SIEMENS AG

A&D MC RD5

START-UP
and
UPGRADE GUIDE
Applies to

SINUMERIK 810/840D
Software Version 06.05.26.00

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2004-12-07
1 Requirements for Upgrade ..................................................................................... 3
1.1 System software 06.05.26.00 3
1.2 Tools 3
2 Back-Up.................................................................................................................... 3
2.1 General requirements for upgrade 3
2.2 Software upgrade with MMC 100.2 4
2.2.1 Requirements............................................................................................................................4
2.2.2 Backing up NC data with MMC 100.2.......................................................................................4
2.3 Software upgrade with MMC 103 / PCU 50 4
2.3.1 Data back-up with MMC 103 or PCU 50...................................................................................4
2.3.2 Replacing software within a software series.............................................................................4
3 CCU 3 ....................................................................................................................... 5
3.1 Upgrading from CCU 1 to CCU 3 5
3.2 Upgrading from CCU 2 to CCU 3 5
3.3 Spindle setpoint display 5
3.4 Alarm 8022 6
4 General Restrictions ............................................................................................... 6
5 Functional Improvements from Version 06.05.11.00 to Version 06.05.24.00 ..... 6
5.1 NCK increment 51.08.00 6
5.2 NCK increment 51.09.00 7
5.3 NCK increment 51.10.00 7
5.4 NCK increment 51.11.00 7
6 Functional Improvements from Version 06.05.24.00 to Version 06.05.25.00 ..... 8
6.1 NCK increment 51.12.00 8
7 Functional Improvements from Version 06.05.25.00 to Version 06.05.26.00 ..... 8
7.1 NCK increment 51.12.01 8

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1 Requirements for Upgrade
Software version 06.05.26.00 (NCK 51.12.01) is a software update release. The NCK functionality
corresponds to software version 06.05.11.00 (NCK 51.07.04).
The Upgrade Instructions for software versions 06.04.15.00 and 06.05.11.00 apply to an upgrade to
version 06.05.26.00.

1.1 System software 06.05.26.00

Export versions
Order number Designation ... on PC card For hardware
6FC5250-6DY30-5AH0 NCU system software 2 axes NCU *.4, NCU 573.5
6FC5250-6CY30-5AH0 NCU system software 6 axes NCU *.4, NCU 573.5
6FC5250-6BY30-5AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4,
NCU 573.5
6FC5250-6AY30-5AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4,
NCU 573.5
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 573.5
6FC5250-6BX30-5AH0 NCU system software 12 axes NCU 572.3/573.2/573.3, NCU *.4,
NCU 573.5
6FC5250-6AX30-5AH0 NCU system software 31 axes NCU 572.3/573.2/573.3, NCU *.4,
NCU 573.5
6FC5450-6AX03-5AH0 CCU system software CCU 3

1.2 Tools

- 6FC5250-6AY00-3AG0 SinuCom NC with SinuCom FFS

SinuCom FFS must be used to program the PC card with software version 6.4.13 and higher.
- 6FC5252-6AX21-5AG0 toolbox V 06.05.02 with basic PLC program 06.05.02 .
The basic PLC program of toolbox 6.3.3 can be used. An upgrade is not always required.
- PG/PC with Step 7 Version 5.2 and higher and optional online MPI link.
- Current documentation for SW 6 with additional function-related information

2 Back-Up
2.1 General requirements for upgrade
Before upgrading the NCK ensure that at least 50kB 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 50KB of static memory should be available. This can be checked with MD18060
INFO_FREE_MEM_STATIC. If the available memory is insufficient, memory space can be freed by
unloading NC programs.
Set machine data 11210 UPLOAD_MD_CHANGES_ONLY = FF, 11220 INI_FILE_MODE = 1 or 2.

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2.2 Software upgrade with MMC 100.2
2.2.1 Requirements
RS232 C (V.24) connection between MMC and PG or PC.

2.2.2 Backing up NC data with MMC 100.2

Select start-up data from the "Data Out" menu in the "Services" operating area. Back up NCK data in
archive format on the PG/PC separately from the PLC data via RS-232-C on PG/PC (individually).
Note:
Compensation data are not backed up with the series start-up file. The compensation data can be backed
up separately to an external PC in the "Services" area via "SK Data Out -SK Data" and selecting sections
"Interpolative compensation", "Circle error compensation", and "Leadscrew error compensation".
(Once the NCU has been upgraded, these data can be loaded back into the NCK ("Services" area
"Softkey Data In" --- MD CEC_ENABLE and ENC_COMP_ENABLE of the axes in question have the value
"0").

2.3 Software upgrade with MMC 103 / PCU 50

2.3.1 Data back-up with MMC 103 or PCU 50
NCK
Before the NCK is upgraded, a back-up must be made to permit recovery of the machine's current
database. This is done by creating a series start-up file.
To create the series start-up file set the manufacturer password and unload a tool in the spindle or buffer.
You can now specify the archive content of the file to be created in menu Services/Series start-up/ Create
start-up archive/ (selection: NC with compensations). (or include any loadable compile cycles)
After the archive name has been defined, data back-up can be started with the Archive softkey.
Now all necessary data (compensation, tools, definitions, loaded programs, machine data, etc. ) are
stored in the Archive 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 the Stop state. The
PLC series start-up file is created in the same way as the NCK back-up, i.e. by selecting the data (select
PLC) and then pressing the Archive softkey.
If you want to upgrade the basic PLC program you will need STEP 7. For this, you will have to install the
new toolbox via 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 new user programs) because they have been modified by the
machine manufacturer. Finally, transfer the blocks to the PLC. A new PLC series start-up file must be
created.

2.3.2 Replacing software within a software series

Replacing the software
Switch off the control and replace the PC card. The card stays in the control (irrespective of the Sinumerik
810D/840D type).
Set switch S3 to position 1, set S4 to position 3 and switch on the control. 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 are 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 Diagnosis/Service Displays/Version.

Loading the back-ups

Once the manufacturer password has been set, the NCK back-up can be loaded in menu Services/ Series
start-up/Load start-up archive/ after selecting the back-up file.
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Once completed, the PLC back-up can be loaded.
Once the PLC back-up file has been loaded you must switch the system off and on again so that all
components are powered up at the same time.

3 CCU 3
3.1 Upgrading 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 into the CCU 3.
For that, you will need to create an upgrade archive with the setting
"$MN_UPLOAD_MD_CHANGES_ONLY=FF".
- Standard start-up CCU 3
When standard start-up of the CCU 3 is complete, be sure to 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 read out
when you load the upgrade archive:
Drive x: Line x: Entry not found in ACC file: N1254 $MD_SPACE_VECTOR_FILTER_TIME
Notice:
MD1254 is assigned default values. Check against the data back-up whether the value is now different
from the default (0.5ms).
- DRAM expansion
After loading of the upgrade archive, MD $MN_USER_MEM_DYNAMIC should be reset 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

3.2 Upgrading from CCU 2 to CCU 3

Memory problems may occur when upgrading a CCU 3 with a CCU 2 series start-up file because the
SRAM memory expansion of the CCU 2 is not defined with option data. On the CCU 3, any SRAM
memory greater than the basic complement (768 Kbytes) is defined by options. In that case, part
programs must be unloaded from the CCU 2 before the series start-up file is created, so that the series
start-up can be reloaded without any problem. If it is not possible to load all the programs again, memory
options must be upgraded.
Note:
The CCU3e software can be flashed. The flash operation is indicated by the number 8 on the 7-segment
display and takes about 2 minutes.
Number 9 on the display indicates that the flash operation is complete.

3.3 Spindle setpoint display

The spindle setpoint display in the HMI spindle window is no longer affected by the content of MD 22410
$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, setpoint speed "0" is displayed.
Example:
M3 S100
g4 F2
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2004-12-07
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
M5 Setpoint display on HMI "100" rpm

3.4 Alarm 8022

Depending on the machine data settings, alarm 8022 may be output.

Remedy: increase MD19250 by "1".

4 General Restrictions

- Software version 06.05.25.00 has not been released for ShopTurn. Software version 06.05.26.00 must
be used.
- The Continuous Dressing function is not enabled in software version 06.05.25.00. Software version
06.05.26.00 must be used for this.
- If Step7 Version 5.3 is being used, the toolbox must be installed if projects (including PLC blocks)
containing hardware components of the toolbox are to be processed.
- NCU *.4 with PLC 314C:
If master/slave configurations are used, the PLC 314C must not be operated as a slave.
If such a configuration is required it must be implemented with a CP module.
- Function G643 (approximate positioning in block) is enabled for applications in the tool change area (e.g.
optimizations for approaching the tool change position).
It is not enabled for applications in the machining process.
- The functions FCUB and FLIN in combination with the compressor COMPCAD are not enabled.
- NCUs nnn.3: The PCU 50 can only be shut down with the Exit button in emergency stop mode if PLC
firmware version < 12.30.10 is used.
- NCUs nnn.4 : The PCU 50 can only be shut down with the Exit button in emergency stop mode if PLC
firmware version < 10.60.17 is used.
- With the NCU 573.3, it is no longer possible to enable 10 channels and 31 axes at the same time.
That number is now limited to eight channels.
- The number of channels is limited to 6 for NCU 572.3 / 572.4, 31-axis software.
The number of axes including the DMP block is limited to 31. If, for example, a DMP block is used with
31-axis software, at total of 30 axes are still possible.

5 Functional Improvements from Version 06.05.11.00 to Version 06.05.24.00

5.1 NCK increment 51.08.00

BRKdb06987 BRKdb08506 BRKdb08596 BRKdb08769 BRKdb08786 BRKdb08840

BRKdb08873 BRKdb08884 CHMdc08516 CHMdc08557 ERLde59971 ERLde60083

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ERLde60489 ERLde60715 ERLde60770 ERLde60874 ERLde61130 ERLde61141
ERLde61494 ERLde61692 ERLde61740 ERLde61866 ERLde61893 ERLde62227
ERLde62462 ERLde62469 ERLde62612 ERLde62665 ERLde62713 ERLde62740
ERLde62797 ERLde62803 ERLde62813 ERLde62834 ERLde62861 ERLde62867
ERLde62900 ERLde62904 ERLde62907 ERLde62911 ERLde62919 ERLde62921
ERLde62930 ERLde62932 ERLde63111 ERLde63132 ERLde63158 ERLde63237
ERLde63315 ERLde63336 ERLde63401 ERLde63422 ERLde63565 ERLde63692
ERLde63721 ERLde63787 ERLde63841 ERLde63876 ERLde64019 ERLde64046
ERLde64089 ERLde64241 ERLde64276 ERLde64367 ERLde64378 ERLde64413
ERLde64505 ERLde64508 ERLde64641 ERLde64657 ERLde64775 ERLde64782
ERLde64878 ERLde64883 ERLde64919 ERLde64976 ERLde65040 ERLde65102
ERLde65133 ERLde65214 ERLde65262 ERLde65293 ERLde65335 ERLde65339
ERLde65402 ERLde65481 ERLde65650 ERLde65859 ERLde65993 ERLde66186
MGLdm00694 MGLdm00697 MGLdm00790 MGLdm00796 MGLdm00797 MGLdm00826
MGLdm00827 MGLdm00828 MGLdm00839 MGLdm00849 MGLdm00853 SWBds05429
SWBds05546

5.2 NCK increment 51.09.00

BRKdb09214 CHMdc08569 ERLde40583 ERLde45520 ERLde46847

ERLde60919 ERLde62825 ERLde62870 ERLde62885 ERLde63448 ERLde64365
ERLde64541 ERLde64727 ERLde64733 ERLde64751 ERLde64829 ERLde65616
ERLde65767 ERLde65785 ERLde65834 ERLde65928 ERLde66002 ERLde66170
ERLde66226 ERLde66364 ERLde66526 ERLde66558 ERLde66589 ERLde66631
ERLde66640 ERLde66679 ERLde66690 ERLde66740 ERLde66790 ERLde66811
ERLde66826 ERLde66845 ERLde66899 ERLde66927 ERLde66939 ERLde66991
ERLde67006 ERLde67010 ERLde67167 ERLde67170 ERLde67172 ERLde67213
ERLde67278 ERLde67308 ERLde67385 ERLde67407 ERLde67408 ERLde67414
ERLde67424 ERLde67440 ERLde67468 ERLde67471 ERLde67497 ERLde67505
ERLde67511 ERLde67524 ERLde67540 ERLde67558 ERLde67623 ERLde67694
ERLde67716 MGLdm00899 SWBds05506

5.3 NCK increment 51.10.00

BRKdb07542 BRKdb08595 BRKdb09228 BRKdb09252 BRKdb09317 CHMdc08360

CHMdc08459 CHMdc08482 ERLde43716 ERLde60830 ERLde61075 ERLde65111
ERLde65153 ERLde65174 ERLde65835 ERLde66551 ERLde66919 ERLde67215
ERLde67263 ERLde67289 ERLde67290 ERLde67305 ERLde67355 ERLde67443
ERLde67475 ERLde67566 ERLde67602 ERLde67678 ERLde67718 ERLde67962
ERLde68045 ERLde68147 ERLde68309 ERLde68321 ERLde68375 ERLde68450
ERLde68456 ERLde68468 ERLde68607 MGLdm00916 MGLdm00932

5.4 NCK increment 51.11.00

ERLde68376
ERLde68924

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6 Functional Improvements from Version 06.05.24.00 to Version 06.05.25.00
6.1 NCK increment 51.12.00

BRKdb03310 BRKdb06087 BRKdb09059 BRKdb09546 CHMdc08853 ERLde38712

ERLde47756 ERLde51061 ERLde60654 ERLde61604 ERLde64158 ERLde64505
ERLde64993 ERLde65950 ERLde66495 ERLde66563 ERLde66566 ERLde66730
ERLde66885 ERLde66902 ERLde67112 ERLde67281 ERLde67282 ERLde67331
ERLde67335 ERLde67351 ERLde67563 ERLde67654 ERLde67720 ERLde67971
ERLde67978 ERLde67980 ERLde67991 ERLde68055 ERLde68190 ERLde68320
ERLde68376 ERLde68512 ERLde68554 ERLde68632 ERLde68763 ERLde68764
ERLde68789 ERLde68792 ERLde68845 ERLde68887 ERLde68907 ERLde68924
ERLde68968 ERLde69004 ERLde69057 ERLde69088 ERLde69091 ERLde69115
ERLde69227 ERLde69234 ERLde69250 ERLde69375 ERLde69552 ERLde69665
ERLde69675 ERLde69786 ERLde69858 ERLde69918 ERLde70163 ERLde70200
ERLde70398 ERLde70442 ERLde70726 ERLde70768 ERLde70785 MGLdm00125
MGLdm00943 MGLdm00946 MGLdm00955 MGLdm00956 MGLdm00969 SWBds05644
SWBds05882 SWBds05923 SWBds05925 SWBds05942

7 Functional Improvements from Version 06.05.25.00 to Version 06.05.26.00

7.1 NCK increment 51.12.01

ERLde48787 ERLde66765 ERLde69118

ERLde70327 ERLde71804 ERLde72654
MGLdm01010 MGLdm01033

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