SIEMENS AG

A&D MC R&D5

UPGRADE INSTRUCTIONS
valid for

SINUMERIK 840D
Software Version 07.04.36.00

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

Page 1 of 15
2010-10-18
1 Requirements for Upgrade ..................................................................................... 4
1.1 System software 07.04.36.00 (NCK Version 67.11.02) 4
1.2 Tools 4
1.3 PLC operating system 4
1.4 Machine control panel 4
2 Data backup............................................................................................................. 5
2.1 General requirements for upgrade 5
2.2 Data backup 5
3 General Information ................................................................................................ 6
3.1 General restrictions 6
3.2 Frames 6
3.3 Series or upgrade archive 6
3.4 Restriction of the number of axes and channels 6
3.5 DMP block 7
3.6 Alarm 14132: Incorrect configuration of orientation axes 7
3.7 Alarm 10752: Local block buffer overflow during tool radius compensation 7
3.8 Alarm 380001 PROFIBUS DP: Run-up error cause 1002 parameter 00 7
3.9 Alarm 15150 Reloading from external sources was aborted 7
3.10 Spindle data 7
3.11 NCU system resources 7
3.12 Series or upgrade archive with software version 7.4 7
3.13 Log File for Sinumerik 840D Version 07.04.34 31 axes 8
3.14 Machine control panel 9
3.15 Contour handwheel 9
3.16 Alarm 1000 system error 100000 9
3.17 NC programs with active basic tool orientation 9
4 Secondary Conditions ............................................................................................ 9
4.1 PLC memory capacity of NCU *.4 9
4.2 Auxiliary functions in OB40 9
4.3 Coupled-axis groupings 9
4.4 NCU link 9
4.5 Gantry axes 9
4.6 Loadable compile cycles 10
4.7 Alarm 4185 10
4.8 Program pre-processing 10
4.9 PLC starting behavior 10
4.10 Alarm 380040 in software version 7.2.nn 10
4.11 Constant Cutting Speed 10
5 Overview of New Functions in Software V 07.04.07.00 and Higher .................. 10
5.1 Couplings 10
5.2 Output order of the M functions can be specified after block search 10
5.3 Conversion routines RTOB/BTOR 10
5.4 Safety 11
5.5 Safety 11
5.6 Safety 11
5.7 TOOLMAN edge location considerations 11
5.8 ET200Pro-F peripherals (I/Os) 11
5.9 DP/AS-I F-LINK 11
5.10 Machine data for individual version input 11
5.11 Access to the PROFIBUS I/Os of the NCK 12
5.12 PLC changes as from software 7.4 12
5.13 Thermal motor protection (as from Drive V06.08.13) 12
5.14 Second transverse axis in the channel 12
Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D
Page 2 of 15
2010-10-18
 5.15 New Machine Data (drive) to evaluate the display of the spindle load 12
5.16 Extension of the master-slave function 12
6 General Notes on Software Upgrades ................................................................. 12
7 New Software Version after Hardware Replacement ......................................... 13
8 Functional Improvements and Further Developments in Comparison to
07.04.34.00....................................................................................................................15

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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2010-10-18
1 Requirements for Upgrade

Software version 07.04.36.00 (NCK 67.11.02) is an update software version.

The current upgrade instructions are part of the delivery releases in ProdIS Update.

1.1 System software 07.04.36.00 (NCK Version 67.11.02)

Export versions
Order number Designation ... on PC card 16MB For hardware
6FC5250-7DY30-4AH0 NCU system software 2 axes NCU *.4/ NCU*.5
6FC5250-7CY30-4AH0 NCU system software 6 axes NCU *.4/ NCU*.5
6FC5250-7BY30-4AH0 NCU system software 12 axes NCU *.4/ NCU*.5
6FC5250-7AY30-4AH0 NCU system software 31 axes NCU *.4/ NCU*.5
6FC5250-7HY30-4AH0 NCU system software for 4 axes, NCU *.4/ NCU*.5
grinding
Standard versions (subject to export restrictions)
Order number Designation ... on PC card 16MB For hardware
6FC5250-7CX30-4AH0 NCU system software 6 axes NCU *.4/ NCU*.5
6FC5250-7BX30-4AH0 NCU system software 12 axes NCU *.4/ NCU*.5
6FC5250-7AX30-4AH0 NCU system software 31 axes NCU *.4/ NCU*.5

Software V07.04.nn cannot be used for older module types.

The following module types are permitted:
6FC5356-0BB14-0AA_
6FC5356-0BB15-0AA_
6FC5357-0BB34-0AE1
6FC5357-0BB_4-0AA_
6FC5357-0BB_5-0AA_
6FC5357-0BB35-0AE0

1.2 Tools
 A 16MB PC card (6FC5247-0AA11-1AA3) is required for software version V07.04.nn.
 6FC5250-6AY00-3AG0 (...-4AG0) SinuCom NC with SinuCom FFS (versions 7.1 / 7.2 are
available in addition; version 7.3 )
 6FC5252-7AX21-4AG0: tool box AB 07.04.01 with basic PLC program 07.04.01.
Tool box V 07.04.03 is the current version.
PG / PC with STEP 7 V5.2 and higher and optional online MPI link.
 Current documentation for SW 7 with additional function-related information.

1.3 PLC operating system

 PLC314C-2DP on NCU *.4 firmware version >= 10.60.22
 PLC317-2DP on NCU *.5 firmware version >= 20.71.30

1.4 Machine control panel

Version 02.01.01
(Version 01.02.03 enables bus address 6 only)

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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2 Data backup
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.

2.2 Data backup

 NCK
Before the NCK is upgraded, a backup must be made to permit recovery of the machine's current
database. This is done by creating a series startup file (see general instructions for software
upgrades).

 PLC
In addition to the NCK backup, a PLC backup must be created. This backup must be performed
with the PLC in the STOP state. Set S4 on the NCU module to position 2. The PLC will then be in
stop position.

STEP 7 is required for upgrade of the basic PLC program. For this purpose, the new tool box must
be installed using SETUP. You also need the customer project of this system. The required blocks
are transferred from the new Toolbox library to the customer project (or a copy). OBs FC12 and
DB 4 must not be transferred (these are blocks for creating new user programs) because they
have been modified by the machine manufacturer. After replacement of the NCK software transfer
the modules to the PLC using STEP7. Create a new PLC series start-up file.

 Replacing the software

Switch off the control and replace the PC card. The card stays in the control.
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 Diagnostics/Service Displays/Version.

 Loading the backups

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

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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3 General Information
3.1 General restrictions
 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.
 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.
 The functions FCUB and FLIN in combination with the compressor COMPCAD have not been
released.
 Slave operation of the PROFIBUS is not possible with NCU*.4. If a configuration like that is
required, it will have to be implemented using a CP module or an NCU *.5.

3.2 Frames
If $MC_MM_SYSTEM_FRAME_MASK bit 1 = 1, the external work offset will be suppressed by G153.
This represents a change in behavior compared to other releases of software version 6.

The default setting of $MC_CHSFRAME_POWERON_MASK has changed. The default value of

MD24008 is now zero (previously "one"). The system frame for the scratching function is therefore also
retained after Power ON / RESET.

3.3 Series or upgrade archive

A series or upgrade archive enables identical machines to be brought into operation quickly and easily.
These machines must be identical in respect of both electrical equipment (e.g. NCU CPU, software) and
mechanical conditions. If they do not match, a series or upgrade archive is not necessarily a suitable
startup method. Another data backup method will then have to be chosen (e.g. separate data backups
with Initial.ini etc.), as machine data may have to be adapted.
Special attention has to be paid to the different memory limits of the NCUs. If they have been fully utilized,
the memory space might not suffice after an NCK software upgrade or replacement of an NCU.
Prior to creating the data backups, machine data $MN_UPLOAD_MD_CHANGES_ONLY is to be
checked. It should be set to the value "0" or "FF"hex. Other values such as "1" may cause problems on
reading in the data backup after software upgrades. The value FFhex is the preferred entry.

3.4 Restriction of the number of axes and channels

As from software version 6.5.10, the different software variants (2-axis...31-axis versions) can be used on
all type *.4 and *.5 NCUs.
PLC programs can thus be maintained as general programs that can be used for different machine
variants. This way it is possible to manage 6, 12 or 31 physical axes out of 31 axes.
The restriction of the number of axes and channels still applies.
The following combinations are possible:

HW \ SW 2A/2C 6A/2C 12A/2C 31A/10C

---------------------------------------------------------------------------------------
561.4 / 5 | 2A/2C 2A/2C 2A/2C 2A/2C
|
571.4 / 5 | 2A/2C 6(31)A/2C 6(12)A/2C 6(31)A/2C
|
572.4 / 5 | 2A/2C 6(31)A/2C 12(31)A/2C *) 31A/6C
|
573.4 / 5 | 2A/2C 6(31)A/2C 12(31)A/2C *) 31A/10C

A=axes, C=channels, 2(31)=2 out of 31 axes

*) For software version 07.02.12 and higher: 12(31)A/4C

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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2010-10-18
3.5 DMP block
The number of axes including the DMP block is limited to 31. If, for example, a DMP block is used with 31-
axis software, a total of 30 axes are still possible.

3.6 Alarm 14132: Incorrect configuration of orientation axes

This alarm is output in case of errors on assigning orientation axes to the machine kinematics. However,
this alarm will also occur if no position measuring system is active on an axis involved in the
transformation.

3.7 Alarm 10752: Local block buffer overflow during tool radius compensation
Output of alarm 10752 can be avoided by increasing machine data
$MC_CUTCOM_MAXNUM_DUMMY_BLOCKS=41.

3.8 Alarm 380001 PROFIBUS DP: Run-up error cause 1002 parameter 00
The alarm is displayed after PLC delete with S4 in position 3. It should not be displayed again after
loading of the basic PLC program.

3.9 Alarm 15150 Reloading from external sources was aborted

Output of alarm 15150 can be avoided by increasing the value of machine data
$MN_MM_EXT_PROG_BUFFER_SIZE.

3.10 Spindle data

The machine data for describing the spindle dynamics must be set so that they approximately correspond
to the actual dynamics of the spindle. If the values are increased unnecessarily, alarms may be issued
during the changeover from spindle to positioning mode.

3.11 NCU system resources

In "Reset" status, the load imposed on the NCU by the position controller and interpolator should not
exceed 60–65%. The current load can be checked under Diagnostics/System resources.

3.12 Series or upgrade archive with software version 7.4

Alarms may occur after a series or upgrade archive has been read in.
As from software version 07.04.07.00, the cycles for generic couplings are automatically read into the NC
from the PC card after a general reset. These cycles occupy dynamic memory.
The settings for the machine data 18170 $MN_MM_NUM_MAX_FUNC_NAMES and 18180
$MN_MM_NUM_MAX_FUNC_PARAM may therefore have to be re-determined.
Typical values are:
18170 $MN_MM_NUM_MAX_FUNC_NAMES (nn) + 18
18180 $MN_MM_NUM_MAX_FUNC_PARAM (nn) + 120

If a series or upgrade archive generated with software version 7.4 is read into a deleted NCU, then the
query "Cycle nn already exists ... overwrite ..." may be displayed. .
This query can be acknowledged negatively.

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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2010-10-18
3.13 Log File for Sinumerik 840D Version 07.04.34 31 axes
·----------------------------------------------------------
| PCM_VERS |
| usage: Version: V02.03 from 21.06.99 |
| <path / name of PCM - imagefile *.abb > |
| SINUMERIK 840D AUT/E231 |
| CONTENTS |
| 07.04.36 840D 31A 50ph_km |
·----------------------------------------------------------·
PCM - Version: 02.18
----------------------------------------------------------------------------------------------
System Versionstamp Date Checksum Linkdate/Time Length at
----------------------------------------------------------------------------------------------
Monitor Loader 67.11.02 30/09/10 300910 17157517 30/09/10 17:13:02 017E44 000140
Communic.Monitor 01.01.07 10.05.94|100594 5C080795 10/05/94 13:26:36 0030D0 017F84
Communic.System 05.07.00 05/03/14|150305 7F89160B 15/03/05 15:01:40 00D0D8 01B054
PLC314C-FB15SI07.04.03 07.04.03*07/04/19 200407 48558BC3 20/04/07 14:24:00 00AAC4 02812C
PLC317-FB15 SI07.04.03 07.04.03*07/04/19 200407 0E59A312 20/04/07 14:28:09 008200 032BF0
Monitor System 67.11.02 30/09/10 300910 D4244CA0 30/09/10 17:11:07 0040E0 03ADF0
Operating System 67.11.02 30/09/10|300910 76A14FD9 30/09/10 17:14:32 00BFAC 03EED0
Numeric ContSI67.11.00 67.11.02 30/09/10| 71010 B1A29076 7/10/10 09:45:46 3C0318 04AE7C
VSA System SI05.01.35 05.01.39 21/07/08 210708 280F3E32 21/07/08 13:03:02 03CA0C 40B194
VSA Data Description 05.01.39 21/07/08 030308 5BB209A7 03/03/08 15:11:56 004C90 447BA0
VSA Default Data 05.01.39 21/07/08 030308 848D5B51 03/03/08 15:11:56 000BB8 44C830
Drive Version Info 05.01.39 21/07/08 190208 62F8CDFA 19/02/08 09:52:32 022648 44D3E8
HSA System SI05.01.35 05.01.39 21/07/08 210708 7664FFF8 21/07/08 13:04:25 03CDB8 46FA30
HSA Data Description 05.01.39 21/07/08 030308 2305260D 03/03/08 15:11:56 005F10 4AC7E8
HSA Default Data 05.01.39 21/07/08 030308 FE9EC7B8 03/03/08 15:11:56 000E98 4B26F8
SLM Data Description 05.01.39 21/07/08 030308 EA1DF0F1 03/03/08 15:11:56 004AD0 4B3590
SLM Default Data 05.01.39 21/07/08 030308 BE7AF4AD 03/03/08 15:11:56 000BB8 4B8060
Inverter Codes 06.08.28 27/01/10 270110 C37BE6C5 27/01/10 13:45:24 0010E8 4B8C18
VSA Motor Codes 06.08.28 27/01/10 270110 207002EF 27/01/10 13:45:25 01160C 4B9D00
HSA Motor Codes 06.08.28 27/01/10 270110 004F0C49 27/01/10 13:45:24 005A5C 4CB30C
SLM Motor Codes 06.08.28 27/01/10 270110 25284227 27/01/10 13:45:25 004ACC 4D0D68
VSA Inverter Data 06.08.28 27/01/10 120110 315B6CE1 12/01/10 20:33:20 000518 4D5834
VSA Motor Data 06.08.28 27/01/10 120110 CDD2122A 12/01/10 20:33:27 012428 4D5D4C
HSA Inverter Data 06.08.28 27/01/10 120110 50631F8B 12/01/10 20:33:23 0003A0 4E8174
HSA Motor Data 06.08.28 27/01/10 120110 3AA6BB5C 12/01/10 20:33:30 007FB0 4E8514
SLM Motor Data 06.08.28 27/01/10 120110 24592DE4 12/01/10 20:33:31 0033A0 4F04C4
DriveSystem SI06.08.20 06.08.28 27/01/10 270110 7BB0B24C 27/01/10 11:30:14 062324 4F3864
VSA-2 Data Description 06.08.28 27/01/10 270110 733BEBA0 27/01/10 11:30:06 00B590 555B88
VSA-2 Default Data 06.08.28 27/01/10 270110 FD907A72 27/01/10 11:30:06 0025CC 561118
HSA-2 Data Description 06.08.28 27/01/10 270110 5170FBD8 27/01/10 11:30:06 00AC50 5636E4
HSA-2 Default Data 06.08.28 27/01/10 270110 BEBA2E5B 27/01/10 11:30:06 0025B4 56E334
SLM-2 Data Description 06.08.28 27/01/10 270110 838CB8A9 27/01/10 11:30:06 00B450 5708E8
SLM-2 Default Data 06.08.28 27/01/10 270110 EA0C9621 27/01/10 11:30:06 0025AC 57BD38
HLA System 01.02.16 09/08/10 090810 E43646FE 09/08/10 09:20:46 0359C0 57E2E4
HLA Data Description 01.02.16 09/08/10 090810 921C71C3 09/08/10 09:21:14 003410 5B3CA4
HLA Default Data 01.02.16 09/08/10 090810 2FA0D51D 09/08/10 09:21:14 000D78 5B70B4
HLA Valve Data 01.02.16 09/08/10 90810 4E205233 9/08/10 09:28:43 001E68 5B7E2C
Driver Module 01.01.01 14.06.94 50899 B838268F 5/08/99 18:30:36 0000C4 5B9C94
Serialnumber 01.01.01 24.01.95 221100 0327C431 22/11/00 11:27:40 0000D4 5B9D58
Adaption Cycles 07.01.09 17/09/07 170907 79430E09 17/09/07 10:57:33 002E60 5B9E2C
Joblist for IBN 02.03.00 03/24/06 71010 66C65DC7 7/10/10 09:46:11 00039C 5BCC8C
Joblist for IBN/KOMP 02.03.00 03/24/06 71010 61431D02 7/10/10 09:46:12 0003CC 5BD028
Joblist for UPGRADE 02.03.00 03/24/06 71010 CE872C31 7/10/10 09:46:13 0003B4 5BD3F4
Link Loader 05.01.01 98/06/03 061098 F50A5D72 06/10/98 08:37:23 00029C 5BD7A8
Link Debugger Aequidis 05.03.01 00/11/28 281100 E5024825 28/11/00 13:42:35 0091AC 5BDA44
Link Software Aequid 05.02.05 02/01/07|070102 6083ACE7 07/01/02 11:05:01 008A8C 5C6BF0
DP Software Aequid 01.00.06 02/08/13|130802 FCAE5BA2 13/08/02 10:36:01 01FC18 5CF67C
NCKS840d-31a10c 67.11.02 09/30/10 71010 AA3DB3D8 7/10/10 09:46:05 0008D8 5EF294
NCKS840d-31a10c 67.11.02 09/30/10 71010 AA3DB3E0 7/10/10 09:46:05 0008D8 5EFB6C
NCKS840d-31a10c6 67.11.02 09/30/10 71010 2A1F87ED 7/10/10 09:46:07 000930 5F0444
NCKS840d-2a2c 67.11.02 09/30/10 71010 F2C95EDC 7/10/10 09:46:04 000DA8 5F0D74
----------------------------------------------------------------------------------------------
number of bytes: 0x005F1B1C length of ABB file: 0x01000000

Siemens AG 2009 All rights reserved Upgrade Instructions SINUMERIK 840D

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2010-10-18
3.14 Machine control panel
The machine control panel is operated on MPI, OPI or via PROFIBUS.

3.15 Contour handwheel

The 'Contour handwheel' function is now locked through an option.
If the function is selected through the VDI interface DB[channel].DBB30 without a set option, travel-out of
NC distances-to-go will not be derived from the handwheel motion (as previously). Present distances-to-
go are moved out of the material and alarm "22400 channel%1 option contour handwheel not set" (cancel
clear) is displayed.

3.16 Alarm 1000 system error 100000

The 16MB PC card can only be used in certain NCU modules (see section 1.1).

3.17 NC programs with active basic tool orientation

NC programs with active basic tool orientation and, if required, combined with the function of tool holders
with orientation capability (swivel, CYCLE800) must be re-loaded.

4 Secondary Conditions
4.1 PLC memory capacity of NCU *.4
A load memory of 480KB is guaranteed for the user. It is possible to exceed this limit, i.e. to occupy more
memory space. However, this may cause problems on reading in PLC series star-up files. Message:
Memory full.

4.2 Auxiliary functions in OB40

Sporadically, the PLC does not recognize auxiliary functions in the following combinations:
H/T function analysis in OB40 (parameter IRAuxfuT/H =true of FB1)
In the part program:
m=qu(55)
h2=33
The H function is lost sporadically.
Remedy: Program m55.

4.3 Coupled-axis groupings

When coupled-axis groupings are switched on via synchronized actions or across the channels, the user
must assure that the control parameters (e.g. acceleration, velocity) of the slave axis are met. In these
cases, no verification is performed in the NC.

4.4 NCU link

When NCUs are combined via the link function, NCUs of the same type (MLFB) always have to be used.
If a link connection with different interpolation cycles is to be configured, the basic system clock rates of
both systems must be the same. Otherwise alarm 4013 is displayed with error code
SYSCLOCK_SAMPLE_TIME_RATIO.
Exception:
It must be taken into consideration that processors with different cycles are used in the NCUs. If a service
job can only replace a module by a faster NCU, the slower NCU must be the master. It is not mandatory to
replace all NCUs.

4.5 Gantry axes

If the slave axis in a gantry grouping rotates in the opposite direction (AX_MOT_DIR=1), the function
generator (rectangular) must not be used.

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2010-10-18
4.6 Loadable compile cycles
It is possible to load a maximum of ten loadable compile cycles. They include libraries with the file
extension ???.ELF.
Loading more than one technological function may cause incorrect value assignments. This effect will
occur if loadable compile cycle applications do not set up their machine data with consecutive ascending
numbers within the three sections NCK, channel and axis MD.
Loading a correct archive may cause mutual overwriting of the contents of individual CC machine data.

4.7 Alarm 4185

Assigned help functions that are neither active nor have been rejected by an alarm are now recognized.
Alarm 4185 is output in this case.

4.8 Program pre-processing

When the program pre-processing function is used, alarms 15170 "Program could not be compiled" and
15450 "Unable to save the compiled program" are output after an upgrade to SW 6.4.
Reason:
Under SW 6.4, the compiled program is no longer stored in SRAM, but in DRAM instead.
However, sufficient DRAM memory has to be reserved for this purpose via MD
$MN_MM_DRAM_FILE_MEM_SIZE.
But there is also the option of storing the compiled program in SRAM, if the DRAM memory space does
not suffice. To do so, set $MN_PREPROCESSING_LEVEL, bit 6.

4.9 PLC starting behavior

- It is impermissible to operate NCU *.4 in switch position 1 of S4. The PLC would not start the cyclic
operation after RESET or Power OFF/ON.
- If the PLC was put to a STOP state by a PI service or a PG operation (e.g. on loading a hardware
configuration), it will have to be restarted by a PG operation or by using switch S4. Power OFF/ON or
RESET will not start the cyclic operation.

4.10 Alarm 380040 in software version 7.2.nn

If the alarm is displayed in powerline, an address conflict between the existing PLC I/Os and the prepared
machine data for solution line has occurred. In the case of an error, an address must be assigned in
machine data MD 13050 Drive Logic Address which has not been configured in the PLC.

4.11 Constant Cutting Speed

The calculation of the cutting speed (in NCK >= 67.03.00) is based on the SZS position (before it was
based on the WCS position).

5 Overview of New Functions in Software V 07.04.07.00 and Higher

5.1 Couplings
Due to the introduction of generic couplings, the user can select the coupling characteristics required for
his application. This is achieved by flexible programming. Additional coupling characteristics can be used
later without a problem.

5.2 Output order of the M functions can be specified after block search
The collected values of the M functions after block search are available through the system variables.
The order can be determined by a predefined procedure.
The correct order and tool dependency, if required, can be ensured in the ASUB after block search by
using an application. Current output of the M functions can be locked with NC start after block search.

5.3 Conversion routines RTOB/BTOR

Conversion routines rtob/btor have been implemented for changeover from REAL<>BOOL.

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2010-10-18
5.4 Safety
The number of safety checksums has been extended for version 7.4.6 and higher:
MD_SAFE_DES_CHECKSUM[0] and [1] and MD_SAFE_ACT_CHECKSUM[0] and [1] are available now.
For 840D powerline the value of the MD_SAFE_DES_CHECKSUM[1]=0.
Both checksums must be copied after upgrade.

5.5 Safety
The maximum values of the following machine data have been increased.
- safe_velo_switch_delay  10 min.
- safe_stop_switch_time_c  10 min.
- safe_stop_switch_time_d  10 min.
- safe_stop_switch_time_e  10 min.
- safe_pulse_disable_delay  10 min.

5.6 Safety
There is a new option handling referring to synchronized actions or synchronized action elements. Up to
NCK version 62 synchronized action level, 2 was set automatically at the same time with option SI. Thus,
channel MD 28250, NUM_SYNC_ELEMENTS could be set to a value > 159.

This has been changed with NCK version 67. Synchronized action level 2 is no longer included in Safety.
Instead there is a new machine data, in which the synchronized action elements for SAFE.SPF are
defined, i.e. MD 28251, NUM_SAFE_SYNC_ELEMENTS.
This machine data can be written with a maximum value of 500 for option "SLP_I_O=1", and with a
maximum value of 5000 for option "SPL_I_O=2".
However, the number of synchronized action elements required should be determined in order to prevent
the performance from being loaded unnecessarily.

With system variable $AC_SAFE_SYNAC_MEM the relevant number of free SI synchronized action
elements can be read.
If this variable is called prior to starting and after running SAFE.SPF, the difference is the number of
elements occupied by SAFE.SPF. This difference adding a certain reserve should be entered in MD
28251.

5.7 TOOLMAN edge location considerations

Magazine edge locations can now be limited with regard to the tool size.

5.8 ET200Pro-F peripherals (I/Os)

ET200Pro-F peripherals (I/Os) are now supported and can also be used in combination with Safety
Integrated.

5.9 DP/AS-I F-LINK

DP/AS-I F-LINK modules are supported with NCU software version >=V7.4.20. The use of DP/AS-I F-
LINK modules requires PLC operating system version 20.70.31.

5.10 Machine data for individual version input

Individual machine data blocks (e.g. channel or axis machine data) can be identified by an individual ID
that can be recognized in the control. For this purpose, machine data (that have not analyzed by the
control) are now provided in the form of a character string, which can also be written through the startup
archive and the standard HMI. The data entered by the user are displayed as additional information in the
version screen of the NCU and can be read out with the machine configuration / version data.
Example:
$MN_OEM_GLOBAL_INFO[0] = mach. type nn / ChanData Version V 1.0

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5.11 Access to the PROFIBUS I/Os of the NCK
The "NckProfibusCom" functionality enables direct data exchange between the NCK and the PROFIBUS
I/Os. Data can be exchanged via synchronized actions in the part program or compile cycles.

5.12 PLC changes as from software 7.4

 This upgrade eliminates the blocks DB6, DB10, DB17, DB19, FC1, FC4, FC6, FC11, FC14, FB16,
FB17, FB18, FB19. Data blocks DB10, DB17, DB19 are set up as CPU DB’s. DB6 is completely
eliminated.
 The interface bit "first cycle" is available in DB10.DBX104.6.
 The maximum number of PLC user alarms has been increased to 32 groups.

5.13 Thermal motor protection (as from Drive V06.08.13)

The purpose of thermal motor protection is to protect the motor from continuous overloading and to
prevent it from heating above the permissible temperature.
A simplified explanation of the thermal motor protection is that a model motor temperature is internally
calculated as a function of the motor type, the measured motor current, a KTY motor temperature sensor,
if present, and the shutdown temperature threshold.
Involving the KTY motor temperature sensor prevents the motor from being overloaded even when
switched on when hot.
The calculated model temperature is related to the permissible shutdown temperature of the motor defined
in MD1607.
MD 1266 displays the current thermal loading motor as a percentage.
Motor temperature alarm 300613 "Maximum permissible motor temperature exceeded" is triggered if the
thermal loading of the motor exceeds 100%, and as a reaction DRIVE-READY and 611D ready are
canceled (no change to previous alarm behavior).
The thermal motor protection is activated by MD 1265 “ACTIVITY_I2TMOT“ bit 0.
The type of motor monitoring can be selected with MD 1265.BIT1:
----------------------------------------------------------------------------------------------------------------------
Bit 1= 0 with evaluation of the KTY sensor
Bit 1= 1 current monitoring only – no evaluation of the KTY sensor
Moreover the thermal motor protection is not activated if the value of MD 1268 =0 (winding time constant).

5.14 Second transverse axis in the channel

Even non-geometry axes may be treated like transverse axis (i.e. programming and display in the
diameter).

5.15 New Machine Data (drive) to evaluate the display of the spindle load
MD 1093[n]: Factor Spindle Load Display "LOAD_FACTOR" (specific to motor parameter sets)
100.0000, max = 200.0000, unit: [%]

5.16 Extension of the master-slave function

As from nck 67.11.00, the balancers can be freely connected.

6 General Notes on Software Upgrades

 Before the upgrade, series startup files and upgrade files must be created, which only contain
machine data that differ from the default values. Machine data 11210
UPLOAD_MD_CHANGES_ONLY = FF is to be set for this purpose. This ensures that the

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 machine data contain the originally set values after a software update even in the case of differing
standard pre-assignments as a result of the respective software versions.
However, machine data with the protection level "System" should be set to the default values
applicable to the relevant software version. A data backup generated with 11210
UPLOAD_MD_CHANGES_ONLY = FF contains the machine data with their current values which
differ from their defaults.

 In order to ensure that the machine data with the protection level "System" contain default values
after a software update, it is essential to save the series startup file and upgrade file without "line
check sum".
Machine data 11230 MD_FILE_STYLE Bit 0 = 0 is to be set for this purpose.

 If the series start-up file with the protection level "Manufacturer" generated by
UPLOAD_MD_CHANGES_ONLY = FF and MD_FILE_STYLE bit 0=0 is read in again, then the
machine data with protection level "System" are not overwritten with the values from the backup
files. They are set to the default values applicable to the relevant software version. This ensures
that no obsolete settings are carried over which might not be executable with new software.

 After the data has been read in, the alarm log contains alarm 4075 "Data not changed because of
lack of access rights". This alarm indicates that default values for system data have not been
overwritten.

 If this procedure is not possible without line check sum (for example with a defective NCU), then a
machine data file should be generated with UPLOAD_MD_CHANGES_ONLY=FF after the
upgrade, and the machine data it contains should be checked. In this case, the following data in
particular should be checked to ensure that they have their default settings.

18240 LUD_HASH_TABLE_SIZE
18242 MAX_SIZE_OF_LUD_VALUE
18250 CHAN_HASH_TABLE_SIZE
18260 NCK_HASH_TABLE_SIZE
18290 FILE_HASH_TABLE_SIZE
18300 DIR_HASH_TABLE_SIZE
18500 EXTCOM_TASK_STACK_SIZE
18502 COM_TASK_STACK_SIZE
18510 SERVO_TASK_STACK_SIZE
18512 IPO_TASK_STACK_SIZE
18520 DRIVE_TASK_STACK_SIZE
18540 PLC_TASK_STACK_SIZE
18900 FPU_ERROR_MODE
18910 FPU_CTRLWORD_INT
18920 FPU_EXEPTION_MASK
28500 PREP_TASK_STACK_SIZE

Alternatively, an existing file can be modified with the tool SinuComArc, by deleting the machine
data listed above (areas: Global.ini, Chan.ini, Initial.ini).

The channel machine data 28070 NUM_BLOCKS_IN_PREP must be checked. The settings have
often been modified by manufacturer-specific applications, for example memory and time
optimizations. In the event of problems, at least the default values should be set here.

7 New Software Version after Hardware Replacement

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  If an NCU is replaced by new hardware, it may happen that the old software version is no longer
executable. It therefore also has to be upgraded to a newer software version by trained service
personnel. In this connection, as from software version 3.7, in each case the last released version
of the software series must be used (e.g. 3.7.20, 4.4.39, 6.2.10 etc.) with which the new NCU can
be operated.

 The prerequisite for upgrading is the possibility of

- editing NCU data backups

- starting up drives
- starting up the PLC

and the availability of the necessary tools (e.g. SinuComArc, IBN-Tool, STEP 7, etc.).

 Memory configuration problems can occur while reading in the data backups, as "old" settings
were also backed up in the data backups (see general notes).
In this case, particular attention has to be paid to MD18210 USER_MEM_DYNAMIC and
MD18230 USER_MEM_BUFFERED. The following data also have to be checked to ensure that
they have their default settings.

18240 LUD_HASH_TABLE_SIZE
18242 MAX_SIZE_OF_LUD_VALUE
18250 CHAN_HASH_TABLE_SIZE
18260 NCK_HASH_TABLE_SIZE
18290 FILE_HASH_TABLE_SIZE
18300 DIR_HASH_TABLE_SIZE
18500 EXTCOM_TASK_STACK_SIZE
18502 COM_TASK_STACK_SIZE
18510 SERVO_TASK_STACK_SIZE
18512 IPO_TASK_STACK_SIZE
18520 DRIVE_TASK_STACK_SIZE
18540 PLC_TASK_STACK_SIZE
18900 FPU_ERROR_MODE
18910 FPU_CTRLWORD_INT
18920 FPU_EXEPTION_MASK
28500 PREP_TASK_STACK_SIZE

Alternatively, an existing file can be modified with the tool SinuComArc, by deleting the machine
data listed above (areas: Global.ini, Chan.ini, Initial.ini).

The channel machine data 28070 NUM_BLOCKS_IN_PREP must be checked. The settings have
often been modified by manufacturer-specific applications, for example memory and time
optimizations. In the event of problems, at least the default values should be set here.

In order to be able to check these data, the series startup file and upgrade file must be processed
with the tool SinuComArc. One checks whether these data are in the backup before then deleting
them. This does not overwrite the new default values.
After reading in the edited data backup, the control should then be started. Memory options still
have to be checked.

 Notes:
The data backups cannot be edited with conventional editors (e.g. Word) and then read in again.

Drive data (BOT files):

There is an internal converter for BOT files, which ensures that drive data backups can be read
into various software versions. However, the converter cannot be guaranteed to work for all
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 software upgrade combinations. Boot file conversion is not provided until drive software version
06.01.01. It may also happen that the drives have to be restarted after an upgrade.

8 Functional Improvements and Further Developments in Comparison to

07.04.34.00

PR_id AP00312351 AP00438906 AP00462110 AP00561768

AP00650537 AP00680644 AP00708548 AP00727423 AP00732897
AP00735139 AP00750540 AP00758509 AP00760407 AP00764173
AP00781359 AP00786501 AP00787396 AP00788173 AP00790723
AP00798904 AP00802917 AP00824203 AP00824205 AP00826082
AP00828840 AP00831604 AP00839243 AP00839627 AP00845355
AP00845916 AP00855132 AP00865595 AP00868195 AP00870845
AP00871113 AP00883130 AP00883866 AP00885930 AP00886036
AP00889698 AP00891065 AP00896697 AP00903836 AP00906862
AP00908541 AP00915145 AP00928623 AP00929238 AP00935867
AP00945243 AP00954995 AP00955240 AP00967338 AP00967383
AP00980739 AP00982791 AP00996659

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