Date: 25.08.

1998

SINUMERIK 840C: Recommendations for hard disk

Note: The recommendations are also published

- in PRODOK-Updates: 6FC5.. SINUMERIK 840C General/Sales
Part 1 - 1998/083, Part 2 - 1998/084
- FAQ in the Intranet: http://sinumerik.erlf.siemens.de/support/index.html
SINUMERIK 840C, TIP 6

MLFBs:

6FC5110-0DB01-0AA1 840C, MMC CPU 486SX VB 8MB

6FC5110-0DB02-0AA1 840C, MMC CPU 486DX VB 8MB
6FC5110-0DB02-0AA2 840C, MMC CPU 486DX2 8MB
6FC5110-0DB03-0AA1 840C, MMC CPU 486DX VB 16MB
6FC5110-0DB03-0AA2 840C, MMC CPU 486DX2 VB 16MB
6FC5110-0DB03-0AA3 840C, MMC CPU 486DX4 32MB
6FC5110-0DB04-0AA1 840C, MMC CPU 486SX VB 16MB
6FC5147-0AA13-0AA0 840C, hard disk with damping element
6FC5147-0AA13-0AA1 840C, hard disk without damping element
6FC5148-0AA17-0AA0 840C, mounting rails ZG2
6FC5148-0AA18-0AA0 840C, mounting rails ZG3
6FC5148-0AA20-0AA0 840C, damping elements 10-100Hz

Hard disks installed in machines and plants are subject to significantly higher stress than in office-based PCs.
The essential stress factors include:

- Vibration and shock during the operation of the machine (especially when writing onto the disk)
- Vibration and shock during transport
- Incorrect storage conditions and if the hard disk is stored for a long time (components with hard disk)
- High hard disk temperatures
- Access frequency and power-on duration
- Uncontrolled machine shutdown (hard disk)
- Temperature gradient of the hard disk

As a result of the higher memory density, the newer hard disks are more sensitive to the specified stress factors.
Thus, we have summarized the following solutions and recommendations:

- Reduce vibration and shock during transport

- Reduce vibration and shock during operation
- Limit the storage time
- Reduce the temperature
- Observe the mounting position
- Reduce access and power-on duration
- Maintain an error-free file structure and optimization of the hard disk
- Implement power-down concepts
- Make it easier to replace the hard disk (spare part)

These recommendations should help the user reduce stress even further so that even when used in machines
and systems, the hard disks can expect a lifetime of greater than 3 years (approximately 2/3 the lifetime of an
office-based PC).

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1. Reduce vibration and shock during transport

In the storage packing, the MMC-CPU requires damping shipping packing when transported, also when the
equipment is returned. This is also valid for the "hard disk without damping element" replacement part
(6FC5147-0AA13-0AA1).

Handling the replacement part packing:

The original packing of the replacement parts (MMC components and hard disks) should also be used when
returning equipment to avoid any transport damage.

Valid limit values for transport:

Typical stressing occurring during transport can involve vibration, falling, tipping over. The manufacturer tests
are carried-out with the original components, including the above mentioned replacement part components.
The following maximum stress levels should not cause any damage:
In the shipping packing (original packing):
1.2 m free fall or tipping over on all edges.
In the storage packing (Siemens component packing):
0.25 m free fall or tipping over on all edges.
DIN EN 60721 Part 3-0 and 3-2 are valid:
Vibration stressing: 2 - 9 Hz max. deflection 3.5 mm; 9 - 200 Hz
max. 1 g; shock stressing 10 g / 11 ms.

System transport:
The same limit values as for transporting the components (refer above) are also valid when transporting the
components with the hard disks installed (cabinets/machine). The hard disks themselves are specified for "non-
operating" shocks 120g (sinusoidal zero to peak, 11ms duration) and "non-operating" vibrations up to 3g
(10...500Hz).

The damping elements for the central controller do not require any additional retaining elements during
transport as a result of their ruggedness.

2. Reducing vibration and shock during operation

The hard disks are protected against vibration and shock during operation using special damping elements,
which are available as standard for the SINUMERIK 840C central controller, or are integrated in the spare part
components. The damping elements are optimized for the frequency range relevant for machines in the
following fashion:
For vibrations from: 10-58 Hz, maximum deflection 0.15mm (peak to peak), from 58 to 100 Hz, maximum
acceleration 1g. For shock stressing, max. 5g, 15ms.

2GB hard disks, from 5/98, may only be used when damping elements are used due to the characteristics of the
hard disks. From 5/98, the hard disks are mounted in the MMC-CPU. The damping elements for the central
controller have, regarding overload, the better characteristics, and protect all of the modules in the central
controller (a set of 4 damping elements with Order No. 6FC5148-0AA20-0AA0). Thus, it is generally specified
for new applications from 5/98. We urgently recommend that if service is required that the damping elements
are retrofitted for the central controller. For cases where this is not possible (tight mounting space), the "hard
disk with damping element" replacement part must be used (6FC65147-0AA13-0AA0). This component is no
longer generally available. However, it is possible in exceptional circumstances after prior consultation.
Additional mounting rails (ZG2: 6FC5148-0AA17-0AA0; ZG3: 6FC5148-0AA18- 0AA0) are required when
using the damping elements on the central controllers 2 and 3. The installation instructions are included.

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3. Limit storage time

For components with hard disk, we recommend that they are stored at room temperature. If this is not observed,
then in order to protect the hard disk, you must wait until start-up:
The temperature difference in degrees K between the storage- and start-up location approximately corresponds
to the waiting time in hours. The permissible relative air humidity as an annual average is 75 percent.
A maximum of 95 percent is permissible for 30 days in the year. Moisture condensation is not permissible.
If the hard disk is stored for longer than one year, the hard disk manufacturer no longer accepts any warranty.
Thus, we recommend that the MMCs with hard disk are powered-up, before this time (one year) expires.

4. Reduce the temperature

The influence of high temperatures on the lifetime of the hard disk is, for the previously used hard disks, is
different depending on the particular hard disk generation and manufacturer; for older hard disk types (170MB
and 540MB), these differences can be significant. For most of the SINUMERIK components, and for the
components with hard disk, a maximum of 55 degrees C ambient temperature is permissible. However, after all
of the experience that we have gathered, we generally recommend to apply any measures which reduce the
MMC ambient temperature, and therefore the hard disk temperature.

The central controller is force-ventilated. For an ambient temperature at the central controller of 55 degrees C,
the hard disk temperature is 60 degrees C. This represents the upper limit for the hard disk. The ambient
temperature can only be reduced by using forced ventilation or by cooling the cabinet utilizing measures
implemented by the machine manufacturer. The ambient temperature is measured in the central controller
below the air intake. When using the "hard disk with damping element" replacement part (6FC5147-0AA13-
0AA0), as an exception, we recommend that the higher-rating fan (6FC5147-0AA07-0AA1) is used for the
central controller, if the ambient temperature at the central controller can exceed 45 degrees C.

5. Observe the mounting position

For the presently used hard disks, the mounting position of the hard disk has, according the manufacturers
data, no effect on its lifetime. We will let you know in plenty of time about any possible limitations for the new
hard disk types.

The mounting position and location of the hard disk is clearly specified when using the MMC in the central
controller.

6. Reducing hard disk accesses and reducing the power-on duration

An essential stress factor for the hard disk are vibrations and shock, which occur when machining workpieces
on the machine, and which differ considerably when hard disks are used in an office environment. If a hard
disk is being accessed, mechanical stressing, e.g. the head hits the disk, which can destroy files. when this
happens, particles are knocked out of the surface, which then multiply due to other collisions, thus scratching
the disk surface more and more. For older hard disk models, data can be written next to the track, or even in an
incorrect track.
As countermeasure, the frequency of hard disk accesses should be reduced as far as possible while machining.
These counter-measures involve both hardware and software measures. This means, that the power-on duration
stress factor can also be simultaneously reduced:
The hard disks which are presently being used, automatically switch themselves into a standby mode if they are
not accessed within 109 minutes.
The hard disk in this case is more protected against stress as far as mechanical vibrations and the continuous
operating time.
At the next access, it automatically runs-up again.

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The MMC-CPU hard disk is write accessed many times in the automatic mode when alarms and messages are
entered in alarm reports 1 and 2. Thus, the entries in the alarm reports should be reduced. Most of the read
accesses to the MMC- CPU hard disk are realized when alarms and messages are displayed.

Software measures < SW 6.1:

With the basic setting in software versions < 6.1, most of the alarms and messages are written on the hard
disk. The number of write operations can only be reduced by changing entries in the MMC configuration file.
In this case, the entries in the PROTMASK1 and PROTMASK2 passwords in the CONFIG configuration file,
should be changed, so that either non, or only the most important alarms and messages are written onto the
hard disk into alarm reports 1 and 2, during machining.
The detailed procedure is provided in the Start-up Guide (6FC5197-xAA50-0AP0) in Section 4.4.2
"Configuration file CONFIG" and in the Section 4.4.2.2 "Format for report masks".

Software measures from SW 6.1, 5.8 and SW 4.9 Hyundai:

In order to minimize the read- and write accesses on the hard disk, the following measures were implemented:
The alarm reports in the basic setting of Regie \ CONFIG are only saved in the RAM memory and are only
written onto the MMC-CPU hard disk after one of the following operator actions:

- "Save to hard disk" softkey in the basic menus of the diagnostics area.
- A report is displayed
- A report is re-displayed

You can re-activate that data is directly written onto the MMC-CPU hard disk by making the entry
(PROTMODE DISK) in the configuration file of the Regie \ CONFIG. Thus, a compatible behavior can be
created as for the system software lower than release 6.

Software measures from SW 6.2

From software 6.2, there is a cache memory for alarm- and message texts. Thus, read accesses are reduced on
the hard disk. By pre-setting the Regie \ CONFIG, this cache memory saves the texts of the 50 last alarms
which occurred in the RAM memory. By making the entry (MELDCACHE ) in the configuration file (Regie \
CONFIG), the number of texts can be changed. It should be observed, that each alarm text in the cache memory
takes-up approx. 100 bytes of RAM memory of the MMC-CPU, i.e. a value should be entered, which
corresponds to the maximum number of alarms occurring under standard operating conditions. The cache
memory for the alarms can be disabled with the entry (MELDCACHE 0) in the configuration file (Regie \
CONFIG). This makes the behavior to system software lower than SW 6. The alarm cache memory may only be
used after first upgrading to SW 6.2 or 5.8.

Hardware measures for WINDOWS users:

As a result of the SWAP mechanism in WINDOWS, the operating system makes hard disk accesses, also
during machining. Under certain conditions, the SWAP file size can be set to "0 KB", thus eliminating
accesses.
The software, supplied by Siemens, is loaded into the MMC-CPU operating memory when the control runs-up.
If no additional operator actions are made after the run-up, depending on the particular memory expansion of
the MMC-CPU, the follow free RAM memory will be available:

Expanded MMC-CPU memory : 8MB 16MB 32MB

Free RAM memory indicated, approx.: 3MB 11MB still not measured

(These values were determined for SW 6.1 and can vary from software to software.)
This means, that the basic MMC software does not require a SWAP file on the hard disk. The user can disable
the data swapping function (where data is swapped onto the hard disk) by setting the SWAP file size to 0 KB.
An OEM user, who generates his own MMC applications must determine for himself, how much memory
space that his application, together with the Siemens applications requires and then he can decide whether it is
possible to disable the SWAP file.

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Setting the SWAP file size:

In order to set the SWAP file size to 0 KB, the following changes must be made at the control system:

2. Select the diagnostics/password menu items

3. Set the password
4. Select the Utilities (Services)/system control menu item
5. Select, using the arrow keys, the Enhanced icon and press enter
6. Press the "Virtual memory" button
7. Press the "Change >>" button, and in the dialog box which is then displayed with the "New Swapfile
Settings" heading, enter a 0 in the "New Size" field
8. Close all of the dialog boxes using the "OK" button
9. Power-down the control and power-up again

Hardware measures for users of the graphic programming (WOP):

The graphic programming (WOP) uses a swap file on the hard disk depending on the RAM size on the MMC-
CPU. When the MMC-CPU with 8MB RAM is used, even when just small programs are generated, the
swapfile is continuously written into. If the programming system is used during machining, the vibration and
shock stress factors, as described above, come into play. Thus, we generally recommend that the MMC-CPU
with 16MB RAM is used. In this case, the number of hard disk accesses is significantly reduced and is
essentially only used to save generated programs.

7. Maintaining an error-free file structure and optimization of hard disk

The failure risk (FAT errors, MMC does not boot, data loss) of the hard disk is significantly reduced by using
measures to maintain a consistent file system, repair after undefined power-down and optimization after
software updates.
Further, measures have been implemented, described and are being worked on, which secure the shutdown
procedure by closing the applications in a defined fashion and running-down the control.

7.1 Repair and optimizing the file structure (consistency check)

Software measures from SW 6.2 and 5.8:

From SW 6.2 and 5.8 FlexOS and WINDOWS, at each system run-up, a checkdisk- (for SINUMERIK system
software FlexOS) or a scandisk run is made (for SINUMERIK system software WINDOWS). Checkdisk and
scandisk are executed with the parameters "automatic error correction, defective file will be erased, memory
space will be made available and no result report". Errors such as allocation error and lost clusters are repaired.
For the SINUMERIK system software FlexOS < 6.2 and 5.8, we recommend that the time interval, set for the
checkdisk (preset, 24 hours) is, if possible, reduced, so that checkdisk is made each time the system runs up.
For SINUMERIK system software WINDOWS from 6.2 and 5.8, each time the manufacturer downloads
software into the system, a DEFRAG run is automatically executed. The user can execute a DEFRAG run via
the service menu after BACKUP.

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7.2 Defined control system run-down using software measures

PLC and MMC are supplied with power together in a group. Thus, using a basic PLC data block, protective
emergency off communications can be realized. If emergency off is initiated, a preliminary power down signal
reaches the MMC via the PLC and the buffer memory. The Siemens- and user-specific applications are closed.
The final control shutdown is realized using the same path in the other direction (MMC-buffer memory-PLC).
It is possible to run-down a control in a defined fashion using SINUMERIK system software WINDOWS from
SW 4.x WINDOWS (by making the appropriate change in the menu diagnostics command "End " or via the
express shutdown function from the PLC).
This procedure is described in the Instruction Manual OEM versions WINDOWS 6FC5198-xAA60 and the
Instruction Manual OEM version WINDOWS 6FC5198-xAA70. Presently, we are developing a defined run-
down function for controls with SINUMERIK system software FlexOS. This will be possible from SW 6.2 and
5.8. The express shutdown function can then be initiated, same as in the WINDOWS version. We urgently
recommend that this function is used for WINDOWS and FlexOS.

7.3 Defined run-down of the control system using hardware measures (emergency off and
UPS)

OEM customers are the main target group for a solution with uninterruptable power supplies (UPS). They
cannot or do not want to configure their software applications to be "shutdown-proof". The other customers are
those who supply their machines into areas which have unreliable line supply networks.
If a UPS is used in a supply system, the MMC receives a power-down signal from the UPS when the machine is
powered-down, or when the supply is interrupted (power outage). The MMC receives this signal via a serial
interface or special I/O pins in the NC area. While the MMC closes all of the applications, the UPS still
provides it with power. The enable signal for the final control shutdown, after the file system has been saved, is
realized along the same path (e.g. serial interface or special I/O pins in the NC area) back to the UPS.
The back-up can then be ended and shutdown.

For weak supply networks, applications can be secured using a commercially-available UPS.
Two solutions are possible.
1. The power-down signal from the UPS is transmitted to the MMC via PLC I/O, using the express shutdown
function. After the application has been shutdown, the UPS receives a power-down signal through the same
data path. This solution can be used with the SINUMERIK system software WINDOWS 4.x and is presently
being developed for the SINUMERIK system software FlexOS 6.2 and 5.8.

2. Communications is realized via special I/O pins, which are controlled from the NC. The power-down signal
from the UPS is send to the buffer memory in the MMC CPU via the CSB (Central Service Board) and the NC-
CPU. After the application has been shut down, the UPS receives its shutdown signal along the same path. It is
scheduled that this solution will be supported from the software side from SW 6.3 onwards.

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8. Replacing the hard disk (replacement parts)

Due to the wear characteristics of the hard disks, the MMC-CPU, from the version specified below, will be
designed o that the hard disks can be replaced.

6FC5110-0DB01-0AA1 from product version E

6FC5110-0DB02-0AA1 from product version E
6FC5110-0DB02-0AA2 from product version A
6FC5110-0DB03-0AA1 from product version E
6FC5110-0DB03-0AA2 from product version A
6FC5110-0DB04-0AA1 from product version E
6FC5110-0DB03-0AA3 from product version A

From July 1998, there is principally only one replacement part available:
6FC65147-0AA13-0AA1 replacement part "Hard disk without damping element" (prerequisite: Central
controller is mounted on damping elements!)
The use of the "Hard disk with damping element" replacement part 6FC65147-0AA13-0AA0, supplied since
May 1997 is only permissible under exceptional circumstances, and only after prior consultation.
The basic software for restore is downloaded into the replacement parts via the Valitek tools or via Interlink as
well as the actual BIOS for the possible required BIOS upgrade, which automatically runs.
The descriptions for an upgrade are provided with the replacement part.

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