SINUMERIK 840D sl 03/03/2006

NCU Software 1.3 SP2

____________________________________________________________________________________
SINUMERIK 840D sl, NCU System Software for six axes ) 6FC5841-1XG10-1YA0
und ShopMill HMI, in six languages, on CF card; with license ) Export 6FC5841-1YG10-1YA0

SINUMERIK 840D sl, NCU System Software for 31 axes ) 6FC5841-3XG10-1YA0

und ShopMill HMI, in six languages, on CF card; with license ) Export 6FC5841-3YG10-1YA0

SINUMERIK 840D sl, NCU System Software for 6/31 axes ) 6FC5841-3XC10-1YA8
and ShopMill HMI, in six languages, on DVD; without license ) Export 6FC5841-3YC10-1YA8
____________________________________________________________________________________

Information about installing and operating the software on SINUMERIK NCU 710.1 and NCU 720.1
Version 1.3 SP 2 of the NCU software consists of the following components:
o NCU base operating system V01.50 + SP07
o NCK software V62.09.01
o PLC BeSy V20.70.30
o PLC FB15 V01.03.02
o CP V01.24.03
o MCP Client V01.03.08
o SINAMICS software V02.30.3000
o HMI Embedded V07.10.85.00
o Technology cycles V06.05.17
o Measuring cycles V06.03.29
o ISO cycles V06.05.02
o ShopMill HMI V07.10.12.00

1. Installing the NCU software:

For installing the NCU software you require the NCU Service System V1.50.07 on USB stick.

1.1 Installing the NCU service system on a USB stick:

The NCU service system is stored as a USB stick image in directory emergency_bootsys_ncu on the CD-ROM.
The copy routine installdisk.exe is stored in the same location. Connect a USB stick 512MB, recommended type
Siemens 6ES7648-0DC20-0AA0, to your programmer or PC (with Windows XP) and note down the letter of the
drive to which the stick is connected. Run routine installdisk to copy the NCU service system to the USB stick:
Installdisk --verbose --blocksize 1m <Image file> <drive letter:>
( -- means 2x minus sign)
Example:
installdisk --verbose --blocksize 1m D:\ emergency_bootsys_ncu\linuxbase-512M.img X:
It is best to copy the image in a DOS shell.
For this you require administrator rights on your PG / PC.
After completion of installdisk remove the USB stick from the PG / PC and insert it again. Under Windows you
can now see an empty USB stick. Now copy the desired NCU software (file with extension .tgz) from directory
ncu_sw on the delivered CD to this USB stick.
The USB stick can be connected to one of the two USB connectors of the NCU 7x0. The NCU will boot from this
USB stick after power ON. The system operates either via a TCU that is connected to the NCU, or via PG / PC
through WinSCP under "Open Terminal".
Instructions on how to use the NCU service system can be found in documentation /IM7/ on the CD-ROM.
Note: Booting the NCU service system from a USB stick of type "SanDisk cruzer mini 1.0GB" does not work.

1.2 Upgrading an NCU 7x0 with NCU software 1.3 (NCU 01.03.01)
IMPORTANT: This procedure exclusively applies to existing systems with NCU software 01.03.01, but not for
preliminary software with versions older than 01.03.01. See 1.3 for NCU software with versions older than
01.03.01.
When the software is upgraded, all user data are maintained in directories /user, /addon, /oem of the CF card as
well as the license key.
o Boot the NCU from the USB stick (see 1.1).

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

o Select the Service Shell by pressing F2 / softkey 2.

o Log in with user name "manufact". An external keyboard may be required for this, as user names must
be written in lower case letters.
o After operating prompt $ of the service shell enter the following command:
sc restore -update -force /data/<ncu-sw>.tgz
The software update will be completed when prompt $ is displayed again.
o Remove the USB stick.
o Boot the NCU (F3 / softkey 3 "Restart").
o You can now start the PLC, drives and NC.
Note: When you work with "Open Terminal" through WinSCP, messages may be displayed indicating that the
communication partner has not reacted for a certain period of time. You can ignore these messages, but please
do not cut the connection in this case.

1.3 New installation of NCU software 1.3 SP2 on CF card

IMPORTANT: This procedure completely deletes anything existing on the CF card; this applies for an empty CF
card as well.
o Boot the NCU from the USB stick (see 1.1).
o Select the Service Shell by pressing F2 / softkey 2.
o Log in with user name "manufact"; when the CF card is empty use "admin", password "SUNRISE"
instead. An external keyboard may be required for this, as user names must be written in lower case
letters.
o After operating prompt $ of the service shell enter the following command:
sc restore -full /data/<ncu-sw>.tgz
Software installation will be completed when prompt $ is displayed again.
o Remove the USB stick.
o Boot the NCU (F3 / softkey 3 "Restart").
o When the system is started with TCU(s) for the first time, the TCU(s) must be logged on to the system.
Enter the TCU name (default TCUx) and the address of an assigned MCP. For the time being, 255 must
always be entered!
o You can now start the PLC, drives and NC.

2. General information:
o After new installation of NCU software 1.3 SP2 on CF card, a general reset of the NCU and PLC must
be performed: Change the SIM / NCK switch into position 1, the PLC switch into position 3 and perform
a power OFF / ON.
o NCU 710 / NCU 720: The PLC program must initiate an immediate reaction to alarm "2120 NCK fan
alarm" by stopping the axes in a controlled manner.
o NCU 710 / NCU 720: The NCU will not power up if a fan module is not installed or if the fan is defective.
o Alarm 15122 "%1 data have been restored, of which %2 machine data, %3 error"
If %3 indicates that more than zero errors have occurred, it is not advisable to continue working with the
data. To avoid further problems, you should read in an up-to-date backup copy of the data.
o It is not always possible to port an NCK series startup file from 840D powerline without processing to
840D sl.
o Prior to overwriting a licensed CF card, a backup of the license key is absolutely necessary. The key is
available in file ‘keys.txt’ and is stored under the path card/keys/sinumerik
The backup of the key can be carried out, for example, with WinSCP, by the PG / PC.
o Each license is assigned to a specific CF card (card ID) and is valid only on the assigned card.
o Handheld unit type B-MPI
In order to make the input / output image of the handheld available for the PLC, the handheld unit must
be connected to the MPI bus of the solution line via distribution unit 6FX2006-1B..01. The handwheel of
the handheld unit can no longer be connected directly to the control system. The handwheel pulses are
now transmitted to the control via PROFIBUS. There are two options:
- In addition to the MPI distribution unit a handwheel connection module PROFIBUS 6FC5303-0AA02-
0AA0 is set. Two handwheels can be connected to this module.
- The handwheel is connected to an already existing machine control panel. Note the permissible cable
lengths.

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

When FB1 is parameterized as usual, the input / output image will no longer be transmitted automatically
via the PLC base program. Transmission is now performed through global data. The hardware
configuration of the PLC must be adjusted accordingly.
A toolbox is required for configuring the hardware of the machine control panel or handwheel connection
module PROFIBUS nodes.
o Mini handheld unit
An additional hardware is now required to operate a mini handheld unit with handwheel. The input image
is connected directly to the PLC I/Os as usual. For transmitting the handwheel signals a machine control
panel or a handwheel connection module PROFIBUS is now required as for the type MPI handheld unit.

3. Information about the NCK:

o Function G643 (block-internal smoothing) has been released 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.
o Function G644 (smoothing at max. possible dynamics) has been released 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.
o Software variant for a max. of six axes: The default setting for the number of axes is 3.
o The "Extended measurement" function with distributed measuring input on the SINAMICS modules is
not available (MEAC, MEASA, MEAWA).
o The function MEAC does not work with export software.
o Gaps in the channel sequence are not permitted in systems with a maximum of two channels.
o Access to drive data via system variable $nn_nn is not enabled. The only available system variables are
those transferred in telegram 116.
o ESR is not enabled.
o $MN_MM_USER_MEM_BUFFERED is currently limited to about 12200.
The part program memory can only be extended when there is free SRAM displayed in MD18060. The
relevant option must be set (+1 means an extension by 2MB) and refers to the sum of:
$MN_MM_U_FILE_MEM_SIZE[ 0 ]; 18352 -> cycles, part programs of end user
$MN_MM_M_FILE_MEM_SIZE[ 0 ]; 18353 -> machine manufacturer's cycles
o ASUBs can now be started along the line of the 840Di functionality via the PROFIBUS PLC I/Os.
Machine data settings must be selected by the same method used on the 840Di system. There are no
high-speed NCK I/Os mapped in DB10 of the PLC. However, the ASUB start options used in earlier
versions (i.e. from DB10 or FC9 via PLC program) are still available.
o With a 31-axis software on an NCU 710.1 you can use six out of 31 axes and two out of 10 channels.
o Number of axes > 15 only after request.
o Win SCP will be required for an update without TCU.
o For updating via TCU a USB full keyboard is required (upper / lower case switchover).
o The "ínstalldisk" tool can only be used under WinXP.
o Machine data 10008 $MN_MAXNUM_PLC_CTRL_AXES is no longer included in the data record. It has
been replaced by MD19160.
o For upgrading use 512MB USB sticks, if possible. Some USB sticks do not work.
o Read-in of drive series startups is cancelled from time to time. Frequently when using NX modules or
higher versions.
o If tool data are missing after series startup read-in, the file must be read in again without deleting the
NC.
o The control sometimes does not start after power ON.
o MD 10062 $mn_posctrl_cycle_delay must be zero. Check the available data backup.
o IMD (integrated monitoring & diagnostic) :
Feedback in GUD variable _PM_MISSING_TOOL_REFRESH after writing the variables to "1" is
updated only after image change.
o Released NCK options:
6FC5800-0AA00-0YB0 - 1 axis / spindle in addition
6FC5800-0AC00-0YB0 - 1 operating mode group (BAG) in addition
6FC5800-0AC10-0YB0 - 1 processing channel in addition
6FC5800-0AD00-0YB0 - 2MB CNC user memory in addition
6FC5800-0AD10-0YB0 - 128KB PLC user memory in addition
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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

6FC5800-0AM00-0YB0 - program preprocessing

6FC5800-0AM01-0YB0 - travel to fixed stop (with force control)
6FC5800-0AM02-0YB0 - pair of synchronized axes (gantry axes)
6FC5800-0AM03-0YB0 - master-slave for drive systems
6FC5800-0AM04-0YB0 - SINUMERIK NCK Runtime OA
6FC5800-0AM06-0YB0 - tangential control
6FC5800-0AM08-0YB0 - contour handwheel
6FC5800-0AM14-0YB0 - synchronous spindle/multi-edge turning
6FC5800-0AM15-0YB0 - multi-axis interpolation (> four axes)
6FC5800-0AM16-0YB0 - spline interpolation for three-axis processing
6FC5800-0AM17-0YB0 - spline interpolation for five-axis processing
6FC5800-0AM18-0YB0 - polynomial interpolation
6FC5800-0AM20-0YB0 - master value coupling and curve tables
6FC5800-0AM21-0YB0 - involute interpolation
6FC5800-0AM22-0YB0 - electronic gears EG
6FC5800-0AM23-0YB0 - axial coupling in the machine coordinate system
6FC5800-0AM26-0YB0 - machining package milling
6FC5800-0AM27-0YB0 - transmit and peripheral surface transformation
6FC5800-0AM28-0YB0 - inclined axis
6FC5800-0AM30-0YB0 - five-axis machining package
6FC5800-0AM31-0YB0 - handling transformation package
6FC5800-0AM34-0YB0 - oscillation, modal and non-modal
6FC5800-0AM36-0YB0 - synchronized actions step 2
6FC5800-0AM43-0YB0 - cross-mode actions
6FC5800-0AM48-0YB0 - 3D tool radius compensation
6FC5800-0AM50-0YB0 - tool management
6FC5800-0AM52-0YB0 - contour monitoring via tunnel function
6FC5800-0AM53-0YB0 - path length evaluation
6FC5800-0AM55-0YB0 - sag compensation, multi-dimensional
6FC5800-0AM60-0YB0 - generator operation
6FC5800-0AN00-0YB0 - additional languages
6FC5800-0AP01-0YB0 - manage network drives
6FC5800-0AP02-0YB0 - SINUMERIK HMI copy license OA
6FC5800-0AP03-0YB0 - SINUMERIK HMI copy license CE
6FC5800-0AP04-0YB0 - workstep programming
6FC5800-0AP11-0YB0 - manual machine
6FC5800-0AP12-0YB0 - additional 256MB HMI user memory on CF card of the NCU
6FC5800-0AP13-0YB0 - identification and processing of residual material
6FC5800-0AP14-0YB0 - multiple clamping of different workpieces
6FC5800-0AP20-0YB0 - 3D-simulation of finished workpiece
6FC5800-0AP21-0YB0 - milling simulation (2D dynamic; 3D static)
6FC5800-0AP23-0YB0 - ShopMill, recording (real-time simulation of the current machining)
6FC5800-0AP24-0YB0 - ShopTurn, simultaneous recording (real-time simulation of the current
machining)
6FC5800-0AP28-0YB0 - measuring cycles

4. Information about the PLC:

o Tool box V01.03.01 is required.
o Parameterization of FB1 for the machine control panel must be checked. The actual quantity must be
indicated.
o Drive data cannot yet be accessed via the PLC (NCVAR selector).
o Activating the target configuration <> actual configuration function causes the PLC to stop.
Remedy: Check in the user program (e.g. SIMATIC blocks FC125, FB125)
o The PLC module IM153-2 MLFB 6ES7 153-2AA02-0XB0 cannot be used.
Remedy: 6ES7 153-1AA03-0XB0
o The PLC series startup file must be generated when the PLC is stopped.
It cannot otherwise be guaranteed that the PLC will switch to cyclic operation when the data backup has

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

been loaded.
o The star / delta switchover function with FC17 requires SINAMICS parameters.
Requirements:
The relevant DDS/MDS must be set up in the drive.
Drive parameters P827[0] Ù P827[1] Ù P827[n] must be set to different values.
The contactor is switched over by application : Drive parameter P833, bit 0=1
The pulses are disabled by the drive: drive parameter P833, bit 0=1
o Use service interface X127 for STEP 7 only.
o The machine control panel (MCP) is operated on PROFIBUS or Ethernet. No mixed operation!

5. Information about the SINAMICS drive:

o No automatic controller optimization
o The "Starter" tool is required for processing the SINAMICS topology (presumably resolved with HMI Adv.
7.2 SP 1) and for handling direct measuring systems.
o It is advisable to set parameter p9906 (topology comparison, "all components" level) to "2". This
corresponds to the "low" level (comparison of component type and order number).
o If a SINAMICS component is replaced and the software upgraded, the firmware release must be
checked and, where necessary, the original firmware release restored.
(Key word: Macro 150399)
Firmware releases can be checked in the following parameters:
Control unit R18 Î Firmware release of CU
Infeed R128 Î Firmware release of infeed
Drive MD R128 Î Firmware release of power section
R148 Î Firmware release of sensor module
o The startup macros have been changed (see separate description).
o For the time being, the starter is still required for determining the motor codes.

6. Information about HMI Embedded:

o The HMI Embedded software V07.10.85 is started automatically as a component of the NCU software
1.3 SP" in the power-up of the NCU7x0. HMI Embedded is also referred to as an "internal HMI".
o HMI Embedded can be operated only via a control panel with TCU connected via Ethernet to X120 on
the NCU7x0.
o The configuring data such as PLC message and alarm texts and HMI option package ("Wizard") must be
stored on the CF card in the NCU in the appropriate directories under /card/user/sinumerik/hmi/... or
/card/oem/sinumerik/hmi/... (see documentation IM2, BE1). The file system on the CF card can be
accessed in "online" mode only, i.e. when the NCU is running. The data can be transferred either by
means of a USB stick or network link via the HMI operator interface (startup / HMI area) or by means of
a network link and the WinSCP tool.
IMPORTANT: File names of configuring files must normally be written in lower case letters.
o Display MD 9990 SW_OPTIONS has no significance. All HMI options must be activated through license
management.
o The option "Additional 256MB HMI user memory on CF card" is required to be able to store part
programs and archives on the CF card ("local drive"). NOTICE! An NCK general reset deletes the option
and renders the "local drive" inaccessible until the option is set again. Existing data stored on the card
are not affected.
o If you are operating an NCU without TCU (i.e. with HMI Advanced on PCU 50), it is advisable to
deactivate HMI Embedded. You can do this by executing command "sc disable hmi" in the service shell.
o A license key can only be entered when softkey "all licenses" was activated once.

6.1. Limitations in HMI Embedded:

o Mouse operation is not supported, operation via touch panel is not permissible.
o Copying a file to CF card by overwriting an existing file with the same name will cause an "internal error"
message. The file with the same name must be deleted beforehand.
o Display MD 9210 USER_CLASS_WRITE_ZOA is not active for "active work offset" in the Parameter
area.
o Display MD 9900 MD_TEXT_SWITCH does not have any effect.
o When the Program or Services area is active, softkey "USB Front" will not automatically be highlighted in

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

black by connecting a USB stick, but access to the USB stick is possible nevertheless.
o Processing of parts programs from a USB data carrier (external processing, EXTCALL) is not
recommended, because the USB data carrier is not protected against removal by accident.
o All projected network drives (access to server via Ethernet) must be permanently accessible during the
runtime of the HMI Embedded.
o For the startup of the SINAMICS drives, an external HMI Advanced 7.2 or IB-Tool 7.2 is required (the
CD SINUCOM includes the IB-tool).
o Processing from external sources / EXTCALL is only permissible with single-channel machines.
o Loadable compile cycles cannot be backed up or read in using NC series startup archive. Loadable
compile cycles are stored on the CF card of the NCU and retained in case of NC memory reset. They
can be handled like HMI configuring data.
o In a parts program with EXTCALL calls, there must be at least one other NC block between two
sequential EXTCALL calls with a processing duration of at least one second.
o When very big files are saved on CF card, the message "Please wait – File being flashed" will be
displayed. This message must be acknowledged by pressing the Recall button. If you want to switch off
the control after having saved the file, you will have to wait for one second for each MB file size.
o Drive alarms that occur immediately after the power-up are not displayed formatted.
o After reading in a NC series startup archive, an explicit restart of the HMI is required, e.g. through NCK
reset or operation with CTRL + Q, Enter
o It is not possible to integrate a user boot screen.
o After a 0-1-0 edge change of PLC interface signal DB19.DBX0.6, the message "Crash log found version
V24" will be displayed after each HMI boot. Remedy: Delete file _ac_logp.bin under path
siemens/sinumerik/hmi.

7. Information about the NCU Base software:

o The Linux operating system of the NCU7x0 is also referred to as the NCU Base software, similar to the
PCU Base software for the PCU 50. You will find the relevant documentation in IM7 on the CD-ROM.
The NCU base software ensures the start among other things of the NC, PLC, and HMI software during
power-up as well as the booting of the TCU if it is present. The NCU Base software is user-oriented, i.e.
you must log in and enter a password in order to acquire specific access authorization. This current login
and password protection is only relevant for accessing a Linux service shell or the CF card using
WinSCP. For startup and servicing activities, the login ID is "manufact" and the password "SUNRISE"
(case-sensitive!). To open the Linux service shell on the TCU, press keys "Area switchover" and "Recall"
(F10 and F9) simultaneously, then "Scan for Servers", "2" or boot from the USB service system.
o For access via the network using WinSCP, enter the above-mentioned login and password on the
"Session" screen. This login procedure also applies after the NCU7x0 has booted from a USB stick with
the NCU service system provided that executable NCU software is installed on the CF card. If this is not
the case (e.g. if the CF card is empty), enter the login ID "admin" and password "SUNRISE".
o You can display a list of the syntax of all available service commands in the service shell by running
command "sc help".
o Important system and network settings in the NCU Base software are preset in file basesys.ini in
directory /card/user/system/etc and can be modified in this file. Changes to network settings via the HMI
Embedded operator interface (Startup area / Logical Drives) are also stored in file basesys.ini.

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

8. Information about technology cycles:

NCU software 1.3 SP2 includes the technology cycles (standard cycles) 06.05.17.00 in an installable form.

Installing the technology cycles:

Step 1 - read in archives

Read in the necessary archive files:
cyccust_gr.arc ;*Archive for user cycles German
cyccust_uk.arc ;*Archive for user cycles English
cycles.arc ;*Archive with all standard cycles (milling and turning)
cycmill.arc ;*Archive with all milling cycles
cycturn.arc ;*Archive with all turning cycles
defines.arc ;*Archive with definition files

In the "Services" area, select softkey "Program data" and navigate to "Cycle archive" with cursor keys; open with
Input key. In the "Cycle archive" area, navigate to "Standard cycles" with cursor keys; open with Input key.
Read in the necessary archive files by selecting the vertical softkey "Read in archive".
Note: The archive files must be selected and read in individually. Once all the relevant archive files have been
read in, you must perform an NCK reset by selecting softkey "NCK Reset" in the "Startup" area.

Step 2 - activate definition files

In the "Program" area, select ETC key ">“ to go to the 3rd level. On this level, select softkey "Definition files",
then select the definitions individually and activate with softkey "Activate".

Step 3 - activate softkey "Swivel cycle" in "Startup" area

In the "Program" area, open "Standard cycles" file "common.com“ with the Input key and delete the semicolon in
line
;SC616 = STARTUP.COM
Then close the file by selecting softkey "Close editor".
Then select softkey "NCK Reset" in the "Startup" area.

Step 4 - activate softkey "Thread recutting" in "Machine" area "Jog"

In the "Program" area, open "Standard cycles" file "common.com“ with the Input key and delete the semicolon in
line
;SC108 = MA_JOG.COM
Then close the file by selecting softkey "Close editor".
Then select softkey "NCK Reset" in the "Startup" area.

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

9. Information about the measuring cycles:

NCU software 1.3 SP2 includes the measuring cycles 06.03.29.00 in an installable form.

Installing the measuring cycles:

Step 1 - machine data settings

The following machine data apply for the application of Siemens standard and measuring cycles.

(1) Machine data (memory-configuring) for Global User Data (GUD):

MD 18130: MM_NUM_GUD_NAMES_CHAN=130

(2) Machine data (memory-configuring) for number of cycles and number of transfer parameters
MD 18180: MM_NUM_MAX_FUNC_PARAM=800

(3) additional machine data for measuring cycles

MD 11420: LEN_PROTOCOL_FILE=5
(maximum file size for protocol file, set in KB)
MD 28082: MM_SYSTEM_FRAME_MASK Bit0 und Bit5 =1
(system frames for scratching and cycles)

Step 2 - read in archives

Read in the necessary archive files:
cyccust_gr.arc ;*Archive for user cycles German
cyccust_uk.arc ;*Archive for user cycles English
mcycles.arc ;*Archive with all measuring cycles (milling and turning)
mcycmill.arc ;*Archive with all measuring cycles for milling
mcycturn.arc ;*Archive with all measuring cycles for turning
defines.arc ;*Archive with definition files
(GUD5.DEF, GUD6.DEF, GUD7_MC.DEF)
jogmcyc.arc ;*Archive with all measuring cycles for measurements in Jog
In the "Services" area, select softkey "Program data" and navigate to "Cycle archive" with cursor keys; open with
Input key. In the "Cycle archive" area, navigate to "Measuring cycles" with cursor keys; open with Input key.
Read in the necessary archive files by selecting 1st vertical softkey "Read in archive".
Note: The archive files must be selected and read in individually. Once all the relevant archive files have been
read in, you must perform an NCK reset by selecting softkey "NCK Reset" in the "Startup" area.

Step 3 - activate definition files

In the "Program" area, select ETC key ">“ to go to the 3rd level. On this level, select softkey "Definition files",
then select definitions GUD5.DEF, GUD6.DEF and GUD7.DEF individually and activate with softkey "Activate".

Step 4 - activate access softkeys "Measurement turning" and "Measurement milling" for support
In the "Program" area, open "Standard cycles" file "common.com“ with the Input key and delete the semicolon in
line
;SC326 = AEDITOR.COM ;* SK "Measurement Turning"
;SC327 = AEDITOR.COM ;* SK "Measurement Milling"
Then close the file by selecting softkey "Close editor".
Then select softkey "NCK Reset" in the "Startup" area.

Step 5 - activate softkey "Measuring cycles" in "Startup" area

In the "Program" area, open "Standard cycles" file "common.com“ with the Input key and delete the semicolon in
line
;SC617 = STARTUP.COM
Then close the file by selecting softkey "Close editor".
Then select softkey "NCK Reset" in the "Startup" area.

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

10. Notes on the cycles (ISO cycles) for the "Online ISO Dialect Interpreter":
NCU software 1.3 SP2 includes the ISO cycles 06.05.02.00 in an installable form.

Installing the ISO cycles:

Installation of the ISO cycles requires previous startup of the standard cycles. Before you begin the startup
process, you should ensure that the existing status is saved to an archive; read out a series startup archive if
necessary.

Documentation: ISO dialects for SINUMERIK 6FC5297-6AE10-0APx

Programming Manual ISO Milling 6FC5298-6AC20-0BPx
Programming Manual ISO Turning 6FC5298-6CA00-0BGx

Step 1 – Machine data settings:

You can activate the Online ISO Dialect Interpreter with machine data 18800 $MN_EXTERN_LANGUAGE. The
language types ISO dialect M (Milling) or T (Turning) can be selected via machine data 10880
$MN_EXTERN_CNC_SYSTEM.

Step 2 - read in archives

isomill.arc ;*Archive with all ISO cycles for milling
isoturn.arc ;*Archive with all ISO cycles for turning
defines.arc ;*Archive with definition file (GUD7_ISO.DEF)

See "Notes on the Technology Cycles" about how to proceed for reading in the archive files.

In the following we provide an overview of the path structure on CF card in which the files for the ISO cycles are
stored.

siemens/
sinumerik/
cycles/
isoc/
hlps/ ;help files
lngs/ ;language files
prog/ ;includes archives for ISO cycles
defines.arc ;includes GUD7_ISO.DEF
isomill.arc ;includes ISO cycles for milling
isoturn.arc ;includes ISO cycles for turning
versions.xml ;XML file including the version number of the ISO cycle
archives
prog.cfs ; zipped prog/ folder
proj/ ;configuration
startstop.sh ;script file for linking the sub folders
versions.xml ;XML file including the version number
proj.cfs ;zipped proj/ folder
versions.xml ;including the version number of the ISO cycles and archives

Step 3 - activate definition files

Activate definition file GUD7.DEF. See "Notes on the Technology Cycles" about how to proceed for activating in
the definitions.

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List of G codes with the relevant shell cycles and technology cycles:

Milling:
G code Shell cycle Siemens technology cycles
G05 CYCLE305
G08 CYCLE308
G10.6 CYCLE3106
G22 CYCLE322
G23 CYCLE323
G27 CYCLE328
G28 CYCLE328
G30 CYCLE330
CYCLE396
G71.1 / 72.2 CYCLE3721
G81 CYCLE381M CYCLE82
G82 CYCLE381M CYCLE82
G85 CYCLE381M CYCLE85
G86 CYCLE381M CYCLE88
G89 CYCLE381M CYCLE85
G83 CYCLE383M CYCLE83
G73 CYCLE383M CYCLE83
G84 CYCLE384M CYCLE3841
G74 CYCLE384M CYCLE3841
G76 CYCLE387M CYCLE86
G87 CYCLE387M CYCLE861

Turning:
G code A/B/C Shell cycle Siemens technology cycles
G05 CYCLE305
G10.6 CYCLE3106
G22 CYCLE322
G23 CYCLE323
G27 CYCLE328
G28 CYCLE328
G30 CYCLE330
CYCLE396
G50.2 / 51.2 CYCLE3512
G70 / 70 / 72 CYCLE370T
G71 / 71 / 73 CYCLE371T CYCLE395
G90 / 77 / 20 CYCLE371T
G72 / 72 / 74 CYCLE372T CYCLE395
G94 / 79 / 24 CYCLE372T
G73 / 73 / 75 CYCLE373T
G74 / 74 / 76 CYCLE374T CYCLE375T
G75 / 75 / 77 CYCLE374T CYCLE375T
G76 / 76 / 78 CYCLE376T CYCLE398
G92 / 78 / 21 CYCLE376T CYCLE398
G83 CYCLE383T CYCLE375T
G87 CYCLE383T CYCLE375T
G84 CYCLE384T CYCLE84
G88 CYCLE384T CYCLE84
G85 CYCLE385T CYCLE375T
G89 CYCLE385T CYCLE375T

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

11. Notes on ShopMill:

General:

Upgrades only in the metric system of units!

The “Work step programming” option is necessary so that ShopMill programs can be created.

Machine data for ShopMill:

The file CMM.8x0 no longer exists, hence the listing of the machine data here. An overview is provided under
the Tool operating area => Extended softkey bar => Machine data softkey.
N10134 $MN_MM_NUM_MMC_UNITS=6 ;minimum
N10260 $MN_CONVERT_SCALING_SYSTEM=1 ;exact
N10602 $MN_FRAME_GEOAX_CHANGE_MODE=1 ;exact
N10610 $MN_MIRROR_REF_AX=0 ;exact
N10700 $MN_PREPROCESSING_LEVEL='H25' ;exact: bit0=1, bit2=1, bit5=1
N10702 $MN_IGNORE_SINGLEBLOCK_MASK='H10' ;exact: bit4=1
N10714 $MN_M_NO_FCT_EOP=32 ;variable
N10715 $MN_M_NO_FCT_CYCLE[0]=6 ;variable
N10716 $MN_M_NO_FCT_CYCLE_NAME[0]="L6" ;variable
N10722 $MN_AXCHANGE_MASK='H4' ;exact: bit2=1
N10735 $MN_JOG_MODE_MASK='H1' ;exact: bit0=1
N11270 $MN_DEFAULT_VALUES_MEM_MASK='H1' ;exact: bit0=1
N11410 $MN_SUPPRESS_ALARM_MASK='H7' ;exact: bit0=1, bit1=1, bit2=1
N11415 $MN_SUPPRESS_ALARM_MASK_2='H20' ;exact: bit5=1
N11450 $MN_SEARCH_RUN_MODE='H7' ;exact: bit0=1, bit1=1, bit2=1
N11604 $MN_ASUP_START_PRIO_LEVEL=1 ;minimum
N17530 $MN_TOOL_DATA_CHANGE_COUNTER='HF' ;exact: bit0=1, bit1=1, bit2=1, bit3=1
N18080 $MN_MM_TOOL_MANAGEMENT_MASK='HB' ;exact: bit0=1, bit1=1, bit3=1
N18088 $MN_MM_NUM_TOOL_CARRIER=1 ;minimum
N18118 $MN_MM_NUM_GUD_MODULES=7 ;minimum
N18120 $MN_MM_NUM_GUD_NAMES_NCK=20 ;minimum
N18130 $MN_MM_NUM_GUD_NAMES_CHAN=250 ;minimum
N18150 $MN_MM_GUD_VALUES_MEM=50 ;minimum
N18160 $MN_MM_NUM_USER_MACROS=30 ;minimum
N18170 $MN_MM_NUM_MAX_FUNC_NAMES=140 ;minimum
N18180 $MN_MM_NUM_MAX_FUNC_PARAM=1700 ;minimum
N18280 $MN_MM_NUM_FILES_PER_DIR=400 ;minimum
N18320 $MN_MM_NUM_FILES_IN_FILESYSTEM=400 ;minimum
N20110 $MC_RESET_MODE_MASK='H4041' ;exact: bit0=1, bit6=1, bit14=1
N20112 $MC_START_MODE_MASK='H400' ;exact: bit10=1
N20126 $MC_TOOL_CARRIER_RESET_VALUE=0 ;variable
N20128 $MC_COLLECT_TOOL_CHANGE=0 ;exact
N20130 $MC_CUTTING_EDGE_RESET_VALUE=1 ;exact
N20150 $MC_GCODE_RESET_VALUES[15]=3 ;exact
N20150 $MC_GCODE_RESET_VALUES[41]=1 ;exact
N20150 $MC_GCODE_RESET_VALUES[51]=2 ;exact
N20150 $MC_GCODE_RESET_VALUES[52]=1 ;variable (1=normal, >1 for Hirth-swivelheads)
N20152 $MC_GCODE_RESET_MODE[5]=1 ;exact
N20152 $MC_GCODE_RESET_MODE[7]=1 ;exact
N20152 $MC_GCODE_RESET_MODE[12]=0 ;exact
N20202 $MC_WAB_MAXNUM_DUMMY_BLOCKS=10 ;minimum
N20240 $MC_CUTCOM_MAXNUM_CHECK_BLOCKS=4 ;exact
N20250 $MC_CUTCOM_MAXNUM_DUMMY_BLOCKS=5 ;exact
N20310 $MC_TOOL_MANAGEMENT_MASK='H80400B' ;exact: bit0,1,3,14,23=1
N20320 $MC_TOOL_TIME_MONITOR_MASK='H1' ;exact: bit0=1
N20734 $MC_EXTERN_FUNCTION_MASK='H8' ;exact: bit3=1

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N22550 $MC_TOOL_CHANGE_MODE=1 ;exact

N22560 $MC_TOOL_CHANGE_M_CODE=206 ;variable
N21100 $MC_ORIENTATION_IS_EULER=0 ;exact
N24006 $MC_CHSFRAME_RESET_MASK='H11' ;exact: bit0=1, bit4=1, bit5=0
N24007 $MC_CHSFRAME_RESET_CLEAR_MASK='H20' ;exact: bit0=0, bit5=1
N24008 $MC_CHSFRAME_POWERON_MASK='H0' ;exact: bit0=0, bit5=0
N24805 $MC_TRACYL_ROT_AX_FRAME_1=1 ;exact
N24855 $MC_TRACYL_ROT_AX_FRAME_2=1 ;exact
N27860 $MC_PROCESSTIMER_MODE='H33' ;exact: bit0=1, bit1=1, bit4=1, bit5=1
N27880 $MC_PART_COUNTER='H101' ;variable
N28000 $MC_MM_REORG_LOG_FILE_MEM=75 ;minimum
N28010 $MC_MM_NUM_REORG_LUD_MODULES=20 ;minimum
N28020 $MC_MM_NUM_LUD_NAMES_TOTAL=800 ;minimum
N28040 $MC_MM_LUD_VALUES_MEM=200 ;minimum
N28082 $MC_MM_SYSTEM_FRAME_MASK='H3D' ;exact: bit0=1, bit2=1, bit3=1, bit4=1, bit5=1
N28083 $MC_MM_SYSTEM_DATAFRAME_MASK='H1F' ;exact: bit0=1, bit5=0, bit6=0
N28400 $MC_MM_ABSBLOCK=1 ;exact
N28402 $MC_MM_ABSBLOCK_BUFFER_CONF[0]=2 ;exact
N28402 $MC_MM_ABSBLOCK_BUFFER_CONF[1]=4 ;exact
N28450 $MC_MM_TOOL_DATA_CHG_BUFF_SIZE=80 ;minimum
N28560 $MC_MM_SEARCH_RUN_RESTORE_MODE='H1' ;exact: bit0=1
N35040 $MA_SPIND_ACTIVE_AFTER_RESET[?]=2 ;exact, ?= axis index for tool spindle
N42440 $SC_FRAME_OFFSET_INCR_PROG=0 ;exact
N42442 $SC_TOOL_OFFSET_INCR_PROG=0 ;exact
N42528 $SC_CUTCOM_DECEL_LIMIT=0.1 ;variable
N42980 $SC_TOFRAME_MODE=2000 ;exact

Recent additions to range of display machine data:

N9739 $MM_CMM_M_CODE_TOOL_FUNC_1_ON
N9740 $MM_CMM_M_CODE_TOOL_FUNC_1_OFF
N9741 $MM_CMM_M_CODE_TOOL_FUNC_2_ON
N9742 $MM_CMM_M_CODE_TOOL_FUNC_2_OFF
N9743 $MM_CMM_M_CODE_TOOL_FUNC_3_ON
N9744 $MM_CMM_M_CODE_TOOL_FUNC_3_OFF
N9745 $MM_CMM_M_CODE_TOOL_FUNC_4_ON
N9746 $MM_CMM_M_CODE_TOOL_FUNC_4_OFF
When the software is upgraded, the display machine data are not initialized with defaults. For this reason, they
must be checked according to the Description of Functions.

PLC interface:

The ShopMill PLC is dispensed with. The adjustment of the interface signals is described in the ShopMill
Description of Functions, in Chapter 6.
In the OB100, during the FB1 call, the parameter MMCToIF = True (transfer of the MMC signals to the
interface...operating types, program influence) must be set. If the parameter is not set to TRUE, no operating
mode change commands (on program selection) or program controls (program test, dryrun...) can be
implemented via the interface.

PCU 50 upgrade:

If you would like to install ShopMill on the PCU 50, the HMI Advanced software (for version, see compat.xls)
must already exist on the PCU 50.
In addition, check the version of the cycle support. The cycle support files for the measuring cycles
(MCSUPP.ARC) and standard cycles (SCSUPP.ARC) are stored under Archive\Cycle archives.

You must make the following changes once the software has been installed:

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NCU Software 1.3 SP2

o The internal HMI must be deactivated via WINSCP. Call point "Open Terminal" under Commands. You can
now run the command sc disable hmi or sc enable hmi in the command line.
o Use of Logdrive.ini: USB Front only functions if the drive letter G: is defined in the Logdrive.ini. When logical
drives are defined under Startup, the following entry must be made in the MMC.INI under F:\USER:
[CONNECTIONS]
;ConnectionNum=8

How to proceed when upgrading the NCK:

o Save GUD (Global User Data) (NC Active Data => User Data => User Data Complete => Data Out in
Archive)
o Create NCK and PLC archives; to do this, switch PLC to stop and back up display machine data
o Load / insert current NCK
o Perform a general reset
o Read in NCK and PLC archives
o Adapt machine data, take note of alarm 4400 if it is displayed!
o Unload / delete definitions

o Cycles and definitions from ShopMill with HMI on NCU:

Read in the Definearchives from Services\Cycle Archive area standard cycles\defines.arc, sequence
cycles\sm_def_e.arc, measuring cycles\defines.arc.
Activate definitions (SMAC.DEF, GUD5.DEF, GUD6.DEF and GUD7.DEF)
Read in the Cyclearchives from Services\Cycle Archive standard cycles\cycles.arc, sequence
cycles\sm_cyc_e.arc, measuring cycles\mcycles.arc & jogmcyc.arc

o Cycles and definitions from ShopMill with PCU 50:

Read in the Definearchive from Services\Archive area SM_DEF.ARC. Load the definitions (GUD7_JS.DEF,
GUD7_MC.DEF, GUD7_SC.DEF, GUD7_SM.DEF, SMAC_SC.DEF and SMAC_SM.DEF) and activate
definitions SMAC.DEF, GUD5.DEF, GUD6.DEF and GUD7.DEF.
Read in the Cyclearchive from Services\Archive area SM_CYC.ARC and load the cycles to the
manufacturer and standard cycles directory if necessary.

(NOTICE! Adapt cycles CYCLE198.SPF and CYCLE199.SPF if necessary after consultation with the machine
manufacturer).

o Read in GUD data (Data In => from archive)

o Reset the NCK
o Delete workpiece TEMP

The system cycle "Prog_Event" is used by the standard cycles and by ShopMill. If "Prog_Event" is also required
to implement user functions, it must be ended by means of the M function from machine data N10714
$MN_M_NO_FCT_EOP. If you create a cycle with the name CYCPE1US.SPF or CYCPE1MA.SPF, it will be
called before the Siemens calls in Prog_Event. If you create a cycle with the name CYCPE_US.SPF or
CYCPE_MA.SPF, it will be called after the Siemens calls. These cycles can be stored under User cycles or OEM
cycles, as "Prog_Event" is overwritten in the OEM cycle directory during upgrading.

Restrictions which apply to ShopMill:

o A successful machine test (segment-specific test according to acceptance protocol) is required for the
release of the following functions:
- five-axis kinematics with turning tilting table
- automatic measuring set-ups for tool or workpiece measurement
- measurement in JOG
o You can only use a TOA area.
o For HMI Advanced 07.02.00 and lower the option Simultaneous Recording ShopMill MD19730 bit 14 has not
been listed under Startup\License.
o Alarm text "17216 channel %1 tool management: remove manual tool from spindle/tool holder %4 and load
manual tool %3, duplo no. %2 " is not displayed completely.

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SINUMERIK 840D sl 03/03/2006
NCU Software 1.3 SP2

The alarm text can be adjusted when using the manual tools (e.g. "17216 channel %1: remove manual tool %4
from spindle and load %3, duplo no. %2"):
PCU 50.3:
As described in section 2.4 'Parameterization of INI files' in documentation 'Starting up the CNC, Part 2 (HMI)',
an adjustment can be made accordingly in file mbdde.ini.
[Textfiles]
NCK=f:\dh\mb.dir\aln_
UserNCK= f:\dh\mb.dir\mynck_
The standard texts are filed in ASCII format in the following files of the PCU 50.3 hard disk.
NCK f:\dh\mb.dir\aln_XY.com (XY is language-dependent, e.g. gr, uk)
NCU 7x0.1:
The original file aln.txt can be found under /card/siemens/sinumerik/hmi/base/lngs/baselng_std/deu (language-
dependent).
The changed file aln.txt can be stored under (/card/user/sinumerik/hmi/lng/deu). A new deu directory (language-
dependent) must be created.
o HMI Advanced: If the display machine data are read in via file functions, a 0 is entered in machine data
$MM_USER_CLASS_APPLICATION and $MM_USER_CLASS_APP_PARAMETER under F:\USER in the
MMC.INI: Machine data function as protection levels in Embedded. Therefore, ShopMill can longer be
started without a system password. This can be avoided by deleting these machine data from the MMC.INI.

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