I DT

System Solution & SINAMICS

I DT MC R&D85
18.12.2012

Upgrade 802D sl software technology

T/M, G/N and CU
V1.4 or higher => V1.4SP7 HF5
(internal 01.40.10.xx or higher => 01.40.70.00)

1.0 Requirements
1.1 CF-Card: Recommended Siemens card “Compact Flash Card 1GB empty”.
MLFB 6FC5313-5AG00-0AA0 or MLFB 6FC5313-5AG00-0AA1
The MLF number was changed. The new CF-Card for Sinumerik 802Dsl is
available with new MLFB 6FC5313-5AG00-0AA3.

Figure 1: View with windows computer management

1.2 BIOS at 802D sl with Version V00_00_03_03 for hardware version 03.02.00.00.
BIOS at 802D sl with Version V02_01_00_00 for hardware version 03.02.00.01.
By using the hardware version 03.02.00.01 is the installed BIOS version
02.01.00.00, no BIOS upgrade is necessary.

1.3 Sinumerik 802D sl (PCU210.3) with version 1.4 or higher.

1.4 Software version 01.04.SP7 HF5 (01.40.70.00) as file 802Dsl.upd with size
245 MB.

1.5 Toolbox version 01.04.07.05.

page 1 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

2.0 Upgrade BIOS version

2.1 With RCS (Remote Control System Version 01.07.00.03 or higher) write the
image file depending on the hardware version refer chapter 1.2
“BIOS_3.3_Updatecard.img” for BIOS version V00_00_03_03 or
“bioscard.img” for BIOS Version 02_01_00_00 on the CF-Card.
RCS is a part of the toolbox.

Notice:
If a control with hardware version 03.02.00.01 was delivered with BIOS
V02_00_00_00 the BIOS should be upgraded to V02_01_00_00.

Handling: In the main menu click "File" > "Write CF card". Dialog box
"Restore drive from image" as follow.
Example for BIOS Version V00_00_03_03.

Figure 2: Chose file and drive

Figure 3: Write BIOS_3.3_Updatecard.img to CF-Card

page 2 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

2.2 Wait until the restoring is finished.

Figure 4: Finish

2.3 Switch OFF the control.

2.4 Plug the RS232 dongle on backside of the control PCU210.3 (connector –X8)
and the CF-Card on front card slot. This dongle is only for BIOS version
V00_00_03_03 necessary.

Figure 5: Dongle details: Pin 2 & 3 and 7 & 8 will be connected

2.5 Switch ON the control and follow the messages on the screen!

2.6 !! After update is finished switch OFF the control and remove the dongle
and the CF-Card from front card slot !!

2.7 The new version is expected after the BIOS update and power up the control.

Figure 6: Rev: v00_00_03_03

page 3 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

3.0 Upgrade 802D sl to version 01.04 SP7 HF5 (version 01.40.70.00)

3.1 By using the CF-Card for the BIOS update the card was for example formatted
with the following partitions.

Figure 7: View with windows computer management

Remove all partitions and create one partition of type FAT.

Figure 8: View with windows computer management

3.2 With RCS (Remote Control System Version 01.05.16.00 or higher) write the
image file “802Dsl.upd” on the CF-Card. RCS is part of the toolbox.
Handling: In the main menu click "File" > "Write CF card". Dialog box
“Write Image…" as follow.

Figure 9: Choose file and drive

Figure 10: Format CF-Card

page 4 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Figure 11: Write 802Dsl.upd to CF-Card

3.3 Wait until the restoring is finished.

Figure 12: Finish

3.4 !! Don´t plug the CF-Card on front card slot !!

After power on wait till the operating system has been started.

3.5 Set at least password level “manufacturer” and check the MD11210
($MN_UPLOAD_MD_CHANGES_ONLY) = fH

3.6 Plug the CF-Card in the front card slot.

3.7 Before updating back up the data on the control in external backup. Copy the
content of \802D\Start-up archive (Drive/NC/PLC/HMI) to the CF-Card.

page 5 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Figure 13: Copy start-up archive

Figure 14: Paste start-up archive

page 6 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

3.8 NC (NC data, NC directories, Display machine data, Compensation), PLC (PLC
program & PLC user alarm texts), drive data and HMI are backed up into one
archive (802dslibn.arc).

Figure 15: Created start-up archive

3.9 Backup the text files for the “i-HELP”. For the languages simple Chinese,
German,
English, Spanish and Portuguese the text files for the “i-HELP” are part of the
system software. When does files has been modified or completed it is
essential to save it with a RCS OEM-project.

3.10 Switch OFF the control.

3.11 Switch ON the control, the update will start and follow the messages on the
screen!

3.12 !! After power OFF remove the CF-Card from the front card slot!!

3.13 After power on, wait till the operating system has been started. The update is
completed. Set at least password level “manufacturer”.

3.14 If the update process has no progress in the blue “Welcome” picture, switch off
the control and remove the update card.
You have two possibilities to solve this behavior.
1. After turning on the control press the select key to enter the start up menu.
Then insert the compact flash card into the slot on the front of the control
system and choose “Software update”.
2. Use another CF-card or another CF-card producer.

page 7 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

3.15 To restore the card to the original use the System Control in Windows and the
Computer management\ Data carrier management to format the CF-card.

4.0 SINAMICS firmware update (see SINAMICS commissioning, load

firmware)
4.1 Select softkey “Drive MD” to enter SINAMICS commissioning area. Make sure,
the status of the CU_I is 35!

Figure 16: SINAMICS component start-up

4.2 Press softkey “SINAMICS IBN” to list the drive commissioning items.

Figure 17: SINAMICS component start-up

page 8 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

4.3 Select item “Load SINAMICS firmware” to update the connected DRIVE CLiQ
components to new firmware version an press “Start”.

Figure18: SINAMICS firmware update

4.4 Wait until SINAMICS firmware update has finished and follow the shown
instructions in the screen.

4.5 After power OFF / ON all SINAMICS components have been updated and the
firmware is completed.

5.0 Reload the archive files created in step 3.7

5.1 Plug the CF-Card with the data backup on front card slot.

5.2 Copy the archive 802dslibn.arc to \802D\Start-up archive (Drive/NC/PLC/HMI).

page 9 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Figure 19: Copy the archive file

Figure 20: Paste the archive file

page 10 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

5.3 Change PLC:

Please replace the subroutine MEAS_JOG (SBR43) version 01.00 with the
MEAS_JOG (SBR43) version 01.03 and delete the content of the symbol table
IS_HMI (USR17). Copy the content of the symbol IS_HMI (USR17) table from
current library version and insert this content in the symbol table in your own
written PLC project.
Install the PLC modifications below for the elements in VB17000000 and
VB18000000 in the MCP_NCK (SBR38) from the current library in your own
written PLC project.

If the OB1 don’t use a call for the PLC_INI (Version 01.07) than
include a call for "PLC_INI" SBR where bit V19005002.0 is reset within PLC_INI.

OB1:

PLC_INI:

page 11 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

The measure JOG function works with an internal ASUP in the control now. If you
use an old startup.arc file from older software version and not the startup archive
from the current toolbox it is necessary to change following channel setting and
machine data:
MD 42940 = 0
MD 42950 = 0

MD 11602 = B
MD 11604 = 7
MD 19340 = 4
MD 10702 = 11

Notice:
If you have used other values in these channel data than you have to verify your
used NC program for boring tools. Correct programming of G17/G18 in program
and using L1 for tool offset, as determined by the Auto Measure function.

Check if all subroutines have the actual version level. You find POE-symbols
(SYS1) in the opened SUBR_LIBRARY.PTP under symbol table and in the
comment the versions of the subroutines. Compare the subroutines versions
from your own PLC project. If there are differences install the new versions.
If your own PLC project includes changes in the subroutines from the library don’t
forget to install the modifications in the new PLC project.

Figure 21: Symbol table subroutine library V02.00.15

page 12 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Changed PLC for more than one PLC-axis in toolbox 01.04.07.00.

If not more than one PLC-axis is used the changes in the PLC library are not
valid.

By using more than one PLC-axis the changed PLC library and the changed
examples are to use. The subroutines PLC_INI (SBR32) version V01.06,
AXIS_CTL (SBR40) version V01.07, PLC_AXIS (SBR41) version V02.00, the
symbol table MD_PLC (USR27) and the description for the library are changed
for more than one PLC-axis. Replace the old versions please.

Special for Sinumerik Manual Machines check the PLC program in the
installed toolbox in path techno and used technology e.g.
/turning/ManMach_T/ ManMachPlus_T.ptp

Figure 22: Symbol table ManMach_T

page 13 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

5.4 Change text files for i-help (see also 3.9):

Compare the actual text files from toolbox with the saved text files (see 3.9) and
add the differences by handling a new RCS OEM-project.

6.0 Load the cycles from toolbox version 01040705

for technology CU, turning and milling 04.04.02.00

for technology grinding 01.04.05.00
for technology nibbling 01.04.05.00

6.1 By using Manual Machine Plus load from the installed toolbox in path
ManMach_T the cycle_mm.spf.

6.2 For all technologies load the cycles_xml_SP7HF5.arc from the installed toolbox
under C:\Program Files\Siemens\Toolbox 802D_sl\V01040705\Special.

6.3 Using customer cycles

If the previous version provides customer cycles and customer cycle masks in
the program editor, the file cycles.xml in directory f:\cycles (Manufacturer
drive\cycles) has to be deleted under following condition:
The cycle masks are programmed using the instructions for sc.com and
cov.com files and the customer main menu Softkey is one of the Siemens
standard cycles Softkeys (horizontal softkey 3 to horizontal softkey 5). Or the
customer main Softkey is embedded in the Siemens menu tree.

7.0 Load the siemens global user data (sgud*.ini) cycles from the
toolbox version 01.04.07.05
7.1 Back up the files tool data, r variables, work offset and global user data from
802D/Data to CF-Card.

page 14 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Figure 23: Copy the files

Figure 24: Paste the files

page 15 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

7.2 Load the sgud.ini from toolbox.

Figure 25: Copy the sgud.ini

Figure 26: Paste the sgud.ini

page 16 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

7.3 Reload the files tool data, r variables, work offset and global user data from

CF-Card to 802D/Data.

Figure 27: Copy the files

Figure 28: Paste the files

page 17 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

8.0 Input method editor

By using the input help for the Chinese simplified, Chinese traditional and
Korean it is necessary to erase following files under F:\config
- dict_chs.dat
- dict_cht.dat
- hit_chs.dat
- hit_cht.dat

Figure 29: Chinese configuration files

9.0 Create data backup as archive (as described in step 3.7)

10.0 Create internal saved data by operating softkey "Save data"

page 18 / 19
 I DT
System Solution & SINAMICS
I DT MC R&D85
18.12.2012

Figure 30: Save data

11.0 Upgrade completed

page 19 / 19