing of $TC_MOP4[t,d] is recommended only in simple cases. A subsequent
block with the STOPRE command is required.
Setpoint update
The setpoint update, i.e. setting the remaining workpiece counters ($TC_MOP4[t,d]) to the
workpiece count setpoint ($TC_MOP13[t,d]) is typically performed via operator input (HMI). It
can, however, also be performed through the RESETMON (state, t, d, ,mon) function as al-
ready described for the service life monitoring.
Example:
DEF INT state ; Defining a variable for the status feedback in the beginning of the program
...
N100 RESETMON(state,12,1,2) ;Updating the setpoint of the workpiece counter for T12, D1
...
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Programming
Programming example
DEF INT state ; Define variable for the status feedback from RE-
SETMON
()
;
G0 X... ; Retraction
T7 ; Load new tool, possibly with M6
$TC_MOP3[$P_TOOLNO,$P_TOOL]=100 ; Prewarning limit 100 pcs.
$TC_MOP4[$P_TOOLNO,$P_TOOL]=700 ; Residual count
$TC_MOP13[$P_TOOLNO,$P_TOOL]=700 ; Setpoint of count
; ; Activation after setting:
$TC_TP9[$P_TOOLNO,$P_TOOL]=2 ; Activation of count monitoring, active tool
STOPRE
ANF:
BEARBEIT ; Subroutine for workpiece machining
SETPIECE(1) ; Update counter
M0 ; Next tool; press NC START to continue
IF ($TC_MOP4[$P_TOOLNO,$P_TOOL]]>1) GOTOB ANF
MSG(”Tool T7 worn − please change”)
M0 ; after changing the tool, press NC START to con-
tinue
RESETMON(state,7,1,2) ;Workpiece counter setpoint update
IF (state<>0) GOTOF ALARM
GOTOB ANF
ALARM: ; display errors:
MSG(”Error RESETMON: ” <<state)
M0
M2
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Programming
8.14 Smooth approach and retraction
Functionality
This function is available with SW 2.0 and higher.
The function ”Smooth approach and retraction” (SPR) is intended to approach the beginning
of a contour tangentially (”smooth”), to a large degree independently of the position of the
starting point. The control system will calculate the intermediate points and will generate the
required traversing blocks. This function is used preferably in conjunction with the tool radius
compensation (TRC). The commands G41, G42 determine the approach / retraction direction
to the left or right of the contour (see also Section 8.6.4 ”Selecting the tool radius compensa-
tion: G41, G42)”.
The approach / retraction path (straight line, quarter or semicircle) is selected using a group of
G commands. To parameterize this path (circle radius, length, approach straight line), special
addresses can be used; this also applies to the infeed motion. The infeed motion can addition-
ally be controlled via another G group.
Programming
G147 ; Approach along a straight line
G148 ; Retraction along a straight line
G247 ; Approach along a quarter
G248 ; Retraction along a quarter
G347 ; Approach along a semi−circle
G348 ; Retraction along a quarter
G340 ; Approach and retraction in the space (default)

G341 ; Approach and retraction in the plane
DISR=... ; Approach and retraction with a straight line (G147/G148):

Distance of the cutter edge from the starting or end point of
the contour
; Approach and retraction along circles (G247, G347/G248, G348):
Radius of the tool center point path
DISCL=... ; Distance of the end point of the fast infeed motion from the machining
plane (safety clearance)
FAD=... ; Velocity of the slow infeed motion
The programmed value acts according to the active command of the
G group 15 (feedrate: G94, G95)
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Programming
R = tool radius
R Con-
P3 P4 tour
R
Approach G147:
P0 − starting point
DISR P3 − intermediate point
P4 − end point SAR, tangential
entry into the contour
Approach Retraction
Retraction using G148:
P4 − end point of contour,
P0 tangential exit from contour
P3 − intermediate point
P0 − end point SAR
Fig. 8-60 Approach along a straight line using the example of G42 or retraction using G41 and completion with
G40
Programming example: Approach / retraction along a straight line in a plane

N10 T1 ... G17 ; Activate tool, X/Y plane
N20 G0 X... Y... ; Approach P0
N30 G42 G147 DISR=8 F600 X4 Y4 ; Approach, point P4 programmed
N40 G1 X40 ; Further in the contour
...
N100 G41 ...
N110 X4 Y4 ; P4 − end point of the contour
N120 G40 G148 DISR=8 F700 X... Y... ; Retraction; point P0 programmed
...
R = tool radius
Con-
P4 tour
Approach G247:
R
P4’ P0 − starting point
P3 − intermediate point
P3’ entry into the contour
P3
Retraction G248:
P4 − end point of contour, tangential
Retraction
exit from contour
Approach P3 − intermediate point
P0 P0 − end point SAR
P3’, P4’ − equidistant points on the center point path
Fig. 8-61 Approach along a quadrant using the example of G42 or retraction using G41 and completion with
G40
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Programming
Programming example: Approach / retraction along a quarter in a plane

N10 T1 ... G17 ; Activate tool, X/Y plane
N20 G0 X... Y... ; Approach P0
N30 G42 G247 DISR=20 F600 X4 Y4 ; Approach, point P4 programmed
N40 G1 X40 ; Further in the contour
...
N100 G41 ...
N110 X4 Y4 ;P4 − end point of the contour
N120 G40 G248 DISR=20 F700 X... Y... ; Retraction; point P0 programmed
...
R = tool radius
Con-
P4 tour
Approach G347:
R P0 − starting point
P4’ P3 − intermediate point
entry into contour
Retraction using G348:
P4 − end point of contour, tangential
Retraction exit from contour
P0
P3’ P3 − intermediate point
P0 − end point SAR
P3 Approach
P3’, P4’ − equidistant points on the center point path
Fig. 8-62 Approach along a semicircle using the example of G42 or retraction using G41 and completion with
G40
Note
Make sure that a positive radius is entered for the tool radius. Otherwise, the directions for
G41, G42 will be changed.
Controlling the infeed motion using DISCL and G340, G341

DISCL=... specifies the distance of point P2 from the machining plane (see Fig. 8-63).
In the case DISCL=0, the following will apply:
S With G340: The whole approach motion consists only of two blocks (P1, P2 and P3 are
identical). The approach contour is generated from P3 to P4.
S With G341: The whole approach motion consists only of three blocks (P2 and P3 are iden-
tical). If P0 and P4 are located in the same plane, only two blocks will result (there will be
no infeed motion from P1 to P3).
It is monitored that the point defined by DISCL lies between P1 and P3, i.e. with all motions
that possess a component which runs vertically to the machining plane, this component must
have the same sign. If a reversal of the direction is detected, a tolerance of 0.01 mm is per-
mitted.
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Programming
P0 P1 P0 P1
Infeed motion
in Z
Straight line,
circle or helix Straight
G340 G341 line or
Z circle
P2,P3
Machining plane: P2
X/Y
P4 P3 P4
Fig. 8-63 Sequence of the approach motion dependent on G340 / G341 (example with G17)
Programming example: Approach along a semicircle with infeed

N10 T1 ... G17 G90 G94 ; Activate tool; plane X/Y
N20 G0 X0 Y0 Z30 ; Approach P0
N30 G41 G347 G340 DISCL=3 DISR=13 Z=0 F500
; Approach along a semicircle with radius: 13mm,
Safety clearance to the plane: 3 mm
N40 G1 X40 Y−10
...
alternatively N30 / N40:
N30 G41 G347 G340 DISCL=3 DISR=13 X40 Y−10 Z0 F500
or
N30 G41 G347 G340 DISCL=3 DISR=13 F500
N40 G1 X40 Y−10 Z0
Explanation with regard to N30 / N40:
Using G0 (from N20), the point P1 (starting point of the semicircle, corrected by the tool ra-
dius) is approached in the plane Z=30, then lowering to the depth (P2, P3) with Z=3 (DISCL).
The contour is reached at point X40 Y−10 in the depth Z=0 (P4) along a helix curve at a fee-
drate of 500 mm/min.
Approach and retraction velocities
S Velocity of the previous block (e.g.: G0):
This is the velocity at which all motions from P0 to P2 are carried out, i.e. the motion which
runs parallel to the machining plane and constitutes a part of the infeed motion until the
safety clearance DISCL is provided.
S Programmed feedrate F:
This feedrate value acts from P3 or P2 if FAD is not programmed. If no F word is pro-
grammed in the SAR block, the velocity of the previous block will act.
6FC5 698−2AA10−1BP5
Programming
S Programming using FAD:

Specification of the feedrate velocity with
− G341: Infeed motion vertically to the machining plane from P2 to P3
− G340: From point P2 or P3 to P4
If FAD is not programmed, this part of the contour will also be traversed using the modally
effective velocity of the previous block if no F word is programmed in the SAR block.
S During retraction, the roles of the modally effective feedrate from the previous block and
the feedrate programmed in the SAR block are changed, i.e. the actual retraction contour
is traversed using the old feedrate, and a new velocity programmed using the F word will
apply correspondingly from P2 to P0.
Programming example: Approach along a quarter, infeed using G341 and FAD
N10 T1 ... G17 G90 G94 ; Activate tool; plane X/Y
N20 G0 X0 Y0 Z30 ; Approach P0
N30 G41 G341 G247 DISCL=5 DISR=13 FAD=500 X40 Y−10 Z=0 F800
N40 G1 X50
...
Explanation with regard to N30:
Using G0 (from N20), the point P1 (starting point of the quarter, corrected by the tool radius) is
approached in the plane Z=30, then lowering to the depth (P2, P3) with Z=5 (DISCL). Using a
feedrate of FAD=500 mm/min, it is lowered to a depth of Z=0 (P3) (G341). Then, the contour
is approached at point X40,Y−10 along a quarter in the plane (P4) using F=800 mm/min.
Intermediate blocks
A maximum of 5 blocks without moving the geometry axes can be inserted between an SAR
block and the next traversing block.
Information
Programming when retracting:
S With an SAR block with a geometry axis programmed, the contour ends at P2. The posi-
tions on the axes that constitute the machining plane result from the retraction contour.
The axis component standing vertically on it is defined by DISCL. With DISCL=0, the mo-
tion will run completely in the plane.
S If in the SAR block only the axis is programmed vertically to the machining plane, the con-
tour will end at P1. The positions of the remaining axes will result, as described above. If
the SAR block is also the TRC disable block, an additional path from P1 to P0 is inserted
such that no motion results at the end of the contour when disabling the TRC.
S If only one axis is programmed, the 2nd missing axis is added modally by its last position
from the previous block.
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Programming
8.15 Milling of the peripheral surface − TRACYL
With SINUMERIK 802D, this function is an option and available with software release 2.0 and
higher.
Functionality
S The kinematic transformation function TRACYL is used for milling machining of the periph-
eral surface of cylindrical objects and allows the production of slots at any position.
S The path of the slots is programmed in the level peripheral surface, which was logically
developed for a specific machining cylinder diameter.
Fig. 8-64 Cartesian coordinate system X, Y, Z when programming TRACYL
S The control system transforms the programmed traversing motions in the Cartesian coordi-
nate system X, Y, Z into motions of the real machine axes. A rotary axis (rotary table) is
required.
S TRACYL must be configured using special machine data. The rotary axis position at which
the value Y=0 is also defined here.
S Milling machines possess a real machine Y axis (YM). It is possible to configure an ex-
tended TRACYL variant for them. This allows slots with slot side offset to be produced:
The slot side and base are perpendicular to each other − even if the milling tool’s diameter
is smaller than the slot width. This is otherwise only possible with exact fitting milling cut-
ters.
6FC5 698−2AA10−1BP5
Programming
Y or CM
Z or ZM
YM
ASM
XM
Fig. 8-65 Machine kinematics with a machine Y axis (YM)
Transverse slot
Longitudinal slot Longitudinal slot
limited in the parallel
with slot side
without slot side offset offset
Fig. 8-66 Various slots (cross section)
Programming
TRACYL(d) ; Activate TRANSMIT (separate block)
TRAFOOF ; Deactivate (separate block)
d − machining diameter of the cylinder in mm
TRAFOOF deactivates any active transformation function.
OFFN address
Distance from the slot side to the programmed path
The slot center line is generally programmed. OFFN defines the (half) slot width for activated
cutter radius compensation (G41, G42).
Programming: OFFN=... ; Distance in mm
6FC5 698−2AA10−1BP5
Programming
Note:
Set OFFN=0 once the slot has been completed. OFFN is also used outside of TRACYL − for
offset programming in combination with G41, G42.
OFFN
OFFN
Fig. 8-67 Use of OFFN for the slot width
Programming notes
In order to mill with TRACYL, the slot center line is programmed in the part program with the
coordinates and the (half) slot width is programmed with OFFN.
OFFN does not go into effect until tool radius compensation is selected. Furthermore, it must
be guaranteed that OFFN >= tool radius to avoid that the opposite slot side is damaged.
A part program for milling a slot generally consists of the following steps:
1. Select a tool Select TRACYL Select a suitable work offset
4. Positioning
5. Program OFFN
6. Select the tool radius compensation
7. Approach block (position TRC and approach slot side)
8. Program the slot path via slot center line
9. Deselect the tool radius compensation
10. Retraction block (retract TRC from slot side)
11. Positioning
12. Clear OFFN
13.TRAFOOF (deselect TRACYL)
14. Reselect the original work offset
(see also following programming example)
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Programming
Information
S Guiding slots:
By using a tool diameter that corresponds exactly to the slot width, it is possible to produce
an exact slot. The tool radius compensation is not activated for this.
With TRACYL, slots can also be produced, whose tool diameter is smaller than the slot
width. For this, the tool radius compensation (G41, GG42) and OFFN are used.
To avoid problems of accuracy, the tool diameter should only be slightly smaller than the
slot width.
S When working with TRACYL with slot side correction, the axis used for the correction (YM)
should stand on the turning center of the rotary axis. Thus, the slot is created centered on
the programmed slot center line.
S Selecting the tool radius compensation (TRC) :
The TRC is in effect for the programmed slot center line. The slot side results. G42 is input
so that the tool traverses to the left of the slot side (to the right of the slot center line). Ac-
cordingly, G41 is to be written to the right of the slot side (to the left of the slot center line).
As an alternative to exchanging G41<−>G42, you can input the slot width with a minus
sign in OFFN.
S Since, even without TRACYL, OFFN is included when TRC is active, OFFN should be re-
set to zero after TRAFOOF. OFFN acts differently with TRACYL than it does without TRA-
CYL.
S It is possible to change OFFN within a part program. This allows the actual slot center line
to be offset from the center.
References: Description of Functions, Section ”Kinematic transformations”
Programming example
Making a hook−shaped slot
Fig. 8-68 Producing a slot (example)
6FC5 698−2AA10−1BP5
Programming
Z D x Pi =
70 35.0 x 3.1415 mm
10
N90 N150 110
0 20 40 60 80 100 Y
N140
N110 N100
OFFN
−30 N120
N130
Fig. 8-69 Programming the slot, values at the slot base
; Machining diameter of the cylinder at the slot base: 35.0 mm

; Desired total slot width: 24.8 mm, the cutter in use has a radius of: 10,123 mm
N10 T1 F400 G94 G54 ; Milling tool, feedrate, feedrate type, zero offset
N15 G153 Y60 ; Approach Y to turning center of C axis
N30 G0 X25 Z50 C120 ; Approach the starting position
N40 TRACYL (35.0) ; Activate TRACYL, machining diameter 35.0 mm
N50 G55 G19 ; Work offset, plane selection: Y/Z plane
N60 S800 M3 ; Turn on spindle
N70 G0 Y70 Z10 ; Starting position Y / Z,
; Y is now geometry axis of the peripheral surface
N80 G1 X17.5 ; Infeed cutter to slot base
N70 OFFN=12.4 ; 12.4 slot side distance to slot center line
N90 G1 Y70 Z1 G42 ; Activate TRC, approach slot side
N100 Z−30 ; Slot section parallel to cylinder axis Slot section parallel to
circumference
N120 G42 G1 Y20 Z−30 ; Restart TRC, approach other slot side,
; slot distance continues to be 12.4 mm to slot center line
N130 Y70 F600 ; Slot section parallel to the circumference
N140 Z1 ; Slot section parallel to cylinder axis
N150 Y70 Z10 G40 ; Deactivate TRC
N160 G0 X25 ; Retract cutter
N170 M5 OFFN=0 ; Turn off spindle, delete slot side distance
N180 TRAFOOF ; Disable TRACYL
N200 G54 G17 G0 X25 Z50 C120 ; Approach starting position
N210 M2
6FC5 698−2AA10−1BP5
Programming
8.16 G functions equivalent to the SINUMERIK 802S/C − Milling
8.16 G functions equivalent to the SINUMERIK 802S/C − Milling
SINUMERIK 802S/C SINUMERIK 802D

G5 CIP
G158 TRANS
G258 ROT
G259 AROT
G900 CFTCP
G901 CFC
All the other G functions are the same as with 802S/C and 802D provided that they exist
there.
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Cycles 9
9.1 Overview of cycles
Cycles are generally applicable technology subroutines that can be used to carry out a spe-
cific machining process, such as drilling of a thread (tapping) or milling of a pocket. These
cycles are adapted to individual tasks by parameter assignment.
The cycles described here are the same as supplied for the SINUMERIK 840D/810D.
Drilling cycle, drilling pattern cycles and milling cycles

The following standard cycles can be carried out using the SINUMERIK 802D control system:
S Drilling cycles
CYCLE81 Drilling, centering
CYCLE82 Drilling, counterboring
CYCLE83 Deep hole drilling
CYCLE84 Rigid tapping
CYCLE840 Tapping with compensating chuck
CYCLE85 Reaming 1 (boring 1)
CYCLE86 Boring (boring 2)
CYCLE87 Drilling with stop 1 (boring 3)
CYCLE88 Drilling with stop 2 (boring 4)
CYCLE89 Reaming 2 (boring 5)
With SINUMERIK 840D, the boring cycles CYCLE85 ... CYCLE89 are called boring 1 ... bor-
ing 5, but are nevertheless identical in their function.
S Drilling pattern cycles
HOLES1 Row of holes
HOLES2 Circle of holes
S Milling cycles
CYCLE71 Face Milling
CYCLE72 Contour milling
CYCLE76 Rectangular spigot milling
CYCLE77 Circular spigot milling
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Cycles
9.2 Programming cycles
LONGHOLE Slot
SLOT1 Groove milling pattern on a circle
SLOT2 Circumferential groove milling pattern
POCKET3 Milling a rectangular pocket (with any milling tool)
POCKET4 Milling a circular pocket (with any milling tool)
CYCLE90 Thread milling
The cycles are supplied with the tool box. They are loaded via the RS232 interface into the
part program memory during the start−up of the control system.
Auxiliary cycle subroutines

The cycle package includes the following auxiliary subroutines:
S cyclesm.spf
S steigung.spf and
S meldung.spf
These must always be loaded in the control.
Call and return conditions

The G functions effective prior to the cycle call and the programmable offsets remain active
beyond the cycle.
The machining plane (G17, G18, G19) must be defined before calling the cycle. A cycle oper-
ates in the current plane with the
S 1st axis of the plane (abscissa)
S 2nd axis of the plane (ordinate)
S Drilling axis/infeed axis, 3rd axis standing vertically to the plane (applicate).
With drilling cycles, the drilling operation is carried out in the axis standing vertically to the
current plane. In milling, the depth infeed is carried out in this axis.
Z Z Z
Y Y
Ordinate Applicate G19 Abscissa
Y
Abscissa
Ordinate
Applicate
G17
G18
Abscissa Ordinate X Applicate X

X
Fig. 9-1 Plane and axis assignment
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Cycles
Table 9-1 Plane and axis assignment
Command Plane Vertical infeed axis

G17 X/Y Z
G18 Z/X Y
G19 Y/Z X
Messages output during execution of a cycle

During some cycles, messages that refer to the state of machining are displayed on the
screen of the control system during program execution.
These message do not interrupt the program execution and continue to be displayed on the
screen until the next message appears.
The message texts and their meaning are listed together with the cycle to which they refer. A
summary is to be found in Section 9.7.4.
Block display during execution of a cycle

The cycle call is displayed in the current block display for the duration of the cycle.
Cycle call and parameter list

The defining parameters for the cycles can be transferred via the parameter list when the
cycle is called.
Note
Cycle calls must always be programmed in a separate block.
Basic instructions with regard to the assignment of standard cycle parameters

The Programming Guide describes the parameter list of every cycle with the
S order and the
S type.
It is imperative to observe the order of the defining parameters.
Each defining parameter of a cycle has a certain data type. The parameter being used must
be specified when the cycle is called. In the parameter list, you can transfer
S R parameters (only numerical values)
S constants.
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Cycles
9.3 Graphical cycle support in the program editor
If R parameters are used in the parameter list, they must first be assigned values in the call-
ing program. Cycles can be called
S with an incomplete parameter list
or
S by leaving out parameters.
If you want to exclude the last transfer parameters that have to be written in a call, you can
prematurely terminate the parameter list with ”)”. If any parameters are to be omitted within
the list, a comma ”..., ,...” must be written as a placeholder.
No plausibility checks are made for parameter values with a limited range of values unless an
error response has been specifically described for a cycle.
If when calling the cycle the parameter list contains more entries than parameters are defined
in the cycle, the general NC alarm 12340 ”Too many parameters” is displayed and the cycle
is not executed.
Cycle call
The individual methods for writing a cycle are shown in the programming examples provided
for the individual cycles.
Simulation of cycles
Programs with cycle calls can be tested first in simulation.
During simulation, the traversing movements of the cycle are visualized on the screen.

The program editor in the control system provides you with programming support to add cycle
calls to the program and to enter parameters.
Function
The cycle support consists of three components:
1. Cycle selection
2. Input screenforms for parameter assignment
3. Help screen for each cycle (is to be found in the interactive screenform).
Overview of required files

The following files constitute the basis for cycle support:
S cov.com
S sc.com
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Cycles
Note
These files must always be loaded in the control system. They are loaded during the start−up
of the control system.
Operating the cycle selection

To add a cycle call to the program, carry out the following steps one after the other:
S Branching to selection bars for the individual cycles is possible in the horizontal softkey
bar using the ”Drilling” and ”Milling” softkeys provided.
S The cycle selection is carried out using the vertical softkey bar until the appropriate input
screenform with the help display appears on the screen.
S Then enter the values for the parameters.
The values can be entered either directly (numerical values) or indirectly (R parameters,
e.g. R27, or expressions consisting of R parameters, e.g. R27+10).
If numerical values are entered, a check is carried out to see whether the value is within
the admissible range.
S Some parameters that may have only a few values are selected using the toggle key.
S For drilling cycles, it is also possible to call a cycle modally using the vertical ”Modal Call”
softkey.
The modal call is selected via ”Deselect modal” from the drilling cycles list box.
S Press ”OK” to confirm (or ”Abort” in case of error).
Recompiling
Recompiling of program codes serves to make modifications to an existing program using the
cycle support.
Position the cursor on the line to be modified and press the ”Recompile” softkey.
This will reopen the input screenform from which the program piece has been created, and
you can modify the values.
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Cycles
9.4 Drilling cycles
9.4 Drilling cycles

9.4.1 General
Drilling cycles are motional sequences defined to DIN 66025 for drilling, boring, tapping etc.
They are called in the form of a subroutine with a defined name and a parameter list.
A total of five cycles is provided for boring. They all follow a different technological procedure
and are therefore parameterized differently.
Table 9-2
Boring cycle Special parameterization features

Reaming 1 CYCLE85 Different feedrates for boring and retraction
Boring CYCLE86 Oriented spindle stop, specification of the retraction
path, retraction at rapid traverse rate, specification of
the direction of rotation of spindle
Drilling with stop 1 CYCLE87 Spindle stop M5 and program stop M0 at the drilling
depth; to continue, press NC_Start, retraction at rapid
traverse, specification of the direction of rotation of the
spindle
Drilling with stop 2 CYCLE88 as with CYCLE87 plus dwell time to drilling depth
Reaming 2 CYCLE89 Boring and retraction at the same feedrate
The drilling cycles can be modal, i.e. they are executed at the end of each block that contains
motion commands. Further cycles created by the user can also be called modally (see also
Section 8.1.6 or 9.3).
There are two types of parameters:
S Geometrical parameters and
S Machining parameters
The geometrical parameters are identical for all drilling cycles, drilling pattern cycles and mill-
ing cycles. They define the reference and retraction planes, the safety clearance and the ab-
solute or relative final drilling depth. Geometrical parameters are assigned once during the
first drilling cycle CYCLE81.
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Cycles
9.4 Drilling cycles
Geometrical parameters
Retraction plane
Safety clearance
Reference plane
Final drilling depth
Fig. 9-2
The machining parameters have a different meaning and effect in the individual cycles. They
are therefore programmed in each cycle separately.
9.4.2 Preconditions

Drilling cycles are programmed independently of the actual axis names. The drilling position
must be approached in the higher−level program before the cycle is called.
The required values for feedrate, spindle speed and direction of spindle rotation must be pro-
grammed in the part program if there are no defining parameters in the drilling cycle.
The G functions and the current data record active before the cycle was called remain active
beyond the cycle.
Plane definition
In the case of drilling cycles, it is generally assumed that the current workpiece coordinate
system in which the machining operation is to be performed is to be defined by selecting
plane G17, G18 or G19 and activating a programmable offset. The drilling axis is always the
axis of this coordinate system which stands vertically to the current plane.
A tool length compensation must be selected before the cycle is called. Its effect is always
perpendicular to the selected plane and remains active even after the end of the cycle.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Tool length comp.

Drilling axis
Fig. 9-3
Dwell time programming

The parameters for dwell times in the drilling cycles are always assigned to the F word and
must therefore be assigned with values in seconds. Any deviations from this procedure must
be expressly stated.
9.4.3 Drilling, centering – CYCLE81
Programming
CYCLE81(RTP, RFP, SDIS, DP, DPR)
Table 9-3 Parameters for CYCLE81
RTP real Retraction plane (absolute)

RFP real Reference plane (absolute)
SDIS real Safety clearance (enter without sign)
DP real Final drilling depth (absolute)
DPR real Final drilling depth relative to the reference plane (enter with-
out sign)
Function
The tool drills at the programmed spindle speed and feedrate to the entered final drilling
depth.
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Cycles
9.4 Drilling cycles
Sequence
Position reached prior to cycle start:
The drilling position is the position in the two axes of the selected plane.
The cycle creates the following sequence of motions:
Approach of the reference plane brought forward by the safety clearance by using G0
S Traversing to the final drilling depth at the feedrate programmed in the calling program
(G1)
S Retraction to the retraction plane with G0
Explanation of the parameters
RFP and RTP (reference plane and retraction plane)
Normally, reference plane (RFP) and return plane (RTP) have different values. In the cycle, it
is assumed that the retraction plane is ahead of the reference plane. This means that the dis-
tance from the retraction plane to the final drilling depth is larger than the distance from the
reference plane to the final drilling depth.
SDIS (safety clearance)
The safety clearance (SDIS) acts with reference to the reference plane. This is brought for-
ward by the safety clearance.
The direction in which the safety clearance acts is determined by the cycle automatically.
DP and DPR (final drilling depth)
The final drilling depth can be specified either absolute (DP) or relative (DPR) to the refer-
ence plane.
With relative specification, the cycle will calculate the resulting depth automatically using the
positions of reference and retraction planes.
Z
G1
G0
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-4
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Further notes
If a value is entered both for DP and for DPR, the final drilling depth is derived from DPR. If
this differs from the absolute depth programmed via DP,
the message ”Depth: Corresponding to value for relative depth” is output in the dialog line.
If the values for reference and retraction planes are identical, a relative depth specification is
not permitted. The error message
61101 ”Reference plane not correctly defined”, and the cycle is not executed. This error mes-
sage is also output if the retraction plane is located after the reference plane, i.e. its distance
to the final drilling depth is smaller.
Programming example: Drilling_centering

By using this program, you can produce 3 drill holes using the CYCLE81 drilling cycle,
whereby this is called using different parameters. The drilling axis is always the Z axis.
Y Y A−B
120
30
0
B X Z
40 90 35 100 108
Fig. 9-5
N10 G0 G17 G90 F200 S300 M3 Specification of the technological values
N20 D3 T3 Z110 Approaching the retraction plane
N30 X40 Y120 Approach of the first drilling position
N40 CYCLE81(110, 100, 2, 35) Cycle call with absolute final drilling depth,
safety clearance and incomplete parameter
list
N50 Y30 Approach of next drill position
N60 CYCLE81(110, 102, , 35) Cycle call without safety clearance
N70 G0 G90 F180 S300 M03 Specification of the technological values
N80 X90 Approach next position
N90 CYCLE81(110, 100, 2, , 65) Cycle call with relative final drilling depth and
safety clearance
N100 M02 End of program
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
9.4.4 Drilling, counterboring – CYCLE82
Programming
CYCLE82(RTP, RFP, SDIS, DP, DPR, DTB)
Parameters

out sign)
DTB real Dwell time at final drilling depth (chip breaking)
Function
depth. A dwell time can be allowed to elapse when the final drilling depth has been reached.
Sequence
S Approach of the reference plane brought forward by the safety clearance by using G0
S Traversing to the final drilling depth with the feedrate (G1) programmed prior to the cycle
call
S Dwell time at final drilling depth

For the parameters RTP, RFP, SDIS, DP, DPR, see CYCLE81
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Z
G0
G1
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-6
DTB (dwell time)

The dwell time to the final drilling depth (chip breaking) is programmed under DTB in sec-
onds.
Note
If a value is entered both for DP and for DPR, the final drilling depth is derived from DPR. If
this differs from the absolute depth programmed via DP, the message ”Depth: Corresponding
to value for relative depth” is output in the message line.
If the values for reference and retraction planes are identical, a relative depth specification is
not permitted. The error message 61101 ”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 plane, i.e. its distance to the final drilling depth is smaller.
Programming example: Boring_counterboring

The program machines a single hole of a depth of 27 mm at position X24 Y15 in the XY plane
with cycle CYCLE82.
The dwell time programmed is 2 s, the safety clearance in the drilling axis Z is 4 mm.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Y Y A−B
B
15
24 X 75 Z
102
Fig. 9-7 Example
N30 X24 Y15 Approaching the drill position
N40 CYCLE82(110, 102, 4, 75, , 2) Cycle call with absolute final drilling depth
and safety clearance
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
9.4.5 Deep hole drilling – CYCLE83
Programming
CYCLE83(RTP, RFP, SDIS, DP, DPR, FDEP, FDPR, DAM, DTB, DTS, FRF, VARI)
Parameters

out sign)
FDEP real First drilling depth (absolute)
FDPR real First drilling depth relative to the reference plane (enter with-
out sign)
DAM real Amount of degression (enter without sign)
DTS real Dwell time at starting point and for swarf removal
FRF real Feedrate factor for the first drilling depth (enter without sign)
Range of values: 0.001 ... 1
VARI int Machining type:
Chip breaking=0
Swarf removal=1
Function
depth.
Deep hole drilling is performed with a depth infeed of a maximum definable depth executed
several times, increasing gradually until the final drilling depth is reached.
The drill can either be retracted to the reference plane + safety clearance after every infeed
depth for swarf removal or retracted in each case by 1 mm for chip breaking.
Sequence
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Cycles
9.4 Drilling cycles

Deep hole drilling with swarf removal (VARI=1):
S Traversing to the first drilling depth with G1, the feedrate for which is derived from the fee-
drate defined with the program call which is subject to parameter FRF (feedrate factor)
S Dwell time at final drilling depth (parameter DTB)
S Retraction to the reference plane brought forward by the safety clearance for swarf re-
moval by using G0
S Dwell time at the starting point (parameter DTS)
S Approach of the drilling depth last reached, reduced by anticipation distance by using G0
S Traversing to the next drilling depth with G1 (sequence of motions is continued until the
final drilling depth is reached)
G1
G0
G4
RTP
RFP+SDIS
RFP
X
FDEP
FDEP
DP=RFP−DPR
Fig. 9-8 Deep hole drilling with swarf removal (VARI=1)
Deep hole drilling with chip breaking (VARI=0):

S Traversing to the first drilling depth with G1, the feedrate for which is derived from the fee-
drate defined with the program call which is subject to parameter FRF (feedrate factor)
S Dwell time at final drilling depth (parameter DTB)
S Retraction by 1 mm from the current drilling depth with G1 and the feedrate programmed
in the calling program (for chip breaking)
S Traversing to the next drilling depth with G1 and the programmed feedrate (sequence of
motions is continued until the final drilling depth is reached)
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
G1
G0
G4
RTP
RFP+SDIS
RFP
X
FDEP
DP=RFP−DPR
Fig. 9-9 Deep hole drilling with swarf removal (VARI=0)

Interrelation of the parameters DP (or DPR), FDEP (or FDPR) and DAM
The intermediate drilling depth are calculated in the cycle on the basis of final drilling depth,
first drilling depth and amount of degression as follows:
S In the first step, the depth parameterized with the first drilling depth is traversed as long as
it does not exceed the total drilling depth.
S From the second drilling depth on, the drilling stroke is obtained by subtracting the amount
of degression from the stroke of the last drilling depth, provided that the latter is greater
than the programmed amount of degression.
S The next drilling strokes correspond to the amount of degression, as long as the remain-
ing depth is greater than twice the amount of degression.
S The last two drilling strokes are divided and traversed equally and are therefore always
greater than half of the amount of degression.
S If the value for the first drilling depth is incompatible with the total depth, the error mes-
sage 61107 ”First drilling depth defined incorrectly” is output and the cycle is not exe-
cuted.
The parameter FDPR has the same effect in the cycle as the parameter DPR. If the values
for the reference and retraction planes are identical, the first drilling depth can be defined as
a relative value.
If the first drilling depth is programmed larger than the final drilling depth, the final drilling
depth is never exceeded. The cycle will reduce the first drilling depth automatically as far as
the final drilling depth is reached when drilling only once, and will therefore drill only once.
DTB (dwell time)

onds.
DTS (dwell time)

The dwell time at the starting point is only performed if VARI=1 (swarf removal).
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
FRF (feedrate factor)

With this parameter, you can specify a reduction factor for the active feedrate which only ap-
plies to the approach to the first drilling depth in the cycle.
VARI (machining type)

If parameter VARI=0 is set, the drill retracts 1 mm after reaching each drilling depth for chip
breaking. If VARI=1 (for swarf removal), the drill traverses in each case to the reference plane
brought forward by the safety clearance.
Note
The anticipation distance is calculated internally in the cycle as follows:
S If the drilling depth is 30 mm, the value of the anticipation distance is always 0.6 mm.
S For larger drilling depths, the formula drilling depth /50 is used (maximum value 7 mm).
Programming example − deep hole drilling

This program executes the cycle CYCLE83 at the positions X80 Y120 and X80 Y60 in the XY
plane. The first drill hole is drilled with a dwell time zero and machining type chip breaking.
The final drilling depth and the first drilling depth are entered as absolute values. In the sec-
ond cycle call, a dwell time of 1 s is programmed. Machining type swarf removal is selected,
the final drilling depth is relative to the reference plane. The drilling axis in both cases is the Z
axis.
Y Y A−B
A
120
B
60
80 X 5 Z
150
Fig. 9-10
N20 D1 T12 Approaching the retraction plane
N30 Z155
N40 X80 Y120 Approach of the first drilling position
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Cycles
9.4 Drilling cycles
N50 CYCLE83(155, 150, 1, 5, 0 , 100, , 20, 0, 0, 1, 0) Call of cycle; depth parameters with absolute
values
N60 X80 Y60 Approach of next drill position
N70 CYCLE83(155, 150, 1, , 145, , 50, 20, 1, 1, 0.5, 1) Call of cycle with relative specifications of fi-
nal drilling depth and 1st drilling depth; the
safety clearance is 1 mm, the feedrate factor
0.5
9.4.6 Rigid tapping – CYCLE84
Programming
CYCLE84(RTP, RFP, SDIS, DP, DPR, DTB, SDAC, MPIT, PIT, POSS, SST, SST1)
Parameters

out sign)
DTB real Dwell time at thread depth (chip breaking)
SDAC int Direction of rotation after end of cycle
Values: 3, 4 or 5 (for M3, M4 or M5)
MPIT real Pitch as thread size (signed)
Range of values 3 (for M3) ... 48 (for M48); the sign deter-
mines the direction of rotation in the thread
PIT real Pitch as a value (signed)
Range of values: 0.001 ... 2000.000 mm); the sign determines
the direction of rotation in the thread
POSS real Spindle position for oriented spindle stop in the cycle (in de-
grees)
SST real Speed for tapping
SST1 real Speed for retraction
Function
The tool drills at the programmed spindle speed and feedrate to the entered final thread
depth.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
CYCLE84 can be used to perform rigid tapping operations. For tapping with compensating
chuck, a separate cycle CYCLE840 is provided.
Note
CYCLE84 can be used if the spindle to be used for the boring operation is technically able to
be operated in the position−controlled spindle operation.
Sequence
S Oriented spindle stop (value in the parameter POSS) and switching the spindle to axis
mode
S Tapping to final drilling depth and speed SST
S Dwell time at thread depth (parameter DTB)
S Retraction to the reference plane brought forward by the safety clearance, speed SST1
and direction reversal
S Retraction to the retraction plane with G0; spindle mode is reinitiated by reprogramming
the spindle speed active before the cycle was called and the direction of rotation pro-
grammed under SDAC

SDAC
Z
G0
Tapping
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-11
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
DTB (dwell time)

The dwell time must be programmed in seconds. When tapping blind holes, it is recom-
mended to omit the dwell time.
SDAC (direction of rotation after end of cycle)

Under SDAC, the direction of rotation after end of cycle is programmed.
The direction reversal when tapping is carried out automatically internally in the cycle.
MPIT and PIT (as a thread size and as a value)

The value for the thread pitch can be defined either as the thread size (for metric threads be-
tween M3 and M48 only) or as a value (distance from one thread turn to the next as a numer-
ical value). The parameter not required in each case is omitted in the call or is assigned the
value zero.
RH or LH threads are defined by the sign of the pitch parameters:
S positive value → RH (as for M3)
S negative value → LH (as for M4)
If the two thread pitch parameters have conflicting values, alarm 61001 ”Thread pitch wrong”
is generated by the cycle and cycle execution is aborted.
POSS (spindle position)

Before tapping, the spindle is stopped with orientation in the cycle and switched to position
control.
The spindle position for this spindle stop is programmed under POSS.
SST (speed)
Parameter SST contains the spindle speed for the tapping block with G331.
SST1 (retraction speed)

The speed for retraction from the tapped hole is programmed under SST1.
If this parameter is assigned the value zero, retraction is carried out at the speed pro-
grammed under SST.
Note
The direction of rotation when tapping in the cycle is always reversed automatically.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Programming example: Rigid tapping

A thread is tapped without compensating chuck at position X30 Y35 in the XY plane; the tap-
ping axis is the Z axis. No dwell time is programmed; the depth is programmed as a relative
value. The parameters for the direction of rotation and for the pitch must be assigned values.
A metric thread M5 is tapped.
Y Y A−B
B
35
30 X Z
6
36
Fig. 9-12
N10 G0 G90 T11 D1 Specification of the technological values
N20 G17 X30 Y35 Z40 Approaching the drill position
N30 CYCLE84(40, 36, 2, , 30, , 3, 5, , 90, 200, 500) Cycle call; parameter PIT has been omitted;
no value is entered for the absolute depth or
the dwell time; spindle stop at 90 degrees;
speed for tapping is 200, speed for retraction
is 500
9.4.7 Tapping with compensating chuck – CYCLE840
Programming
CYCLE840(RTP, RFP, SDIS, DP, DPR, DTB, SDR, SDAC, ENC, MPIT, PIT)
Parameters
Table 9-7 Parameter of CYCLE840

6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Table 9-7 Parameter of CYCLE840, cont’d

out sign)
DTB real Dwell time at thread depth (chip breaking)
SDR int Direction of rotation for retraction
Values: 0 (automatic reversal of the direction of rotation)
3 or 4 (for M3 or M4)
SDAC int Direction of rotation after end of cycle
Values: 3, 4 or 5 (for M3, M4 or M5)
ENC int Tapping with/without encoder
Values: 0 = with encoder
1 = without encoder
MPIT real Thread pitch as the thread size (signed)
Range of values 3 (for M3) ... 48 (for M48)
PIT real Pitch as a value (signed)
Range of values: 0.001 ... 2000.000 mm
Function
The tool drills at the programmed spindle speed and feedrate to the entered final thread
depth.
Using this cycle, you can perform tapping with compensating chuck
S without encoder and
S with encoder.
Sequence of operations: Tapping with compensating chuck without encoder

6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
SDAC
Z G0
G63
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
SDR
Fig. 9-13
S Tapping to the final drilling depth
S Dwell time at tapping depth (parameter DTB)
S Retraction to the reference plane brought forward by the safety clearance
Sequence of operations: Tapping with compensating chuck with encoder

SDAC
Z G0
G33
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
SDR
Fig. 9-14
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
S Tapping to the final drilling depth
S Dwell time at thread depth (parameter DTB)
S Retraction to the reference plane brought forward by the safety clearance

DTB (dwell time)

The dwell time must be programmed in seconds.
SDR (direction of rotation for retraction)

SDR=0 must be set if the spindle direction is to reverse automatically.
If the machine data are defined such that no encoder is set (in this case, machine data
MD30200 NUM_ENCS is 0), the parameter must be assigned the value 3 or 4 for the direc-
tion of rotation; otherwise, alarm 61202 ”No spindle direction programmed” is output and the
cycle is aborted.
SDAC (direction of rotation)

Because the cycle can also be called modally (see Section 9.3), it requires a direction of rota-
tion for tapping further threaded holes. This is programmed in parameter SDAC and corre-
sponds to the direction of rotation programmed before the first call in the higher−level pro-
gram. If SDR=0, the value assigned to SDAC has no meaning in the cycle and can be
omitted in the parameterization.
ENC (tapping)
If tapping is to be performed without encoder although an encoder exists, parameter ENC
must be assigned value 1.
If, however, no encoder is installed and the parameter is assigned the value 0, it is ignored in
the cycle.
MPIT and PIT (as a thread size and as a value)

The parameter for the spindle pitch is only relevant if tapping is performed with encoder. The
cycle calculates the feedrate from the spindle speed and the pitch.
The value for the thread pitch can be defined either as the thread size (for metric threads be-
tween M3 and M48 only) or as a value (distance from one thread turn to the next as a numer-
ical value). The parameter not required in each case is omitted in the call or is assigned the
value zero.
If the two thread pitch parameters have conflicting values, alarm 61001 ”Thread pitch wrong”
is generated by the cycle and cycle execution is aborted.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Further notes
Depending on the settings in machine data MD30200 NUM_ENCS, the cycle selects whether
tapping is to be performed with or without encoder.
The direction of rotation for the spindle must be programmed with M3 orM4.
In thread blocks with G63, the values of the feedrate override switch and spindle speed over-
ride switch are frozen to 100%.
A longer compensating chuck is usually required for tapping without encoder.
Programming example: Tapping without encoder

In this program, a thread is tapped without encoder at position X35 Y35 in the XY plane; the
tapping axis is the Z axis. The parameters SDR and SDAC for the direction of rotation must
be assigned; parameter ENC is assigned the value 1, the value for the depth is the absolute
value. Pitch parameter PIT can be omitted. A compensating chuck is used in machining.
Y Y A−B
B
35
35 X 15 Z
56
Fig. 9-15
N10 G90 G0 T11 D1 S500 M3 Specification of the technological values
N30 G1 F200 Determination of the path feed
N40 CYCLE840(59, 56, , 15, 0, 1, 4, 3, 1, , ) Cycle call, dwell time 1 s, direction of rotation
for retraction M4, direction of rotation after
cycle M3, no safety clearance
Parameters MPIT and PIT are omitted
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Example: Tapping with encoder

In this program, a thread is tapped with encoder at position X35 Y35 in the XY plane. The
drilling axis is the Z axis. The pitch parameter must be defined, automatic reversal of the di-
rection of rotation is programmed. A compensating chuck is used in machining.
Y Y A−B
B
35
35 X 15 Z
56
Fig. 9-16
N30 CYCLE840(59, 56, , 15, 0, 0, 4, 3, 0, 0, 3.5) Cycle call, without safety clearance, with ab-
solute depth specification
9.4.8 Reaming 1 (boring 1) – CYCLE85
Programming
CYCLE85(RTP, RFP, SDIS, DP, DPR, DTB, FFR, RFF)
Parameters

6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Table 9-8 Parameters for CYCLE85, cont’d
out sign)
FFR real Feedrate
RFF real Retraction feedrate
Function
depth.
The inward and outward movement is performed at the feedrate assigned to FFR and RFF
respectively.
Sequence
S Traversing to the final drilling depth with G1 and at the feedrate programmed under the
parameter FFR
S Retraction to the reference plane brought forward by the safety clearance with G1 and the
retraction feedrate defined under the parameter RFF

6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Z
G0
G1
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-17
DTB (dwell time)

The dwell time to the final drilling depth is programmed under DTB in seconds.
FFR (feedrate)
The feedrate value programmed under FFR is active in drilling.
RFF (retraction feedrate)

The feedrate value programmed under RFF is active when retracting from the hole to the ref-
erence plane + safety clearance.
Programming example: First boring pass

CYCLE85 is called at position Z70 X50 in the ZX plane. The boring axis is the Y axis. The
value for the final drilling depth in the cycle call is programmed as a relative value; no dwell
time is programmed. The workpiece upper edge is at Y102.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
X X A−B
B
50
70 Z 77 Y
102
Fig. 9-18
N10 T11 D1
N20 G18 Z70 X50 Y105 Approaching the drill position
N30 CYCLE85(105, 102, 2, , 25, , 300, 450) Cycle call, no dwell time programmed
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
9.4.9 Boring (boring 2) – CYCLE86
Programming
CYCLE86(RTP, RFP, SDIS, DP, DPR, DTB, SDIR, RPA, RPO, RPAP, POSS)
Parameters

out sign)
SDIR int Direction of rotation
Values: 3 (for M3)
4 (for M4)
RPA real Retraction path in the 1st axis of the plane (incremental, enter
with sign)
RPO real Retraction path in the 2nd axis of the plane (incremental, en-
ter with sign)
RPAP real Retraction path in the boring axis (incremental, enter with
sign)
POSS real Spindle position for oriented spindle stop in the cycle (in de-
grees)
Function
The cycle supports the boring of holes with a boring bar.
depth.
With boring 2, oriented spindle stop is activated once the drilling depth has been reached.
Then, the programmed retraction positions are approached in rapid traverse and, from there,
the retraction plane.
Sequence
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles

S Traversing to final drilling depth with G1 and the feedrate programmed prior to the cycle
call
S Dwell time to final drilling depth
S Oriented spindle stop at the spindle position programmed under POSS
S Traverse retraction path in up to three axes with G0
S Retraction in the boring axis to the reference plane brought forward by the safety clear-
ance by using G0
S Retraction to the retraction plane with G0 (initial drilling position in both axes of the plane)

Z
G0
G1
G4
SPOS
RTP
RFP+SDIS
RFP
X
DP=
RFP−DPR
Fig. 9-19
DTB (dwell time)

onds.
SDIR (direction of rotation)

With this parameter, you determine the direction of rotation with which boring is performed in
the cycle. If values other than 3 or 4 (M3/M4) are generated, alarm 61102 ”No spindle direc-
tion programmed” is generated and the cycle is not executed.
RPA (retraction path in the 1st axis)

Use this parameter to define a retraction movement in the 1st axis (abscissa), which is exe-
cuted after the final drilling depth has been reached and oriented spindle stop has been per-
formed.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
RPO (retraction path in the 2nd axis)

Use this parameter to define a retraction movement in the 2nd axis (ordinate), which is exe-
cuted after the final drilling depth has been reached and oriented spindle stop has been per-
formed.
RPAP (retraction path in the boring axis)

Use this parameter to define a retraction movement in the boring axis, which is executed after
the final drilling axis has been reached and oriented spindle stop has been performed.
POSS (spindle position)

Use POSS to program the spindle position for the oriented spindle stop in degrees which is
performed after the final drilling depth has been reached.
Note
It is possible to stop the active spindle with orientation. The angular value is programmed
using a transfer parameter.
CYCLE84 can be used if the spindle to be used for the drilling operation is technically able to
execute the SPOS command.
Programming example: Second boring pass

CYCLE86 is called at position X70 Y50 in the ZX plane. The drilling axis is the Z axis. The
final drilling depth is programmed as an absolute value; no safety clearance is specified. The
dwell time at the final drilling depth is 2 s. The workpiece upper edge is at Z110. In the cycle,
the spindle is to rotate with M3 and to stop at 45 degrees.
Y Y A−B
B
50
70 X 77 Z
110
Fig. 9-20
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
N20 T11 D1 Z112 Approaching the retraction plane
N40 CYCLE86(112, 110, , 77, 0, 2, 3, –1, –1, 1, 45) Cycle call with absolute drilling depth
9.4.10 Boring with Stop 1 (boring 3) – CYCLE87
Programming
CYCLE87 (RTP, RFP, SDIS, DP, DPR, SDIR)
Parameters
Table 9-10 Parameter CYCLE87

out sign)
Values: 3 (for M3)
4 (for M4)
Function
depth.
During boring 3, a spindle stop without orientation M5 is generated after reaching the final
drilling depth, followed by a programmed stop M0. Pressing the NC START key continues the
retraction movement at rapid traverse until the retraction plane is reached.
Sequence
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles

call
S Spindle stop with M5
S Press NC START

Z
G0
G1
M5/M0
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-21
This parameter determines the direction of rotation with which the drilling operation is carried
out in the cycle.
If values other than 3 or 4 (M3/M4) are generated, alarm 61102 ”No spindle direction pro-
grammed” is generated and the cycle is aborted.
Programming example: Third boring

CYCLE87 is called at position X70 Y50 in the XY plane. The drilling axis is the Z axis. The
final drilling depth is specified as an absolute value. The safety clearance is 2 mm.
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Y Y A−B
B
50
70 X 77 Z
110
Fig. 9-22
DEF REAL DP, SDIS Definition of the parameters
N10 DP=77 SDIS=2 Value assignments
N20 G0 G17 G90 F200 S300 Specification of the technological values
N50 CYCLE87 (113, 110, SDIS, DP, , 3) Cycle call with programmed direction of rota-
tion of spindle M3
9.4.11 Drilling with stop 2 (boring 4) – CYCLE88
Programming
CYCLE88(RTP, RFP, SDIS, DP, DPR, DTB, SDIR)
Parameters

out sign)
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles

Values: 3 (for M3)
4 (for M4)
Function
depth. When boring with stop, a spindle stop without orientation M5 and a programmed stop
are generated when the final drilling depth is reached. Pressing the NC START key continues
the retraction movement at rapid traverse until the retraction plane is reached.
Sequence
call
S Spindle and program stop with M5 M0. After program stop, press the NC START key.

Z
G0
G1
G4
M5/M0
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-23
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
DTB (dwell time)

onds.

The programmed direction of rotation is active for the distance to be traversed to the final
drilling depth.
If values other than 3 or 4 (M3/M4) are generated, alarm 61102 ”No spindle direction pro-
grammed” is generated and the cycle is aborted.
Programming example: Fourth boring pass

CYCLE88 is called at position X80 Y90 in the XY plane. The drilling axis is the Z axis. The
safety clearance is programmed with 3 mm; the final drilling depth is specified relative to the
reference plane.
M4 is active in the cycle.
N10 G17 G90 F100 S450 Specification of the technological values
N20 G0 X80 Y90 Z105 Approach drilling position
N30 CYCLE88 (105, 102, 3, , 72, 3, 4) Cycle call with programmed spindle direction
M4
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
9.4.12 Reaming 2 (boring 5) – CYCLE89
Programming
CYCLE89 (RTP, RFP, SDIS, DP, DPR, DTB)
Parameters
Table 9-12 Parameter CYCLE89

out sign)
Function
depth. When the final drilling depth is reached, the programmed dwell time is active.
Sequence
call
S Dwell time to final drilling depth
S Retraction up to the reference plane brought forward by the safety clearance using G1
and the same feedrate value

6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
Z
G0
G1
G4
RTP
RFP+SDIS
RFP
X
DP=RFP−DPR
Fig. 9-24
DTB (dwell time)
onds.
Programming example: Fifth boring

At X80 Y90 in the XY plane, the drilling cycle CYCLE89 is called with a safety clearance of 5
mm and specification of the final drilling depth as an absolute value. The drilling axis is the Z
axis.
Y Y A−B
B
90
80 X 72 Z
102
Fig. 9-25
DEF REAL RFP, RTP, DP, DTB Definition of the parameters
RFP=102 RTP=107 DP=72 DTB=3 Value assignments
N10 G90 G17 F100 S450 M4 Specification of the technological values
6FC5 698−2AA10−1BP5
Cycles
9.4 Drilling cycles
N20 G0 X80 Y90 Z107 Approach drilling position

N30 CYCLE89(RTP, RFP, 5, DP, , DTB) Cycle call
6FC5 698−2AA10−1BP5
Cycles
9.5 Drilling pattern cycles

The drilling pattern cycles describe only the geometry of an arrangement of drilling holes in
the plane. The link to a drilling process is established via the modal call of this drilling cycle
before the drilling cycle is programmed.
9.5.1 Preconditions
Drilling pattern cycles without drilling cycle call

Drilling pattern cycles can also be used for other applications without the first drilling cycle
first being called because the drilling pattern cycles can be parameterized without reference
to the drilling cycle used.
If there was no modal call of the subroutine prior to calling the drilling pattern cycle, error
message 62100 ”No drilling cycle active” appears.
You can acknowledge this error message by pressing the error acknowledgment key and
continue the program execution by pressing NC START. The drilling pattern cycle will then
approach each of the positions calculated from the input data one after the other without call-
ing a subroutine at these points.
Behavior when quantity parameter is zero

The number of holes in a drilling pattern must be parameterized. If the value of the quantity
parameter is zero when the cycle is called (or if this parameter is omitted from the parameter
list), alarm 61103 ”Number of holes is zero” and the cycle is aborted.
Checks in case of limited ranges of input values

Generally, there are no plausibility checks for defining parameters in the drilling pattern
cycles.
6FC5 698−2AA10−1BP5
Cycles
9.5.2 Row of holes – HOLES1
Programming
HOLES1 (SPCA, SPCO, STA1, FDIS, DBH, NUM)
Parameters
Table 9-13 Parameters for HOLES1
SPCA real 1st axis of the plane (abscissa) of a reference point on the
straight line (absolute)
SPCO real 2nd axis of the plane (ordinate) of this reference point (abso-
lute)
STA1 real Angle to the 1st axis of the plane (abscissa)
−180<STA1<=180 degrees
FDIS real Distance from the first hole to the reference point (enter with-
out sign)
DBH real Distance between the holes (enter without sign)
NUM int Number of holes
Function
This cycle can be used to produce a row of holes, i.e. a number of holes arranged along a
straight line, or a grid of holes. The type of hole is determined by the drilling hole cycle that
has already been called modally.
Sequence
To avoid unnecessary travel, the cycle calculates whether the row of holes is machined start-
ing from the first hole or the last hole from the actual position of the plane axes and the ge-
ometry of the row of holes. The drilling positions are then approached one after the other at
rapid traverse.
Z Z Z
G17 G18 G19 Y
Y
Y
X X
X
Fig. 9-26
6FC5 698−2AA10−1BP5
Cycles
SPCA
DBH
FDIS
STA1
SPCO
X
Fig. 9-27
SPCA and SPCO (reference point of 1st axis of the plane and 2nd axis of the plane)
One point along the straight line of the row of holes is defined as the reference point for de-
termining the distances between the holes. The distance to the first hole FDIS is defined from
this point.
STA1 (angle)
The straight line can be in any position in the plane. It is specified both by the point defined
by SPCA and SPCO and by the angle contained by the straight line with the 1st axis of the
plane of the workpiece coordinate system that is active when the cycle is called. The angle is
entered under STA1 in degrees.
FDIS and DBH (distance)

The distance of the first hole and the reference point defined under SPCA and SPCO is pro-
grammed with FDIS. The parameter DBH contains the distance between any two holes.
NUM (number)
The NUM parameter is used to define the number of holes.
6FC5 698−2AA10−1BP5
Cycles
Programming example: Row of holes

Use this program to machine a row of holes consisting of 5 threaded holes arranged parallel
to the Z axis of the ZX plane and which have a distance of 20 mm one to another. The start-
ing point of the row of holes is at Z20 and X30 whereby the first hole has a distance of 10 mm
from this point. The geometry of the row of holes is described by the cycle HOLES1. First,
drilling is carried out using CYCLE82, and then tapping is performed using CYCLE84 (tap-
ping without compensating chuck). The holes are 80 mm in depth (difference between refer-
ence plane and final drilling depth).
Z Z
A A−B
20
20
20 20
10
20
B
30 X Y
22
102
Fig. 9-28
N10 G90 F30 S500 M3 T10 D1 Specification of the technological values for
the machining step
N20 G17 G90 X20 Z105 Y30 Approach starting position
N30 MCALL CYCLE82(105, 102, 2, 22, 0, 1) Modal call of the drilling cycle
N40 HOLES1(20, 30, 0, 10, 20, 5) Call of row−of−holes cycle; the cycle starts
with the first hole; only the drill positions are
approached in this cycle
N50 MCALL Deselect modal call
... Tool change
N60 G90 G0 X30 Z110 Y105 Traverse to position next to the 5th hole
N70 MCALL CYCLE84(105, 102, 2, 22, 0, , 3, , 4.2, Modal call of the tapping cycle
,300, )
N80 HOLES1(20, 30, 0, 10, 20, 5) call of the row−of−holes cycle started with the
5th hole in the row
6FC5 698−2AA10−1BP5
Cycles
Programming example: Grid of holes

Use this program to machine a grid of holes consisting of 5 rows with 5 holes each, which are
arranged in the XY plane, with a distance of 10 mm between them. The starting point of the
grid is at X30 Y20.
The example uses R parameters as transfer parameters for the cycle.
Y
10
20
10 10 X
30
Fig. 9-29
R10=102 Reference plane

R11=105 Retraction plane
R12=2 Safety clearance
R13=75 Drilling depth
R14=30 Reference point: Row of holes of the 1st
R15=20 axis of the plane
R16=0 Reference point: Row of holes of the
R17=10 2nd axis of the plane
R18=10 Starting angle
R19=5 Distance of the 1st hole to the reference
R20=5 point
R21=0 Distance between the holes
R22=10 Number of holes per row
Number of rows
Count of rows
Distance between the rows
N10 G90 F300 S500 M3 T10 D1 Specification of the technological values
N20 G17 G0 X=R14 Y=R15 Z105 Approach starting position
N30 MCALL CYCLE82(R11, R10, R12, R13, 0, 1) Modal call of the drilling cycle
N40 LABEL1: Call of the row−of−holes cycle
N41 HOLES1(R14, R15, R16, R17, R18, R19)

N50 R15=R15+R22 Calculate y value for the next line
N60 R21=R21+1 Increment line counter
N70 IF R21<R20 GOTOB LABEL1 Return to LABEL1 if the condition is fulfilled
6FC5 698−2AA10−1BP5
Cycles
N90 G90 G0 X30 Y20 Z105 Approach starting position
9.5.3 Circle of holes – HOLES2
Programming
HOLES2 (CPA, CPO, RAD, STA1, INDA, NUM)
Parameters
Table 9-14 Parameters for HOLES2
CPA real Center point of circle of holes (absolute), 1st axis of the plane
CPO real Center point of circle of holes (absolute), 2nd axis of the
plane
RAD real Radius of circle of holes (enter without sign)
STA1 real Starting angle
Range of values: −180<STA1<=180 degrees
INDA real Incrementing angle
NUM int Number of holes
Function
Use this circle to machine a circle of holes. The machining plane must be defined before the
cycle is called.
The type of hole is determined by the drilling hole cycle that has already been called modally.
Fig. 9-30
6FC5 698−2AA10−1BP5
Cycles
Sequence
In the cycle, the drilling positions are approached one after the other in the plane with G0.
Fig. 9-31
Y CPA
INDA
STA1
RAD
CPO
Fig. 9-32
CPA, CPO and RAD (center point position and radius)

The position of the circle of holes in the machining plane is defined via center point (parame-
ters CPA and CPO) and radius (parameter RAD). Only positive values are permitted for the
radius.
6FC5 698−2AA10−1BP5
Cycles
STA1 and INDA (starting and incremental angle)

These parameters define the arrangement of the holes on the circle of holes.
Parameter STA1 specifies the angle of rotation between the positive direction of the 1st axis
(abscissa) in the workpiece coordinate system active before the cycle was called and the first
hole. Parameter INDA contains the angle of rotation from one hole to the next.
If parameter INDA is assigned the value zero, the indexing angle is calculated internally from
the number of holes which are positioned equally in a circle.
NUM (number)
Parameter NUM defines the number of holes.
Programming example: Circle of holes

The program uses CYCLE82 to produce 4 holes having a depth of 30 mm. The final drilling
depth is specified as a relative value to the reference plane. The circle is defined by the cen-
ter point X70 Y60 and the radius 42 mm in the XY plane. The starting angle is 33 degrees.
The safety clearance along the drilling axis Z is 2 mm.
Y Y
33°
42
60
B
70 X 30 Z
Fig. 9-33
N10 G90 F140 S170 M3 T10 D1 Specification of the technological values
N30 MCALL CYCLE82(2, 0, 2, , 30, 0) Modal call of the drilling cycle, without dwell
time, DP is not programmed
N40 HOLES2 (70, 60, 42, 33, 0, 4) Call of the circle−of−holes cycle; the incre-
mental angle is calculated in the cycle since
the parameter INDA has been omitted
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6 Milling cycles
9.6.1 Preconditions

Milling cycles are programmed independently of the particular axis name.
Before you call the milling cycles, a tool compensation must be activated.
The appropriate values for feedrate, spindle speed and direction of rotation of spindle must
be programmed in the part program if the appropriate parameters are not provided in the mill-
ing cycle.
The center point coordinates for the milling pattern or the pocket to e machined are pro-
grammed in a rectangular coordinate system.
The G functions active prior to the cycle call and the current programmable frame remain ac-
tive beyond the cycle.
Plane definition
The milling cycles assume that the current coordinate system is reached by selecting a plane
G17, G18 or G19 and activation of a programmable frame (if required). The infeed axis is
always the 3rd axis of this coordinate system
Z Z Z
2nd axis 3rd axis 1st axis
G19
2nd axis
3rd axis
1st axis
Y
Y Y
G17
G18
1st axis 2nd axis X 3rd axis X

X
Fig. 9-34 Plane and axis assignment
Messages with regard to the machining state

During the execution of the milling cycles, various messages that refer to the machining sta-
tus are displayed on the screen. The following messages are possible:
S ”Elongated hole <no.>First figure is being machined”
S ”Groove <no.>Another figure is being machined”
S ”Circumferential groove <no.>Last figure is being machined”
no.> in the message text always stands for the number of the figure currently machined.
These message do not interrupt the program execution and continue to be displayed until the
next message is displayed or the cycle is completed.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6.2 Face milling − CYCLE71
Programming
CYCLE71(_RTP, _RFP, _SDIS, _DP, _PA, _PO, _LENG, _WID, _STA,_MID, _MIDA, _FDP,
_FALD, _FFP1, _VARI, _FDP1)
Parameters
_RTP real Retraction plane (absolute)

_RFP real Reference plane (absolute)
_SDIS real Safety clearance (to be added to the reference plane; enter
without sign)
_DP real Depth (absolute)
_PA real Starting point (absolute), 1st axis of the plane
_PO real Starting point (absolute), 2nd axis of the plane
_LENG real Length of the rectangle in the 1st axis, incremental.
The corner from which the dimension starts results from the
sign.
_WID real Length of the rectangle in the 2nd axis, incremental.
The corner from which the dimension starts results from the
sign.
_STA real Angle between longitudinal axis and the 1st axis of the plane
(enter without sign)
Range of values: 0° ≤ _STA < 180°
_MID real Maximum infeed depth (enter without sign)
_MIDA real Maximum infeed width during solid machining in the plane as
a value (enter without sign)
_FDP real Retraction travel in the finishing direction (incremental, enter
without sign)
_FALD real Finishing dimension in the depth (incremental, enter without
sign)
_FFP1 real Feedrate for surface machining
_VARI integer Machining type (enter without sign)
UNIT DIGIT
Values:
1 roughing
2 finishing
TENS DIGIT
Values: 1 parallel to the 1st axis of the plane, in one direction
2 parallel to the 2nd axis of the plane, in one direction
3 parallel to the 1st axis of the plane
4 parallel to the 2nd axis of the plane,
with alternating direction
_FDP1 real Overrun travel in the direction of the plane infeed (incremen-
tal, enter without sign)
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Function
Use CYCLE71 to face mill any rectangular surface. The cycle distinguishes between rough-
ing (solid machining of the surface in several steps up to finishing dimension) and finishing
(end milling the surface in one step). The maximum infeed in width and depth can be speci-
fied.
The cycle operates without cutter radius compensation. The depth infeed is carried out in the
open.
Y Y
_LENG _LENG
_WID
_WID
X X
Y _LENG Y _LENG
_WID
_WID
X X
Possible solid machining strategies for face milling
Fig. 9-35
Sequence
Starting position is any position from which the infeed point can be approached at the height
of the retraction plane without collision.
S With G0, the infeed point is approached at the height of the current position, and then,
from this position, with G0, too, the reference plane brought forward by the safety clear-
ance is approached; then, also with G0, feeding to the machining plane. G0 is possible
since infeed in the open is possible.
Various solid machining strategies are provided (paraxially in one direction or oscillating to
and fro).
S Sequence of motions when roughing:
According to the programmed values _DP, _MID and _FALD, face milling can be carried
out in several planes. Machining is carried out from the top downwards, i.e. one plane
each is removed and then the next depth infeed is carried out in the open (parameters
_FDP). The traversing paths for solid machining in the plane depend on the values of the
parameters _LENG, _WID, _MIDA, _FDP, _FDP1 and the cutter radius of the active tool.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
The first path to be milled is always traversed such that the infeed depth exactly corre-
sponds to _MIDA so that no width infeed larger than the maximum possible width infeed
results. The tool center point thus does not always travel exactly on the edge (only if
_MIDA = cutter radius). The dimension by which the tool traverses outside the edge is
always equal to cutter diameter − _MIDA even if only 1 surface cut is performed, i. e. sur-
face width + overrun less _MIDA. The other paths for width infeed are calculated internally
so that as to produce a uniform path width (<=_MIDA).
S Sequence of motions when finishing:
When finishing, the surface is milled once in the plane. This means that the finishing al-
lowance when roughing has to be selected also such that the residual depth can be re-
moved with the finishing tool in one step.
After each surface milling pass in the plane, the tool will retract. The retraction travel is
programmed under the parameter _FDP.
When machining in one direction, the tool will retract in one direction by finishing allow-
ance + safety clearance, and the next starting point is approached at rapid traverse.
When roughing in one direction, the tool will retract by the calculated infeed depth + safety
clearance. The depth infeed is performed at the same point as in roughing.
After completion of finishing, the tool will retract to the retraction plane _RTP at the posi-
tion last reached.
_FDP
_FDP
X
Milling motion when finishing in one direction
(machining type 42)
Fig. 9-36

For the parameters _RTP, _RFP, _SDIS, see CYCLE81.
For the parameters _STA, _MID, _FFP1, see POCKET3.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_LENG _FDP1
Y
_MIDA
_WID
_PO
_PA
_FDP
Infeed point
X
Roughing with _MIDA larger than milling radius
(machining type 41)
Fig. 9-37
_DP (depth)
The depth can be specified as an absolute value (_DP) to the reference plane.
_PA, _PO (starting point)

Use the parameters _PA and _PO to define the starting point of the area in the axes of the
plane.
_LENG, _WID (length)

Use the parameters _LENG and WID to define the length and width of a rectangle in the
plane. The position of the rectangle referred to _PA and _PO results from the sign.
_MIDA (max. infeed width)

Use this parameter to define the maximum infeed width when solid machining in a plane.
Analogously to the known calculation method for the infeed depth (equal distribution of the
total depth with the maximum possible value), the width is distributed equally, maximally with
the value programmed under _MIDA.
If this parameter is not programmed or has value 0, the cycle will internally use 80% of the
milling tool diameter as the maximum infeed depth.
_FDP (retraction travel)

Use this parameter to define the dimension for the retraction travel in the plane. This parame-
ter should reasonably always have a value greater than zero.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_FDP1 (overrun travel)

Use this parameter to specify an overrun travel in the direction of the plane infeed (_MIDA).
Thus, it is possible to compensate the difference between the current cutter radius and the
tool nose radius (e.g. cutter radius or cutting tips arranged at an angle). The last cutter center
point path thus always results as _LENG (or _WID) + _FDP1 − tool radius (from the com-
pensation table).
Cutter diameter from the tool table
_FDP1
Area
Fig. 9-38
_FALD (finishing allowance)

In roughing, a finishing allowance in the depth is taken into account which is programmed
under this parameter.
The residual material remained as the finishing allowance must always be specified for finish-
ing so to ensure that the tool can be retracted and then fed to the starting point of the next cut
without collision.
_VARI (machining type)

Use the parameter _VARI to define the machining type.
Possible values are:
Units digit:
1=roughing to finishing allowance
2=finishing
Tens digit:
1=parallel to the 1st axis of the plane; in one direction
2=parallel to the 2nd axis of the plane; in one direction
3=parallel to the 1st axis of the plane; with alternating direction
4=parallel to the 2nd axis of the plane; with alternating direction
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
If a different value is programmed for the parameter _VARI, the cycle is aborted after output
of alarm 61002 ”Machining type defined incorrectly”.
Further notes
A tool compensation must be programmed before the cycle is called. Otherwise, the cycle is
aborted and alarm 61000 ”No tool compensation active” is output.
Programming example: Face milling
Parameters for the cycle call:

S Retraction plane: 10 mm
S Reference plane: 0 mm
S Safety clearance: 2 mm
S Milling depth: −11 mm
S Starting point of the rectangle X = 100 mm
Y = 100 mm
S Rectangle size X = +60 mm
Y = +40 mm
S Angle of rotation in the plane 10 degrees
S Max. infeed depth 6 mm
S Max. infeed depth 10 mm
S Retraction travel at the end of the milling path: 5 mm
S No finishing allowance −
S Feedrate for surface machining: 4,000 mm/min
S Machining type: Roughing parallel to the X axis with alternating direction
S Overrun at the last cut due to the cutting edge geometry 2 mm
A milling cutter with 10 mm radius is used.
N10 T2 D2
N20 G17 G0 G90 G54 G94 F2000 X0 Y0 Z20 Approach starting position
N30 CYCLE71(10, 0, 2, −11, 100, 100, 60, 40, 10, 6, Cycle call
10, 5, 0, 4000, 31, 2)
N40 G0 G90 X0 Y0
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6.3 Contour milling − CYCLE72
Programming
CYCLE72 (_KNAME, _RTP, _RFP, _SDIS, _DP, _MID, _FAL, _FALD, _FFP1, _FFD, _VARI,
_RL, _AS1, _LP1, _FF3, _AS2, _LP2)
Parameters
_KNAME string Name of contour subroutine

without sign)
_MID real Maximum infeed depth (incremental; enter without sign)
_FAL real Finishing allowance at the edge contour (enter without sign)
_FALD real Finishing allowance at the base (incremental, enter without
sign)
_FFD real Feedrate for depth infeed (enter without sign)
_VARI integer Machining type (enter without sign)
UNIT DIGIT
Values: 1 roughing
2 finishing
TENS DIGIT
Values: 0 Intermediate path with G0
1 Intermediate path with G1
HUNDREDS DIGIT
Values: 0 Retraction at contour end to _RTP
1 Retraction at contour end to _RFP + _SDIS
2 Retraction at contour end by _SDIS
3 No retraction at the contour end
_RL integer Traveling around the contour either centrally, to the right or to
the left (with G40, G41 or G42; enter without sign)
Values: 40...G40 (approach and retraction − only one
straight line)
41...G41
42...G42
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_AS1 integer Specification of the approach direction/approach path: (enter

without sign)
Units digit:
Values: 1...Straight line tangential
2...Quadrant
3...Semicircle
Tens digit:
Values: 0...Approach of contour in the plane
1...Approach of contour along a spatial
path
_LP1 real Length of the approach travel (with straight−line) or radius of
the approach arc (with circle) (enter without sign)
The other parameters can be selected as options.
_FF3 real Retraction feedrate and feedrate for intermediate positions in

the plane (in the open)
_AS2 integer Specification of the retraction direction/retraction path: (enter
without sign)
Units digit:
Values: 1...Straight line tangential
2...Quadrant
3...Semicircle
Tens digit:
Values: 0...Retraction from contour in the plane
1...Retraction from contour along a spatial
path
_LP2 real Length of the retraction travel (with straight−line) or radius of
the retraction arc (with circle) (enter without sign)
Function
Use CYCLE72 to mill along any contour defined in any contour defined in a subroutine. The
cycle operates with or without cutter radius compensation.
It is not imperative that the contour is closed. Internal or external machining is defined via the
position of the cutter radius compensation (centrally, left or right to the contour).
The contour must be programmed in the direction as it is to be milled and must consist of a
minimum of 2 contour blocks (starting and end point), since the contour subroutine is called
directly internally in the cycle.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
ÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏ
Contour starting point
ÏÏÏ
ÎÎÎÎÎÎÎÎÎ
ÎÎÎ
ÏÏÏ
ÎÎÎÎÎÎÎÎÎ
ÎÎÎ
ÏÏÏ
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎÎ ÏÏÏ
ÎÎÎ
ÏÏÏÏÏÏÏÏÏÏÏÏ
ÏÏÏÏÏÏÏÏÏÏÏÏ X
Fig. 9-39
Functions of the cycle:

S Selection of roughing (single−pass traversing parallel to contour, taking into account a
finishing allowance, if necessary at several depth until the finishing allowance is reached)
and finishing (single−pass traversing along the final contour if necessary at several
depths)
S Smooth approach to and retraction from the contour either tangentially or radially (quad-
rant or semicircle)
S Programmable depth infeeds
Intermediate motions either at rapid traverse rate or at feedrate
Sequence
Starting position is any position from which the contour starting point can be approached at
the height of the retraction plane without collision.
The cycle generates the following sequence of motions when roughing:
The depth infeeds are distributed equally with the maximum possible value of the specified
parameters.
S Traversing to the starting point for first milling with G0/G1 (and _FF3). This point is calcu-
lated internally in the control system and depends on
− the contour starting point (first point in the subroutine),
− the direction of the contour at the starting point,
− the approach mode and its parameters and
− the tool radius.
In this block, the cutter radius compensation is activated.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
S Depth infeed to the first or next machining depth plus programmed safety clearance with
G0/G1. The first machining depth results from
− the total depth,
− the finishing allowance and
− the maximum possible depth infeed.
S Approach of the contour vertically with depth infeed and then in the plane at the pro-
grammed feedrate or 3D with the feedrate programmed under _FAD according to the pro-
gramming for smooth approach.
S Milling along the contour with G40/G41/G42.
S Smooth retraction from the contour with G1 and always still feedrate for the surface ma-
chining by the retraction amount.
S Retraction with G0 /G1 (and feedrate for intermediate paths _FF3), depending on the pro-
gramming.
S Retraction to the depth infeed point with G0/G1 (and _FF3).
S This sequence is repeated on the next machining plane up to finishing allowance in the
depth.
A completion of roughing, the tool stands above the point (calculated internally in the control)
of retraction from the contour at the height of the retraction plane.
The cycle generates the following sequence of motions when finishing:
During finishing, milling is performed at the relevant infeed along the base of the contour until
the final dimension is reached.
Smooth approach and retraction of the contour is carried out according to the existing param-
eters. The appropriate path is calculated internally in the control system.
At the end of the cycle, the tool is positioned at the contour retraction point at the height of
the retraction level.
Further notes:
Contour programming
When programming the contour, please observe the following:
S No programmable offset must be selected in the subroutine prior to the first programmed
position.
S The first block of the contour subroutine is a straight line block containing G90 / G0 or
G90 / G1 and defines the start of the contour.
S The starting condition of the contour is the first position in the machining plane which is
programmed in the contour subroutine.
S The cutter radius compensation is selected / deselected by the higher−level cycle; there-
fore, no G40, G41, G42 is programmed in the contour subroutine.

For the parameters _MID, _FAL, _FALD, _FFP1, _FFD, _DP, see POCKET3.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Reference plane _RFP
Finishing dimension to depth _

Finishing dimension at de
X
Fig. 9-40
_KNAME (name)
The contour to be milled is programmed completely in a subroutine. _KNAME defines the
name of the contour subroutine.
1. The contour can be defined as a subroutine:
_KNAME=name of subroutine
The name of the contour subroutine is subject to all name conventions described in the
Programming Guide.
Input:
− The subroutine already exists −−> enter name, continue
− The subroutine does not yet exist −−> enter name and press softkey ”new file”. A pro-
gram (main program) with the entered name is created and the program will jump to
the contour editor.
Use the ”Technol. mask” softkey to confirm your input and return to the cycle help
screenform.
2. The contour can also be a section of the calling program:
_KNAME=name of starting label: name of end label
Input:
− Contour is already described −−> name of starting label: Enter name of end label
− Contour is not yet described −−> enter name of starting label and press softkey ”con-
tour append”.
Starting and end label are automatically created from the name you have entered; then
the program will jump to the contour editor.
Use the ”Technol. mask” softkey to confirm your input and return to the cycle help
screenform.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Examples:
_KNAME=”KONTUR_1” The milling contour is the complete program

Kontur_1.
_KNAME=”ANFANG:ENDE” The milling contour is defined as a section in
the calling program, which starts from the
block containing label ANFANG to the block
containing label ENDE.
_LP1, _LP2 (length, radius)

Use parameter _LP1 to program the approach travel or approach radius (distance from the
tool external edge to the contour starting point), and _LP2 to program the retraction travel or
retraction radius (distance from the tool external edge to the contour end point).
The value _LP1, _LP2 must be >0. In the case of zero, error 61116 ”Approach or retraction
path=0” is output.
Note
When using G40, the approach or retraction travel is the distance from the tool center point to the
starting or end point of the contour.

Use the parameter _VARI to define the machining type. Possible values are:
UNIT DIGIT
Values: 1 roughing
2 finishing
TENS DIGIT
Values: 0 Intermediate path with G0
1 Intermediate path with G1
HUNDREDS DIGIT
Values: 0 Retraction at contour end to _RTP
1 Retraction at contour end to _RFP + _SDIS
2 Retraction at contour end by _SDIS
3 No retraction at the contour end
_RL (traveling around the contour)

With the parameter _RL, you will program traveling around the contour centrally, to the right
or to the left with G40, G41 or G42. For possible values, see at ”Parameters for CYCLE72”.
_AS1, _AS2 (approach direction/path, retraction direction/retraction path)

Use the parameter _AS1 to program the specification of the approach path and _AS2 to pro-
gram that of the retraction path. For possible values, see at ”Parameters for CYCLE72”. If
_AS2 is not programmed, then the behavior of the retraction path is analogously to that of the
approach path.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Smooth approach of the contour along a spatial path (helix or straight line) should only be
programmed if the tool is not yet in mesh or is suitable for this type of approach.
ÌÌÌ
Traveling around the contour from the left or from t
_AS1/_AS2 ÌÌÌ
ÌÌÌ
Appr./retract. from contour
along a straight line
ÌÌÌ
ÌÌÌ
Appro./retract.from contour
along a quadrant
_AS1/_AS2
ÌÌÌ
ÌÌÌ
Approach/retr. from contour
ÌÌÌ
along a semicircle
_AS1/_AS2
Traveling around the contour centrally
ÑÑÑ
ÑÑÑ
_AS1/_AS2 Approach/retr. from contour
along a straight line
Fig. 9-41
In the case of central (G40) approach and retraction, only possible along a straight line.
_FF3 (retraction feedrate)

Use parameter _FF3 to define a retraction feedrate for intermediate positions in the plane (in
the open) if the intermediate motions are to be carried out with feedrate (G01). If no feedrate
value is programmed, the intermediate motions with G01 are carried out at surface feedrate.
Further notes
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Programming example 1: Milling around a closed contour externally

This program is used to mill the contour shown in the diagram below.
Y Contour starting point

Programmed
Contour direction
Final contour
Final contour + finishing allowance
Fig. 9-42
Parameters for the cycle call:

S Retraction plane 250 mm
S Reference plane 200
S Safety clearance 3 mm
S Depth 175 mm
S Maximum depth infeed 10 mm
S Finishing allowance in the depth 1.5 mm
S Feedrate for depth infeed 400 mm/min
S Finishing allowance in the plane 1 mm
S Feedrate in the plane 800 mm/min
S Machining: Roughing up to finishing allowance; intermediate paths with G1, for intermedi-
ate paths retraction in Z to _RFP + _SDIS
Parameters for approach:
S G41 − left of the contour, i.e. external machining
S Approach and retraction along a quadrant in the plane 20 mm radius
S Retraction feedrate 1,000 mm/min
N10 T3 D1 T3: Milling cutter with radius 7
N20 S500 M3 F3000 Program feedrate, speed
N30 G17 G0 G90 X100 Y200 Z250 G94 Approach starting position
N40 CYCLE72(”EX72CONTOUR”, 250, 200, 3, 175, Cycle call

10,1, 1.5, 800, 400, 111, 41, 2, 20, 1000, 2, 20)
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Cycles
9.6 Milling cycles
N50 X100 Y200

%_N_EX72CONTOUR_SPF Subroutine for milling contour (for example)
N100 G1 G90 X150 Y160 Starting point of contour
N110 X230 CHF=10

N120 Y80 CHF=10
N130 X125
N140 Y135
N150 G2 X150 Y160 CR=25
N160 M2
N170 M02
Programming example 2
Milling around a closed contour externally, as in programming example 1, with contour pro-
gramming in the calling program
N10 T3 D1 T3: Milling cutter with radius 7
N20 S500 M3 F3000 Program feedrate, speed
N30 G17 G0 G90 X100 Y200 Z250 G94 Approach starting position
N40 CYCLE72 ( ”PIECE_245:PIECE_245_E”, 250, Cycle call

200, 3, 175, 10,1, 1.5, 800, 400, 11, 41, 2, 20, 1000,
2, 20)
N50 X100 Y200
N60 M2
N70 PIECE_245: Contour
N80 G1 G90 X150 Y160

N90 X230 CHF=10
N100 Y80 CHF=10
N110 X125
N120 Y135
N130 G2 X150 Y160 CR=25
N140 PIECE_245_E: End of contour
N150 M2
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Cycles
9.6 Milling cycles
9.6.4 Rectangular spigot milling − CYCLE76
Programming
CYCLE76 (_RTP, _RFP, _SDIS, _DP, _DPR, _LENG, _WID, _CRAD, _PA, _PO, _STA,
_MID, _FAL, _FALD, _FFP1, _FFD, _CDIR, _VARI, _AP1, _AP2)
Parameters

_SDIS real Safety clearance (enter without sign)
_DP real Final drilling depth (absolute)
_DPR real Final drilling depth relative to the reference plane (enter with-
out sign)
_LENG real Spigot length (enter without sign)
_WID real Spigot length (enter without sign)
_CARD real Spigot corner radius (enter without sign)
_PA real Reference point of spigot, abscissa (absolute)
_PO real Reference point of spigot, ordinate (absolute)
_STA real Angle between longitudinal axis and 1st axis of the plane
_MID real Maximum depth infeed (incremental; enter without sign)
_FAL real Final machining allowance at the margin contour (incremen-
tal)
sign)
_FFP1 real Feedrate at the contour
_FFD real Feedrate for depth infeed
_CDIR integer Milling direction (enter without sign)
Values: 0 Climb milling
1 opposed milling
2 with G2 (independent of spindle direction)
3 with G3
_VARI integer Technology
Values: 1 Roughing up to final machining allowance
2 Finishing (allowance X/Y/Z=0)
_AP1 real Length of blank spigot
Function
Use this cycle to machine rectangular spigots in the machining plane. For finishing, a face
cutter is required. The depth infeed is always carried out in the position upstream of the semi-
circle style approach to the contour.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Fig. 9-43
Sequence
The starting point is a position in the positive range of the abscissa with the approach semi-
circle and the programmed raw dimension on the abscissa end taken into account.
Sequence of motions when roughing (_VARI=1)
Approach to and retraction from the contour:
Approach to and retraction from the contour in a sem

with the spindle rotating CW and climb milling
Approach to contour
Retraction from contour
Fig. 9-44
The retraction plane (_RTP) is approached at rapid traverse rate to be able to position then at
this height to the starting point in the machining plane. The starting point is defined with refer-
ence to 0 deg. of the abscissa.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
The tool is feed to the safety clearance (_SDIS) at rapid traverse with subsequent traversing
to the machining depth at feedrate. To approach the spigot contour, the tool will travel along a
semicircle path.
The mill direction can be determined either as climb milling or as opposed (conventional) mill-
ing with reference to the spindle direction.
If the spigot is traveled around once, the contour is left along a semicircle in the plane, and
the tool is fed to the next machining depth.
Then, the contour is approached along a semicircle again, and the spigot is traveled around
once. This process is repeated until the programmed spigot depth is reached. Then, the re-
traction plane (_RTP) is approached at rapid traverse rate.
Depth infeed:
S Feeding to the safety clearance
S Insertion to machining depth
The first machining depth is calculated from:
S the total depth,
S the finishing allowance and
S the maximum possible depth infeed.
Sequence of motions when finishing (_VARI=2)
According to the set parameters _FAL and _FALD, either finishing is carried out at the sur-
face contour or at the base or both together. The approach strategy corresponds to the mo-
tions in the plane as with roughing.

For the parameters _RTP, _RFP, _SDIS, _DP, _DPR, see CYCLE81.
For the parameters _MID, _FAL, _FALD, _FFP1, _FFD, see POCKET3.
_LENG, _WID and _CRAD (spigot length, spigot width and corner radius)
Use the parameters _LENG, _WID and _CRAD to define the form of a spigot in the plane.
The spigot is always dimensioned from the center. The amount of the length (_LENG) always
refers to the abscissa (with a plane angle of 0 deg.).
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Spigot dimensioned from the center point

Y
_PA
_STA
_CRAD
_WID
_LENG
_PO
X
Fig. 9-45
_PA, _PO (reference point)
Use the parameters _PA and _PO to define the reference point of the spigot along the ab-
scissa and the ordinate.
This is the spigot center point.
_STA (angle)
_STA specifies the angle between the 1st axis of the plane (abscissa) and the longitudinal
axis of the spigot.
_CDIR (milling direction)
Use this parameter to specify the machining direction for the spigot.
Using the parameter _CDIR, the milling direction
S can be programmed directly with ”2 for G2” and ”3 for G3” or,
S alternatively, ”Synchronized operation” or ”Reverse rotation”.
synchronized operation or reverse rotation are determined internally in the cycle via the di-
rection of rotation of the spindle activated prior to calling the cycle.
Synchronized operation Reverse rotation
M3 → G3 M3 → G2
M4 → G2 M4 → G3

S 1=roughing
S 2=finishing
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_AP1, _AP2 (blank dimensions)
When machining the spigot, it is possible to take into account blank dimensions (e.g. when
machining precast parts).
The blank dimensions for length and width (_AP1 and _AP2) are programmed without sign
and are placed by the cycle symmetrically around the pocket center point via calculation. The
internally calculated radius of the approach semicircle depends on this dimension.
_AP2
_AP1
Fig. 9-46
Further notes
aborted and alarm 61009 ”Active tool number=0” is output.
Internally in the cycle, a new current workpiece coordinate system is used which influences
the actual value display. The zero point of this coordinate system is to be found in the pocket
center point.
At the end of the cycle, the original c ordinate system is active again.
Programming example for a spigot

Use this program to machine a spigot in the XY plane which is 60 mm in length, 40 mm in
width, and which has a corner radius of 15 mm and is mm in depth. The spigot has an angle
of 10 degrees relative to the X axis and is premanufactured with a length allowance of 80 mm
and a width allowance of 50 mm.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Y Y
A A−B
R15
10_
60
B
80 X Z
17,5
Fig. 9-47
N10 G90 G0 G17 X100 Y100 T20 D1 S3000 M3 Specification of the technological values
N11 M6
N30 CYCLE76 (10, 0, 2, −17.5, , −60, −40, 15, 80, 60, Cycle call
10, 11, , , 900, 800, 0, 1, 80, 50)
9.6.5 Circular spigot milling − CYCLE77
Programming
CYCLE77 (_RTP, _RFP, _SDIS, _DP, _DPR, _PRAD, _PA, _PO, _MID, _FAL, _FALD,
_FFP1, _FFD, _CDIR, _VARI, _AP1)
Parameters
The following input parameters are always required:

_DPR real Depth relative to the reference plane (enter without sign)
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_PRAD real Spigot diameter (enter without sign)

_PA real Center point of spigot, abscissa (absolute)
_PO real Center point of spigot, ordinate (absolute)
_MID real Maximum depth infeed (incremental; enter without sign)
_FAL real Final machining allowance at the margin contour (incremen-
tal)
sign)
_FFP1 real Feedrate at the contour
_FFD real Feedrate for depth infeed (or spatial infeed)
_CDIR integer Milling direction (enter without sign)
Values: 0 Climb milling
1 opposed milling
3 with G3
_VARI integer Technology
Values: 1 Roughing up to final machining allowance
2 Finishing (allowance X/Y/Z=0)
_AP1 real Length of blank spigot
Function
Use this cycle to machine circular spigots in the machining plane. For finishing, a face cutter
is required. The depth infeed is always carried out in the position upstream of the semicircle
style approach to the contour.
Fig. 9-48
Sequence
The starting point is a position in the positive range of the abscissa with the approach semi-
circle and the programmed raw dimension taken into account.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Sequence of motions when roughing (_VARI=1)

Approach to and retraction from the contour:
Approach to and retraction from the contour in a semic

with the spindle rotating CW and climb milling
Approach to contour
Retraction from contour
Fig. 9-49
The retraction plane (_RTP) is approached at rapid traverse rate to be able to position then at
this height to the starting point in the machining plane. The starting point is defined with refer-
ence to 0 deg. of the axis of the abscissa.
The tool is feed to the safety clearance (_SDIS) at rapid traverse with subsequent traversing
to the machining depth at feedrate. To approach the spigot contour, the tool is approached
along a semicircle path, taking into account the programmed blank spigot.
The mill direction can be determined either as climb milling or as opposed (conventional) mill-
ing with reference to the spindle direction.
If the spigot is traveled around once, the contour is left along a semicircle in the plane, and
the tool is fed to the next machining depth.
Then, the contour is approached along a semicircle again, and the spigot is traveled around
once. This process is repeated until the programmed spigot depth is reached.
Then, the retraction plane (_RTP) is approached at rapid traverse rate.
Depth infeed:
S Feeding to the safety clearance
S Insertion to machining depth
The first machining depth is calculated from:
S the total depth,
S the finishing allowance and
S the maximum possible depth infeed.
Sequence of motions when finishing (_VARI=2)
According to the set parameters _FAL and _FALD, either finishing is carried out at the sur-
face contour or at the base or both together. The approach strategy corresponds to the mo-
tions in the plane as with roughing.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles

For the parameters _RTP, _RFP, _SDIS, _DP, _DPR, see CYCLE81.
For the parameters _MID, _FAL, _FALD, _FFP1, _FFD, see POCKET3.
_PRAD (spigot diameter)
Enter the diameter without sign.
_PA, _PO (spigot center)
Use the parameters _PA and _PO to define the reference point of the spigot.
Use this parameter to specify the machining direction for the spigot. By using the parameter
_CDIR, the milling direction
Synchronized operation or reverse rotation are determined internally in the cycle via the di-
M3 → G3 M3 → G2
M4 → G2 M4 → G3
Use the parameter _VARI to define the machining type. Possible values are:
S 1=roughing
S 2=finishing
_AP1 (diameter of the blank spigot)
Use this parameter to define the blank dimension of the spigot (without sign). The internally
calculated radius of the approach semicircle depends on this dimension.
Further notes
aborted and alarm 61009 ”Active tool number=0” is output.
center point.
At the end of the cycle, the original coordinate system is active again.
Programming example for a circular spigot

Machining a spigot from a blank with a diameter of 55 mm and a maximum infeed of 10 mm
per cut; specification of a final machining allowance for subsequent finishing of the spigot
surface. The whole machining is performed with reverse rotation.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Y Y
A A−B
55
∅
50
∅
70
60 B X Z
20
Fig. 9-50
N10 G90 G17 G0 S1800 M3 D1 T1 Specification of the technological values
N11 M6
N20 CYCLE77 (10, 0, 3, −20, ,50, 60, 70, 10, 0.5, 0, Calling the roughing cycle
900, 800, 1, 1, 55)
N30 D1 T2 M6 Tool change
N40 S2400 M3 Specification of the technological values
N50 CYCLE77 (10, 0, 3, −20, , 50, 60, 70, 10, 0, 0, Calling the finishing cycle
800, 800, 1, 2, 55)
9.6.6 Slots on a circle − LONGHOLE
Programming
LONGHOLE (RTP, RFP, SDIS, DP, DPR, NUM, LENG, CPA, CPO, RAD, STA1, INDA, FFD,
FFP1, MID)
Parameters
Table 9-19 LONGHOLE parameters

DP real Groove depth (absolute)
DPR real Slot depth relative to the reference plane (enter without sign)
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Table 9-19 LONGHOLE parameters, cont’d
NUM integer Number of slots

LENG real Slot length (enter without sign)
CPA real Center point of the circle (absolute), 1st axis of the plane
CPO real Center point of the circle (absolute), 2nd axis of the plane
RAD real Radius of the circle (enter without sign)
FFD real Feedrate for depth infeed
FFP1 real Feedrate for surface machining
MID real Maximum infeed depth for one infeed (enter without sign)
Important
The cycle requires a milling cutter with an ”end tooth cutting across center” (DIN844).
Function
Use this cycle to machine slots arranged on a circle. The longitudinal axis of the slots is
aligned radially.
Contrary to the groove, the width of the slot is determined by the tool diameter.
Internally in the cycle, an optimum traversing path of the tool is determined, ruling out unnec-
essary idle passes. If several depth infeeds are required to machine a slot, the infeed is car-
ried out alternately at the end points. The path to be traversed along the longitudinal axis of
the slot will change its direction after each infeed. The cycle will search for the shortest path
when changing to the next slot.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Fig. 9-51
Sequence
Initial position is any position from which each of the elongated holes can be approached
without collision.
S Using G0, the starting position for the cycle is approached. In both axes of the current
plane, the next end point of the first slot to be machined is approached at the height of the
retraction plane in this applicate, and then the applicate is lowered to the reference plane
brought forward by the safety clearance.
S Each slot is milled in a reciprocating motion. The machining in the plane is performed us-
ing G1 and the feedrate programmed under FFP1. The infeed to the next machining depth
calculated using G1 internally in the cycle and using feedrate is performed at each rever-
sal point until the final depth is reached.
S Retraction to the retraction plane using G0 and approach to the next slot on the shortest
path.
S After the last slot has been machined, the tool is moved with G0 to the position in the ma-
chining plane, which was reached last and which is specified in the diagram below, and
the cycle is ended.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Fig. 9-52

For the parameters RTP, RFP, SDIS, see CYCLE81.
Y
CPA
INDA
LENG
STA1
RAD
CPO
Fig. 9-53
DP and DPR (elongated hole final drilling depth)
The slot depth can be specified either absolute (DP) or relative (DPR) to the reference plane.
NUM (number)
Use the parameter NUM to specify the number of slots.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
LENG (elongated hole final drilling depth)
The length of the slot is programmed under LENG.

If the cycle detects that this length is less than the milling diameter, the cycle is aborted with
alarm 61105 ”Cutter radius too large”.
MID (infeed depth)
Use this parameter to define the maximum infeed depth.

The depth infeed is performed by the cycle in equally sized infeed steps.
Using MID and the total depth, the cycle automatically calculates this infeed which lies be-
tween 0.5 x maximum infeed depth and the maximum infeed depth. The minimum possible
number of infeed steps is used as the basis. MID=0 means that the cut to pocket depth is
made with one feed.
The depth infeed starts from the reference plane brought forward by the safety clearance (de-
pending on _ZSD[1]).
FFD and FFP1 (feedrate for depth and surface)
The feedrate FFP1 is active for all movements in the plane traversed at feedrate when rough-
ing. FFD acts for infeeds vertically to this plane.
CPA, CPO and RAD (center point and radius)
The position of the circle of holes in the machining plane is defined by the center point (CPA,
CPO) and the radius (RAD). Only positive values are permitted for the radius.
The arrangement of the slots on the circle is defined by these parameters.

If INDA=0, the incrementing angle is calculated from the number of slots so that they are ar-
ranged equally around the circle.
Further notes
If mutual contour violations of the slots result from incorrect values of the parameters that
determine the arrangement and the size of the slots, the cycle will not start the machining.
The cycle is aborted and the error message
61104 ”Contour violation of grooves/slots” is output.
During the cycle, the workpiece coordinate system is offset and rotated. The values in the
workpiece coordinate system (WCS) displayed on the actual value display are such that the
longitudinal axis of the slot that has just been machined corresponds to the 1st axis of the
current machining plane.
After the cycle has been completed, the workpiece coordinate system is in the same position
again as it was before the cycle was called.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Programming example: Machining slots

By using this program, you can machine 4 slots of the length 30 mm and the relative depth 23
mm (difference between the reference plane and the slot root), which are arranged on a circle
with the center point Z45 Y40 and the radius 20 mm in the YZ plane. The starting angle is 45
degrees, the advancing angle is 90 degrees. The maximum infeed depth is 6 mm, the safety
clearance 1 mm.
Z Z
90° A A−B
45°
20
45
30
B Y 23 X
40
Fig. 9-54
N10 G19 G90 D9 T10 S600 M3 Specification of the technological values
N20 G0 Y50 Z25 X5 Approach starting point
N30 LONGHOLE (5, 0, 1, , 23, 4, 30, 40, 45, 20, 45, Cycle call
90, 100 , 320, 6)
9.6.7 Slots on a circle − SLOT1
Programming
SLOT1(RTP, RFP, SDIS, DP, DPR, NUM, LENG, WID, CPA, CPO, RAD, STA1, INDA, FFD,
FFP1, MID, CDIR, FAL, VARI, MIDF, FFP2, SSF)
Parameters
Table 9-20 Parameters for SLOT1

6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Table 9-20 Parameters for SLOT1, cont’d

LENG real Slot length (enter without sign)
WID real Slot width (enter without sign)
CDIR integer Milling direction for machining the slot
Values: 2 (for G2)
3 (for G3)
FAL real Finishing allowance at the slot edge (enter without sign)
VARI integer Machining type
Values: 0=complete machining
1=roughing
2=finishing
MIDF real Maximum infeed depth for finishing
FFP2 real Feedrate for finishing
SSF real Speed when finishing
Note
Function
The cycle SLOT1 is a combined roughing−finishing cycle.
Use this cycle to machine slots arranged on a circle. The longitudinal axis of the slots is
aligned radially. Unlike the elongated hole, a value is defined for the slot width.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Fig. 9-55
Sequence
The starting position can be any position from which each of the slots can be approached
without collision.
S Approach of the position specified in the diagram 9-56 on the right with G0 at the begin-
ning of the cycle
S Complete machining of a slot is carried out in the following steps:
− Approach of the reference plane brought forward by the safety clearance by using G0
− Infeed to the next machining depth with G1 and with feedrate value FFD
− Solid machining of the slot to the finishing allowance at the slot edge with feedrate
value FFP1. Then finishing with feedrate value FFP2 and spindle speed SSF along the
contour according to the machining direction programmed under CDIR.
− The depth infeed is always carried out at the same position in the machining plane
until the end depth of the slot is reached.
S Retract tool to the retraction plane and move to the next slot with G0.
S After the last slot has been machined, the tool is moved with G0 to the end position in the
machining plane, which is specified in the diagram below, and the cycle is ended.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
G0 G0
G0
G0
Fig. 9-56

Y
CPA
INDA
STA1
WID
CPO
Fig. 9-57
DP and DPR (slot depth)

The slot depth can be specified either absolute (DP) or relative (DPR) to the reference plane.
NUM (number)
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
LENG and WID (slot length and slot width)

Use the parameters LENG and WID to define the form of a slot in the plane. The milling cut-
ter diameter must be smaller than the slot width. Otherwise, alarm 61105 ”Cutter radius too
large” will be activated and the cycle aborted.
The milling cutter diameter must not be smaller than half of the slot width. This is not
checked.


The arrangement of the slot on the circle is defined by these parameters.
STA1 specifies the angle between the positive direction of the 1st axis (abscissa) in the work-
piece coordinate system active before the cycle was called and the first slot. Parameter INDA
contains the angle from one slot to the next.
If INDA=0, the incrementing angle is calculated from the number of slots so that they are ar-
ranged equally around the circle.
FFD and FFP1 (feedrate for depth and surface)

The feedrate FFD is active for all infeed movements perpendicular to the machining plane.
The feedrate FFP1 is active for all movements in the plane traversed at feedrate when rough-
ing.
MID (infeed depth)

Use this parameter to define the maximum infeed depth.
Using MID and the total depth, the cycle automatically calculates this infeed which lies be-
tween 0.5 x maximum infeed depth and the maximum infeed depth. The minimum possible
number of infeed steps is used as the basis. MID=0 means that the cut to slot depth is made
with one feed.
The depth infeed commences at the reference plane moved forward by the safety clearance.
CDIR (milling direction)

Use this parameter to specify the machining direction for the slot. Possible values are:
S ”2” for G2
S ”3” for G3
If the parameter is set to an illegal value, then the message ”Wrong milling direction, G3 will
be generated” will be displayed in the dialog line. In this case, the cycle is continued and G3
is automatically generated.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
FAL (finishing allowance)

Use this parameter to program a finishing allowance at the slot edge. FAL does not influence
the depth infeed.
If the value of FAL is greater than allowed for the specified width and the milling cutter used,
FAL is automatically reduced to the maximum possible value. In the case of roughing, milling
is performed with a reciprocating movement and depth infeed at both end points of the slot.
VARI, MIDF, FFP2 and SSF (machining type, infeed depth, feedrate and speed)
Use the parameter VARI to define the machining type.
S 0=complete machining in two parts
− Solid machining of the slot (SLOT1, SLOT2) to the finishing allowance is performed at
the spindle speed programmed before the cycle was called and with feedrate FFP1.
Depth infeed is defined with MID.
− Solid machining of the remaining machining allowance is carried out at the spindle
speed defined via SSF and the feedrate FFP2. Depth infeed is defined with MIDF.
If MIDF=0, the infeed is equal to the final depth.
− If FFP2 is not programmed, feedrate FFP1 is active. This also applies analogously if
SSF is not specified, i.e. the speed programmed prior to the cycle call will apply.
S 1=roughing
The slot (SLOT1, SLOT2) is solid−machined up to the finishing allowance at the speed
programmed before the cycle call and at the feedrate FFP1. The depth infeed is pro-
grammed via MID.
S 2=finishing
The cycle requires that the slot (SLOT1, SLOT2) is already machined to a residual finish-
ing allowance and that it is only necessary to machine the final finishing allowance. If
FFP2 and SSF are not programmed, the feedrate FFP1 or the speed programmed before
the cycle call is active. Depth infeed is defined with MIDF.
If a different value is programmed for the parameter VARI, the cycle is aborted after output of
alarm 61102 ”Machining type defined incorrectly”.
Further notes
If incorrect values are assigned to the parameters that determine the arrangement and size of
the slots and thus cause mutual contour violation of the slots, the cycle is not started. The
cycle is canceled, and the error message 61104 ”Contour violation of slots/elongated holes”
is output.
workpiece coordinate system displayed on the actual value display are such that the longitu-
dinal axis of the slot that has just been machined corresponds to the 1st axis of the current
machining plane.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Contour violation
Fig. 9-58
Programming example: Slots

4 slots are milled.
The slots have the following dimensions: Length 30 mm, width 15 mm and depth 23 mm. The
safety clearance is 1 mm, the finishing allowance 0.5 mm, the milling direction is G2, and the
maximum infeed in the depth is 6 mm.
The slot is to be machined completely. infeed during finishing is to be performed directly to
the pocket depth and the same feedrate and speed are to be used.
Z Z
A A−B
90°
45°
20
30
45
15
Y 23 X
40 B
Fig. 9-59
N20 G0 X20 Y50 Z5 Approach starting position
N30 SLOT1(5, 0, 1, −23, , 4, 30, 15, 40, 45, 20, 45, 90, Cycle call, parameters VARI, MIDF, FFP2 and
100, 320, 6, 2, 0.5, 0, , 0, ) SSF omitted
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6.8 Circumferential slot − SLOT2
Programming
SLOT2(RTP, RFP, SDIS, DP, DPR, NUM, AFSL, WID, CPA, CPO, RAD, STA1, INDA, FFD,
FFP1, MID, CDIR, FAL, VARI, MIDF, FFP2, SSF)
Parameters
Table 9-21 Parameters for SLOT2

AFSL real Angle for the slot length (enter without sign)
WID real Circumferential slot width (enter without sign)
CDIR integer Milling direction for machining the circumferential slot
Values: 2 (for G2)
3 (for G3)
FAL real Finishing allowance at the slot edge (enter without sign)
VARI integer Machining type
Values: 0=complete machining
1=roughing
2=finishing
MIDF real Maximum infeed depth for finishing
FFP2 real Feedrate for finishing
SSF real Speed when finishing
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Note
Function
The cycle SLOT2 is a combined roughing−finishing cycle.
Use this cycle to machine circumferential slots arranged on a circle.
Fig. 9-60
Sequence
The starting position can be any position from which each of the slots can be approached
without collision.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
G0
G0
G0
Fig. 9-61

S G0 is used to approach the position specified in the diagram below at cycle start.
S The steps when machining a circumferential slot are the same as when machining an
elongated hole.
S After a circumferential slot is machine completely, the tool is retracted to the retraction
plane and the next slot is machined with G0.
S After the last slot has been machined, the tool is moved with G0 to the end position in the
machining plane, which is specified in the diagram below, and the cycle is ended.

For the parameters DP, DPR, FFD, FFP1, MID, CDIR, FAL, VARI, MIDF, FFP2, SSF, see
SLOT1.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Y
CPA
INDA AFSL
STA1
CPO
WID
Fig. 9-62
NUM (number)
AFSL and WID (angle and circumferential slot width)

Use the parameters AFSL and WID to define the form of a slot in the plane. The cycle checks
whether the slot width is violated with the active tool. Otherwise, alarm 61105 ”Cutter radius
too large” will be activated and the cycle aborted.


The arrangement of the circumferential slots on the circle is defined by these parameters.
STA1 specifies the angle between the positive direction of the 1st axis of the plane in the
workpiece coordinate system active before the cycle was called and the first circumferential
slot.
Parameter INDA contains the angle from one circumferential slot to the next.
If INDA=0, the incrementing angle is calculated from the number of circumferential slots so
that they are arranged equally around the circle.
Further notes
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
If incorrect values are assigned to the parameters that determine the arrangement and size of
the slots and thus cause mutual contour violation of the slots, the cycle is not started.
The cycle is canceled, and the error message 61104 ”Contour violation of slots/elongated
holes” is output.
workpiece coordinate system displayed on the actual value display are always such that the
circumferential slot just machined starts at the 1st axis of the current machining plane and the
zero point of the WCS is located in the center point of the circle.
Contour violation
Fig. 9-63
Programming example: Slots2

Use this program to machine 3 circumferential slots arranged at a circle with center point X60
Y60 and radius 42 mm in the XY plane. The circumferential slots have the following dimen-
sions: Width 15 mm, angle for slot length 70 degrees, depth 23 mm. The starting angle is 0
degrees, and the incrementing angle is 120 degrees. A finishing allowance of 0.5 mm is
taken into account at the contour of the slots, the safety clearance in the infeed axis Z is 2
mm, and the maximum depth infeed is 6 mm. The slots are to be machined completely.
Speed and feedrate are to be the same when finishing. The infeed when finishing is to be
performed to slot depth.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Y Y
A−B
A
70°
15
120°
42
60
B
60 X Z
23
Fig. 9-64
N20 G0 X60 Y60 Z5 Approach starting position
N30 SLOT2(2, 0, 2, −23, , 3, 70, 15, 60, 60, 42, , 120, Cycle call
100, 300, 6, 2, 0.5, 0, , 0, ) Reference plane+SDIS=retraction plane
means: Lowering in the infeed axis with G0 to
reference plane+SDIS no longer applicable,
parameters VAR, MIDF, FFP2 and SSF
omitted
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6.9 Milling a rectangular pocket − POCKET3
Programming
POCKET3(_RTP, _RFP, _SDIS, _DP, _LENG, _WID, _CRAD, _PA, _PO, _STA, _MID, _FAL,
_FALD, _FFP1, _FFD, _CDIR, _VARI, _MIDA, _AP1, _AP2, _AD, _RAD1, _DP1)
Parameters
Table 9-22 Parameters for POCKET3

_DP real Pocket depth (absolute)
_LENG real Pocket length, for dimensioning from the corner with sign
_WID real Pocket width, for dimensioning from the corner with sign
_CRAD real Pocket corner radius (enter without sign)
_PA real Pocket reference point (absolute), 1st axis of the plane
_PO real Pocket reference point (absolute), 2nd axis of the plane
_STA real Angle between the pocket longitudinal axis and the 1st axis of
the plane (enter without sign)
Range of values: 0° ≤ _STA < 180°
_FAL real Finishing allowance at the pocket edge (enter without sign)
_FALD real Finishing allowance at the base (enter without sign)
_CDIR integer Milling direction: (enter without sign)
Values: 0 climb milling (as spindle direction)
1 opposed milling
3 with G3
_VARI integer Machining type
UNITS DIGIT
Values: 1 roughing
2 finishing
TENS DIGIT
Values: 0 perpendicular to pocket center with G0
1 perpendicular to pocket center with G1
2 along a helix
3 oscillating along the pocket longitudinal
axis
The other parameters can be selected as options. Specify the plunge−cut strategy and the
overlap for solid machining (to be entered without sign):
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_MIDA real Maximum infeed width as a value in solid machining in the

plane
_AP1 real Blank dimension of pocket length
_AP2 real Blank dimension of pocket width
_AD real Blank pocket depth dimension from reference plane
_RAD1 real Radius of the helical path on insertion (relative to the tool cen-
ter point path) or maximum insertion angle for oscillating mo-
tion
_DP1 real Insertion depth per 360° revolution on insertion along helical
path
Function
The cycle can be sued for roughing and finishing. For finishing, a face cutter is required.
The depth infeed is always started from the pocket center point and performed there verti-
cally; thus predrilling can be suitably performed at this position.
S The milling direction can be determined either using a G command (G2/G3) or from the
spindle direction as synchronous or opposed milling.
S For solid machining, the maximum infeed width in the plane can be programmed.
S Finishing allowance also for the pocket base
S There are three different insertion strategies:
− vertically to the pocket center
− along a helical path around the pocket center
− oscillating at the pocket central axis
S Shorter approach paths in the plane for finishing
S Consideration of a blank contour in the plane and a blank dimension at the base (optimum
machining of preformed pockets possible).
Fig. 9-65
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Sequence
Starting position is any position from which the pocket center point can be approached at the
height of the retraction plane without collision.
Sequence of motions when roughing:
With G0, the pocket center point is approached at the retraction level, and then, from this
position, with G0, too, the reference plane brought forward by the safety clearance is ap-
proached. The machining of the pocket is then carried out according to the selected insertion
strategy, taking into account the programmed blank dimensions.
G2
G3
Fig. 9-66
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Sequence of motions when finishing

Finishing is performed in the order from the edge until the finishing allowance on the base is
reached, and then the base is finished. If one of the finishing allowances is equal to zero, this
part of the finishing process is skipped.
S Finishing on the edge
While finishing on the edge, the tool will traverse around the pocket contour only once.
For finishing on the edge, the path includes one quadrant reaching the corner radius. The
radius of this path is normally 2 mm or, if ”less space” is provided, equals to the difference
between the corner radius and the mill radius.
If the finishing allowance on the edge is larger than 2 mm, the approach radius is in-
creased accordingly.
The depth infeed is performed with G0 in the open towards the pocket center, and the
starting point of the approach path is also reached with G0.
S Finishing on the base
During finishing on the base, the machine performs G0 towards the pocket center until
reaching a distance equal to pocket depth + finishing allowance + safety clearance. From
this point onwards, the tool is always fed in vertically at the depth (since a tool with a
front cutting edge is used for base finishing).
The base surface of the pocket is machined once.
Insertion strategies:
S Inserting vertically to the pocket center means that the current infeed depth calculated
internally in the cycle (≤ maximum infeed depth programmed under _MID) is executed in a
block containing G0 or G1.
S Insertion at a helical path means that the cutter center point traverses along the helical
path determined by the radius _RAD1 and the depth per revolution _DP1. The feedrate is
also programmed under _FFD. The direction of rotation of this helical path corresponds to
the direction of rotation with which the pocket will be machined.
The insertion depth programmed under _DP1 is taken into account as the maximum
depth and is always calculated as an integer number of revolutions of the helical path.
If the current depth required for an infeed (this can be several revolutions on the helical
path) is reached, a full circle is still executed to eliminate the inclined path of insertion.
Then solid machining of the pocket starts on this plane until finishing allowance.
The starting point of the described helical path is at the longitudinal axis of the pocket in
”plus direction” and is approached with G1.
S Insertion with oscillation to the central axis of the pocket means that the cutter center point
inserts oscillating an a straight line to and fro until it has reached the next current depth.
The maximum insertion angle is programmed under _RAD1, and the length of the oscilla-
tion travel is calculated in the cycle. If the current depth is reached, the travel is executed
once more without depth infeed in order to eliminate the inclined insertion path. The fee-
drate is programmed under _FFD.
Taking into account the blank dimensions

During solid machining of the pockets, it is possible to take into account blank dimensions
(e.g. when machining precast parts).
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_AP1 pocket length blank dim.
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
X
_AP2 blank dim.
Pocket width
Fig. 9-67
The blank dimensions for length and width (_AP1 and _AP2) are programmed without sign
and are placed by the cycle symmetrically around the pocket center point via calculation. You
will define the part of the pocket which is no longer to be machined by solid machining. The
blank dimension for the depth (_AD) is also programmed without sign and taken into account
by the reference plane in the direction of the pocket depth.
The depth infeed when taking into account blank dimensions is carried out according to the
programmed type (helical path, oscillating, vertically). If the cycle detects that there is space
enough in the pocket center because of the given blank contour and the radius of the active
tool, the infeed is carried out vertically to the pocket center point as long as it is possible in
order not to traverse extensive insertion paths in the open.
Solid machining of the pocket is carried out starting from the top downwards.

For the parameter _DP, see LONGHOLE.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Pocket dim. from the center point

Y
_PA
_STA
_CRAD
G2
_PO
G3
Fig. 9-68
_LENG, _WID and _CRAD (pocket length, pocket width and corner radius)
Use the parameters _LENG, _WID and _CRAD to define the form of a pocket in the plane.
If you cannot traverse the programmed corner radius with the active tool since its radius is
larger, then the corner radius of the machine pocket corresponds to the tool radius.
If the milling tool radius is larger than half of the length or width of the pocket, then the cycle
will be aborted and alarm 61105 ”Cutter radius too large” is output.
_PA, _PO (reference point)

Use the parameters _PA and _PO to define the reference point of the pocket in the axes of
the plane.
This is the pocket center point.
_STA (angle)
_STA specifies the angle between the 1st axis of the plane (abscissa) and the longitudinal
axis of the pocket.
_MID (infeed depth)

Use this parameter to define the maximum infeed depth in roughing.
Using _MID and the entire depth, the cycle will calculate this infeed automatically. The mini-
mum possible number of infeed steps is used as the basis.
_MID=0 means that the cut to pocket depth is made with one feed.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_FAL (finishing allowance on the edge)

The finishing allowance affects the machining of the pocket in the plane only on the edge.
If finishing allowance ≥ tool diameter, complete solid machining of then pocket is not guaran-
teed. The message ”Caution: Finishing allowance ≥ tool diameter” appears; the cycle, how-
ever, is continued.
_FALD (finishing allowance at the base)

In roughing, a separate finishing allowance is taken into account at the base.
_FFD and _FFP1 (feedrate for depth and surface)

The feedrate _FFD is effective when inserting into the material.
The feedrate FFP1 is active for all movements in the plane which are traversed at feedrate
when roughing.

Use this parameter to specify the machining direction for the pocket.
By using the parameter _CDIR, the milling direction
Synchronized operation or reverse rotation are determined internally in the cycle via the di-
M3 → G3 M3 → G2
M4 → G2 M4 → G3

Units digit:
S 1=roughing
S 2=finishing
Tens digit (infeed):
S 0=vertically to pocket center with G0
S 2=along a helical path
S 3=oscillating to pocket length axis
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_MIDA (max. infeed width)

Use this parameter to define the maximum infeed width when solid machining in a plane.
Analogously to the known calculation method for the infeed depth (equal distribution of the
total depth with the maximum possible value), the width is distributed equally, maximally with
the value programmed under _MIDA.
If this parameter is not programmed or has value 0, the cycle will internally use 80% of the
milling tool diameter as the maximum infeed depth.
Further notes
applies if the calculated width infeed from edge machining is recalculated when reaching the
full pocket in the depth; otherwise the width infeed calculated at the beginning is kept for the
whole cycle.
_AP1, _AP2, _AD (blank dimension)

Use the parameters _AP1, _AP2 and _AD to define the blank dimension (incremental) of the
pocket in the plane and in the depth.
_RAD1 (radius)
Use the parameter _RAD1 to define the radius of the helical path (referred to the tool center
point path) or the max. insertion angle for the oscillating motion.
_DP1 (insertion depth)

Use the parameter _DP1 to define the infeed depth when inserting to the helical path.
center point. At the end of the cycle, the original coordinate system is active again.
Programming example: Pocket

Use this program to machine a pocket in the XY plane which is 60 mm in length, 40 mm in
width, and which has a corner radius of 8 mm and is 17.5 mm in depth. The pocket has an
angle of 0 degrees to the X axis. The finishing allowance for the pocket edges is 0.75 mm, at
the base 0.2 mm, and the safety clearance in the Z axis added to the reference plane is 0.5
mm. The pocket center point is at X60 and Y40, the maximum depth infeed is 4 mm.
The machining direction results from the direction of rotation of the spindle in the case of
climb milling. A milling cutter with 5 mm radius is used.
Merely a rough machining operation is to be carried out.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Y Y
A A−B
R8
40
B
60 X Z
17,5
Fig. 9-69
N10 G90 T1 D1 S600 M4 Specification of the technological values
N30 POCKET3(5, 0, 0.5, −17.5, 60, 40, 8, 60, 40, 0, 4, Cycle call
0.75, 0.2, 1000, 750, 0, 11, 5, , , , , )
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
9.6.10 Milling a circular pocket − POCKET4
Programming
POCKET4(_RTP, _RFP, _SDIS, _DP, _PRAD, _PA, _PO, _MID, _FAL, _FALD, _FFP1, _FFD,
_CDIR, _VARI, _MIDA, _AP1, _AD, _RAD1, _DP1)
Parameters
Table 9-23 Parameters for POCKET4

without sign)
_DP real Pocket depth (absolute)
_PRAD real Pocket radius
_PA real Pocket center point (absolute), 1st axis of the plane
_PO real Pocket center point (absolute), 2nd axis of the plane
_FAL real Finishing allowance at the pocket edge (enter without sign)
_FALD real Finishing allowance at the base (enter without sign)
_CDIR integer Milling direction: (enter without sign)
Values: 0 climb milling (as spindle direction)
1 opposed milling
3 with G3
_VARI integer Machining type
UNITS DIGIT
Values: 1 roughing
2 finishing
TENS DIGIT
Values: 0 vertically to pocket center with G0
1 vertically to pocket center with G1
2 along helical path
The other parameters can be selected as options. Specify the plunge−cut strategy and the
overlap for solid machining (to be entered without sign):
_MIDA real Maximum infeed width as a value in solid machining in the

plane
_AP1 real Pocket radius blank dimension
_AD real Blank pocket depth dimension from reference plane
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_RAD1 real Radius of the helical path during insertion (referred to the tool
center point path)
_DP1 real Insertion depth per 360° revolution on insertion along helical
path
Function
Use this cycle to machine circular pockets in the machining plane. For finishing, a face cutter
is required.
The depth infeed is always started from the pocket center point and performed there verti-
cally; thus predrilling can be suitably performed at this position.
S The milling direction can be determined either using a G command (G2/G3) or from the
spindle direction as synchronous or opposed milling.
S For solid machining, the maximum infeed width in the plane can be programmed.
S Finishing allowance also for the pocket base
S Two different insertion strategies:
− vertically to pocket center
− along a helical path around the pocket center
S Shorter approach paths in the plane for finishing
S Consideration of a blank contour in the plane and a blank dimension at the base (optimum
machining of preformed pockets possible).
S _MIDA is recalculated during edge machining.
Sequence
Starting position is any position from which the pocket center point can be approached at the
height of the retraction plane without collision.
Sequence of motions when roughing (VARI=X1):
With G0, the pocket center point is approached at the retraction level, and then, from this
position, with G0, too, the reference plane brought forward by the safety clearance is ap-
proached. The machining of the pocket is then carried out according to the selected insertion
strategy, taking into account the programmed blank dimensions.
Sequence of motions when finishing:
Finishing is performed in the order from the edge until the finishing allowance on the base is
reached, and then the base is finished. If one of the finishing allowances is equal to zero, this
part of the finishing process is skipped.
S Finishing on the edge
While finishing on the edge, the tool will traverse around the pocket contour only once.
For finishing on the edge, the path includes one quadrant reaching the pocket radius. The
radius of this path is 2 mm as the maximum or, if ”less space” is provided, equals to the
difference between the pocket radius and the mill radius.
The depth infeed is performed with G0 in the open towards the pocket center, and the
starting point of the approach path is also reached with G0.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
S Finishing on the base

During finishing on the base, the machine performs G0 towards the pocket center until
reaching a distance equal to pocket depth + finishing allowance + safety clearance. From
this point onwards, the tool is always fed in vertically at the depth (since a tool with a
front cutting edge is used for base finishing).
The base surface of the pocket is machined once.
Insertion strategies:
see section ”POCKET3”
Taking into account the blank dimensions

During solid machining of the pockets, it is possible to take into account blank dimensions
(e.g. when machining precast parts).
With circular pockets, the blank dimension _AP1 is also a circle (with a smaller radius than
the pocket radius).
For further explanations, see POCKET3.

For the parameters _DP, _MID, _FAL, _FALD, _FFP1, _FFD, _CDIR, _MIDA, _AP1, _AD,
_RAD1, _DP1, see POCKET3.
_PA
G3 G2
_PO
Fig. 9-70
_PRAD (pocket radius)

The form of the circular pocket is determined solely by its radius.
If this is smaller than the tool radius of the active tool, then the cycle is aborted and alarm
61105 ”Cutter radius too large” is output.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
_PA, _PO (pocket center point)

Use the parameters _PA and _PO to define the pocket center point. Circular pockets are al-
ways dimensioned across the center.

Units digit:
S 1=roughing
S 2=finishing
Tens digit (infeed):
S 2=along a helical path
Further notes
center point.
At the end of the cycle, the original coordinate system is active again.
Programming example: Circular pocket

With this program, you can machine a circular pocket in the YZ plane. The center point is
determined by Y50 Z50. The infeed axis for the depth infeed is the X axis. Neither finishing
dimension, nor safety clearance are specified. The pocket is machined with conventional (op-
posed) milling. Infeed is performed along a helical path.
A milling cutter with 10 mm radius is used.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
Z Z
A A−B
50
50
B
Y X
50
20
Fig. 9-71
N10 G17 G90 G0 S650 M3 T1 D1 Specification of the technological values
N20 X50 Y50 Approach starting position
N30 POCKET4(3, 0, 0, −20, 25, 50, 60, 6, 0, 0, 200, Cycle call

100, 1, 21, 0, 0, 0, 2, 3) The parameters _FAL, _FALD are omitted
9.6.11 Thread milling − CYCLE90
Programming
CYCLE90 (RTP, RFP, SDIS, DP, DPR, DIATH, KDIAM, PIT, FFR, CDIR, TYPTH, CPA, CPO)
Parameters

out sign)
DIATH real Nominal diameter, outer diameter of the thread
KDIAM real Core diameter, internal diameter of the thread
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
PIT real Thread lead; Range of values: 0.001 ... 2000.000 mm

FFR real Feedrate for thread milling (enter without sign)
CDIR int Direction of rotation for thread milling
Values: 2 (for thread milling using G2)
3 (for thread milling using G3)
TYPTH int Thread type
Values: 0=internal thread
1=external thread
CPA real Center point of circle, abscissa (absolute)
CPO real Center point of circle, ordinate (absolute)
Function
Using the cycle CYCLE90, you can produce internal or external threads. The path when mill-
ing threads is based on a helix interpolation. All three geometry axes of the current plane,
which you will define before calling the cycle, are involved in this motion.
Fig. 9-72
Sequence when producing an external thread

The starting position is any position from which the starting position at the outside diameter of
the thread at the height of the retraction plane can be reached without collision.
When milling threads using G2, this starting position is between the positive abscissa and the
positive ordinate in the current plane (i.e. not in the 1st quadrant of the coordinate system).
When milling threads using G3, the starting position is between the positive abscissa and the
negative ordinate (i.e. in the 4th quadrant of the coordinate system).
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
The distance from the thread diameter depends on the size of the thread and the tool radius
used.
Z
Y
CPA
CPO
X
Pos. of starting point

Pos. of starting point when milling threads
when milling threads using G2
using G3
Fig. 9-73

S Positioning on the starting point using G0 at the height of the retraction plane in the appli-
cate of the current plane
S Infeed to the reference plane brought forward by the safety clearance for swarf removal,
using G0
S Approach motion to the thread diameter along a circle path opposite to the direction
G2/G3programmed under CDIR
S Thread milling along a helix path using G2/G3 and the feedrate value FFR
S Retraction motion along a circle path in the opposite direction of rotation G2/G3 at the re-
duced feedrate FFR
S Retraction to the retraction plane along the applicate using G0
Sequence when producing an internal thread

The starting position is any position from which the center point of the thread at the height of
the retraction plane can be reached without collision.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles

S Positioning on the center point using G0 at the height of the retraction plane in the appli-
cate of the current plane
S Infeed to the reference plane brought forward by the safety clearance for swarf removal,
using G0
S Approach to an approach circle calculated internally in the cycle using G1 and the re-
duced feedrate FFR
S Approach motion to the thread diameter along a circle path according to the direction
G2/G3programmed under CDIR
S Thread milling along a helix path using G2/G3 and the feedrate value FFR
S Retraction motion along a circle path in the same direction of rotation at the reduced fee-
drate FFR
S Retraction to the center point of the thread using G0
S Retraction to the retraction plane along the applicate using G0
Thread from the bottom to the top
For technological reasons, it can be reasonable to machine a thread also from the bottom to
the top. In this case, the retraction plane RTP will be behind the thread depth DP.
This machining is possible, but the depth specifications must be programmed as absolute
values and the retraction plane must be approached before calling the cycle or a position af-
ter the retraction plane must be approached.
Programming example (thread from the bottom to the top)
A thread with a lead of 3 mm is to start from −20 and to be milled to 0. The retraction plane is
at 8.
N10 G17 X100 Y100 S300 M3 T1 D1 F1000

N20 Z8
N30 CYCLE90(8, −20, 0, −60, 0, 46, 40, 3, 800, 3, 0,
50, 50)
N40 M2
The drill hole must have a depth of at least −21.5 (a half lead more).
Overrun travels towards the thread length
The travel−in / travel−out movements when milling threads is executed in all three axes in-
volved. This will result in an additional travel along the vertical axis at the thread run−out,
which goes beyond the programmed thread depth.
The overrun travel is calculated as follows:
P 2*WR+ RDIFF
∆z = *
4 DIATH
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
∆z Overrun travel, internally

p Lead/pitch of the thread
WR Tool radius
DIATH Outer diameter of the thread
RDIFF Radius difference for the retraction circle
With internal threads, RDIFF = DIATH/2 − WR,
with external threads, RDIFF = DIATH/2 + WR.

Z Z
RTP RTP
RFP+SDIS RFP+SDIS
RFP RFP
DPR
DPR
DP
X X
Y Y
CPA CPA
CDIR CDIR
CPO
CPO
X X
Fig. 9-74
DIATH, KDIAM and PIT (nominal/core diameters and thread lead/pitch)
These parameters are used to determine the thread data nominal diameter, core diameter
and lead/pitch. The parameter DIATH is the external, and KDIAM is the internal diameter of
the thread. The travel−in / travel−out movements are created internally in the cycle, based on
these parameters.
FFR (feedrate)
The value of the parameter FFR is specified as the current feedrate value for thread milling. It
is effective when thread milling on a helix path.
This value will be reduced in the cycle for the travel−in / travel−out movements. The retraction
is performed outside the helix path using G0.
CDIR (direction of rotation)
This parameter is used to specify the value for the machining direction of the thread.
If the parameter has an illegal value, the following message will appear:
”Wrong milling direction; G3 is generated”.
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
In this case, the cycle is continued and G3 is automatically generated.
TYPTH (thread type)
The parameter TYPTH is used to define whether you want to machine an external or an inter-
nal thread.
CPA and CPO (center point)
These parameters are used to define the center point of the drill hole or of the spigot on
which the thread will be produced.
Further notes
The cutter radius is calculated internally in the cycle. Therefore, a tool compensation must be
programmed before calling the cycle. Otherwise, the alarm 61000 ”No tool compensation ac-
tive” appears and the cycle is aborted.
If the tool radius=0 or negative, the cycle is also aborted and this alarm is issued.
With internal threads, the tool radius is monitored and alarm 61105 ”Cutter radius too large” is
output, and the cycle is aborted.
Programming example: Internal thread

Using this program, you can mill an internal thread at point X60 Y50 of the G17 plane.
Y Y
A−B
A
50
B
60 X 40 Z
Fig. 9-75
6FC5 698−2AA10−1BP5
Cycles
9.6 Milling cycles
DEF REAL RTP=48, RFP=40, SDIS=5, DPR=40, Definition of the variable with value assign-
DIATH=60, KDIAM=50 ments
DEF REAL PIT=2, FFR=500, CPA=60,CPO=50
DEF INT CDIR=2, TYPTH=0
N10 G90 G0 G17 X0 Y0 Z80 S200 M3 Approach starting position
N20 T5 D1 Specification of the technological values
N30 CYCLE90 (RTP, RFP, SDIS, DP, DPR, DIATH, Cycle call
KDIAM, PIT, FFR, CDIR, TYPTH, CPA CPO)
N40 G0 G90 Z100 Approach position after cycle
6FC5 698−2AA10−1BP5
Cycles
9.7 Error messages and error handling
9.7.1 General notes
If error conditions are detected in the cycles, an alarm is generated and the execution of the
cycle is aborted.
Furthermore, the cycles display their messages in the message line of the control system.
These message will not interrupt the program execution.
The errors with their reactions and the messages in the message line of the control system
are described in conjunction with the individual cycles.
9.7.2 Error handling in the cycles
If error conditions are detected in the cycles, an alarm is generated and the machining is
aborted.
Alarms with numbers between 61000 and 62999 generated in the cycles. This range of num-
bers, in turn, is divided again with regard to alarm responses and cancel criteria.
The error text that is displayed together with the alarm number gives you more detailed infor-
mation on the error cause.
Table 9-25
Alarm Number Clear Criterion Alarm Response

61000 ... 61999 NC_RESET Block preparation in the NC is
aborted
62000 ... 62999 Clear key The block preparation is inter-
rupted; the cycle can be con-
tinued with NC START after
the alarm has been cleared.
9.7.3 Overview of cycle alarms
The error numbers are classified as follows:
6 _ X _ _
S X=0 General cycle alarms

S X=1 Alarms generated by the drilling, drilling pattern and milling cycles
The Table below includes a list of all errors occurring in the cycles with their location of occur-
rence and appropriate instructions for fault correction.
6FC5 698−2AA10−1BP5
Cycles
Table 9-26
Alarm Alarm Text Source Explanation, Remedy

Number
61000 ”No tool compensation ac- SLOT1 D offset must be programmed prior to cycle call
tive” SLOT2
POCKET3
POCKET4
CYCLE71
CYCLE72
61001 ”Illegal thread pitch” CYCLE84 Check the parameters for the thread size or the speci-
CYCLE840 fications for the thread (are contradicting)
61002 ”Machining type defined SLOT1 The value of parameters VARI for the machining type
incorrectly” SLOT2 is specified incorrectly and must be changed
POCKET3
POCKET4
CYCLE71
CYCLE72
61003 ”No feedrate programmed CYCLE71 The parameter for the feed is incorrectly specified and
in the cycle” CYCLE72 must be changed.
61009 ”Active tool number = 0” CYCLE71 No tool (T) is programmed prior to the cycle call.
CYCLE72
61010 ”Finishing allowance too CYCLE72 The finishing allowance at the root is larger than the
large” overall depth; it must be reduced.
61011 ”Scaling not permitted” CYCLE71 A scaling factor is active what is not permissible for
CYCLE72 this cycle.
61101 ”Reference plane defined CYCLE71 Either different values for reference and retraction
incorrectly” CYCLE72 plane must be selected in the case of relative specifi-
CYCLE81 cation of the depth or an absolute value must be speci-
to fied for the depth.
CYCLE89
CYCLE840
SLOT1
SLOT2
POCKET3
POCKET4
61102 ”No spindle direction pro- CYCLE86 The parameter SDIR (or SDR in CYCLE840) must be
grammed” CYCLE88 programmed
CYCLE840
POCKET3
POCKET4
61103 ”Number of holes is zero” HOLES1 No value for the number of holes programmed
HOLES2
61104 ”Contour violation of the SLOT1 Faulty parameterization of the milling pattern in the
slots / elongated holes” SLOT2 parameters defining the position of the slots/long holes
on the circle and their form
61105 ”Cutter radius too large” SLOT1 The diameter of the cutter used is too large for the
SLOT2 figure to be manufactured; either use a tool with
POCKET3 smaller radius or change the contour
POCKET4
61106 ”Number or distance of HOLES2 Parameters NUM or INDA parameterized incorrectly;
circle elements” SLOT1 the arrangement of the circle elements within a full
SLOT2 circle is not possible
6FC5 698−2AA10−1BP5
Cycles
Table 9-26 , Fortsetzung
Alarm Alarm Text Source Explanation, Remedy

Number
61107 ”First drilling depth de- CYCLE83 First drilling depth is opposite to total drilling depth
fined incorrectly”
61108 ”No permissible values for POCKET3 The parameters _RAD1 and _DP for defining the path
the parameters _RAD1 POCKET4 for depth infeed were incorrectly specified.
and _DP1”
61109 ”Parameter _CDIR de- POCKET3 The value of the _CDIR parameter for the milling direc-
fined incorrectly” POCKET4 tion was specified incorrectly and must be changed.
61110 ”Finishing allowance at POCKET3 The finishing allowance on the root has been specified
the base > depth infeed” POCKET4 greater than the maximum depth infeed; either reduce
the finishing allowance or increase the depth infeed.
61111 ”Infeed width > tool diam- CYCLE71 The programmed infeed width is larger than the diame-
eter” POCKET3 ter of the active tool; it must be reduced.
POCKET4
61112 Tool radius negative” CYCLE72 The radius of the active tool is negative; this is not per-
missible.
61113 ”Parameter _CRAD for POCKET3 The parameter for the corner radius _CRAD was spe-
corner radius too large” cified too large; it must be reduced.
61114 ”Machining direction CYCLE72 The machining direction of the cutter radius path com-
G41/G42 defined incor- pensation G41/G42 was selected incorrectly.
rectly”
61115 ”Approach or retraction CYCLE72 The approach / retraction mode for the contour was
mode (straight line/circle/ incorrectly defined; check parameter _AS1 or _AS2.
plane/space) defined in-
correctly”
61116 ”Approach or retraction CYCLE72 The approach orretraction travel is specified with zero;
path=0” it must be increased; check parameter _LP1 or _LP2.
61117 ”Active tool radius <= 0” CYCLE71 The radius of the active tool is negative or zero; this is
POCKET3 not permissible!
POCKET4
61118 ”Length or width = 0” CYCLE71 The length or width of the milling face is not permissi-
ble; check the parameters _LENG and _WID.
61124 ”No infeed width pro- CYCLE71 With the simulation active without tool, a value for the
grammed” infeed width _MIDA must always be programmed.
62100 ”No drilling cycle active” HOLES1 No drilling cycle has been called modally before the
HOLES2 drilling cycle has been called.
9.7.4 Messages in the cycles
The cycles display their messages in the message line of the control system. 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. The following messages are possible:
6FC5 698−2AA10−1BP5
Cycles
Table 9-27
Message Text Source

”Depth: according to the value for the relative depth” CYCLE81...CYCLE89, CYCLE840
”Slot is being processed” SLOT1
”Circumferential slot is being processed” SLOT2
”Wrong milling direction; G3 is generated”. SLOT1, SLOT2
”1st drilling depth: according to the value for the rela- CYCLE83
tive depth”
no.> in the message text always stands for the number of the figure currently machined.
6FC5 698−2AA10−1BP5
Cycles
6FC5 698−2AA10−1BP5
Index
Index
A Deep hole drilling with chip breaking, 9-255
Deep hole drilling with swarf removal, 9-255
Absolute drilling depth, 9-293 , 9-322
Determining the tool offsets, , 3-33
absolute drilling depth, 9-249
Drilling, 9-248
Address, 8-130
Drilling cycles, 9-241
Axis assignment, 9-243
Drilling pattern cycles, 9-241 , 9-281
Drilling pattern cycles without drilling cycle call,
9-281
B Drilling, counterboring, 9-251
Behavior when quantity parameter is zero, 9-281
Block search , 5-65
Block structure, 8-131 E
Boring, 9-246
Elongated hole final drilling depth, 9-317
Boring 1, 9-266
Entering tools and tool offsets, 3-31
Boring 2, 9-270
External thread, 9-346
Boring 3, 9-273
Boring 4, 9-275
Boring 5, 9-278
Boring cycle, 9-246 F
Face milling, 9-290
Fundamentals of NC programming, 8-129
C
Call conditions, 9-242 , 9-247
Centering, 9-248 G
Character set, 8-132 Geometrical parameters, 9-246
Circle of holes, 9-286 Grooves on a circle − SLOT1, 9-319
Circular spigot milling − CYCLE77, 9-310
Circumferential slot − SLOT2, 9-326
Configuring input screenforms, 9-245 H
Cycle alarms, 9-352
Handwheel, 4-53
Cycle call, 9-243
HOLES1, 9-282
Cycle support in the program editor, 9-244
HOLES2, 9-286
CYCLE71 , 9-290
CYCLE72, 9-296
CYCLE77, 9-310
CYCLE81, 9-248 I
CYCLE82, 9-251 Interface parameters, 7-114
CYCLE83, 9-254 Internal thread, 9-347
CYCLE84, 9-258
CYCLE840, 9-261
CYCLE85, 9-266 J
CYCLE86, 9-270
Jog, 4-50
CYCLE87, 9-273
Jog mode, 4-50
CYCLE88, 9-275
CYCLE89, 9-278
CYCLE90, 9-345
L
LONGHOLE, 9-314
D
Data transfer, 6-92
Deep hole drilling, 9-254
SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition Index-357
6FC5 698−2AA10−1BP5
Index
M Reapproach after cancellation, 5-67

Reference plane, 9-249
Machine operating area, 4-50
Relative drilling depth, 9-322
Machine zero, 3-42
relative drilling depth, 9-249 , 9-293
Machining parameters, 9-246
Repositioning after interrupting, 5-67
Machining plane, 9-242
Retraction plane, 9-249
Manual input, 4-54
Rigid tapping, 9-258
MDA mode, 4-54
Row of holes, 9-282
Messages, 9-354
Milling a circular pocket − POCKET4, 9-341
Milling a rectangular pocket − POCKET3, 9-332
Milling cycles, 9-241 S
Safety clearance, 9-249
Screen layout, 1-11
N Setting data, 3-45
Simulation of cycles, 9-244
Non−printable special characters, 8-133
SLOT1, 9-319
SLOT2, 9-326
Slots on a circle − LONGHOLE, 9-314
O SPOS, 9-259 , 9-260
Operating areas, 1-14
Operating the cycle selection, 9-245
Overview of cycle alarms, 9-352 T
Overview of cycle files, 9-244
Tapping with compensating chuck, 9-261
Tapping with compensating chuck with encoder,
9-263
P Tapping with compensating chuck without enco-
Parameters operating area, 3-31 der, 9-262
Part program, selecting, starting, 5-64 Thread milling, 9-345
Part program , stopping, canceling, 5-66 Tool zero, 3-42
Path milling, 9-296
Plane definition, 9-242
Plausibility checks, 9-281 V
POCKET3, 9-332
V24 interface, 6-92
POCKET4, 9-341
Printable special characters, 8-132
W
R Word structure , 8-130
Work offset, 3-42
R parameters , 3-48
Index-358 SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition
6FC5 698−2AA10−1BP5
To: Suggestions
SIEMENS AG Corrections
A&D MC BMS For publication/manual:
Postfach 3180
SINUMERIK 802D
D−91050 Erlangen
(Tel. +49 (0) 180 5050 − 222 [hotline]
Fax +49 (0) 9131 98 − 63315 [documentation]
E−mail: [email protected]) User Documentation
Operation and Programming
From: Milling
Order No.: 6FC5698−2AA10−1BP5
Name 08.05Edition
Company/Dept.
Should you come across any printing
Address errors when reading this publication,
please notify us on this sheet.
Zip code: City: Suggestions for improvement are
Telephone: / also welcome.
Telefax: /
Suggestions and/or corrections

SINUMERIK 802D Document Structure
General Documentation: Catalog
SINUMERIK 802D
Turning,
Milling
User Documentation Operation and Programming
SINUMERIK 802D SINUMERIK 802D
Turning Milling
User Documentation Diagnostics Guide
SINUMERIK 802D
Turning,
Milling
Manufacturer/Service Documentation: Start−up
SINUMERIK 802D
Turning, SIMODRIVE
Milling 611UDocument
ation
Manufacturer/Service Documentation: Description of Functions
SINUMERIK 802D
Turning,
Milling

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Introduction 1

Control system Software version

Siemens AG Copyright (E) Siemens AG 2005.

Addressees of the documentation

iv SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition

SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition v

vi SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition

8.6 Tool and tool offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-195

9.5.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-281

”Recall” key ”Position” operating area key

ETC key ”Program” operating area key

”Acknowledge alarm” key ”Parameter” operating area

without function ”Program Manager” operating area

Info key ”Alarm” / ”System” operating areas

SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition ix

External Machine Control Panel

User−defined key with LED

User−defined key without LED

SPINDLE START RIGHT

x SINUMERIK 802D Operation and Programming Milling (BP−F), 08/05 Edition

Fig. 1-1 Screen layout

The screen is divided into the following main areas:

Fig. 1-2 Status area

Table 1-1 Explanation of the display elements in the status area

Screen Con- Display Meaning

4 Program controls in the AUTOMATIC mode

Path N: − NC internal ”drive”

7 Selected part program (main program)

Tip and softkey area

Fig. 1-3 Tip and softkey area

Screen Con- Display Meaning

Mixed notation active (uppercase/lowercase letters)

Data transfer running

Connection to the PLC programming tool active

4 Softkey bar vertical and horizontal

Use this softkey to quit the screenform.

Use this softkey to cancel the input; the window is closed.

1.2 Operating areas

Position Machine operation

Offset/Parameters Input of offset values and setting data

Program Creation of part programs

Program Manager Part program directory

System Diagnosis, start−up

Alarm Alarm and message lists

1.3 Accessibility options

Fig. 1-4 Calculator

Characters permitted for input

R Square root function

Task Input −> Result

Use the G2 / G3 softkey to define the direction of rotation of the circle.

Enter the following coordinates or angles:

This function will select the relevant end position.

Use the softkeys and to select the given configuration.

tion. Use the softkeys to select the given configuration.

1.3.2 Editing Chinese characters

This function is only available in the Chinese language version.

Fig. 1-9 Chinese editor

Alt S Is used to turn on / turn off the editor

Alt L Switches between uppercase and lowercase letters