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 for upgrading software... 3 2.2 Software upgrade with MMC 100.2... 4 2.2.1 Requirements... 4 2.2.2 Backup of NC data with MMC 100.2... 4 2.3 Software upgrade with MMC 103 / PCU 50... 4 2.3.1 Data backup with MMC 103 or PCU 50... 4 2.3.2 Software replacement within the same software series... 4 3 CCU3... 5 3.1 Upgrade from CCU1 to CCU3... 5 3.2 Upgrade from CCU2 to CCU3... 5 4 General notes... 6 4.1 General restrictions... 6 4.2 Software version display... 6 4.3 Frames... 6 4.3.1 6 4.3.2 6 4.4 Series start-up file... 6 4.5 Series startup with MMC 103 software version < 5.3... 6 4.6 Limitation of number of axes and channels... 7 4.7 DMP modules... 7 5 NCU 572.4 / 573.4... 7 5.1 PLC 6FC5 314-6CF00-0AB0... 7 5.2 PLC operating system version 10.60.15... 7 5.3 PLC toolbox... 8 6 Supplementary conditions... 8 6.1 Display of PLC memory configuration... 8 6.2 Upgrading with gaps in channel axis sequence... 8 6.3 Auxiliary functions in OB40... 8 6.4 Synchronous spindle... 8 6.5 Coupled-axis groupings... 8 6.6 NCU link... 8 6.7 Gantry axes... 9 6.8 Performance 2 control module... 9 6.9 PLC axis with FC18... 9 6.10 Transmit... 9 6.11 Memory management... 9 7 Errors corrected in software version 6.3.26 and later... 10 Page 2 of 10

These instructions describe how to upgrade the software on the SINUMERIK 810D, CCU3 / 840D systems to the new product release 6.3.30. The software version 6.3.30 (NCK 48.05.00) is a software update version. The NCK functionality corresponds to software version 6.3.26. 1 Requirements for upgrading software System software Versions not subject to export restrictions 6FC5250-6PX10-3AH0 :NCU system software 2 axes on PC card for NCU 561.2/561.3 6FC5250-6BX10-3AH0 :NCU system software 6 axes on PC card for NCU 571.3 6FC5250-6BY30-3AH0 :NCU system software 12 axes on PC card for NCU 572.3/572.4/573.2/573.3/573.4 6FC5250-6AY30-3AH0 :NCU system software 31 axes on PC card for NCU 572.3/572.4/573.2/573.3/573.4 6FC5450-6AY03-3AH0:CCU system software on PC card for CCU3 Versions subject to export restrictions 6FC5250-6BX30-3AH0 :NCU system software 12 axes on PC card for NCU 572.3/572.4/573.2/ 573.3/573.4 6FC5250-6AX30-3AH0 :NCU system software 31 axes on PC card for NCU 572.3/572.4/573.2/ 573.3/573.4 6FC5450-6AX03-3AH0 :CCU system software on PC card for CCU3 Tools - 6FC5252-6AX21-3AG0 :Toolbox V 06.03.03 with basic PLC program 6.3.3 - PG/PC with STEP7, version 4.02 and optional online MPI connection. - Current documentation for SW 6 with more detailed information about functions 2 Data backup 2.1 General requirements for upgrading software Before you upgrade the NCK, you must make sure that at least 50 KB 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 50 KB 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 11210 UPLOAD_MD_CHANGES_ONLY = FF, 11220 INI_FILE_MODE to "1" or "2". Page 3 of 10

2.2 Software upgrade with MMC 100.2 2.2.1 Requirements You must make the following cable connections. RS-232-C connection between MMC and PG/PG for machine / drive and user data. 2.2.2 Backup of NC data with MMC 100.2 Select start-up data in menu "Data Out" in the "Services" area. Back up NCK data in archive format via the RS-232-C interface to PG/PC (individually) separately to the PLC data. Note : Compensation 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"). 2.3 Software upgrade with MMC 103 / PCU 50 2.3.1 Data backup with MMC 103 or PCU 50 NCK 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: NC with Compensations) in menu Services/Series Startup/Create Startup Archive/. 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. PLC 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: PLC) 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. 2.3.2 Software replacement within the same software series Replace software 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. Page 4 of 10

You can check the software version in menu Diagnosis/Service Displays/Version. Load data backups After you have set the manufacturer password, you can choose and then import the NCK data backup file by selecting menu options Services/Series Startup/Import Startup Archive/. When this import is completed, you can import the PLC data backup. After you have imported the PLC backup data, you must switch the system off and on again to allow all components to boot together. 3 CCU3 3.1 Upgrade from CCU1 to CCU3 - 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 NOTICE: MD1254 is set to default values. You must use the data backup to check whether its value has changed from the default setting (0.5 ms). - 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 3.2 Upgrade from CCU2 to CCU3 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 (768 KB) 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. Note: CCU3e software can be flashed. A Flash process is identified by "8" on the 7-segment display and takes approximately 2 minutes. A "9" is displayed to indicate completion of the Flash operation. Page 5 of 10

4 General notes 4.1 General restrictions - 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 573.3. The number of channels has been limited to eight. - The number of channels on the NCU 561.2 / 561.3 / 571.2 is limited to 1. - The number of channels on the NCU 572.3, 31-axis SW, is limited to 6. 4.2 Software version display The display of the NCK software version in the Diagnosis display (header) and machine data has been modified in conformance with Catalog NC60. Example: 06.03.19. 840D 06A.. 65 ph_km This example shows the software for 6 axes (06A). This software is compatible with the NCU 571.3. 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. 4.3 Frames 4.3.1 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. 4.3.2 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. 4.4 Series start-up file 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. 4.5 Series startup with MMC 103 software version < 5.3 If you create a series start-up file using an NCK SW version higher than NCK 05.02.06, the user cycles are integrated twice. With NCK software version 5.02.06 and later, the NC features a new directory "CMA_DIR" (cycles for machine manufacturers). The MMC does not yet recognize this directory (only Page 6 of 10

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. 4.6 Limitation of number of axes and channels 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. 4.7 DMP modules 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 30 axes can be parameterized. 5 NCU 572.4 / 573.4 5.1 PLC 6FC5 314-6CF00-0AB0 A new PLC based on the IBC16 chip has been has been developed with the NCU 572.4 / 573.4. The SINUMERIK order number for PLC 6FC5 314-6CF00-0AB0 corresponds to Simatic order number 6ES7 314-6CF00-0AB0 Upgrade requirements - STEP7 version 5.1 service pack 2, Hotfix 3 or STEP7 on HMI version 5.1 with service pack 3 - NCU software release >= 5.3.27 or >= 6.3.15 - PLC firmware version 10.60.15 - Toolbox 6.3.2 - Basic PLC program 5.3.5 or >= 6.3.2 - HMI ADV version >= 5.3.20, 6.1.15 or 6.2.12 - HMI EMB version >= 6.2.34. 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). Changes as compared to PLC 315-2DP - Performance is faster by about a factor of 3 - User memory 480 KB - 32 PROFIBUS slaves - 256 timers - 256 counters. 5.2 PLC operating system version 10.60.15 If you intend to run software version 6.3.30 with an NCU572.4 or 573.4, you must install the PLC operating system version 10.60.15. Version 10.60.11 is not compatible and must be replaced by the above version as part of the upgrade. Page 7 of 10

5.3 PLC toolbox Hardware configuration: 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 573.4 as the hardware catalog for the PLC of the NCU 573.4 ( S7 PLC 314-C-2DP- 6CF00 ) has been modified. 6 Supplementary conditions 6.1 Display of PLC memory configuration The memory configuration display in S7 is not correct. The user is guaranteed 480 KB of load memory. It is possible to exceed this load memory limit, i.e. to use more than 480 KB, but problems may then be encountered when PLC series start-up files are imported. Alarm: Memory full. 6.2 Upgrading with gaps in channel axis sequence If there are gaps in the channel axis definition and you are upgrading from a SW version earlier than 05.03.13 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. 6.3 Auxiliary functions in OB40 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. 6.4 Synchronous spindle 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. 6.5 Coupled-axis groupings 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. 6.6 NCU link 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. Page 8 of 10

Exception: Please 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. NCU MLFB (component) Component item no. Processor PLC 573.2 6FC5357-0BB33-0AE1 GWE-570038.9634.36 Pentium II 266 MHz PLC 315-DP X200 MCE4 MOD PENTIUM II 266 MHz 573.3 6FC5357-0BB33-0AE2 GWE-570038.9635.11 Pentium III 500 MHz PLC 315-DP X200 MOD MIKROPR PENTIUM II 500 MHz MMC-2 5V 573.4 6FC5357-0BB34-0AE0 GWE-570038.9635.20 Pentium III 500 MHz PLC 314C-2DP X200 MOD MIKROPR PENTIUM II 500 MHz MMC-2 5V 6.7 Gantry axes The function generator (rectangle) may not be used if the following axis in the gantry grouping turns in reverse (AX_MOT_DIR=1). 6.8 Performance 2 control module Mixed operation is possible between the new measuring circuit module Performance 2 and older control modules. However, the SinuComNC tool is required to start up a configuration of this type. 6.9 PLC axis with FC18 If the FC18 is started almost simultaneously and a RESET is given, then this may lead to a blockade of the starting sequence. The axis remains a PLC axis and can only be switched to neutral again by an NCK P/O reset. 6.10 Transmit System errors may occur with transmit active and machining in the pole. Transmit may be disabled as it is not required for machining in the pole. 6.11 Memory management The option check on the basis of the compiler switch 'ncu3' was not active for the 12/31 axis software. The option check is active again. The default value of the free SRAM memory is 0.5 MB for ncu2 and 2.5 MB for ncu3. Page 9 of 10

7 Errors corrected in software version 6.3.26 and later BRKdb06859 BRKdb06996 BRKdb06999 BRKdb07080 BRKdb07202 CHMdc07494 CHMdc07540 CHMdc07609 CHMdc07684 CHMdc07708 ERLde37039 ERLde37630 ERLde38385 ERLde38399 ERLde38431 ERLde44073 ERLde44764 ERLde45144 ERLde45364 ERLde45863 ERLde45926 ERLde46210 ERLde46708 ERLde46720 ERLde46816 ERLde46833 ERLde47193 ERLde47355 ERLde47705 ERLde47756 ERLde47796 ERLde47934 ERLde47965 ERLde48074 ERLde48137 ERLde48268 ERLde48527 ERLde48643 ERLde48696 ERLde48709 ERLde48791 ERLde48883 ERLde48891 ERLde48920 ERLde48962 ERLde48983 ERLde48994 ERLde48995 ERLde48997 ERLde49038 ERLde49139 ERLde49182 ERLde49187 ERLde49256 ERLde49263 ERLde49276 ERLde49278 ERLde49313 ERLde49344 ERLde49350 ERLde49353 ERLde49376 ERLde49383 ERLde49385 ERLde49437 ERLde49440 ERLde49476 ERLde49550 ERLde49560 ERLde49604 ERLde49628 ERLde49644 ERLde49669 ERLde49686 ERLde49697 ERLde49713 ERLde49741 ERLde49745 ERLde49847 ERLde50065 ERLde50076 ERLde50133 ERLde50285 ERLde50311 ERLde50375 ERLde50511 ERLde50592 ERLde50715 ERLde50878 ERLde50952 ERLde51032 ERLde51051 ERLde51333 ERLde51567 ERLde51833 ERLde51900 ERLde52124 ERLde52168 ERLde52862 ERLde52873 MGLdm00236 MGLdm00266 MGLdm00274 MGLdm00282 MGLdm00287 MGLdm00289 MGLdm00292 MGLdm00307 MGLdm00317 MGLdm00337 MGLdm00343 MGLdm00357 MGLdm00358 SWBds04788 Page 10 of 10