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1 67$5783$1'83*5$'(,16758&7,216 SIEMENS AG A&D MC E5 )RU 6,180(5,.'6RIWZDUH9HUVLRQ Page 1 of 12

2 3UHUHTXLVLWHVIRUWKHXSJUDGH 'DWDEDFNXS 2.1 Data back-up with MMC Prerequisites Backing up NC data with MMC Data back-up with MMC 103 / PCU PLC program back-up... 5 *HQHUDOQRWHV 3.1 General limitations Software version display NCU link and axis container Series start-up file Series start-up with MMC 103 software version earlier than Alarm HZRUPRGLILHGIXQFWLRQDOLW\ 4.1 DRF with transverse axis Deselecting the DRF, $AA_OFF offset $AA_OFF in JOG operating mode Block change time adjustable Motion of path axes with G Software cams Gear change in DRY RUN and program test Gear change in synchronized action or with FC Rapid lift Electronic gears Extended stopping and retracting (ESR) Overlaid movements with orientation transformations Involute interpolation Fifth order polynomials Number of wait marks Referencing during correction Block-internal smoothing G643 (not released) Event-driven program calls Tool management Rotary axis positions Selecting exact stop conditions PLC basic program / tool box Tool box FC Machine control panel DRAM Filesystem for cycles archive (option; order number 6FC5251-0AF00-0AA0) NCU Link Master/Slave for Drives... 9 %RXQGDU\FRQGLWLRQV 5.1 Upgrading channel axis spacings Help functions in OB Outputting the F word to the PLC External zero shift for rotary axis in the Inch system Synchronous spindle Repositioning mode Alarm 10794, 10795, Coupled-axis groupings NCU LINK FC18 with active transformation Wait marks Page 2 of 12

3 5.12 Transmit and TRC Sinucopy / Flash File System Parameterization Program test for coupled motion (UURUVFRUUHFWHG Page 3 of 12

4 A software upgrade of the SINUMERIK system 840D from software version 5.3 to the new product release 6.2 is described. 3UHUHTXLVLWHVIRUWKHXSJUDGH 6\VWHPVRIWZDUH ([SRUWFRPSOLDQWYHUVLRQV 6FC5250-6PX10-2AH0: NCU system software 2 axes on PC Card for NCU FC5250-6BX10-2AH0: NCU system software 6 axes on PC Card for NCU FC5250-6BY30-2AH0: NCU system software 12 axes on PC Card for NCU / / FC5250-6AY30-2AH0: NCU system software 31 axes on PC Card for NCU / / ([SRUWUHVWULFWHGYHUVLRQV 6FC5250-6BX30-2AH0: NCU system software 12 axes on PC Card for NCU / / FC5250-6AX30-2AH0: NCU system software 31 axes on PC Card for NCU / / RROV - 6FC5252-6AX21-1AG0: Tool box version with PLC basic program PG/PC with Step 7 and online MPI link feature. - Current documentation for SW 6 'DWDEDFNXS 'DWDEDFNXSZLWK00& 3UHUHTXLVLWHV The following cable connections are required: RS-232 link between MMC and PG/PC for machine/drive data and user data. %DFNLQJXS1&GDWDZLWK00& Select startup data under menu "Data out" in the "Services" area. Back up (single) NCK data in archiving format to PG/PC separately from the PLC data via RS-232 interface. 1RWLFH Compensation data are not saved in the series start-up. The compensation data can be backed up separately to an external PC in the Services area over "SK Data out - SK data" by selecting areas "Compensation with interpolation", "Circle error compensation" and "Leadscrew error compensation". This data can be reloaded in the NCK when the NCU has been upgraded (Services area "Softkey data in" --- MD CEC_ENABLE and ENC_COMP_ENABLE for the axes are set to "0"). 'DWDEDFNXSZLWK00&3&8 Back up the upgrade security file in PC format on the hard disk (softkey: Archive) or an external medium (for example diskette or via RS-232) in the "Services" area with the softkey "Upgrade". Compensating data are saved with the upgrade security file. Furthermore, data from different areas can also be backed up separately in the area "Services / Data management / Programs data / NC active data ". For example: ÕOpen directory "NC active data" ÕSelect directories ÕSoftkey data OUT Page 4 of 12

5 ÕSelect RS-232, diskette or archive on hard disk ÕThe currently saved data are displayed in the window 3/&SURJUDPEDFNXS Create a PLC data back-up in the "Services" area Series start-up with the PLC in the stop state. To upgrade to version 6 a new PLC basic program has to be integrated (GP version 6.1.2). An S7 project must therefore be created with the current PLC program, and the basic program must be integrated in this project. When the project has been created in this manner, it can then be loaded with S7 with the PLC in the stop state. *HQHUDOQRWHV *HQHUDOOLPLWDWLRQV Function G643 "Block internal rounding" is not released Function Master/Slave in combination with torque forward control is not released Function Smoothing of continuous-path speed is not released Functions FCUB, FLIN in combination with COMPCAD are not released. Extended interpolation of orientations is released for test purposes. Generic "Trafo5 Typ40" is not released. Function temperature compensation is the only function from the function package overlaid movements for orientation transformations which is released. 6RIWZDUHYHUVLRQGLVSOD\ The display of the NCK software version in the diagnostics screen (header) and machine data has been changed to correspond with catalog NC60. Example: '$SKBNP This refers to the software for 6 axes (06A). This software can be run on NCU The reference to the hardware should not be established any more over the diagnostics screen, but indirectly over the number of axes instead (see item 1). 1&8OLQNDQGD[LVFRQWDLQHU This function is released for a group of maximum eight NCUs. Please note that the function can only be combined with other functions to a limited extent. The functions in question are realized in the Servo area (for example Gantry, Master Slave). (see also Description of Functions Special Functions) 6HULHVVWDUWXSILOH The series startup allows machines of similar type to be started up quickly and easily. These machines must be similar electrically (for example NCU CPU, software) and mechanically. If these conditions are not met, the series start-up is not necessarily a suitable procedure for startup. In such cases a different procedure for data back-up (for example separate data back-up with Initial.ini etc.) must be used, as machine data may have to be adapted. Particular attention should be given to the different memory boundaries in the NCUs. Should these boundaries be exceeded memory bottlenecks can arise, after an NCK software upgrade or an NCU replacement. 6HULHVVWDUWXSZLWK00&VRIWZDUHYHUVLRQHDUOLHUWKDQ If a series machine start-up is created with NCK SW versions later than NCK , the user cycles are integrated twice. The NC contains a new directory "CMA_DIR" (cycles for machine manufacturers) with NCK software version onwards. The MMC does not recognize this directory yet (up till MMC Page 5 of 12

6 version 5.3): it saves the user cycles two times. The message "File already exists overwrite yes/no" appears for the user cycles when the series machine start-up files are being read. The user cycles already exist, and need not be overwritten. $ODUP Alarm sometimes appears when the control system is switched on. The alarm indicates that one or more files on the NC are incorrect. Searching for these files is very time consuming. NRKDUMP.MPF was often the file in question. Alarm "6693 file%1 is missing" is output now. Should the alarm occur you should notify the hot line and establish which file is missing. Should the file be required for machining, it must be reloaded in the control system. 1HZRUPRGLILHGIXQFWLRQDOLW\ '5)ZLWKWUDQVYHUVHD[LV The machine data $MC_TOOL_PARAMETER_DEF_MASK can be used to define that only half of the path of the defined increment is traversed during a DRF handwheel traverse of a transverse axis. 'HVHOHFWLQJWKH'5)$$B2))RIIVHW The part program instruction CORROF allows an axial deselection of the DRF and position offset because of $AA_OFF. The deselection behavior of $AA_OFF during RESET can now be set with machine data $AA_OFF_MODE. $$B2))LQ-2*RSHUDWLQJPRGH An interpolation of the position offset as a superimposed movement takes place in operating mode JOG when $AA_OFF is altered. The function is enabled with $MA_AA_OFF_MODE. %ORFNFKDQJHWLPHDGMXVWDEOH In addition to the current movement end criterion, a block change can be carried out now within the braking ramp of a single axis interpolation. The setting data $SA_IPOBRAKE_BLOCK_EXCHANGE determines when the block change takes place. 0RWLRQRISDWKD[HVZLWK* Path axes can be moved in two different modes in rapid traverse movements. The path axes are interpolated together, or each path axis traverses as a single axis. Define the mode with $MC_G0_LINEAR_MODE. 6RIWZDUHFDPV Up to eight cams can be output per IPO clock pulse with timer-controlled cam output. The mutual interaction of the cams (output with priority) does not apply. With the introduction of path timing cams, a cam pulse duration independent of axis velocity, reversal of travel direction and change of axis position (for example by preset) can be realized. Page 6 of 12

7 *HDUFKDQJHLQ'5<581DQGSURJUDPWHVW The behavior during a gear change with active DRY RUN or program test can be defined by settings in $MA_SPIND_FUNCTION_MASK. You can decide here whether the gear change is output with the above active functions or not. The system variable $P_GEAR returns the gear stage programmed by the part program (and not necessarily output to the PLC). The active gear stage can be read with $AC_GEAR. *HDUFKDQJHLQV\QFKURQL]HGDFWLRQRUZLWK)& The gear stage suitable to the speed can be determined and inserted automatically by defining spindle speed direction and speed by PLC with FC18. This is the same as the M40 functionality when programming the part program. M functions M40 to M45 can also be programmed now in synchronized actions. 5DSLGOLIW The target position for rapid lift can be approached now with all axes. Up till now only one axis could execute rapid lift. Thus partial retraction paths of axes selected for the frame are also traversed with active frame rotation. (OHFWURQLFJHDUV Non-linear links in the electronic gear unit can now be realized with curve tables. ([WHQGHGVWRSSLQJDQGUHWUDFWLQJ(65 The functionality ESR "Extended Stop and Retract" allows the control system to respond to selectable sources of errors in a manner that is flexible; that avoids damaging workpiece and tool; and that offers protection for man and machine. Because gearing design utilizes expensive workpieces and tools, great emphasis is placed on fast and careful separation (retracting) and stopping of machining. 2YHUODLGPRYHPHQWVZLWKRULHQWDWLRQWUDQVIRUPDWLRQV The programmed movement in active orientation transformations (for example Trafo5) can be overlaid in realtime movements whose direction depends on the current tool orientation. These are movements arising from temperature compensation for example. In this function temperature compensation values are assigned to the tool instead of the machine axis. Thus expansion changes, as they occur in 5-axis heads (longitudinal expansion of the tool spindle for example) and expansion changes that are turned when the tool orientation is changed, can be compensated.,qyroxwhlqwhusrodwlrq A spiral-shaped contour in the form of a so-called circle involute can be programmed and interpolated in an NC block with the function "Involute interpolation". This has the advantage that, due to the precise smooth description of the contour, the continuous-path speed does not fluctuate as much as if the approached contour were interpolated. Typically, a higher continuous-path speed and thus a reduction in machining times is achieved. )LIWKRUGHUSRO\QRPLDOV The extension of the NC programming to fifth order polynomials allows a better approximation of defined contours, without generating blocks with a short traverse path. Constant-acceleration axis traverses can thus be programmed as well. Fifth order polynomials are programmed in the same way as existing polynomials. Page 7 of 12

8 1XPEHURIZDLWPDUNV Ninety-nine WAIT marks are now available for NCUs and HIHUHQFLQJGXULQJFRUUHFWLRQ Measuring systems can also be referenced at an encoder zero mark during correction. %ORFNLQWHUQDOVPRRWKLQJ*(not released) No internal motion block is generated by function G643: the smoothing motion is performed by the programmed NC blocks. The rounding area can thus be formed to suit the axis. The block transitions are continuous in acceleration in all axes, in contrast with the existing rounding function where block transitions are only continuous in speed. The G643 configuration allows either maximum axis deviations or the maximum contour deviation to be defined. The maximum angular displacement of the tool orientation can be specified for rotary axes used for tool orientation. This means that the rounding tolerance for the tool orientation can be set independently of the special kinematics of the machine. The activation is only possible when the options for polynomial interpolation and orientation transformation are enabled. The behavior of the rounding functions G642 and G643 is defined by the machine data $MC_SMOOTHING_MODE. The tolerances are programmed with the setting data $SC_SMOOTH_CONTUR_TOL, $SC_SMOOTH_ORI_TOL. By setting $MC_IGNORE_OVL_FACTOR_FOR_ADIS=TRUE block transitions are always rounded regardless of the set overload factor. (YHQWGULYHQSURJUDPFDOOV An application program is triggered when certain events occur. This allows the user to call up initial settings of functions or initializations with a part program command. Machine data $MC_PROG_EVENT_MASK allows you to define channel-specific which event (part program start, part program end, operator panel reset or startup) should activate the application program. The program must be stored in the permanent path /_N_CMA_DIR/_N_PROG_EVENT_SPF. The application program can find out which event activated the program with the system variable $P_PROG_EVENT. 7RROPDQDJHPHQW The new functions are described in the documentation "FB Tool Management SW 6.1". 5RWDU\D[LVSRVLWLRQV When calculating rotary axis positions in machining cycles for modulo axes the system must always check that the calculated position lies within 360 degrees. The modulo range of a rotary axis can be set to a value other than 360 with machine data ($MA_MODULO_RANGE). Additional program branching and machine data read calls are thus required in the machining cycles. To reduce the CPU time required for a machining cycle, function MODAXVAL() can be used to calculate a modulo position. The modulo value for the specified axis can be calculated with the new function <modulo value> = MODAXVAL(<axis>, <value>). 6HOHFWLQJH[DFWVWRSFRQGLWLRQV In active exact stop activated non-modal with G9 or modal with G60, the exact stop criteria G601, G602 and G603 serve to define how accurately the corner point is approached and when the next block is selected. Thus corners are rounded differently regardless of the dynamic response of the axes and the continuous-path speed. The exact stop criteria are modal and act with active G60 or G9 only. Page 8 of 12

9 It is recommended that a "coarser" exact stop criterion is activated automatically for certain travel motions (for example infeed motions), without it being explicitly programmed. This can be achieved by automatically using "Positioning window coarse" or the condition "Setpoint reached" with rapid feed (G00). A machine data is used to define which exact stop condition should be automatically effective. 3/&EDVLFSURJUDPWRROER[ 7RROER[ Simatic-compliant Installshield of the tool box with automatic registration of the basic program library. Suitable for operation under Windows 95/98/2000/ME, Windows NT. )& Byte DB[axis].DBB4 can be transmitted to the NCK with function 7 of FC21, independently of the cyclical update of the interface. This byte contains axis-specific travel and halt signals. 0DFKLQHFRQWUROSDQHO MCP modules FC19, FC24, FC25, FC26 can now be configured flexibly with reference to axis numbers over axis tables. '5$0)LOHV\VWHPIRUF\FOHVDUFKLYH RSWLRQRUGHUQXPEHU)&$)$$ The passive file system in the NCK (NC program memory) contains Siemens files (for example cycles), machine manufacturer files and user files (part programs for example). These files are partly changed online or left unchanged (for example standard cycles). The entire file system is stored in SRAM. The advantage of SRAM over DRAM is that the contents are not lost when the control system is switched off. However, this often clashes with the user's desire to have a lot of NC program memory available. All files not modified online need not be stored in SRAM. They can be stored in a backup memory and loaded into DRAM during startup. An alternative DRAM file system is thus needed and you need to know which files remain unchanged until the next system shutdown. Machine data $MN_DRAM_FILESYSTEM_MASK and $MN_MM_DRAM_FILE_MEM_SIZE serve to define which cycles (CST, or CMA) are stored, and how big the remaining DRAM memory is. This function can only be used with +0,$GYDQFHGYHUVLRQ. 1&8/LQN The function has been implemented according to the function discription and according a. m. restrictions (3.3) 0DVWHU6ODYHIRU'ULYHV The function Master/Slave is now part of the system software. It's no longer availible on the Technology Card. Due to this fact the numbering of the machine parameters has been changed. With no change of parameter names the numbering start now with 37xxx (before 63xxx). %RXQGDU\FRQGLWLRQV 8SJUDGLQJFKDQQHOD[LVVSDFLQJV If there are gaps in the channel axis definition, and if a software version earlier than is upgraded to release 6, the zero shifts must be entered manually, or the series machine start-up file must be read in again without deleting the NC. Page 9 of 12

10 +HOSIXQFWLRQVLQ2% Sometimes the following combination of help functions are not detected in the PLC. H/T function evaluation in OB40 (parameter IRAuxfuT/H =true in FB1) In the part program: m=qu(55) h2=33 The H function is lost sporadically. Remedy: Program m55. 2XWSXWWLQJWKH)ZRUGWRWKH3/& When MD22200=1 and MD22240=1 (that is output F word to PLC) is set, the decoded dynamic help function M8 is not output to the PLC interface in following block N10 g1 x100 m8 f1000. Remedy: Decode the M word and discharge a dynamic signal. ([WHUQDO]HURVKLIWIRUURWDU\D[LVLQWKH,QFKV\VWHP If an external zero-point shift is specified with system frame ($MC_MM_SYSTEM_FRAME_MASK, bit 1= 1) for a rotary axis and selected Inch system, the zero shift is evaluated incorrectly by a factor of \QFKURQRXVVSLQGOH In the case of a cross-channel synchronous spindle link, a setpoint step change can occur with the following spindle, when the leadscrew is replaced after a successful link in another channel. Remedy: Define link with spindle identifiers, not with axis identifiers. If the synchronous spindle link is switched on when the leadscrew is in an acceleration phase, the following spindle accelerates with increased accelerations as defined in the MD. Alarms such as contour monitoring can occur. When the synchronous spindle link is switched on all selected spindles must be enabled. If this is not the case, a positional offset between leading and following spindle can occur during positioning in synchronous spindle operation. 5HSRVLWLRQLQJPRGH Traversing errors can occur if a part program is interrupted with an active tool, JOG selected and tool retracted from the contour and repositioned afterwards with REPOS over the key on the MCP. The tool can travel beyond the interruption position. This problem occurs when GEO axes are traversed. Remedy: Traverse with the machine axes. $ODUP Alarms (10794,10795, ) can occur if a REPOSA is triggered during contour definition programming and active modal roundings. Due to the block structure the control system cannot calculate the correct interruption point. Remedy: Restart program or block search for a position before contour definition programming. &RXSOHGD[LVJURXSLQJV The user must ensure that control parameters (acceleration, speed for example) of the following axis are maintained when coupled-axis groupings are enabled over synchronized actions or cross-channel. No check is made in the NC in these cases. Page 10 of 12

11 1&8/,1. When NCUs are linked with the function Link, NCUs of the same type (MLFB) should always be used. When a link is configured with different interpolation times, the system clock cycles must be the same on both systems as otherwise alarm 4013 is output with error identifier SYSCLOCK_SAMPLE_TIME_RATIO. )&ZLWKDFWLYHWUDQVIRUPDWLRQ If a GEO axis is traversed over FC18 with active transformation, message InPos appears upon alarm, although the setpoint position has not been reached. :DLWPDUNV Channels are synchronized with WAIT MARKS. If a REPOSA is triggered while a channel is on a wait mark and if a channel-specific DELETE DISTANCE-TO-GO is carried out as well as the REPOSA, the WAIT MARK is acknowledged. The channel synchronization is thus lost. 7UDQVPLWDQG75& Only tools without tool point direction should be used in SW versions 5 and 6 with active Transmit (with tool point direction 9 only). Otherwise invalid contours are obtained with radius compensation. 6LQXFRS\)ODVK)LOH6\VWHP Files cannot be written to the PC Card in the FFS with Sinucopy. If files are copied to FFS with SINUCOPY, they will be deleted with the next control system boot! 3DUDPHWHUL]DWLRQ If a block with parameter assignments (run-in variables and main run variables) appears before a block, in which an axis is loaded into the channel, the parameterization is not carried out correctly! Example: N2 r0=777 N3 r0=0 r1=0 stepa=999 $a_dbw[0]=0 N4 g0 g91 x=0.01 N5 release(x) N6 stopre N7 r1=stepa ("stepa" setting incorrect) (r1=0) Remedy: Insert an additional block (for example G4 F0.010) before N3. 3URJUDPWHVWIRUFRXSOHGPRWLRQ If the function program test is selected with active coupled-axis grouping, system error 1016, can occur. (UURUVFRUUHFWHG ERLde24199 ERLde24090 Page 11 of 12

12 ERLde24754 BRKdb02259 ERLde23841 ERLde22415 ERLde32161 ERLde32378 ERLde24270 ERLde27994 ERLde36616 ERLde35928 ERLde35891 ERLde36011 ERLde34842 ERLde36780 ERLde38351 Page 12 of 12

INSTALLATION & UPGRADE INSTRUCTIONS

INSTALLATION & UPGRADE INSTRUCTIONS SIEMENS AG A&D MC E5 Valid for SINUMERIK 840D Software Version 6.3.15 Page 1 of 17 1 Requirements for Upgrading... 4 2 Data Backup... 4 2.1 Data backup with MMC 100.2...