Document Outline

• Controls and displays of the MANUALplus
  • Keys on visual display unit
  • Operating mode keys
  • smart.Turn keys
  • Navigation keys
  • Numeric keypad
  • Special keys
  • Machine operating panel
• Operating panel of the MANUALplus
• MANUALplus 620, software and features
  • Intended place of operation
  • Legal information
  • New functions of software 548328-04
  • New functions of software 548328-05 and 54843x-01
  • New functions of software 54843x-02
• About this manual
  • Do you want any changes, or have you found any errors?
    • 1 Introduction and fundamentals ..... 33
    • 2 Basics of operation ..... 49
    • 3 Machine mode of operation ..... 71
    • 4 Cycle programming ..... 121
    • 5 ICP programming ..... 359
    • 6 Graphic simulation ..... 467
    • 7 Tool and technology database ..... 483
    • 8 Organization mode of operation ..... 519
    • 9 Tables and overviews ..... 571
    • 10 Overview of cycles ..... 605
• Introduction and fundamentals
  • 1.1 The MANUALplus
    • The MANUALplus for cycle lathes
    • MANUALplus for CNC lathes
  • 1.2 Configuration
    • Slide position
    • Tool carrier systems
    • The C axis
    • The Y axis
    • Full-surface machining
  • 1.3 Features
    • Configuration
    • Operating modes
  • 1.4 Data backup
  • 1.5 Explanation of terms
  • 1.6 MANUALplus design
  • 1.7 Fundamentals
    • Position encoders and reference marks
    • Axis designations
    • Coordinate system
    • Absolute coordinates
    • Incremental coordinates
    • Polar coordinates
    • Machine zero point
    • Workpiece zero point
    • Units of measure
  • 1.8 Tool dimensions
    • Tool length
    • Tool compensation
    • Tool-tip radius compensation (TRC)
    • Milling cutter radius compensation (MCRC)
• Basics of operation
  • 2.1 General information on operation
    • Operation
    • Setup
    • Programming – Teach-in
    • Programming – smart.Turn
  • 2.2 The MANUALplus screen
  • 2.3 Operation and data input
    • Operating modes
    • Menu selection
    • Soft keys
    • Data input
    • smart.Turn dialogs
    • List operations
    • Alphanumeric keyboard
  • 2.4 Integrated calculator
    • Calculator functions
    • Adjusting the position of the calculator
  • 2.5 Types of programs
  • 2.6 The error messages
    • Display of errors
    • Opening the error window
    • Closing the error window
    • Detailed error messages
    • "Details" soft key
    • Clearing errors
    • Error log file
    • Keystroke log file
    • Saving service files
  • 2.7 TURNguide context-sensitive help system
    • Application
    • Working with the TURNguide
    • Downloading current help files
• Machine mode of operation
  • 3.1 Machine mode of operation
  • 3.2 Switch-on / Switch-off
    • Switch-on
    • Monitoring EnDat encoders
    • Traversing the reference marks
    • Switch-off
  • 3.3 Machine data
    • Input of machine data
    • Machine data display
    • Cycle statuses
    • Axis feed rate
    • Spindle
  • 3.4 Setting up a tool list
    • Machine with turret
    • Machine with multifix
    • Tools in different quadrants
    • Filling the turret list from the database
    • Filling the turret list
    • Tool call
    • Driven tools
    • Tool life monitoring
  • 3.5 Machine setup
    • Defining the workpiece zero point
    • Homing the axes
    • Setting the protection zone
    • Defining the tool change position
    • Setting C-axis values
    • Setting up machine dimensions
    • Calibrating the tool touch probe
    • Displaying operating times
    • Setting the system time
  • 3.6 Tool measurement
    • Touch off
    • Touch probe (tool touch probe)
    • Optical gauge
    • Tool compensation
  • 3.7 "Manual Operation" operating mode
    • Tool change
    • Spindle
    • Handwheel operation
    • Manual direction keys
    • Teach-in cycles in Manual mode
  • 3.8 Teach-in mode
    • Teach-in mode
    • Programming Teach-in cycles
  • 3.9 Program Run mode
    • Loading a program
    • Comparing a tool list
    • Before executing a program
    • Finding a start block
    • Program execution
    • Entering compensation values during program run
    • Program execution in "dry run" mode
  • 3.10 Graphic simulation
  • 3.11 Program management
    • Program selection
    • File manager
    • Project management
  • 3.12 Conversion into DIN format
    • Making a conversion
  • 3.13 Units of measure
• Cycle programming
  • 4.1 Working with cycles
    • Cycle starting point
    • Help graphics
    • DIN macros
    • Graphical test run (simulation)
    • Contour follow-up in Teach-in mode
    • Cycle keys
    • Switching functions (M functions)
    • Comments
    • Cycle menu
    • Addresses used in many cycles
  • 4.2 Workpiece blank cycles
    • Bar/tube blank
    • ICP workpiece blank contour
  • 4.3 Single cut cycles
    • Rapid traverse positioning
    • Approaching the tool change position
    • Linear machining, longitudinal
    • Linear machining, transverse
    • Linear machining at angle
    • Circular machining
    • Chamfer
    • Rounding arc
    • M functions
  • 4.4 Turning cycles
    • Tool position
    • Roughing, longitudinal
    • Cut, transverse
    • Roughing, longitudinal—expanded
    • Roughing, transverse—expanded
    • Finishing cut, longitudinal
    • Finishing cut, transverse
    • Finishing cut, longitudinal—expanded
    • Finishing cut, transverse—expanded
    • Cut, longitudinal plunge
    • Cut, transverse plunge
    • Cut, longitudinal plunging—expanded
    • Cut, transverse plunging—expanded
    • Cut, longitudinal finishing plunge
    • Cut, transverse finishing plunge
    • Cut, longitudinal finishing plunge—expanded
    • Cut, transverse finishing plunge—expanded
    • Cut, ICP contour-parallel, longitudinal
    • Cut, ICP contour-parallel, transverse
    • Cut, ICP contour-parallel, longitudinal finishing
    • Cut, ICP contour-parallel, transverse finishing
    • ICP cutting, longitudinal
    • ICP cutting, transverse
    • ICP longitudinal finishing cut
    • ICP transverse finishing cut
    • Examples of turning cycles
  • 4.5 Recessing cycles
    • Cutting and infeed directions for recessing cycles
    • Undercut position
    • Contour forms
    • Recessing, radial
    • Recessing, axial
    • Recessing, radial—expanded
    • Recessing, axial—expanded
    • Recessing radial, finishing
    • Recessing axial, finishing
    • Recessing radial, finishing—expanded
    • Recessing axial, finishing—expanded
    • ICP recessing cycles, radial
    • ICP recessing cycles, axial
    • ICP recessing, radial finishing
    • ICP recessing, axial finishing
    • Recess turning
    • Recess turning, radial
    • Recess turning, axial
    • Recess turning, radial—expanded
    • Recessing turning, axial—expanded
    • Recess turning, radial finishing
    • Recess turning, axial finishing
    • Recess turning, radial finishing—expanded
    • Recess turning, axial finishing—expanded
    • ICP recess turning, radial
    • ICP recess turning, axial
    • ICP recess turning, radial finishing
    • ICP recess turning, axial finishing
    • Undercutting type H
    • Undercutting type K
    • Undercutting type U
    • Parting
    • Examples of recessing cycles
  • 4.6 Thread and undercut cycles
    • Thread position, undercut position
    • Handwheel superimposition
    • Feed angle, thread depth, proportioning of cuts
    • Thread run-in / thread run-out
    • Last cut
    • Thread cycle (longitudinal)
    • Thread cycle (longitudinal)—expanded
    • Tapered thread
    • API thread
    • Recut (longitudinal) thread
    • Recut (longitudinal) thread—expanded
    • Recut tapered thread
    • Recut API thread
    • Undercut DIN 76
    • Undercut DIN 509 E
    • Undercut DIN 509 F
    • Examples of thread and undercut cycles
  • 4.7 Drilling cycles
    • Drilling, axial
    • Radial drilling
    • Deep-hole drilling, axial
    • Deep-hole drilling, radial
    • Tapping, axial
    • Tapping, radial
    • Thread milling, axial
    • Examples of drilling cycles
  • 4.8 Milling cycles
    • Rapid positioning milling
    • Slot, axial
    • Figure, axial
    • ICP contour, axial
    • Face milling
    • Slot, radial
    • Figure, radial
    • ICP contour, radial
    • Helical-slot milling, radial
    • Milling direction for contour milling
    • Milling direction for pocket milling
    • Example of milling cycle
    • Engraving, axial
    • Engraving, radial
    • Engraving, axial/radial
  • 4.9 Drilling and milling patterns
    • Linear drilling pattern, axial
    • Milling pattern linear, axial
    • Drilling pattern circular, axial
    • Milling pattern circular, axial
    • Drilling pattern linear, radial
    • Linear milling pattern, radial
    • Drilling pattern circular, radial
    • Circular milling pattern, radial
    • Examples of pattern machining
  • 4.10 DIN cycles
    • DIN cycle
• ICP programming
  • 5.1 ICP contours
    • Loading contours
    • Form elements
    • Machining attributes
    • Calculation of contour geometry
  • 5.2 ICP editor in cycle mode
    • Editing contours for cycles
    • File organization with the ICP editor
  • 5.3 ICP editor in smart.Turn
    • Editing a contour in smart.Turn
  • 5.4 Creating an ICP contour
    • Entering an ICP contour
    • Absolute or incremental dimensioning
    • Transitions between contour elements
    • Fits and inside threads
    • Polar coordinates
    • Angular input
    • Contour graphics
    • Selection of solutions
    • Colors in contour graphics
    • Selection functions
    • Zero point shift
    • Copying a contour section in linear series
    • Copying a contour section in circular series
    • Copying a contour section by mirroring
    • Inverting
    • Contour direction (cycle programming)
  • 5.5 Editing ICP contours
    • Superimposing form elements
    • Adding contour elements
    • Editing or deleting the last contour element
    • Deleting a contour element
    • Editing contour elements
  • 5.6 The zoom function in the ICP editor
    • Changing the view
  • 5.7 Defining the workpiece blank
    • "Bar" blank
    • "Tube" blank
  • 5.8 Contour elements of a turning contour
    • Basic elements of a turning contour
    • Contour form elements
  • 5.9 Contour elements on face
    • Starting point of face contour
    • Vertical lines on face
    • Horizontal lines on face
    • Line at angle on face
    • Circular arc on face
    • Chamfer/rounding arc on the face
  • 5.10 Contour elements on lateral surface
    • Starting point of lateral surface contour
    • Vertical lines on lateral surface
    • Horizontal lines on lateral surface
    • Line at angle on lateral surface
    • Circular arc on lateral surface
    • Chamfers/rounding arcs on a lateral surface
  • 5.11 C and Y axis machining in smart.Turn
    • Reference data, nested contours
    • Representation of the ICP elements in the smart.Turn program
  • 5.12 Face contours in smart.Turn
    • Reference data for complex face contours
    • TURN PLUS attributes
    • Circle on face
    • Rectangle on face
    • Polygon on face
    • Linear slot on face
    • Circular slot on face
    • Hole on face
    • Linear pattern on face
    • Circular pattern on face
  • 5.13 Lateral surface contours in smart.Turn
    • Reference data of lateral surface
    • TURN PLUS attributes
    • Circle on lateral surface
    • Rectangle on lateral surface
    • Polygon on lateral surface
    • Linear slot on lateral surface
    • Circular slot on lateral surface
    • Hole on lateral surface
    • Linear pattern on lateral surface
    • Circular pattern on lateral surface
  • 5.14 Contours in the XY plane
    • Reference data in XY plane
    • Starting point of contour in XY plane
    • Vertical lines in XY plane
    • Horizontal lines in XY plane
    • Line at angle in XY plane
    • Circular arc in XY plane
    • Chamfer/rounding arc in XY plane
    • Circle in XY plane
    • Rectangle in XY plane
    • Polygon in XY plane
    • Linear slot in XY plane
    • Circular slot in XY plane
    • Hole in XY plane
    • Linear pattern in XY plane
    • Circular pattern in XY plane
    • Single surface in XY plane
    • Centric polygon in XY plane
  • 5.15 Contours in the YZ plane
    • Reference data in YZ plane
    • TURN PLUS attributes
    • Starting point of contour in YZ plane
    • Vertical lines in YZ plane
    • Horizontal lines in YZ plane
    • Line at angle in YZ plane
    • Circular arc in YZ plane
    • Chamfer/rounding arc in YZ plane
    • Circle in YZ plane
    • Rectangle in YZ plane
    • Polygon in YZ plane
    • Linear slot in YZ plane
    • Circular slot in YZ plane
    • Hole in YZ plane
    • Linear pattern in YZ plane
    • Circular pattern in YZ plane
    • Single surface in YZ plane
    • Centric polygons in YZ plane
  • 5.16 Loading existing contours
    • Integrating cycle contours in smart.Turn
    • DXF contours (option)
• Graphic simulation
  • 6.1 Simulation mode of operation
    • Using the graphic simulation
    • The miscellaneous functions
  • 6.2 Simulation window
    • Setting up the views
    • Single-window view
    • Multiple window view
  • 6.3 Views
    • Traverse path display
    • Tool depiction
    • Material-removal graphic
    • 3-D view
  • 6.4 The zoom function
    • Adjusting the visible section
  • 6.5 Simulation with mid-program startup
    • Startup block with smart.Turn programs
    • Mid-program startup in cycle programs
  • 6.6 Time calculation
    • Showing the machining times
  • 6.7 Saving the contour
    • Saving the generated contour in the simulation
• Tool and technology database
  • 7.1 Tool database
    • Tool types
    • Multipoint tools
    • Tool life management
  • 7.2 Tool editor
    • Tool list
    • Editing the tool data
    • Tool texts
    • Editing multipoint tools
    • Editing tool-life data
    • Manual change systems
  • 7.3 Tool data
    • General tool parameters
    • Standard turning tools
    • Recessing tools
    • Thread-cutting tools
    • Twist drills and indexable-insert drills
    • NC center drill
    • Centering tool
    • Counterbore
    • Countersink
    • Tap
    • Standard milling tools
    • Thread milling tools
    • Angle cutters
    • Milling pins
    • Touch probes
  • 7.4 Technology database
    • Technology editor
    • Editing a workpiece material or cutting material list
    • Displaying/editing cutting data
• Organization mode of operation
  • 8.1 Organization mode of operation
  • 8.2 Parameters
    • Parameter editor
    • List of user parameters
    • Machining parameters (processing)
    • General settings
    • Thread cutting
  • 8.3 Transfer
    • Data backup
    • Data exchange with TNCremo
    • External access
    • Connections
    • Ethernet interface (with software 548328-xx)
    • Ethernet interface (with software 54843x-xx)
    • USB connection
    • Data transfer options
    • Transferring programs (files)
    • Transferring parameters
    • Transferring tool data
    • Service files
    • Creating a data backup file
    • Importing NC programs from predecessor controls
  • 8.4 Service pack
    • Installing a service pack
• Tables and overviews
  • 9.1 Thread pitch
    • Thread parameters
    • Thread pitch
  • 9.2 Undercut parameters
    • DIN 76—undercut parameters
    • DIN 509 E – undercut parameters
    • DIN 509 F – undercut parameters
  • 9.3 Technical information
  • 9.4 Compatibility in DIN programs
    • Syntax elements of the MANUALplus 620
• Overview of cycles
  • 10.1 Workpiece blank cycles, single cut cycles
  • 10.2 Turning cycles
  • 10.3 Recessing and recess-turning cycles
  • 10.4 Thread cycles
  • 10.5 Drilling cycles
  • 10.6 Milling cycles