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1 67$5783DQG83*5$'(,16758&7,216 SIEMENS AG A&D MC E5 9DOLGIRU 6,180(5,.'6RIWZDUH9HUVLRQ Page 1 of 10

2 5HTXLUHPHQWVIRUXSJUDGLQJVRIWZDUH 'DWDEDFNXS *HQHUDOUHTXLUHPHQWVIRUXSJUDGLQJVRIWZDUH 2.2 Software upgrade with MMC Requirements Backup of NC data with MMC Software upgrade with MMC 103 / PCU 'DWDEDFNXSZLWK00&RU3&8 6RIWZDUHUHSODFHPHQWZLWKLQWKHVDPHVRIWZDUHVHULHV &&8 3.1 Upgrade from CCU1 to CCU Upgrade from CCU2 to CCU *HQHUDOQRWHV 4.1 General restrictions Software version display Frames Series start-up file Series startup with MMC 103 software version < Limitation of number of axes and channels DMP modules &8 5.1 PLC 6FC CF00-0AB PLC operating system version PLC toolbox XSSOHPHQWDU\FRQGLWLRQV 6.1 Display of PLC memory configuration Upgrading with gaps in channel axis sequence Auxiliary functions in OB Synchronous spindle Coupled-axis groupings NCU link Extended M function output Performance 2 control module... 9 (UURUVFRUUHFWHGLQVRIWZDUHYHUVLRQDQGODWHU Page 2 of 10

3 These instructions describe how to upgrade the software on the SINUMERIK 810D, CCU3 / 840D systems to the new product release HTXLUHPHQWVIRUXSJUDGLQJVRIWZDUH 6\VWHPVRIWZDUH 9HUVLRQVQRWVXEMHFWWRH[SRUWUHVWULFWLRQV 6FC5250-6PX10-3AH0 :NCU system software 2 axes on PC card for NCU 561.2/ FC5250-6BX10-3AH0 :NCU system software 6 axes on PC card for NCU FC5250-6BY30-3AH0 :NCU system software 12 axes on PC card for NCU 572.3/572.4/573.2/573.3/ FC5250-6AY30-3AH0 :NCU system software 31 axes on PC card for NCU 572.3/572.4/573.2/573.3/ FC5450-6AY03-3AH0:CCU system software on PC card for CCU3 9HUVLRQVVXEMHFWWRH[SRUWUHVWULFWLRQV 6FC5250-6BX30-3AH0 :NCU system software 12 axes on PC card for NCU 572.3/572.4/573.2/ 573.3/ FC5250-6AX30-3AH0 :NCU system software 31 axes on PC card for NCU 572.3/572.4/573.2/ 573.3/ FC5450-6AX03-3AH0 :CCU system software on PC card for CCU3 7RROV - 6FC5252-6AX21-3AG0 :Toolbox V with basic PLC program PG/PC with STEP7, version 4.02 and optional online MPI connection. - Current documentation for SW 6 with more detailed information about functions 'DWDEDFNXS *HQHUDOUHTXLUHPHQWVIRUXSJUDGLQJVRIWZDUH Before you upgrade the NCK, you must make sure that at least 50KB dynamic memory per channel is available. You can check this in MD18050 INFO_FREE_MEM_DYNAMIC. If there is less than the required amount of memory available, you must increase the setting in MD18210 USER_MEM_DYNAMIC to provide more. If memory cannot be made available in this way, you must install a more powerful CPU or free up memory space not required elsewhere. The machine data marked with D-RAM in the list would be ideal for this purpose. An additional 50KB of static memory must also be available. You can check this in MD18060 INFO_FREE_MEM_STATIC. You can unload NC programs to free up static memory if necessary. Set machine data UPLOAD_MD_CHANGES_ONLY = FF, INI_FILE_MODE to "1" or "2". 6RIWZDUHXSJUDGHZLWK00& 5HTXLUHPHQWV You must make the following cable connections. RS-232-C connection between MMC and PG/PG for machine / drive and user data. Page 3 of 10

4 %DFNXSRI1&GDWDZLWK00& Select start-up data in menu "Data Out" in the "Services" area. Back up NCK data in archive format via the RS-232 interface to PG/PC (individually) separately to the PLC data. 1RWHCompensation data are not backed up with the series start-up data. You can back up compensation data individually to an external PC by selecting "SK Data Out SK Data" and areas "Interpolative Compensation", "Circle Error Compensation" and "Leadscrew Error Compensation" in the Services area. (Once the NCU software has been upgraded, these data can be loaded back to the NCK ("Softkey Data In" in Services area --- MD CEC_ENABLE or ENC_COMP_ENABLE of relevant axes are set to "0"). 6RIWZDUHXSJUDGHZLWK00&3&8 'DWDEDFNXSZLWK00&RU3&8 1&. Before you upgrade the NCK software, you must create a data backup so that you can later restore the current database for the machine. You can do this by creating series backup files. To create these files, you need to set the Manufacturer password and unload any tool from the spindle or buffer location. You can now select the archive content of the file to be created (selection: 1&ZLWK&RPSHQVDWLRQV) in menu 6HUYLFHV6HULHV6WDUW8S&UHDWH6WDUWXS$UFKLYH. After you have entered the archive name, start the data backup by clicking soft key Archive. All important data (compensations, tools, definitions, loaded programs, machine data, etc.) are now saved to the Archive path. 3/& In addition to the NCK data backup, you must also create a PLC data backup. You must do this with the PLC in the Stop state. Set S4 on the NCU module to position 2 to switch the PLC to the Stop state. You create the PLC series start-up file in the same way as an NCK data backup, i.e. by selecting the data (selection: 3/&) via the Archive soft key. You will need STEP7 if you wish to upgrade the basic PLC program. To do this, use SETUP to install the new toolbox. You will also need the customer project for the installation. The required blocks must be transferred from the new Toolbox library to the customer project (or copy). In this case, OBs, FC12 and DB 4 must not be transferred (these are the blocks for generating a new user program) because they will have been modified by the machine manufacturer. The blocks must then be transferred to the PLC. A new PLC series start-up file must be created. 6RIWZDUHUHSODFHPHQWZLWKLQWKHVDPHVRIWZDUHVHULHV 5HSODFHVRIWZDUH Switch off the control and replace the PCMCIA card which then remains in the control (irrespective of the type of SINUMERIK 810D/840D). Set switch S3 to position 1 and S4 to position 3 and switch on. After booting, the control is in the state " "6" is displayed on 7-segment display / PLC LED PS flashing / PF red ". NC standard machine data have now been loaded. NC and PLC are reset. Now start up the PLC by setting switch S4 from position 3 to position 0 => S4 to position 3 => S4 to position 0. The PLC must now switch to Run mode. Set S3 to position 0. You can check the software version in menu 'LDJQRVLV6HUYLFH'LVSOD\V9HUVLRQ. /RDGGDWDEDFNXSV After you have set the manufacturer password, you can choose and then import the NCK data backup file by selecting menu options 6HUYLFHV6HULHV6WDUWXS,PSRUW6WDUWXS$UFKLYH/. When this import is completed, you can import the PLC data backup. Page 4 of 10

5 After you have imported the PLC backup data, you must switch the system off and on again to allow all components to boot together. &&8 8SJUDGHIURP&&8WR&&8 - Back up NC data on CCU1 The drive boot files must be backed up in ASCII format to that they can be loaded to the CCU3. To do this, you must create an upgrade archive by setting "$MN_UPLOAD_MD_CHANGES_ONLY=FF". - Standard start-up of CCU3 On completion of the CCU3 standard start-up process, you should note the value of MD18210 $MN_USER_MEM_DYNAMIC. - Import upgrade archive Drive machine data 1254 has been renamed. The following message is therefore output when the upgrade archive is read in: Drive x: Line x: Entry not found in ACC file: N1254 $MD_SPACE_VECTOR_FILTER_TIME 127,&( MD1254 is set to default values. You must use the data backup to check whether its value has changed from the default setting (0.5ms). - DRAM configuration After the upgrade archive has been imported, MD $MN_USER_MEM_DYNAMIC must be set to the CCU3 default setting. - Important changes to standard machine data CCU1 MD10072=1 MD10134=3 MD28070=30 MD28520=1 CCU3 MD10072=0.5 MD10134=6 MD28070=38 MD28520=3 8SJUDGHIURP&&8WR&&8 Since the SRAM configuration cannot be defined via option data for the CCU2, memory problems may be encountered when a CCU3 is upgraded using a CCU2 series start-up file. On the CCU3, the SRAM deviation from the basic configuration (768KB) is defined by options. In this case, you must unload part programs before you create series start-up files on the CCU2 so that they can be re-imported without problems. If you cannot reload all programs, you must retrofit memory options. 1RWHCCU3esoftwareFDQbe flasheda Flash processis identified by "8" on the 7-segment display and takes approximately 2 minutes. A "9" is displayed to indicate completion of the Flash operation. *HQHUDOQRWHV *HQHUDOUHVWULFWLRQV Page 5 of 10

6 - The G643 function (smoothing inside block) is approved for applications connected with tool changes (e.g. optimization on approach to tool change position). It is not approved for applications in the machining process. - The Overlaid Motions with Orientation Transformations function is approved for testing. - The Extended Interpolation of Orientations function is approved for testing. - It is no longer possible to simultaneously activate ten channels and 31 axes on the NCU The number of channels has been limited to eight. - The number of channels on the NCU / / is limited to 1. - The number of channels on the NCU 572.3, 31-axis SW, is limited to 6. 6RIWZDUHYHUVLRQGLVSOD\ The display of the NCK software version in the Diagnosis display (header) and machine data has been modified in conformance with Catalog NC60. Example: '$SKBNP This example shows the software for 6 axes (06A). This software is compatible with the NCU The reference to a particular hardware must not be defined via the Diagnosis display as before, but indirectly via the number of axes (cf. point 1). Version displays showing the word PRELIMINARY instead of the order number (MLFB) relate to software that has been provided for test purposes only. )UDPHV When $MC_MM_SYSTEM_FRAME_MASK bit 1 is set to 1, the external zero offset is suppressed by G153. This behavior differs to other software 6 versions. The default setting for $MC_CHSFRAME_POWERON_MASK has changed. MD24008 now has a default setting of zero (previously "1"). The system frame for scratching thus remains valid after power ON / Reset. 6HULHVVWDUWXSILOH Series start-up operations enable you to start up machines of the same type quickly and easily. These machines must really be identical, both in terms of their electrical equipment (e.g. NCU CPU, software) and their mechanical features. If they are not completely identical, the series start-up method might not be an appropriate option. You should then opt for a different method for backing up data (e.g. separate data backup with Initial.ini etc.) as it may be necessary to adapt certain machine data. Of particular relevance are the different memory limits on the various NCUs. If the total memory capacity is utilized, memory shortages may be encountered when the NCK software is upgraded or an NCU is replaced. Before you create a data backup file, you must check machine data $MN_UPLOAD_MD_CHANGES_ONLY. It should be preset to "0" or "FFhex". Any other values, such as "1", may cause problems when a data backup is imported after a software upgrade. The preferred setting is FFhex. 6HULHVVWDUWXSZLWK00&VRIWZDUHYHUVLRQ If you create a series start-up file using an NCK SW version higher than NCK , the user cycles are integrated twice. With NCK software version and later, the NC features a new directory "CMA_DIR" (cycles for machine manufacturers). The MMC does not yet recognize this directory (only from MMC version 5.3 and later) and therefore saves user cycles a second time. When you import the series start-up file, the message "File exists. Overwrite Yes/No" is displayed for user cycles. Since these have already been imported, they do not need to be overwritten. Page 6 of 10

7 /LPLWDWLRQRIQXPEHURID[HVDQGFKDQQHOV The limit on the number of axes or channels in the individual software variants does not influence the display of machine data specific to axes or channels. In other words, the machine data for 31 axes are still displayed in the 12-axis software variant. It is thus possible to assign axis numbers higher than 12 even when the total number of axes is 12 or less. The limitation is programmed via MD NUM_AXES_IN_SYSTEM. '03PRGXOHV The number of axes including DMP modules is limited to 31. If, for example, one DMP module is utilized in a 31-axis software variant, then only another 31 axes can be parameterized.. 1&8 3/&)&&)$% A new PLC based on the IBC16 chip has been has been developed with the NCU / The SINUMERIK order number for PLC 6FC CF00-0AB0 corresponds to Simatic order number 6ES CF00-0AB0 8SJUDGHUHTXLUHPHQWV - STEP7 version 5.1 service pack 2, Hotfix 3or STEP7 on HMI version 5.1 with service pack 3 - NCU software release >= or PLC firmware version Toolbox Basic PLC program or HMI ADV version >= , or HMI EMB version >= If PLC projects with an S7 hardware configuration are to be installed, a new PLC hardware configuration will need to be generated. For this purpose, PLC CPU 314C-2DP must be integrated in the hardware configuration (from the toolbox). &KDQJHVDVFRPSDUHGWR3/&'3 - Performance is faster by about a factor of 3 - User memory 480KB - 32 PROFIBUS slaves timers counters. 3/&RSHUDWLQJV\VWHPYHUVLRQ If you intend to run software version with an NCU572.4 or 573.4, you must install PLC Besy version Version is not compatible and must be replaced by the above version as part of the upgrade. 3/&WRROER[ +DUGZDUHFRQILJXUDWLRQ SINUMERIK components are now stored in a special "SINUMERIK" folder. In earlier versions, they are still stored in the "Rack 300" folder. You will need this toolbox to configure the NCU as the hardware catalog for the PLC of the NCU ( S7 PLC 314-C-2DP- 6CF00 ) has been modified. Page 7 of 10

8 6XSSOHPHQWDU\FRQGLWLRQV 'LVSOD\RI3/&PHPRU\FRQILJXUDWLRQ The memory configuration display in S7 is not correct. The user is guaranteed 480KB of load memory. It is possible to exceed this load memory limit, i.e. to use more than 480KB, but problems may then be encountered when PLC series start-up files are imported. Alarm: Memory full. 8SJUDGLQJZLWKJDSVLQFKDQQHOD[LVVHTXHQFH If there are gaps in the channel axis definition and you are upgrading from a SW version earlier than to version 6, you will need to enter the zero offsets by hand, or import the series start-up file again without resetting the NC. $X[LOLDU\IXQFWLRQVLQ2% Auxiliary functions in the following combinations are sometimes not recognized in the PLC: H/T function evaluation in OB40 (parameter IRAuxfuT/H =true of FB1) In the part program: m=qu(55) h2=33 The H function goes missing sporadically. Remedy: Program m55. 6\QFKURQRXVVSLQGOH If the synchronous spindle coupling is activated while the leading spindle is accelerating, the following spindle will accelerate faster than the value set in the relevant MD. Alarms such as "contour monitoring" may be activated. When the synchronous spindle coupling is activated, all spindles in the coupling must have been enabled. If this is not the case, a positional offset between the leading and following spindles may develop when the spindles are positioned in synchronous spindle mode. &RXSOHGD[LVJURXSLQJV When coupled-axis groupings are activated via synchronized actions or on a cross-channel basis, the user must ensure that the control parameters (e.g. acceleration, velocity) of the following axis are not violated. These parameters are not monitored in the NC. 1&8OLQN If you couple NCUs using the Link function, you must always use NCUs of the same type (MLFB order number). If you want to configure a link connection with different Ipo cycles, the basic system cycles on both systems must be identical. Otherwise alarm 4013 with error identifier SYSCLOCK_SAMPLE_TIME_RATIO will be generated. ([FHSWLRQPlease note in the case of the NCU573 that different processors with different cycles are in circulation. If a module has to be replaced by a faster NCU as a servicing measure, the slower NCU must act as the master. It is not essential to replace all NCUs. Page 8 of 10

9 NCU MLFB (component) Component item no. Processor PLC FC5357-0BB33-0AE1 GWE HQWLXP,,0+] PLC 315-DP X200 MCE4 MOD PENTIUM II 266MHz FC5357-0BB33-0AE2 GWE HQWLXP,,,0+] PLC 315-DP X200 MOD MIKROPR PENTIUM II 500MHz MMC-2 5V FC5357-0BB34-0AE0 GWE HQWLXP,,,0+] PLC 314C-2DP X200 MOD MIKROPR PENTIUM II 500MHz MMC-2 5V ([WHQGHG0IXQFWLRQRXWSXW If you program an Mxx=0, the M function will now work correctly as a "Program Stop". This behavior is not, however, compatible with earlier software versions. 3HUIRUPDQFHFRQWUROPRGXOH It is possible to co-operate the new measuring circuit module Performance 2 with older control modules. However, the SinuComNc tool is required to start up a configuration of this type. (UURUVFRUUHFWHGLQVRIWZDUHYHUVLRQDQGODWHU BRKdb05483 BRKdb06518 BRKdb06605 BRKdb06662 BRKdb06717 BRKdb06725 CHMdc07053 CHMdc07080 CHMdc07129 ERLde31238 ERLde32387 ERLde32862 ERLde33156 ERLde36500 ERLde37706 ERLde38824 ERLde39510 ERLde39647 ERLde40805 ERLde40883 ERLde42036 ERLde42259 ERLde42645 ERLde43629 ERLde43820 ERLde44015 ERLde44556 ERLde45080 ERLde45575 ERLde46036 ERLde46141 ERLde46210 ERLde46213 ERLde46227 ERLde46230 ERLde46273 ERLde46297 ERLde46304 ERLde46339 ERLde46473 ERLde46476 ERLde46490 ERLde46519 ERLde46537 ERLde46541 ERLde46555 ERLde46655 ERLde46713 ERLde46714 ERLde46730 ERLde46741 ERLde46777 ERLde46789 ERLde46802 ERLde46841 ERLde46846 ERLde46857 ERLde46858 ERLde46907 ERLde46908 ERLde46928 ERLde46930 ERLde46932 ERLde46937 ERLde46942 ERLde46962 ERLde46990 ERLde47003 ERLde47016 ERLde47034 ERLde47051 ERLde47082 ERLde47121 ERLde47124 ERLde47150 ERLde47153 ERLde47156 ERLde47169 ERLde47172 ERLde47204 ERLde47256 ERLde47277 ERLde47415 ERLde47434 ERLde47442 ERLde47547 MGLdm00064 MGLdm00145 MGLdm00172 SWBds04646 SWBds04651 BRKdb05483 BRKdb06518 BRKdb06605 BRKdb06662 BRKdb06717 BRKdb06725 CHMdc07053 CHMdc07080 CHMdc07129 ERLde31238 ERLde32387 ERLde32862 ERLde33156 ERLde36500 ERLde37706 ERLde38824 ERLde39510 ERLde39647 ERLde40805 ERLde40883 ERLde42036 ERLde42259 ERLde42645 ERLde43629 ERLde43820 ERLde44015 ERLde44556 ERLde45080 ERLde45575 ERLde46036 ERLde46141 ERLde46210 ERLde46213 ERLde46227 ERLde46230 ERLde46273 ERLde46297 ERLde46304 ERLde46339 ERLde46473 ERLde46476 ERLde46490 ERLde46519 ERLde46537 ERLde46541 ERLde46555 ERLde46655 ERLde46713 ERLde46714 ERLde46730 ERLde46741 ERLde46777 ERLde46789 ERLde46802 Page 9 of 10

10 ERLde46841 ERLde46846 ERLde46857 ERLde46858 ERLde46907 ERLde46908 ERLde46928 ERLde46930 ERLde46932 ERLde46937 ERLde46942 ERLde46962 ERLde46990 ERLde47003 ERLde47016 ERLde47034 ERLde47051 ERLde47082 ERLde47121 ERLde47124 ERLde47150 ERLde47153 ERLde47156 ERLde47169 ERLde47172 ERLde47204 ERLde47256 ERLde47277 ERLde47415 ERLde47434 ERLde47442 ERLde47547 MGLdm00064 MGLdm00145 MGLdm00172 SWBds04646 SWBds04651 BRKdb06856 BRKdb06902 BRKdb06907 BRKdb06908 CHMdc07126 CHMdc07389 CHMdc07391 CHMdc07392 CHMdc07469 ERLde39043 ERLde41100 ERLde43626 ERLde44073 ERLde44230 ERLde45142 ERLde45535 ERLde45743 ERLde46196 ERLde46943 ERLde46973 ERLde47059 ERLde47071 ERLde47143 ERLde47155 ERLde47260 ERLde47287 ERLde47315 ERLde47317 ERLde47325 ERLde47341 ERLde47352 ERLde47357 ERLde47399 ERLde47433 ERLde47475 ERLde47575 ERLde47582 ERLde47628 ERLde47633 ERLde47662 ERLde47696 ERLde47717 ERLde47720 ERLde47725 ERLde47774 ERLde47804 ERLde47807 ERLde47824 ERLde47835 ERLde47838 ERLde47844 ERLde47845 ERLde47863 ERLde47866 ERLde47889 ERLde47898 ERLde47918 ERLde47923 ERLde47924 ERLde47946 ERLde47950 ERLde47954 ERLde47968 ERLde47972 ERLde47983 ERLde48048 ERLde48049 ERLde48068 ERLde48078 ERLde48087 ERLde48088 ERLde48095 ERLde48096 ERLde48122 ERLde48146 ERLde48224 ERLde48231 ERLde48309 ERLde48407 ERLde48414 ERLde48415 ERLde48445 ERLde48473 ERLde48527 ERLde48683 MGLdm00138 MGLdm00169 MGLdm00190 MGLdm00192 MGLdm00206 MGLdm00212 MGLdm00216 MGLdm00218 MGLdm00224 MGLdm00225 SWBds04710 ERLde49276 Page 10 of 10

START-UP and UPGRADE INSTRUCTIONS

START-UP and UPGRADE INSTRUCTIONS SIEMENS AG A&D MC RD5 Valid for SINUMERIK 810/840D Software Version 6.3.30 Page 1 of 10 1 Requirements for upgrading software... 3 2 Data backup... 3 2.1 General requirements