SIEMENS 12.03.

2018
SINUMERIK 840D sl / 828D
Attached Siemens cycle packages for SW 4.7 SP6

1. Reference documents ..........................................................................................................2

1.1. List of reference documents and editions ......................................................................2
1.2. Documentation overview – where cycle topics are described ........................................2
2. Compatibility.........................................................................................................................4
2.1. Compatibility to cycle packages 840D sl / 828D from SW 4.5 SP3 ................................4
2.2. Compatibility to grinding programs with 802D sl SW 1.4................................................5
2.3. Adapting machine manufacturer cycles .........................................................................5
2.3.1. Change status of the CUST cycles between SW 4.5 SP3 and SW 4.7 SP5 ...........5
2.3.2. Special notes regarding upgrading .........................................................................6
3. Changes with respect to the previous release ......................................................................7
3.1. Changes from SW 4.7 SP5 ...........................................................................................7
3.2. Supplementary conditions .............................................................................................8
4. Notes for using this cycle package .......................................................................................9
4.1. Summarizing notes regarding manufacturer cycle CUST_TECHCYC ...........................9
4.1.1. New functions.........................................................................................................9
4.1.2. Functional changes, expansions to existing markers ..............................................9
4.2. Summarizing notes regarding manufacturer cycle CUST_800.......................................9
4.2.1. New functions.........................................................................................................9
4.2.2. Functional changes, expansions to existing markers ..............................................9
4.2.3. Expanded functionality for swiveling with OEM transformation .............................10
4.2.4. Example, generating blocks in CUST cycles – CUST_800 ...................................10
4.3. Summarizing notes regarding manufacturer cycle CUST_832.....................................11
4.4. Summarizing notes regarding manufacturer cycle CUST_MEAPROT .........................11
4.5. Notes regarding software limit position evaluation when measuring workpieces..........12
4.6. Notes regarding the name of the swivel data set indirect programming .......................12
4.7. Note regarding increasing the number of calibration data sets ....................................13
4.8. Notes regarding measuring kinematics CYCLE996 .....................................................13

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Attached Siemens cycle packages for SW 4.7 SP6

1. Reference documents

1.1. List of reference documents and editions

/1/ SINUMERIK 840D sl / 828D
Measuring cycles – Programming Manual 10/2015 (SW 4.7 SP2)

/2/ SINUMERIK 840D sl / SINUMERIK Operate (IM9)

Commissioning Manual 10/2015 (SW 4.7 SP2)

/3/ SINUMERIK 840D sl / 840D / 840Di

Cycles – Programming Manual 01/2008 (SW 1.5 840D sl or SW 7.5 840D)

/4/ SINUMERIK 840D sl / 828D

Milling – Operating Manual 10/2015 (SW 4.7 SP2)

/5/ SINUMERIK 840D sl / 828D

Turning – Operating Manual 10/2015 (SW 4.7 SP2)

/6/ SINUMERIK 840D sl / 828D

Production planning – Programming Manual 10/2015 (SW 4.7 SP2)

/7/ SINUMERIK 840D sl / 828D

Grinding – Operating Manual 10/2015 (SW 4.7 SP2)

/8/ SINUMERIK 840D sl / 828D

Function Manual Special Functions T4 10/2015 (SW 4.7 SP2)

1.2. Documentation overview – where cycle topics are described

Document Contents

SINUMERIK 840D sl/828D In Chapter Setting up the machine – all functions for measuring
Milling in JOG workpiece and tools on milling machines
Operating Manual Chapter – Generating a G-code program
Chapter – Generating a ShopMill program
Chapter – Programming technological functions (including all
drilling, milling and turning cycles)

SINUMERIK 840D sl/828D In Chapter Setting up the machine – measuring tools in JOG on
Turning lathes
Operating Manual Chapter – Generating a G-code program
Chapter – Generating a ShopTurn program
Chapter – Programming technological functions (including all
drilling, turning and milling cycles)

SINUMERIK 840D sl/828D Chapter – Basics/measuring principle etc. (as before)

Measuring cycles Chapter – All measuring versions, workpiece and tool
Programming Manual measuring, turning and milling – SK oriented
Chapter – Overview parameter list of the measuring cycles (for
external programming): contains the call interfaces for all
measuring cycles in the G-code and detailed description of the
transfer parameters

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Chapter – Attachments, list for the changeover to SW from

2.7/4.4

SINUMERIK 840D sl/828D Chapter – Externally programming cycles: contains the call
Programming Manual Job Planning interfaces for all technological cycles in the G-code and detailed
description of the transfer parameters

SINUMERIK 840D sl Chapter – Simulation and simultaneous recording

SINUMERIK Operate (IM9) Chapter – Configuring cycles
Commissioning Manual Contains a description of the machine and setting data for
cycles, swiveling, JobShop, adapting manufacturer cycles
(CUST_TECHCYC, CUST_MEACYC etc.)

SINUMERIK 840D sl/828D Chapter – Generating a G-code program

Grinding Chapter – Programming technological functions (including all
Operating Manual grinding cycles)

SINUMERIK 840D sl/828D T4: Automatic post optimization with AST (included, all AST
Function Manual Special Functions cycles)
(only for 840D sl, description for machine manufacturers)

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Attached Siemens cycle packages for SW 4.7 SP6

2. Compatibility
2.1. Compatibility to cycle packages 840D sl / 828D from SW 4.5 SP3

In the following points, the behavior of the cycles has changed when compared to software releases from
SW 4.5 SP3 and higher:

Technology cycles:

- From 4.5 SP6: Change to the drilling cycles, if an absolute drilling depth is not programmed – and the
incremental drilling depth = 0 – or is also not programmed:
Alarm 61019 "Parameter DP, DPR incorrectly defined" is now output if DPR=0, DPR is not
programmed – and DP is not programmed.
Examples:
CYCLE81(7,5,2, ,0) ; alarm 61019
CYCLE81(7,5,2, , ) ; alarm 61019
CYCLE81(7,5,2,0,0) ;absolute, DP=0 applies
CYCLE81(7,5,2,0, ) ;absolute, DP=0 applies

- From SW 4.7: Changes in cycles for thread cutting (CYCLE99, CYCLE97) and threaded chain
(CYCLE98)
The behavior for thread synchronization (operation using softkey below JOG) has been aligned to
CYCLE 99 in CYCLE97 and CYCLE98. This means that: Thread synchronization is only possible, if no
transformation, no TCARR and no rotation around X or Z are active.

- From SW 4.7 SP1: Changes in the high-speed settings cycle (CYCLE832) in conjunction with Top
Surface:
Output CTOL for Top Surface as contour tolerance
Output CTOL for Advanced Surface as axis tolerance (*root (3)) (compatibility)

- From SW 4.7 SP2 HF1: Modified behavior for the swivel cycle (CYCLE800) – or direct with tool
carrier:
The following machine data must be observed:
MD 20196 $MC_TOCARR_ROTAX_MODE bit 2
Bit 2 = 0 … compatibility, is recommended in the case that the software is upgraded
Bit 2 = 1 … compatibility, is recommended when being commissioned for the first time

The setting, bit 2 = 1 means that the control, when swiveling in the pole position (initial position), only
calculates a unique solution.
Existing NC programs with swivel function must then be checked, as the positioning
behavior/response could have changed!

- From SW 4.7 SP5: Up until now, when retracting to the retraction position in Z and Z, XY, the position
of the tool adapter was kept. For example, for a swiveled B axis, when retracting to the retraction
position, the head could violate the software limit position ($MA_POS_LIMIT_MINUS).
When retracting Z and Z, XY to the retraction position, the entered retraction position is now
approached in the MCS. This avoids violating the software limit position.
The new behavior has been implemented in CUST_800; through adaptation, the old behavior can be
restored in CUST_800.

Measuring cycles:

- From 4.7 SP4: The function when measuring workpieces with automatic tool compensation has been
improved.

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Attached Siemens cycle packages for SW 4.7 SP6

The tool compensation precisely aligns itself to the statuses in the tool manager.
"Tool is active" and "Tool was in use"
These statuses are also evaluated if there are no tool groups (known as "Replacement tools").
Locked tools are not corrected/compensated. Alarm 61404 "Tool correction not executed" is then
output.

ShopTurn cycles:

- From 4.5 SP5: Regarding the note "Starting point or end point of the machining outside the retraction
planes":
For programs with contour machining from earlier software releases, for an NC start, it is possible that
one of the alarms 61281 "Starting point of machining outside retraction planes" or
61282 "End point of the machining outside the retraction planes" is displayed.
In this case, adapt the retraction planes in the program header.

2.2. Compatibility to grinding programs with 802D sl SW 1.4

802Dsl grinding programs that have not been adapted cannot be executed. This is as a result of the new
tool concept (grinding disks and dressing tool).

2.3. Adapting machine manufacturer cycles

2.3.1. Change status of the CUST cycles between SW 4.5 SP3 and SW 4.7 SP5

The table provides an overview of the changes in the machine manufacturer cycles with respect to
software releases from 4.5 SP3 (this also applies to the following SPx and HFx releases).

Cycle Function, significance Adaptations after the upgrade

CUST_TECHCYC Manufacture cycle to adapt the includes new functions when compared
functions of the technological cycles to
SW 4.5 SP3 and 4.7 SP3
CUST_800 Manufacturer cycle for adaptation to includes new functions when compared
the function swivel plane and swivel to
tool (CYCLE800) SW 4.5 SP3 and 4.7 SP3
CUST_832 Manufacturer cycle for the adaptation includes new functions when compared
of the High speed settings function to
(CYCLE832) SW 4.7 SP2
CUST_MEACYC Manufacturer cycle to adapt functions no change since SW 4.5 SP3
for measuring cycles
CUST_T Cycle is used to track T-preparation no change since SW 4.5 SP3
after SERUPRO
CUST_M6 Cycle is used to track the tool change no change since SW 4.5 SP3
after SERUPRO
CUST_MULTICHAN Manufacturer cycle for lathes with no change with respect to all previous
several channels releases
CUST_CLAMP Manufacturer's cycle for clamping no change with respect to all previous
elements releases
CUST_MEAPROT Manufacturer cycle for logging no change with respect to SW 4.7 SP3
measuring cycles and higher

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Attached Siemens cycle packages for SW 4.7 SP6

2.3.2. Special notes regarding upgrading

New function jump-in entry points or modified functions to the individually changed CUST cycles
see Chapter Notes for using this cycle package

To use the new functions, the cycles must be copied and appropriately adapted by the machine
manufacturer.

Note:
Generally, the machine manufacturer is recommended to copy all CUST cycles with changed functionality
with respect to the initial state before the upgrade and then readapt them.

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3. Changes with respect to the previous release

3.1. Changes from SW 4.7 SP5

This chapter only describes the changes regarding the released software version 4.7 SP4 – i.e. for cycle
packages ZYKL_840DSL_04.07.67.02.

New functions, functional changes / expansions, technology cycles:

- Expanded functions, swivel cycle (CYCLE800) to indirectly program the swivel data set (Technical
Story 500162):
The name of the swivel data set can now also be indirectly programmed using a GUD variable.
see Chapter "Notes regarding the name of the swivel data set indirect programming“
- Improvement in the function used to generate blocks in CUST cycles (User Story 546456):
The individual marks for blocks have been combined in the manufacture cycles CUST_TECHCYC,
CUST_800 and CUST_832 to make blocks easier to read. This is not associated with any functional
changes!
Example, see Chapter „Example, generating blocks in CUST cycles – CUST_800“
- Expanded functionality for the thread cutting cycle (CYCLE99) to improve the dynamic response
(User Story 598936):
From SW 4.7 SP5 with NCK 99.19.06, the dynamic response when transitioning between thread
blocks (G33, G34, G35, G335 and G336) has been improved.
The new blending (smoothing) behavior is active in CYCLE99. This means that in thread blocks,
which are used as entry or exit – or as transition element of the thread itself – the dynamic adaptation
has been improved by using a higher percentage of the block length for the adaptation.
This behavior is now automatically active after upgrading, if
SD 42010 $SC_THREAD_RAMP_DISP[2] = -1 (default value).
With
SD 55218 $SCS_FUNCTION_MASK_TURN_SET bit 5 = 1
the previous behavior can be restored (compatibility).

New functions, functional changes / expansions, measuring cycles:

- Expanded functionality for measuring cycles – number of calibration data fields increased for
workpiece probes (User Story 429529)
40 calibration data sets are now available for workpiece probes.
see Chapter „Note regarding increasing the number of calibration data sets"
- Expanded functionality for measuring cycles – alarm traversing path reduction can be deactivated
(Technical Story 526695)
Using the setting data bit
SD 54750 $SNS_MEA_ALARM_MASK bit 2 = 1
the traversing path reduction function in the measuring block – referred to the software limit position
– can be deactivated. This can make sense for certain machine types, e.g. special kinematics – such
as robot transformation.

3.2. Changes from SW 4.7 SP6

This chapter only describes those changes related to the released software version for 4.7 SP5,
i.e. for the ZYKL_840DSL_04.07.70.03 cycle packages.

New functions, functional changes/expansions to measuring cycles:

Measuring cycles now also support configurations with simulated spindle (US675770)

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Attached Siemens cycle packages for SW 4.7 SP6

3.3. Supplementary conditions

- The following general condition applies when using the HighSpeed Settings cycle (CYCLE832)
together with the TopSurface function:
If a CUST_832.SPF is already available in the manufacturer's cycle directory or user cycles, and the
new TopSurface function is to be used, then this CUST cycle must be upgraded to a version from 4.7
SP2 HF1 and higher.
- The following general conditions apply when using the new CYCLE9960:
(1) The kinematic description of the machine must be saved in the control using kinematic
chains (including variable aggregates).
(2) A release on a machine-for-machine basis is required when using the CYCLE9960.
- Notes regarding taking measurements at a counter spindle (with CYCLE978):
(1) It is assumed that to work and take measurements at the counter spindle, mirroring in the tool
axis (Z) is active.
(2) Further, that the alignment of the tool with respect to the main and counter spindle is realized
by rotating around a B axis using a tool carrier that can be orientated.
To suppress a position change of the tool spindle (with the associated probe), when taking
measurements at the counter spindle, the channel-specific
SD55740 $SCS_MEA_FUNCTION_MASK, bit1 should be set to = 0
This means that function "Coupling the tool spindle position with a coordinate rotation
around the tool axis (Z)" is deactivated. The tool spindle remains at the position that was
specified by the previous swivel cycle CYCLE800.
(3) When taking measurements at the counter spindle, calibration must be performed at the main
spindle with active G17.
- Note regarding workpiece measurement with mixed technologies (MD 52000 and 52001 both > 0):
A cutting-edge 5 … 8 must be entered in the tool compensation data of the probe.
- Notes regarding tool measurement, turning tools on lathes with Y axis (CYCLE982):
To avoid traversing motion of a Y axis when measuring tools, in the setting data
SD54629 $SNS_MEA_TP_TRIG_MINUS_DIR_AX3[n] and
SD54630 $SNS_MEA_TP_TRIG_PLUS_DIR_AX3[n]
a target position must be entered for the Y axis.
- Note regarding aligning edge in the program (CYCLE998):
Align edge in the program with CYCLE998 must always be programmed without specifying a
protection zone.
- Note regarding PROG_EVENT in conjunction with swiveling without CYCLE800 and block search:
If, in a part program where a tool carrier is selected and deselected without CYCLE800 call, a block
search between selection and deselection is performed, then for a channel reset, the number of the
last
selected tool carrier is in MD20126 TOOL_CARRIER_REST_VALUE. The precondition is that the
Progevent events are handled via system cycle PROG_EVENT.
In subcycle CYCPE_MA of the PROG_EVENT, for a channel reset event, MD20126 must be reset to
the required value.

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Attached Siemens cycle packages for SW 4.7 SP6

4. Notes for using this cycle package

4.1. Summarizing notes regarding manufacturer cycle CUST_TECHCYC
4.1.1. New functions
In manufacturer cycle CUST_TECHCYC, the following new functions have been introduced when
compared to SW 4.5 SP3:

_M115 … after tool preselection (ShopTurn)

_M116 … at tool change point (ShopTurn)
_M117 … before tool change T command (ShopMill, ShopTurn, CYCLE206)
_M118 … output of M and H functions after a tool change (ShopMill, ShopTurn)

_M231 ... start of program (ShopMill program)

_M232 ... end of program header (ShopMill program)
_M235 ... end of program loop (ShopMill program)
_M236 ... end of program (ShopMill program)

_M900 ... before unmachined part (blank) output (ShopMill, ShopTurn)

4.1.2. Functional changes, expansions to existing markers

Manufacture cycle CUST_TECHCYC has been functionally expanded with respect to SW 4.5 SP3 to
address the following applications:

- Position 4th axis after block search (e.g. linear axis of the counterspindle, tailstock, back rest)
Marker: _M30
- After end of tool change cycle (with tool change)
Marker: _M111
- Definition: Coupling, counterspindle / main spindle
Marker: _M120
- Definition: Coupling, main spindle / counterspindle
Marker: _M122
- Definition: CYCLE86 – Adapt spindle position to the tool orientation
Marker: _M300

4.2. Summarizing notes regarding manufacturer cycle CUST_800

4.2.1. New functions
In manufacturer cycle CUST_800, the following new functions have been introduced when compared to
SW 4.5 SP3:

_M440, _M450 … retraction in the tool direction zero (no distance traversed)
_M47 ... retract axis Z to fixed MCS position before tool alignment
_M48 ... retract axis Z and then the XY axes to fixed MCS position before tool alignment
_M75 ...align tool: Deselection
_M996 ... positioning rotary axes for kinematic measurement (called from CYLE9960)

4.2.2. Functional changes, expansions to existing markers

Manufacture cycle CUST_800 has been functionally expanded with respect to SW 4.7 SP3 to address the
following applications:

- Automatically unload and load old swivel head (ShopMill)

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Markers: _M6 and_M7

Now, after deselecting the tool carrier, the rotary axes are no longer automatically traversed to 0°
in JOG. This restores the behavior/response of SW 4.5.
- Retraction to retraction positions (in Z or Z, XY)
Markers: _M41 and _M42
The new behavior/response in CUST_800 was implemented at the markers. When retracting Z
and Z, XY to the retraction position, the entered retraction position is now approached in the
MCS.
By making the following adaption, in CUST_800 the previous response/behavior (approach
position in WCS) can be restored by commenting-out the deselection of the tool carrier at the
following position:
…
IF (_MODE==41)OR(_MODE==42)
; TCARR=0
_ALARM=GETTCOR(_LEN,"-T:M")
….

- Retraction in the tool direction when turning on milling machines

Markers: _M44 and_M45 and _M47 and _M48

The machine manufacturer (OEM) should check the markers listed above and adapt if required.

4.2.3. Expanded functionality for swiveling with OEM transformation

Manufacture cycle CUST_800 has been functionally expanded with respect to SW 4.7 SP3.

The following markers must be adapted depending on which modes are to be used:
_M20, _M21, _M22, _M30, _M57, _M58 und _M59.
In these markers, the 1st four-axis/five-axis transformation is activated with TRAORI(1) – and deactivated
with TRAFOOF. These two commands must be adapted to the corresponding kinematic situations.

4.2.4. Example, generating blocks in CUST cycles – CUST_800

Each functional marker is combined to create a block.

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Attached Siemens cycle packages for SW 4.7 SP6

Note regarding processing CUST cycles with block generation:

If you wish to adapt the CUST cycles with block generation at your machine, then please use an external
editor – or copy the cycle as file from CST.DIR into CMA.DIR and adapt it there.
If blocks are copied from a CUST cycle, and are reinserted, then these are automatically adapted by the
Operate editor. This can subsequently result in incorrect behavior/response at the machine.

4.3. Summarizing notes regarding manufacturer cycle CUST_832

In manufacturer cycle CUST_832, the following new functions (for TopSurface) have been introduced
when compared to SW 4.7 SP2:

_M_INIT … Init CYCLE832

_M_TOP_SURFACE_FINISH … finishing with COMPSURF
_M_TOP_SURFACE_SEMIFINISH … pre-finishing with COMPSURF
_M_TOP_SURFACE_ROUGH … roughing with COMPSURF

4.4. Summarizing notes regarding manufacturer cycle CUST_MEAPROT

Manufacture cycle CUST_MEAPROT has been functionally expanded with respect to SW 4.7 SP3 to
address the following applications:
- Changes to the marker
_LAB5
MDs 51019 and 51020 are now also taking into account in the measurement log.

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(MD 51019 $MNS_DISP_RES_ROT_WO display resolution rotation in ZO and

MD 51020 $MNS_DISP_RES_ANG display resolution angle)

4.5. Notes regarding software limit position evaluation when measuring

workpieces
For all measuring functions performed parallel to the axis, a continuous reference is now made to the
axis-specific software limit positions in the machine coordinate system. This means that if a software limit
position is located just behind a setpoint to measured, then the repositioning traversing path is
correspondingly reduced. This means that the setpoint can be measured without the traversing path
extending beyond the software limit position, which would otherwise initiate the corresponding NCK alarm.
NC functions "TRAORI" and "Swivel" can be active.

This function is implemented in all measurement versions when measuring in JOG. This is also true for all
measurement versions in the automatic program, where measurements are made parallel to the axis.

Fault situations associated with this:

- It can occur that due to the distance reduction as a result of the software limit positions, the
measuring path no longer reaches the object to be measured. After unsuccessful probing
attempts, Alarm 61401 "Probe does not switch, traversing path limited due to software limit
switch" is output.
- If, due to the measured distance reduction, the probe collides in the infeed axis, then Alarm 61402
"Probe collision, traversing path limited due to software limit switch" is displayed.
- If the traversing path is limited, before retracting the infeed axis, an alarm is displayed that can be
acknowledged:
62314 "Traversing path limited due to software limit position, collision monitoring was activated,
continue with NC-START / cancel with RESET"

Using the setting data bit

SD 54750 $SNS_MEA_ALARM_MASK bit 2 = 1
the traversing path reduction function in the measuring block – referred to the software limit position – can
be deactivated. This can make sense for certain machine types, e.g. special kinematics – such as robot
transformation.

4.6. Notes regarding the name of the swivel data set indirect programming
The GUD _TC_CHANGE defined in the channel is a string with a length of 32. Using this variable, before
the CYCLE800 call, it is possible to define which swivel data set is called in CYCLE800 – independent of
what is actually programmed in the call.
GUD variable _TC_CHANGE is reinitialized with each RESET. At the end of CYCLE800, the variable is
also deleted; this means that before each new CYCLE800 call, the variable must be written to again.
The swivel data set is changed in CYCLE800 after the CUST_800 jump out to marker _M40; this means
that the variable can also be written in CUST_800.

Programming example:

N10 _TC_CHANGE="HEAD_2"
N20 CYCLE800(0,"HEAD_1",100000,57,0,0,0,0,0,0,0,0,0,-1,100,1)
N30 M0 ;* HEAD_2 is active

N40 _TC_CHANGE="HEAD_3"
N50 CYCLE800(0,"HEAD_1",100000,57,0,0,0,0,0,0,0,0,0,-1,100,1)
N60 M0 ;* HEAD_3 is active

N70 CYCLE800(0,"HEAD_1",100000,57,0,0,0,0,0,0,0,0,0,-1,100,1)

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N80 M0 ;* HEAD_1 is active1

N90 _TC_CHANGE="TABLE_2"
N100 CYCLE800(0,"TABLE_1",100000,57,0,0,0,0,0,0,0,0,0,-1,100,1)
N110 M0 ;* TABLE_2 is active
N120 M2

Programmed general conditions in CYCLE800:

The swivel data set specified in_TC_CHANGE is checked for the following properties:
- The swivel data set to be activated must be enabled
- The following parameters must match the swivel data set selected in the screen form
o $TC_CARR23 (swivel data set type)
o $TC_CARR37 (swivel mode, ones position)
o $TC_CARR37 (select tracking, ten thousands position)
o The selected mode (bits 6,7) in the screen form (axis-by-axis, solid space, projection
angle/direct) to TC_CARR37

4.7. Note regarding increasing the number of calibration data sets

The number of calibration data arrays that are used (up to a maximum of 40), must be set in machine data
MD 51600 $MNS_MEA_CAL_WP_NUM

After reading in an NC archive, it must be ensured that this value can be overwritten.

4.8. Notes regarding measuring kinematics CYCLE996

When normalizing the 2nd rotary axis of a table kinematic, the corresponding value of vector I3 is set
(vector from the point of rotation of the 1st rotary axes to the point of rotation of the 2nd rotary axes – or to
the reference point of the tool adapter). Before SW4.7 SP4, (closing) vector I4 was normalized – which
was incorrect. Calling CYCLE996 to calculate table kinematics must be checked. If necessary, the
normalization value of the 2nd rotary axis must be adapted.

1
Before each new CYCLE800 call, variable _TC_CHANGE must be written to again

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