START-UP & UPGRADE GUIDE

Transcription

1 START-UP & UPGRADE GUIDE SIEMENS AG A&D MC RD5 Applies to SINUMERIK 810/840D Software Version / Page 1 of 17

2 1 Prerequisites for Upgrade Back-up General prerequisites for upgrade Software upgrade with MMC Prerequisites Back-up of NC data with MMC Software upgrade with MMC 103 / PCU Back-up with MMC 103 or PCU Software replacement within a software series CCU Upgrade from CCU 1 to CCU Upgrade from CCU 2 to CCU General Information General restrictions Software version display Frames Series start-up file Series start-up with MMC 103 software version lower than Limitation of the number of axes and channels... 8 DMP modules Alarm "Orientation axes configured incorrectly" Alarm , on the 810D with CCU NCU / PLC 6FC CF00-0AB PLC operating system version PLC toolbox Alarm Program preprocessing General Conditions PLC memory configuration display Upgrade in case of channel axis gaps Auxiliary functions in the OB Synchronous spindle Coupled-axis groupings NCU Link Gantry axes Closed-loop control module Performance Transmit Memory management Loadable compile cycles New Functions Compressor Tool management Handling of the buffer memory for turret Master toolholder / master spindle Intermediate gears Curve tables Synchronous spindles Disable synchronization Knee-shaped acceleration characteristic Page 2 of 17

3 7.6 Neue Variablen Gantry Overlaying of movements in case of transformations Temperature compensation Tool offset by means of handwheel Online tool length offset Programmable slave axis dynamic response D circumferential milling with limiting surfaces Collision monitoring on inside contours (CDON, CDOF) Reset delay Master / slave linkages Programmable search path for subprogram calls Initialization of data Block change at RTLIOF / IPOBRKA Automatic IPO buffer control Deselect REPOS motion Master value linkage Actual-value linkage Virtual master axis Changes of export restrictions Output specifications of predefined auxiliary functions Execute string as part program line Adjustable feed for approach PLC series start-up file Functional Improvements from Version to Page 3 of 17

4 The following is a description of a software upgrade of the SINUMERIK System 810D, CCU 3 / 840D for the new product version / (NCK / ). 1 Prerequisites for Upgrade System software Export versions Order number Designation... on PC card For hardware 6FC5250-6PX10-4AH0 NCU system software 2 axes NCU 561.2, FC5250-6BX10-4AH0 NCU system software 6 axes NCU 571.2, FC5250-6DY30-4AH0 NCU system software 2 axes NCU *.4 6FC5250-6CY30-4AH0 NCU system software 6 axes NCU *.4 6FC5250-6BY30-4AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4 6FC5250-6AY30-4AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4 6FC5450-6AY03-4AH0 CCU system software CCU 3 Standard versions (subject to export restrictions) Order number Designation... on PC card For hardware 6FC5250-6CX30-4AH0 NCU system software 6 axes NCU *.4 6FC5250-6BX30-4AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4 6FC5250-6AX30-4AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4 6FC5450-6AX03-4AH0 CCU system software CCU 3 Note: Software version has been prepared for the NCU and NCU (cf. Section 4.6). Tools - 6FC5260-2FX10-2AG3: SINUCOPY-FFS update on CD-ROM, V To program the PC card, SINUCOPY-FFS must be used as of software version FC5252-6AX21-4AG0 :Toolbox V with PLC basic program (available soon) The PLC basic program of Toolbox cannot be used. An upgrade is not always required. - PG/PC with STEP7 from Version 5.0 and optional online MPI link. - Current documentation for SW 6 with additional function-related information 2 Back-up 2.1 General prerequisites for upgrade Prior to an NCK upgrade, it must be ensured that a minimum of 50KB of dynamic memory per channel is available. This can be verified in MD18050 INFO_FREE_MEM_DYNAMIC. If less memory is available, additional memory must be provided by extending MD18210 USER_MEM_DYNAMIC. If this is not possible, a higher performance CPU must be used, or unused memory must be released. The machine data, which are identified in the list as D-RAM, are suitable for this purpose. An additional 50KB of static memory should be available. This can be verified via MD18060 INFO_FREE_MEM_STATIC. If the available memory is insufficient, the unloading of NC programs can make more memory available. Set the machine data UPLOAD_MD_CHANGES_ONLY = FF, INI_FILE_MODE = 1 or 2. Page 4 of 17

5 2.2 Software upgrade with MMC Prerequisites RS232C connection between MMC and PG or PC Back-up of NC data with MMC Select start-up data from the Data Out menu in the Services operating area. Back up NCK data in the archive format on the PG/PC separately from the PLC data via RS-232-C on PG/PC. Note: Compensation data will not be backed up with the series start-up. The compensation data can be backed up separately on an external PC in the Services area via "SK Data Out SK Data" and selection of the sections "Interpolatory compensation", "Circle error compensation" and "Leadscrew error compensation". (Once the upgrade of the NCU is completed, these data can be reloaded into the NCK (Services area, "Softkey Data In" --- MD CEC_ENABLE or ENC_COMP_ENABLE of the respective axes has the value "0"). 2.3 Software upgrade with MMC 103 / PCU Back-up with MMC 103 or PCU 50 NCK Prior to the NCK upgrade, a back-up must be performed in order to permit the recovery of the machine's current database. This can be done by performing a series start-up. To create the series start-up file, it is necessary to set the manufacturer password and to unload a tool in the spindle or buffer storage. Now the archive content of the file to be created can be defined in the menu Services/Series start-up/start-up archive/ (selection: NC with compensations). Once the archive name has been defined, the back-up is started via the Archive softkey. Now all necessary data (compensations, tools, definitions, loaded programs, machine data, etc.) are saved in the Archives path. PLC In addition to the NCK back-up, a PLC back-up must be created. This back-up must be performed with the PLC in Stop state. Set S4 on the NCU module to position 2. This will switch the PLC to Stop state. The PLC series start-up is made in the same manner as the NCK back-up after selecting the data (selection: PLC) through the Archive softkey. If it is necessary to upgrade the PLC basic program, this will require STEP7. For this purpose, the new toolbox must be installed via SETUP. In addition, the customer project of this system is required. The required blocks are transferred from the new toolbox library to the customer project (or a copy). In this process, the OBs, FC12 and DB 4 must not be transferred (these are the blocks for a new creation of a user program), because they have been modified by the machine manufacturer. Then the blocks must be transferred to the PLC. A new PLC series start-up file must be created Software replacement within a software series Replacing the software Switch off the control and replace the PC card. The card remains in the control (regardless of the type of the SINUMERIK 810D/840D). Set switch S3 to position 1, set S4 to position 3 and switch the control on. Once the start-up is completed, the state "7-segment display shows the digit 6 / PLC LED PS flashes / PF red" is established. The NC standard machine data have now been loaded. NC and PLC are cleared. PLC start-up is then made through the sequence of S4 from position 3 to position 0 => S4 in position 3 => S4 in position 0. Now the PLC must switch to the Run mode. Set S3 to position 0. The software version can be verified in the menu Diagnostics/Service displays/version. Page 5 of 17

6 Loading the back-ups Once the manufacturer password has been set, the NCK back-up can be loaded in the menu Services/Series start-up/load start-up archive/ after selecting the back-up file. Once completed, the PLC back-up can be loaded. When the PLC back-up has been loaded, the system must be switched off/on in order to achieve the simultaneous start-up of all components. 3 CCU Upgrade from CCU 1 to CCU 3 - NC back-up CCU 1 The drive boot files must be saved in ASCII format, so that they can be loaded with the CCU 3. For this purpose, an upgrade archive should be created using the setting "$MN_UPLOAD_MD_CHANGES_ONLY=FF". - Standard start-up CCU 3 After the standard start-up of the CCU 3, the value of the MD18210 $MN_USER_MEM_DYNAMIC should be noted. - Load upgrade archive A name change has been made with drive machine data This is why the following message is generated when the upgrade archive is loaded: Drive x: Line x: Entry not found in ACC file: N1254 $MD_SPACE_VECTOR_FILTER_TIME NOTICE: MD 1254 is preset with defaults. The back-up must be used to check if the value has been changed from the default (0.5 ms). - DRAM expansion After loading of the upgrade archive, the MD $MN_USER_MEM_DYNAMIC should be set to the default value of the CCU 3. - Essential changes in the default machine data CCU 1 CCU 3 MD10072=1 MD10134=3 MD28070=30 MD28520=1 MD10072=0.5 MD10134=6 MD28070=38 MD28520=3 3.2 Upgrade from CCU 2 to CCU 3 Due to the fact that the SRAM memory expansion with the CCU 2 is not defined via option data, memory problems may occur during an upgrade of a CCU 3 with a series start-up file of the CCU 2. For the CCU 3, the SRAM memory that deviates from the basic configuration (768KB) is defined by options. For this reason, part programs need to be unloaded from the CCU 2 before the series start-up is created, in order to ensure that the series start-up can be loaded properly. If it is not possible to reload all programs, memory options must be upgraded. Page 6 of 17

7 Note: The CCU 3e software can be flashed. The flash operation is indicated by the digit 8 on the 7- segment display and takes about 2 minutes. The end of the flash operation is indicated by the digit 9. 4 General Information 4.1 General restrictions - The function G643 (Approximate positioning in block) is released for applications in the tool change area (e.g. optimizations when approaching the tool change position). It is not released for applications in the machining process. - The functions FCUB, FLIN in combination with the compressor COMPCAD are not released. - The ProfiSafe function is not released. - The shutdown of the PCU 50 via the EXIT button is only permitted in the Emergency STOP state. - With the NCU 573.3, it is no longer possible to enable 10 channels and 31 axes at the same time. The number is limited to eight channels. - With the NCU / Version A / 571.2, the number of channels is limited to 1. - With the NCU 572.3, 31-axis SW, the number of channels is limited to Software version display The display of the NCK software version in the diagnostic display (header) and the machine data have been changed in compliance with the NC catalog. Example: D 06A.. 65 ph_km This is the software for 6 axes (06A). This software runs on the NCU The reference to the hardware must no longer be established via the diagnostic display, but indirectly via the number of axes (refer to item 1). Version displays with the addition PRELIMINARY instead of the MLFB designate software that is only provided for test purposes. 4.3 Frames If $MC_MM_SYSTEM_FRAME_MASK bit 1 = 1, the external work offset is disabled by G153. This response has been changed compared to other SW 6 versions The default setting of $MC_CHSFRAME_POWERON_MASK has changed. The default setting of MD24008 is now zero (formerly "1"). This means that the system frame for scratching will be retained even after power ON / Reset. 4.4 Series start-up file The series start-up makes it possible to start up machines of the same design quickly and easily. This machines must be identical both in terms of the electrical equipment (e.g. NCU CPU, software) and mechanical conditions. If this match does not exist, the series start-up is not necessarily an adequate start-up procedure. In this case, a different back-up procedure (e.g. separate back-up with Initial.ini etc.) must be used, because it may be necessary to adjust machine data. Particular attention must be paid to the memory limits that are different for the NCUs. If these are exhausted, memory bottlenecks can occur after an upgrade of the NCK software or the replacement of an NCU. Before the back-ups are performed, the machine data $MN_UPLOAD_MD_CHANGES_ONLY must be verified. It should be preset with the value "0" or "FF"hex. Other values such as "1" can cause problems with the restoring of the back-up after a software upgrade. The preferred value is FFhex. Page 7 of 17

8 4.5 Series start-up with MMC 103 software version lower than 5.3 If a series start-up is created with NCK SW versions higher than NCK , the user cycles are also integrated twice. As of NCK software version , the NC has a new directory CMA_DIR (cycles for machine manufacturers). The MMC does not yet know this directory (only from MMC version 5.3) and saves the user cycles a second time. Therefore, when the series start-up file is loaded, a message File exists, overwrite yes/no is generated for the user cycles. The user cycles already exist and need not be overwritten. 4.6 Limitation of the number of axes and channels As from software version , the various software designs (version with 2 axes to version with 31 axes) can be used on all NCUs of type nnn.4. The limitation of the number of axes and channels still applies, but it does no longer limit the maximum settable number of machine axes or channels. It is thus possible, that a 10 th machine axis exists with a 6-axes software, if the total number of physical axes does not exceed 6. DMP modules The number of axes including the DMP modules is limited to 31. If e.g. a DMP module is used for a 31- axis software, a total of 30 axes are still possible 4.7 Alarm "Orientation axes configured incorrectly" This alarm is output if the assignment of orientation axes to the machine kinematics is not correct. However, this alarm is also output if there is no position measuring system active on one of the axes carrying out the transformation. 4.8 Alarm , on the 810D with CCU 3 The software upgrade on a Sin810 with CCU 3 and external axis expansion plug-in unit must be carried out by means of the upgrade archive. Otherwise it is possible that the above-mentioned alarms for the external controllers are output. 5 NCU / PLC 6FC CF00-0AB0 With the NCU / 573.4, a new PLC on the basis of the IBC16 chip is implemented. The SINUMERIK order number of the PLC 6FC CF00-0AB0 corresponds to the SIMATIC order number 6ES CF00-0AB0 Prerequisites for upgrade - STEP7 Version 5.1 Service Pack 2, Hotfix 3 or STEP7 on HMI Version 5.1 with Service Pack 3 - NCU Software Version >= or >= PLC Firmware Version Toolbox PLC Basic Program or >= HMI Advanced Version >= , or HMI Embedded Version >= If PLC projects shall be reused with S7 hardware configurations, the PLC hardware configuration must be newly created. This requires the integration of the PLC CPU 314C-2DP into the hardware configuration (from the toolbox). Page 8 of 17

9 Changes as compared to PLC 315-2DP - Performance is by a factor of about 3 faster - User memory 480KB - 32 PROFIBUS slaves timers counters 5.2 PLC operating system version If the software version >= is used with a NCU or 573.4, the use of the PLC operating system version is mandatory. Version is not able to run and must be replaced with the above version during the upgrade. 5.3 PLC toolbox Hardware configuration: The SINUMERIK components are now located in a separate "SINUMERIK" folder. With the previous versions, they are still in the "Rack 300" folder. This toolbox is required for the configuration of the NCU 573.4, because the hardware catalog for the PLC of the NCU (S7 PLC 314-C-2DP- 6CF00) has changed. 5.4 Alarm 4185 Auxiliary function allocations that did not become effective and have not been rejected by an alarm are now recognized. Alarm 4185 is issued in this case. 5.5 Program preprocessing When the program preprocessing function is used, the alarms "Program compilation not possible" and "Saving compiled program not possible" are reported after an upgrade to SW 6.4. Cause: With SW 6.4, the compiled program is no longer saved in the SRAM, but rather in the DRAM. However, this requires that sufficient DRAM memory is reserved via MD $MN_MM_DRAM_FILE_MEM_SIZE. However, it is still possible to save the compiled program in the SRAM in case of insufficient DRAM memory. This requires $MN_PREPROCESSING_LEVEL, bit 6 to be set. 6 General Conditions 6.1 PLC memory configuration display The memory configuration display under S7 is not correct. The user is guaranteed 480KB of loading memory. It is possible to exceed this limit, i.e. to continue to use memory. However, this can cause problems when the PLC series start-up file is loaded. Message: Memory full. 6.2 Upgrade in case of channel axis gaps If the channel axis definition contains gaps, and if an upgrade is made from a software version lower than to Version 6, the work offsets must be entered by hand, or the series start-up files must be loaded again without clearing the NC. 6.3 Auxiliary functions in the OB40 In the following combination, it may happen that auxiliary functions are temporarily not recognized in the PLC: H/T function evaluation in OB40 (Parameter IRAuxfuT/H =true of FB1) Page 9 of 17

10 In the part program: m=qu(55) h2=33 The H function is temporarily lost. Remedy: Program m Synchronous spindle If the synchronous spindle linkage is enabled while the master spindle is in an acceleration phase, the slave spindle will accelerate at a higher rate than specified in the MD. Alarms such as contour monitoring can occur If the synchronous spindle linkage is enabled, all spindles involved must be released. If this is not the case, a position offset between the master spindle and the slave spindle can occur during positioning in synchronous spindle mode. 6.5 Coupled-axis groupings When coupled-axis groupings are enabled via synchronized actions or across all channels, the user must ensure that the control parameters (e.g. acceleration, speed) of the slave axis are observed. No verification is made in the NC in such cases. 6.6 NCU Link If NCUs are interconnected via the Link function, NCUs of the same type (order number) must always be used. If it is desired to configure a link connection with different interpolation cycles, the system clock cycles in both systems must be identical. Otherwise, an alarm 4013 with the error ID SYSCLOCK_SAMPLE_TIME_RATIO will occur. Exception: It should be noted that processors with different cycles are used with the NCU 573. If, in case of service, a module can only be replaced with a faster NCU, the slower NCU must be the master. It is not always necessary to replace all NCUs. NCU Order No. (component) Component material No FC5357-0BB33-0AE1 GWE FC5357-0BB33-0AE2 GWE FC5357-0BB34-0AE0 GWE Processor Pentium II 266MHz X200 MCE4 MOD PENTIUM II 266MHz PLC PLC 315-2DP Pentium III 500MHz PLC 315-2DP X200 MOD MIKROPR PENTIUM II 500MHz MMC-2 5V Pentium III 500MHz PLC 314C-2DP X200 MOD MIKROPR PENTIUM II 500MHz MMC-2 5V 6.7 Gantry axes If the slave axis of the gantry grouping has an inverse direction of rotation (AX_MOT_DIR=1), the use of the function generator (square-wave) is not permitted. 6.8 Closed-loop control module Performance 2 Mixed operation using the new Performance 2 measuring circuit module and older closed-loop control modules is possible. However, the Tool SinuComNC will be required for start-up. Page 10 of 17

11 6.9 Transmit System errors can occur during active Transmit and pole processing. Since Transmit is not required for pole processing, it can be disabled Memory management For the 12/31-axis software, the option check was not active due to the compiler switch 'ncu3'. The option is checked again. The default of the available SRAM memory is 0.5MB for NCU 2 and 2.5MB for NCU Loadable compile cycles A maximum of ten loadable compile cycles can be loaded. This also includes libraries with the file extension???.elf. Loading more than one technological function can lead to incorrect value allocations. This can happen if loadable compile cycle applications do not organize their machine data by ascending consecutive numbers within the three areas of NCK, channel and axis MD. During the loading of a correct archive, it can happen that the contents of individual CC machine data overwrite each other. 7 New Functions 7.1 Compressor Orientations that are programmed independent of the kinematics by means of direction vectors (or Euler or RPY angles) are compressed. 7.2 Tool management Handling of the buffer memory for turret The tool change command on the PLC is additionally provided with the two new data Owner magazine address/magazine location address of the new tool. Using these data, the PLC is able to safely position the tool turret Master toolholder / master spindle The value defined via the commands SETMTH/SETMS is retained beyond the end of the program. 7.3 Intermediate gears In addition to the firmly configured motor/load transmission ratios, variably programmable intermediate gears can also be implemented, like they are used e.g. for interfacing driven tools. Switchover between the motor/load gear and the load intermediate gear is possible in any position. To permit a new referencing without an interrupting reset, the machine data $MA_REFP_MOVE_DIST and $MA_REFP_MOVE_DIST_CORR were also changed to become effective with NewConfig. 7.4 Curve tables With software version 6.3, the commands CTABSSV and CTABSEV to read the start value or end value of a curve table segment of the slave axis were introduced. In addition, more commands for the diagnostics of axis linkages and curve tables have been introduced. 7.5 Synchronous spindles Disable synchronization The interface signal DB[axis].DBX31.5 permits disabling of the synchronization of the slave spindle. Page 11 of 17

12 7.5.2 Knee-shaped acceleration characteristic Spindle motors usually have a speed-dependent acceleration capability. For this reason, the setpoint acceleration must be reduced starting at a specific speed. 7.6 Neue Variablen - $P_CHANNO, type INT Scan of current channel number - $AA_TOFF[ GeoAx], type REAL Position offset in tool coordinate system - $AA_TOFF_VAL[ GeoAx], type REAL Integrated position offset in tool coordinate system - $AA_TOFF_PREP_DIFF[ GeoAx] $AA_TOFF_PREP_DIFF[ ] can be used to determine, depending on the direction, the difference between the currently effective value of $AA_TOFF[ ] and the value when the current motion block was prepared. - $VA_EG_SYNCDIFF_S[a], type DOUBLE Signed synchronism difference with ELG (a = slave axis) - $AC_TANEB, type DOUBLE Angle between the 3D path tangent at the end point of the current block and the 3D path tangent at the start point of the following block - $AC_TOOLO_ACT[i], i = 1, 2, 3, type REAL i-th component of the vector of the current setpoint tool orientation - $AC_TOOLO_END[i], i = 1, 2, 3, type REAL i -th component of the vector of the tool end orientation of the current block - $AC_TOOLO_DIFF, type REAL Residual angle in degrees, i.e. the angle between the vectors $AC_TOOLO_END[i] and $AC_TOOLO_ACT[i]. - $VC_TOOLO[i], i = 1, 2, 3, type Real i th component of the vector of the actual tool orientation - $VC_TOOLO_DIFF, type Real Angle in degrees between the setpoint and actual tool orientation - $VC_TOOLO_STAT, type INTEGER Status variable for actual tool orientation 7.7 Gantry Modulo rotary axes can be linked in a gantry grouping. It is thus possible that both axes (master and slave axis) are modulo rotary axes or that only one axis (either the master or slave axis) is a modulo rotary axis. 7.8 Overlaying of movements in case of transformations With the orientation transformation active, it is possible to overlay a programmed movement with other movements in real time, with the direction of such movements depending on the current tool orientation Temperature compensation With this function, the temperature compensation values are no longer allocated to the machine axes, but rather to the tool. This permits the compensation of changes due to expansion, like they can occur in 5- axis heads (e.g. longitudinal expansion of the tool spindle) and are included in a rotation of the tool orientation Tool offset by means of handwheel With this function, the handwheel override acts in the direction of the tool, i.e. when the tool orientation is changed, the applied handwheel override is also rotated. For this reason, the tool length can be reduced or enlarged in real time, so that e.g. a given part to be machined in five axes can be (approximately) machined with an adjustable allowance. The tool offset by means of the handwheel is enabled by setting the machine data $MC_TOOL_OFFSET_DRF_ON to a value not equal to zero. Page 12 of 17

13 7.8.3 Online tool length offset The online tool length offset is used to change the effective tool lengths in real time so that these length changes are also considered in tool orientation changes. It is thus possible to machine e.g. a workpiece to be machined in 5 axes, for which a finishing program is available, (approximately) with a roughing allowance. If the tool is not perpendicular to the workpiece surface during machining or if the contour includes curves whose radii are smaller than the offset dimension, deviations from the actual offset surface will result. The creation of accurate offset surfaces is not possible with tool length offset alone. Tool length offsets are applied via a new synchronized action variable $AA_TOFF[ ]. This is a 3- dimensional variable, corresponding to the three tool directions. The geometry axis designators are used as an index. Only so many offset directions can be active as there are active geometry axes. All offsets can be active at the same time. The online tool length offset function is applicable to: - Orientation transformations (TRAORI ) - Orientable tool carriers (TCARR ). 7.9 Programmable slave axis dynamic response The axis dynamic response and the acceleration performance of the slave axis can be influenced by the part program. The programmed offset values are effective in the TANG, TRAIL, LEAD, COUP and ELG linkage modes. For the dynamic offset values (VELOLIMA, ACCLIMA, JERKLIMA), it is not distinguished where they are applied. Programmed dynamic offsets that are made in a part program, also influence the slave axes whose linkage was activated in synchronized actions. In turn, dynamic offsets that are set in synchronized actions will also influence linkages from a part program D circumferential milling with limiting surfaces For circumferential milling, the radius-dependent insertion depth for limiting surfaces has been optimized. NC programs generated by CAD systems usually approximate the center-point path of a standard tool. The CNC must correct the original contour for other tools. The G codes CUT3DCC and CUT3DCCD have been introduced for this purpose. - CUT3DCC: 3D circumferential milling while considering a limiting surface. The NC program describes the contour on the machining surface. - CUT3DCCD: 3D circumferential milling while considering a limiting surface. The NC program describes the center-point path of the standard tool Collision monitoring on inside contours (CDON, CDOF) Expansion of the G-code group 23 with the new G code CDOF2. If this G code is active, no offset value and no offset direction is calculated in blocks or parts of blocks in which the angle between the path direction and the tool orientation is smaller than the limit angle defined with machine data ($MC_CUTCOM_PARALLEL_ORI_LIMIT). Instead, the offset direction is determined from the adjacent blocks in which the offset direction is well defined. For this reason, straight line blocks whose traversing direction is parallel to the tool orientation, are also permitted in this situation, because such blocks are treated as pure dummy blocks. Previously, such blocks resulted in the alarm "Path parallel to tool orientation " Reset delay With the NCU reset via the start-up tool of the HMI, it can happen that vertical axes without counterweight fall slightly due to the response time of the brakes. Now, NC Ready is removed first, followed by the setting of the hardware reset. This makes it possible to apply the brakes before the position control is canceled (through the hardware reset). The delay between Pi-Reset and the actual triggering of the hardware reset can be set via the machine data $MN_REBOOT_DELAY_TIME. Note: This does not work for the pushbutton reset on the NCU module, because this is hardwired. Page 13 of 17

14 7.13 Master / slave linkages The functionality of the master/slave linkage has been expanded with new applications. - Linkage and separation of rotating, speed-controlled spindles - Dynamic configuration of linkages 7.14 Programmable search path for subprogram calls Subprograms that have been stored outside the standard search path, e.g. in a different workpiece directory, need no longer be called up with the absolute path indication. To make this possible, the part program command CALLPATH is introduced. As a parameter, a string (constant or variable) is specified to indicate the directory by which the standard search path is expanded. Example: CALLPATH( /_N_WKS_DIR/_N_MYWPD_WPD ) 7.15 Initialization of data For the global use of data in part programs, it is possible to automatically initialize variables by assigning variables. In this manner, data can be preassigned defaults as a function of specific machine situations. This applies to variables of the following types: GUD, R parameters, setting data, synchronized action variables. Example: Attribute: REDEF (variable) INIPO 2: INIT on power ON Here, the data are overwritten with the default 2 during the buffered restart of the NC Block change at RTLIOF / IPOBRKA IPOBRKA has been provided with an additional criterion for the release of the block change. The release is made only when the respective axis has reached the programmed value x (in per cent of the braking ramp) and its current actual or setpoint position is not more than one tolerance away from the end position of the block Automatic IPO buffer control The automatic IPO buffer control is used to avoid the stop&go operation caused by block cycle problems in favor of a more consistent path speed. It is enabled by the modal G code FIFOCTRL. There are no machine data or other parameters. As long as the function is not disabled by STARTFIFO or STOPFIFO, it will attempt to move with as consistent an average speed as possible Deselect REPOS motion The PLC interface signal DB[axis].DBX.10.0 = true makes it possible to prevent the REPOS motion for positioning axes (not for geo or orientation axes!). The function is enabled with $MN_REPOS_MODE_MASK (BIT-7) = Master value linkage Actual-value linkage With actual-value linkage, a systematic position offset is created between the master and the slave axis. The reason for this is the IPO/position controller dead time which lies between the actual value of the master axis and the actual value of the slave axis. From SW version 6.4, the position offset is compensated by this dead time through a linear extrapolation of the master value. Page 14 of 17

15 Virtual master axis The use of a virtual master axis will cause a position offset between the master and the slave axis. The cause for this is a delay in the processing of the actual value of a virtual axis. The servo provides the actual value to the IPO, which uses this value to calculate a setpoint value as the input variable for the master value linkage. Contrary to this, the slave axis is interpolated in the NCK, i.e. the setpoint for the servo is what causes the approach of the actual position. This means that the master and slave axis positions have an age difference of 3 IPO cycles. For a 1:1 linkage, the following offset is created: delta = 3 * path per IPO cycle delta = 3 * path per IPO cycle - 1 * path per servo cycle delta = 3 * path per IPO cycle + (V)^2 / (2 * A) ; Simulated master value linkage Actual value linkage Setpoint value linkage V: Speed of the master axis A: max. acceleration of the slave axis delta: Position of master axis - Position of slave axis The offset can be corrected in synchronized actions, but requires additional programming effort as well as the knowledge of the delay times with the user Changes of export restrictions The export versions of the NCU system software from SW version 6.4, take the changed export regulations according to export list position AL: 2D002 into account. In the export versions, only functions are still disabled that would allow "... to simultaneously coordinate more than 4 interpolating axes for path control". The previous restrictions relating to real-time machining have been eliminated. The following features are now available in the export versions with full/limited functionality: - Continuous dressing (basic version) - Synchronized actions (basic version) Restriction: Only up to 4 axes! - Synchronized actions Level 2 (6FC5251-0AD05-0AA0) Restriction: Only up to 4 axes! - Evaluation of internal drive variables (6FC5251-0AB17-0AA0) - Measurement Level 2 (6FC5250-0AD00-0AA0) 7.21 Output specifications of predefined auxiliary functions Auxiliary functions can be configured with respect to their output time. Previously, it was only possible to preset the output time for a group. With the new machine data, it is possible to explicitly specify the output times for specific predefined auxiliary functions. The following output times can be set: - Acknowledgement normal after an OB1 cycle - Acknowledgement quick with OB40 - No output to VDI - Spindle response after acknowledgement - Output before motion - Output during motion - Output at end of block The output specifications have the following weights, in the order given below: Page 15 of 17

16 $MC_AUXFU_PREDEF_SPEC[ index ] $MC_AUXFU_GROUP_SPEC[ grpindex ] $MC_AUXFU_(M,S,T,H,F,D,DL)_SYNC_TYPE Therefore, the predefined output specifications will always apply for the predefined auxiliary functions. Notes: From SW 6.4, spindle M functions (e.g. M3/M4/M5) are always output before the traversing motion, even if the MD $MC_AUXFU_M_SYNC_TYPE=1 (output during motion). However, the output time of the spindle M functions can be adjusted in the MD $MC_AUXFU_PREDEF_SPEC. - It is not possible to overwrite the predefined auxiliary functions via the configuration of user-defined auxiliary functions. An attempt to do so will e.g. generate the alarm 4185 Channel K1 invalid configuration of an auxiliary function SM I1 S5. This alarm is also output if invalid auxiliary function groups have been defined. This was not monitored in software versions lower than < Example: M3 stored in 5 th auxiliary function group, although only 2 nd group is allowed here. - The spindle auxiliary functions M1=40 through M1=45 are now always assigned to the 4 th auxiliary function group (see MD $MC_AUXFU_PREDEF_GROUP). - For the programming of M40 through M45, the address extension of the master spindle will automatically be output at the interface from SW Execute string as part program line The part program command EXECSTRING is used to design the type of part program command in a variable manner. The command is passed a string as a parameter, which contains the actual part program line to be executed. The part program command EXECSTRING is programmed in a separate part program line. Example: N110 DEF STRING [10] MFCT1 = M7 N200 EXECSTRING(MFCT1 << M4711 ) ; execute part program line M7 M Adjustable feed for approach With an active G95, a program stop due to a stopped spindle can occur after a block search or ASUP call. The MD42120 $SC_APPROACH_FEED now permits to set a feed for these approach motions PLC series start-up file It is possible to create PLC series start-up files in HMI format under STEP7. 8 Functional Improvements from Version to BRKdb07084 ERLde48656 ERLde51798 ERLde52856 ERLde53600 ERLde56504 BRKdb07376 ERLde48804 ERLde51802 ERLde52857 ERLde53669 ERLde56700 BRKdb07420 ERLde49122 ERLde51816 ERLde52862 ERLde53698 MGLdm00017 BRKdb07445 ERLde49254 ERLde51886 ERLde52873 ERLde53844 MGLdm00124 BRKdb07572 ERLde49259 ERLde52095 ERLde52897 ERLde53850 MGLdm00290 BRKdb07608 ERLde49319 ERLde52124 ERLde52900 ERLde53972 MGLdm00302 BRKdb07609 ERLde49350 ERLde52156 ERLde52901 ERLde53976 MGLdm00306 Page 16 of 17

17 BRKdb07631 ERLde49604 ERLde52168 ERLde52925 ERLde54005 MGLdm00316 BRKdb07757 ERLde49633 ERLde52206 ERLde52969 ERLde54013 MGLdm00337 CHMdc07677 ERLde49646 ERLde52250 ERLde52971 ERLde54155 MGLdm00362 CHMdc07866 ERLde49934 ERLde52307 ERLde52980 ERLde54194 MGLdm00374 ERLde28201 ERLde50081 ERLde52375 ERLde52995 ERLde54263 MGLdm00395 ERLde32537 ERLde50113 ERLde52488 ERLde53030 ERLde54267 MGLdm00418 ERLde39716 ERLde50443 ERLde52493 ERLde53052 ERLde54333 MGLdm00453 ERLde39717 ERLde50785 ERLde52495 ERLde53056 ERLde54361 MGLdm00454 ERLde40113 ERLde50855 ERLde52498 ERLde53057 ERLde54387 MGLdm00486 ERLde40259 ERLde50883 ERLde52514 ERLde53086 ERLde54458 MGLdm00490 ERLde40811 ERLde50974 ERLde52528 ERLde53125 ERLde54459 MGLdm00492 ERLde42175 ERLde50997 ERLde52540 ERLde53189 ERLde54468 MGLdm00493 ERLde42720 ERLde51053 ERLde52583 ERLde53244 ERLde54584 MGLdm00498 ERLde43278 ERLde51272 ERLde52590 ERLde53246 ERLde54611 MGLdm00505 ERLde43394 ERLde51394 ERLde52706 ERLde53259 ERLde54797 MGLdm00512 ERLde43449 ERLde51395 ERLde52735 ERLde53266 ERLde54869 MGLdm00515 ERLde43805 ERLde51460 ERLde52755 ERLde53267 ERLde55522 MGLdm00521 ERLde45863 ERLde51554 ERLde52772 ERLde53355 ERLde55696 MGLdm00522 ERLde46495 ERLde51567 ERLde52788 ERLde53399 ERLde55874 MGLdm00533 ERLde47002 ERLde51620 ERLde52807 ERLde53423 ERLde55969 SWBds04771 ERLde47355 ERLde51632 ERLde52808 ERLde53451 ERLde56026 ERLde47735 ERLde51652 ERLde52818 ERLde53486 ERLde56036 ERLde47858 ERLde51752 ERLde52842 ERLde53529 ERLde56404 Page 17 of 17