STARTUP and UPGRADE INSTRUCTIONS

Transcription

1 STARTUP and UPGRADE INSTRUCTIONS SIEMENS AG A&D MC RD5 valid for SINUMERIK 810/840D Software version Page 1 of 13

2 Requirements for upgrade System software Tools 3 Data backup General requirements for upgrade Data backup 4 CCU Upgrading from CCU 1 to CCU Upgrading from CCU 2 to CCU 3 5 Upgrading to CCU 3.4 with PLC 314C-2DP...5 Notes Spindle dynamics Spindle setpoint display Upgrading to CCU3 / "Handling" function Output specifications of predefined auxiliary functions Changes in Safety machine data ( ) NCU system resources Output of auxiliary function M06 after block search 7 General notes on software upgrades 7 New software version after hardware replacement...8 General restrictions...10 Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Functional improvements from version to Page 2 of 13

3 Requirements for upgrade Software version ( NCK ) is a software update version. The NCK functionality basically corresponds to software version ( NCK ). The upgrade instructions for software versions and are the basis for an upgrade to version The current upgrade instructions are part of the delivery releases in ProdIS Update. 1.1 System software Export versions Order number Designation... on PC card For hardware 6FC5250-6DY30-5AH0 NCU system software 2 axes NCU *.4, NCU *.5 6FC5250-6CY30-5AH0 NCU system software 6 axes NCU *.4, NCU *.5 6FC5250-6BY30-5AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4, NCU *.5 6FC5250-6AY30-5AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4, NCU *.5 6FC5450-6AY03-5AH0 CCU system software CCU 3.* Standard versions (subject to export restrictions) Order number Designation... on PC card For hardware 6FC5250-6CX30-5AH0 NCU system software 6 axes NCU *.4, NCU *.5 6FC5250-6BX30-5AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4, NCU *.5 6FC5250-6AX30-5AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4, NCU *.5 6FC5450-6AX03-5AH0 CCU system software CCU 3.* 1.2 Tools 6FC5250-6AY00-3AG0 (...-4AG0) SinuCom NC with SinuCom FFS. SinuCom FFS must be used to program the PC card with SW and higher. 6FC5252-6AX21-5AG0 Toolbox V with basic PLC program The basic PLC program of Toolbox can be used. An upgrade is not mandatory. PG/PC with STEP 7 V5.2 and higher and optional online MPI link. Current documentation for SW 6 with additional function-related information. Data backup 1.3 General requirements for upgrade Before upgrading the NCK ensure that at least 50 KB dynamic memory is available for each channel. This can be checked 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 more powerful 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 50 KB of static memory should be available. This can be checked in MD18060 INFO_FREE_MEM_STATIC. If the available memory is insufficient, memory space can be freed by unloading NC programs. Page 3 of 13

4 Set machine data UPLOAD_MD_CHANGES_ONLY = FF, INI_FILE_MODE = 1 or Data backup CCU 3 NCK Before the NCK is upgraded, a backup must be made to permit recovery of the machine's current database. This is done by creating a series startup file (see general instructions for software upgrades). PLC In addition to the NCK data backup, a PLC data backup must be created. This data backup must be performed with the PLC in the STOP state. Set S4 on the NCU module to position 2. The PLC will then be in the Stop state. If you want to upgrade the basic PLC program you will need STEP 7. For this purpose, the new Toolbox must be installed using SETUP. You also need the customer project of this system. The required blocks are transferred from the new Toolbox library to the customer project (or a copy). OBs FC12 and DB 4 must not be transferred (these are blocks for creating a new user program) because they have been modified by the machine manufacturer. After replacement of the NCK software transfer the blocks to the PLC using STEP 7. A new PLC series startup file must be created. Replacing the software Switch the control off and replace the PC card. The card stays in the control. Set switches S3 to position 1 and S4 to position 3 and switch the control on. When it has powered up, the state "7-segment display shows digit 6 / PLC LED PS flashes / PF red" is established. The NC standard machine data have now been loaded. NC and PLC have been cleared. The PLC is started up by switching S4 from position 3 to position 0 => S4 in position 3 => S4 in position 0. Now the PLC must switch to Run mode. Set S3 to position 0. You can check the software version in menu Diagnostics/Service Displays/Version. Loading the data backups Once the manufacturer password has been set, the NCK data backup can be loaded in the menu Services/Series startup/load startup archive/ after selecting the backup file. Once completed, the PLC data backup can be loaded. Once the PLC data backup has been loaded, you must switch the system off and on again so that all components are powered up simultaneously. 1.5 Upgrading from CCU 1 to CCU 3 NC data backup CCU 1 The drive boot files must be saved in ASCII format so that they can be loaded to the CCU 3. For this purpose, you should create an upgrade archive with the setting "$MN_UPLOAD_MD_CHANGES_ONLY=FF". Standard startup CCU 3 After the standard startup of the CCU 3 you should note down the value of MD18210 $MN_USER_MEM_DYNAMIC. Loading the upgrade archive The name of drive machine data 1254 has been changed. That is why the following message is output when you load the upgrade archive: Drive x: Line x: Entry not found in ACC file: N1254 $MD_SPACE_VECTOR_FILTER_TIME Page 4 of 13

5 Notice! MD1254 is assigned default values. Check against the data backup whether the value is now different from the default (0.5 ms). DRAM expansion After loading the upgrade archive, MD $MN_USER_MEM_DYNAMIC should be set to the default value of the CCU 3. Important changes to standard machine data CCU 1 CCU 3 MD10072=1 MD10072=0.5 MD10134=3 MD10134=6 MD28070=30 MD28070=38 MD28520=1 MD28520=3 1.6 Upgrading from CCU 2 to CCU 3 Memory problems may occur when upgrading a CCU 3 with a CCU 2 series startup file because the SRAM memory expansion of the CCU 2 is not defined via option data. On the CCU 3 any SRAM memory greater than the basic complement (768 KB) is defined by options. In that case, part programs must be unloaded from the CCU 2 before the series startup file is created to ensure that the data backup can be reloaded without errors. If it is not possible to load all programs again, memory options must be upgraded. Note: The CCU3e software can be flashed. The flash procedure is indicated by digit 8 on the 7-segment display and takes about 2 minutes. The end of the flash procedure is displayed by digit 9. Upgrading to CCU 3.4 with PLC 314C-2DP Along with the *.4 NCUs, the PLC 314C-2DP was introduced for Sinumerik 810D with the CCU 3.4. The order number is 6FC5410-0AY03-1AA0. Requirements for upgrade - STEP 7 version >= 5.1 service pack 2, hotfix 3 or STEP 7 on HMI version >= 5.1 with service pack 3 - CCU software version >= PLC firmware version >= Toolbox >= Basic PLC program >= HMI ADV version >= , >= or >= , 6.3.xx, 6.4.xx - HMI EMB version >= If PLC projects with S7 hardware configurations are to be taken over, a new PLC hardware configuration will have to be created or adapted. For this purpose, the PLC CPU 314C-2DP must be integrated into the hardware configuration ( e.g. through replacement of components). The hardware components are available after the installation of Toolbox V under the STEP 7 hardware configuration. The programming tool STEP 7 and knowledge of SIMATIC STEP 7 are therefore required. PLC changes compared to PLC 315-2DP - Performance is approx. 3 times faster - User memory max. 480 KB - Min. 16, max. 32 PROFIBUS slaves / size SDB 2000 <= 32 KB timers counters NC performance The GX1 processor is now clocked with 266 MHz (previously 233 MHz). Page 5 of 13

6 Notes 1.7 Spindle dynamics The machine data for describing the spindle dynamics must be set so that they approximately correspond to the actual dynamics of the spindle. If the values are increased unnecessarily, alarms may be issued during the changeover from spindle to positioning mode. 1.8 Spindle setpoint display The spindle setpoint display in the HMI spindle window is no longer affected by the content of MD $MC_F_VALUES_ACTIVE_AFTER_RESET. The response is now as follows: $MN_DISPLAY_FUNCTION_MASK, bit 1=0 When the spindle is at zero speed, set speed "0" is displayed. Example: M3 S100 g4 F2 M5 Setpoint display on HMI "0" rpm $MN_DISPLAY_FUNCTION_MASK, bit 1=1 When the spindle is at zero speed, set speed "100" is displayed. Example: M3 S100 g4 F2 1.9 Upgrading to CCU3 / "Handling" function As of SW 6.4 the "Handling" function is no longer available in the default version, but can be loaded. This means that the technological function "Handling" must be obtained via esupport or from Siemens Sales. For additional information refer to the upgrade instructions for the compile cycles Output specifications of predefined auxiliary functions Machine data $MC_AUXFU_PREDEF_SPEC introduced with SW 6.4 may cause incompatibilities during auxiliary function output. If required, the output specifications of prededined auxiliary functions can be adjusted via machine data $MC_AUXFU_PREDEF_SPEC. The output specifications of user-defined auxiliary functions can be defined via machine data $MC_AUXFU_ASSIGN_SPEC. The output specifications have the following significance: $MC_AUXFU_PREDEF_SPEC[ index ] $MC_AUXFU_GROUP_SPEC[ grpindex ] $MC_AUXFU_(M,S,T,H,F,D,DL)_SYNC_TYPE This means that the predefined output specifications always apply to the predefined auxiliary functions. Notes: - As of SW 6.4 the spindle M functions (e.g. M3/M4/M5) are output by default prior to traversing, even though MD $MC_AUXFU_M_SYNC_TYPE=1 (output during motion). However, the time the spindle M functions are to be output can be adjusted in MD $MC_AUXFU_PREDEF_SPEC. - The pre-defined auxiliary functions cannot be overwritten through the configuration of user-defined auxiliary functions. Alarm "4185 channel K1 illegal configuration of an auxiliary function..." will be output in this case. This alarm will also be output, if illegal auxiliary function groups have been defined. This was not monitored in software versions < Example: M3 laid into fifth auxiliary function group, although only second group is permissible. Page 6 of 13

7 - The spindle auxiliary functions M1=40 to M1=45 are now assigned to the fourth auxiliary function group by default (see MD $MC_AUXFU_PREDEF_GROUP). - As of SW 6.4, the master spindle address extension is automatically output at the interface if M40 to M45 are programmed Changes in Safety machine data ( ) The maximum values of the following machine data have been increased. - safe_velo_switch_delay 10 min. - safe_stop_switch_time_c 10 min. - safe_stop_switch_time_d 10 min. - safe_stop_switch_time_e 10 min. - safe_pulse_disable_delay 10 min NCU system resources In the "Reset" state, the load imposed on the NCU by the position controller and interpolator should not exceed 60% to 65%. The current load can be checked under Diagnostics/System resources Output of auxiliary function M06 after block search Given default machine data and definition of an auxiliary function group for M6 this M function is no longer output after block search as of NCK software version and as of version Possible remedy 1: Redeclaration from M06 to L06 Possible remedy 2: Mx = 06 Possible remedy 3: Change the auxiliary function group including M6 in MD $mc_auxfu_predef_group[>=5] into a free group. Example: Assignment MD22000[0]=5 MD22010[0]=M MD22020[0]=0 MD22030[0]=6 MD22035[0]=H21 Modification MD $mc_auxfu_predef_group[5]=5 General notes on software upgrades Before the upgrade, series startup files and upgrade files must be created, which contain only those machine data that differ from the default values. Machine data UPLOAD_MD_CHANGES_ONLY = FF is to be set for this purpose. This ensures that the machine data are assigned the originally set values after a software update even in the case of different default settings through the individual software versions. However, machine data with the protection level "System" should be set to the default values applicable to the relevant software version. A data backup generated with Page 7 of 13

8 UPLOAD_MD_CHANGES_ONLY = FF contains the machine data with their current values that differ from their defaults. In order to ensure that the machine data with the protection level "System" contain default values after a software update, it is essential to save the series startup file and upgrade file without "line checksum". For this purpose, set machine data MD_FILE_STYLE bit 0 = 0. If the series startup file with the protection level "Manufacturer" generated by UPLOAD_MD_CHANGES_ONLY = FF and MD_FILE_STYLE bit 0=0 is read in again, then the machine data with protection level "System" are not overwritten with the values from the backup files. They are set to the default values applicable to the relevant software version. This ensures that no obsolete settings are carried over which might not be executable with new software. After the data has been read in, the alarm log contains alarm 4075 "Data not changed because of lack of access rights". This alarm indicates that default values for system data have not been overwritten. If this procedure without line checksum is not possible (for example with a defective NCU), then a machine data file should be created with UPLOAD_MD_CHANGES_ONLY=FF after the upgrade, and the machine data it contains should be checked. In this case, especially the following data should be checked for default settings: LUD_HASH_TABLE_SIZE MAX_SIZE_OF_LUD_VALUE CHAN_HASH_TABLE_SIZE NCK_HASH_TABLE_SIZE FILE_HASH_TABLE_SIZE DIR_HASH_TABLE_SIZE EXTCOM_TASK_STACK_SIZE COM_TASK_STACK_SIZE SERVO_TASK_STACK_SIZE IPO_TASK_STACK_SIZE DRIVE_TASK_STACK_SIZE PLC_TASK_STACK_SIZE FPU_ERROR_MODE FPU_CTRLWORD_INT FPU_EXEPTION_MASK PREP_TASK_STACK_SIZE Alternatively, an existing file can be modified with the SinuComArc tool, by deleting the machine data listed above (areas: Global.ini, Chan.ini, Initial.ini). The channel machine data NUM_BLOCKS_IN_PREP must be checked. The settings are often affected by manufacturer-specific applications, for example memory and time optimizations. In the event of problems, at least the default value should be set here. New software version after hardware replacement If an NCU is replaced by new hardware, it may happen that the old software version is no longer executable. It therefore also has to be upgraded to a higher software version by trained service personnel. As of software version 3.7, always use the latest release of the software series (e.g , , , etc.) to ensure that the NCU is operating properly. Page 8 of 13

9 The prerequisite for upgrading is the possibility of - editing NCU data backups, - starting up drives, - starting up the PLC, and the availability of the necessary tools (e.g. SinuComArc, IBN-Tool, STEP 7, etc... ). Memory configuration problems can occur while reading in the data backups, as "old" settings were also backed up in the data backups (see general notes). In this case, particular attention has to be paid to MD18210 USER_MEM_DYNAMIC and MD18230 USER_MEM_BUFFERED. In addition, the following data have to be checked for default settings LUD_HASH_TABLE_SIZE MAX_SIZE_OF_LUD_VALUE CHAN_HASH_TABLE_SIZE NCK_HASH_TABLE_SIZE FILE_HASH_TABLE_SIZE DIR_HASH_TABLE_SIZE EXTCOM_TASK_STACK_SIZE COM_TASK_STACK_SIZE SERVO_TASK_STACK_SIZE IPO_TASK_STACK_SIZE DRIVE_TASK_STACK_SIZE PLC_TASK_STACK_SIZE FPU_ERROR_MODE FPU_CTRLWORD_INT FPU_EXEPTION_MASK PREP_TASK_STACK_SIZE Alternatively, an existing file can be modified with the SinuComArc tool, by deleting the machine data listed above (areas: Global.ini, Chan.ini, Initial.ini). The channel machine data NUM_BLOCKS_IN_PREP must be checked. The settings are often affected by manufacturer-specific applications, for example memory and time optimizations. In the event of problems, at least the default value should be set here. In order to be able to check these data, the series startup file and upgrade file must be processed with the SinuComArc tool. Check whether these data are included in the backup before then deleting them. This does not overwrite the new default values. After reading in the edited data backup, the control should then start up. Memory options still have to be checked. Notes: The data backups cannot be edited with conventional editors (e.g. Word) and then read in again. Drive data (BOT files): There is an internal converter for BOT files, which ensures that drive data backups can be read into various software versions. However, the converter cannot be guaranteed to work for all software upgrade combinations. Boot file conversion is not provided until drive software version It might therefore be necessary to recommission the drives after an upgrade. Page 9 of 13

10 General restrictions - If STEP 7 version 5.3 is being used, the Toolbox has to be installed, if projects (including PLC blocks) containing hardware components of the Toolbox are to be processed. - Slave operation of the PROFIBUS is not possible with CCU3.4/NCU*.4. If such a configuration is required, it must be implemented with a CP module or an NCU *.5. - Function G643 (block-internal smoothing) has been released for appliations in the tool change area (e.g. optimizations for approaching the tool change position). It is not released for applications in the machining process. - The functions FCUB and FLIN in combination with the compressor COMPCAD have not been released. - NCUs nnn.3 : The PCU 50 can only be shut down with the Exit button in emergency stop mode, if a PLC firmware version < is used. - NCUs nnn.4 : The PCU 50 can only be shut down with the Exit button in emergency stop mode, if a PLC firmware version < is used. - With the NCU it is no longer possible to enable 10 channels and 31 axes simultaneously. That number is now limited to eight channels. This restriction does not apply to the replacement type (6FC5357-0BB33-0AA*) - The number of channels is limited to 6 for NCU 572.3/572.4, 31-axis software. This restriction does not apply to the replacement types (6FC5357-0BB23-0AA*) and (6FC5357-0BB24-0AA*). - The number of axes including the DMP block is limited to 31. If, for example, a DMP block is used with 31-axis software, a total of 30 axes is still possible. Functional improvements from version to NCK CHMdc09429 CHMdc09531 ERLde61316 ERLde67598 ERLde72139 ERLde72182 ERLde72821 ERLde73327 ERLde73840 ERLde74083 ERLde74167 ERLde74448 ERLde74561 ERLde74571 ERLde74755 ERLde74866 ERLde74903 ERLde74990 ERLde75001 ERLde75002 ERLde75016 ERLde75160 ERLde75169 ERLde75195 ERLde75200 ERLde75210 ERLde75213 ERLde75269 ERLde75308 ERLde75332 ERLde75345 ERLde75354 ERLde75400 ERLde75575 ERLde75602 ERLde75645 ERLde75668 ERLde75712 ERLde75766 MGLdm00998 MGLdm01072 MGLdm01093 MGLdm01128 MGLdm01139 Functional improvements from version to NCK , NCK SWBds06649 MGLdm01164 ERLde69918 ERLde75308 ERLde77207 ERLde78450 ERLde78538 Functional improvements from version to NCK , NCK BRKdb10126 CHMdc09774 ERLde57400 ERLde69918 ERLde71058 ERLde71788 ERLde74199 ERLde74686 ERLde74975 ERLde75099 ERLde75308 ERLde75521 Page 10 of 13

11 ERLde75524 ERLde75562 ERLde75827 ERLde76073 ERLde76076 ERLde76504 ERLde76527 ERLde76822 ERLde77103 ERLde77207 ERLde77284 ERLde77435 ERLde77571 ERLde77587 ERLde77588 ERLde77701 ERLde77729 ERLde77844 ERLde77851 ERLde77862 ERLde77960 ERLde78011 ERLde78070 ERLde78092 ERLde78178 ERLde78278 ERLde78353 ERLde78400 ERLde78450 ERLde78514 ERLde78518 ERLde78538 ERLde78578 ERLde78586 ERLde78646 ERLde78742 ERLde78838 ERLde79105 ERLde79212 ERLde79268 ERLde79308 ERLde79315 ERLde79461 ERLde79554 ERLde79577 ERLde79597 ERLde79764 ERLde79820 ERLde79821 ERLde79898 ERLde79922 ERLde79962 ERLde79973 ERLde80015 ERLde80158 ERLde80178 ERLde80197 ERLde80258 MGLdm01004 MGLdm01091 MGLdm01126 MGLdm01131 MGLdm01141 MGLdm01164 MGLdm01236 MGLdm01254 MGLdm01281 MGLdm01314 MGLdm01332 Functional improvements from version to NCK ERLde81264 Functional improvements from version to NCK CHMdc09905 CHMdc10015 CHMdc10020 CHMdc10092 ERLde66636 ERLde74782 ERLde74951 ERLde76510 ERLde78602 ERLde79533 ERLde80273 ERLde80354 ERLde80545 ERLde80648 ERLde80658 ERLde80661 ERLde80662 ERLde80855 ERLde81078 ERLde81297 ERLde81401 ERLde81524 ERLde81534 ERLde81764 ERLde81837 ERLde81917 ERLde81957 ERLde81958 ERLde81965 ERLde81968 ERLde82034 ERLde82046 ERLde82116 ERLde82137 ERLde82142 ERLde82429 ERLde82448 ERLde82579 ERLde82648 ERLde82714 ERLde82719 ERLde82722 ERLde82736 ERLde82963 ERLde83148 ERLde83287 ERLde83565 ERLde83587 ERLde83608 ERLde83872 ERLde84036 ERLde84239 ERLde84350 MGLdm01342 MGLdm01364 NCK ERLde70346 ERLde74199 ERLde75417 ERLde79594 ERLde82239 ERLde82445 ERLde82803 ERLde84494 ERLde84631 ERLde84803 ERLde84905 ERLde85151 ERLde85351 ERLde85592 ERLde86041 ERLde86396 ERLde86399 ERLde86479 ERLde86883 MGLdm MGLdm01385 SWBds06222 NCU ERLde88165 ERLde88207 Page 11 of 13

12 Functional improvements from version to NCU NCK AP = CHMdc09094 AP = ERLde77824 AP = ERLde81530 AP = ERLde82648 AP = ERLde82827 AP = ERLde84160 AP = ERLde84535 AP = ERLde85303 AP = ERLde86650 AP = ERLde87441 AP = ERLde87648 AP = ERLde87711 AP = MGLdm01402 AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP = ERLde82055 AP AP Functional improvements from version to NCU AP = ERLde68594 AP = ERLde76678 AP = ERLde87735 AP AP AP AP AP AP AP AP AP AP AP AP AP Functional improvements from version to NCU AP Functional improvements from version to AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP Page 12 of 13

13 AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP Functional improvements from version to AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP AP Functional improvements from version to AP AP AP AP AP AP AP AP AP Page 13 of 13