SINUMERIK 810D / 840D 09.02.

2011
Upgrade Instructions
HMI Embedded PCU 20 V06.05.80.01

1. General information
2. How to install the system software
3. How to install the system software with the PC memory card
4. New features and bugfixes
5. How to integrate user ramp-up screens
6. How to use Compact Flash Cards
7. Supplementary conditions

1. General information

The software can no longer be installed under the DOS operating system.
Requirement: Operating system Windows NT4.0 / Windows2000 / WIN XP
Despite a different specification in the Installation & Start-Up Guide,
installation under Win98 and WIN ME is not possible.

With the installation program, the application parameters can be modified, meaning
that
- languages can be changed
- text can be added or edited
- additional languages can be selected
- operator panel machine data and MPI parameters (NETNAMES.INI) can be changed
or replaced
- the human-machine interface can be extended.

In principle, the installation software is installed on the hard disk of a PC/PG.

For software version 06.05 and higher, two installation paths are offered for the
PCU 20.
- For a PCU 20 (PCU20-8MB) with 8MB Flash memory that generates an 8MB ABB
file, 2 languages can be installed.
- For a PCU 20 (PCU20-16MB) with 16MB Flash memory that generates a 16MB ABB
file, 6 languages can be installed.
-
The languages English, German, French, Italian, Spanish and Chinese Simplified are
available. Other languages can be added as an option by means of a language CD
(6FC5253-6BX10-_XG0).

Through the menus and input fields of the installation software, help texts can be
called up by pressing the F1 key.

Alarm texts, default display machine data and the selected languages are saved on
the PCU 20 and must be specified with the upgrade.

The desired foreground language can be activated with MD 9003 FIRST_LANGUAGE.

PCU 20 hardware versions:

6FC5210-0DF00-0AA0

SINUMERIK 810D/840D
PCU20: SPC 166MHZ; 16MB DRAM
8MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

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SINUMERIK 810D / 840D Upgrade Instructions 09.02.2011
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6FC5210-0DF00-1AA0 (keine allg. Freigabe)

SINUMERIK 810D/840D
PCU20: SPC 233MHZ; 32MB DRAM
8MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

6FC5210-0DF00-0AA1

SINUMERIK 810D/840D
PCU20: SPC 166MHZ; 32MB DRAM
16MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

6FC5210-0DF00-1AA1

SINUMERIK 810D/840D
PCU20: SPC 233MHZ; 32MB DRAM
16MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

6FC5210-0DF00-0AA2

SINUMERIK 810D/840D
PCU20: SPC 266MHZ; 32MB DRAM
16MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

6FC5210-0DF00-1AA2

SINUMERIK 810D/840D
PCU20: SPC 333MHZ; 32MB DRAM
16MB FLASH; DC 24V
WITH CURRENT HMI SOFTWARE

2. How to install the system software

Procedure:

See Installation & Start-Up Guide IAM_IM2_D.pdf included in the software CD under
SW_6_5\Documentation.

Note:
Under Windows 95/98 ME, WIN NT4.0, Windows 2000 or WIN XP you will have to install
the “Acrobat Reader” software in order to read the pdf files on the CD.
The current version can be downloaded from www.adobe.com.

3. How to install the system software with the PC memory card

Procedure for the PCU 20:

Start the PCU 20, wait for the serial number to be displayed and then press key
“6” on the operator panel. The PCU 20 is started in the update mode. If a PC
card is available, a menu will be displayed in which the update variant can be
selected.

-: Update from PC card: with default configuration data

0: Update from PC card: without updating configuration data
8: Copy/Save internal Flash to PC card (incl. configuration and OEM data)
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SINUMERIK 810D / 840D Upgrade Instructions 09.02.2011
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+: Add/replace separate files to internal flash

By pressing “-“, the data are copied directly from the PC card.

By pressing “0”, user data such as the configured network data can be saved on
the PC card and transferred again to the PCU 20 hardware with the new software
version.

By pressing “8”, the entire PCU 20 Flash image can be transferred to an ATA or
Compact Flash Card (data backup). The file name is PCU_20.ABB; if this file is
already available, it will be overwritten without checkback.

By pressing “+”, user-specific files (e.g. extending the human-machine

interface, PLC status screens) can be added to or removed from the Flash image.
As data source target you can use a floppy drive or a Compact Flash Card, for
example.

4. New functions as compared to SW 06.03.40

Software installation, application disks have been omitted and replaced by a new installation tool.
Improved software update for the PCU 20
Reference list for trip recorders
Displaying the remaining hold time
Extending the engraving cycle
Geometry processor and grinding stock allowances
Mold making, accelerating the editor
Enabling recompilation through a wizard without #
Consistent 8-digit version designation
Practice-oriented layout of the system resources screen
Compile cycles can be archived in the course of series installation and start-up
Upgrade archives in the Services area of HMI Embedded
Selection of the channel display via PLC
Information on language changeover in the PLC
Display support for ISO cycles
Logical drives in the Services area

For 06.05.50.00

HMI Embedded and JobShop:

1. TM:
(ToDo8140) PLU 54.2700: New tool type angle head cutter
2. TM:
(ToDo9296) Tools created directly in the magazine were partly not displayed on the magazine location

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SINUMERIK 810D / 840D Upgrade Instructions 09.02.2011
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3. TM:
(ToDo 9371): On relocating a tool from the spindle to the magazine, the relocation popup window was overlayed
by the graphical magazine display
4. TM:
Incorrect polling of the overflow has been corrected in the new tool data change service.
5. I/O field:
(ToDo9336) Value inputs in the I/O fields were not limited to the maximum number of specified digits.
6. MMC command interpreter:
For the new MMC command for the workpiece counter, system notebook NB_SY_DB_156 was recycled.
7. S3D:
S3D: Depending on the tool type, a finer "step angle" is selected now in order to achieve a clean chamfer when
using the centering spike of a large centering tool, for example.
8. Cycles operating area:
(ToDo9366) The Cycles operating area is now faded in on operating area softkey 11 for JobShop applications.
9. Geometry processor:
If a POL element was added to the sequence in the basic program, the Gp_para structure was not updated. Reason:
In the function if_gpAppend (\gp\src\if_gp.c), the GP_para structure was not updated for POL.
MGLdm00933 R&D: The parameter of SFC18 error message is not displayed.
MGLdm00970 R&D: Cyclic methods (MMC) do not function any more.

For 06.05.51.00

HMI Embedded and JobShop:

1. External execution:
Indication of percentage (%) of the external program already executed or loaded into the NC missing.
2. DDIR:
Error when opening files: The error message "Send confirmation error" was erroneously displayed
3. Editor:
Exception error due to damaged act_wvb has been fixed
4. Editor:
Incorrect message while overwriting
5. Header:
Variable increment not displayed in header
6. S3D:
The following additions were made to the MTS log file simulation: If there are rotary axes that can be
swiveled, we will provide MTS with the positions of these axes. If TRAORI is active this is also reported
7. Wizard:
Overlay the wizards entry softkeys in ShopMill and ShopTurn for AUTO and MANUAL so that the wizard
interfaces can be opened at different sizes.
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8. TOOLMAN:
Detailed view of angle head cutter, the wear characteristics have not been updated
9. TOOLMAN:
Detailed view of angle head cutter, the protection levels were not effective at length 2 and length 3
10. TOOLMAN:
The graphical magazine display was not updated by "External" entry of a diameter.
11. TOOLMAN:
Error when switching to oversize tool if the new tool data modification service is not active has been
fixed.
12. TOOLMAN:
TOOLMAN crashing while importing tool data has been fixed. Tool data successfully updated after error
/ overflow.
13. TOOLMAN:
Image for small facing tools has been improved
14. TOOLMAN:
Save tool data contained an error for tools with multiple cutting edges.
15. 2D simulation: The scaling of the broken-line graphic was 1 pixel out in some cases
16. Cycles:
Standard cycles 06.05.10.00 and
measuring cycles 06.03.21
integrated.
17. New conversion parameter CON_FILE_NAME_PLUS_DOT for CON_STRING: New conversion
parameter CON_FILE_NAME_PLUS_DOT for CON_STRING added. The new parameter allows the
same characters as CON_FILE_NAME, with the addition of “.” (DOT).
CHMdc09201 CYCLE60/ cannot proceed to next page.
ERLde39340 Press F10 to run WIN32:MMC0.EXE
ERLde57250 SI: User confirmation required if number of axes higher than five
ERLde67993 Program/contour: output M30 will exit the SK bar.
ERLde68366 Program/memory management: Status “Memory limit reached”.
ERLde68555 MDA: Error 100106 occurred while saving
ERLde68720 SI: Diagnosis: external stops are displayed even if not authorized.
ERLde69166 Read/write from GUD failed
ERLde69413 Request: Please enter fourth dimension for value field.
ERLde70023 English language: Incorrect alarm text for alarm 400106.
ERLde70042 String variable with default setting from language file.
ERLde70097 Network: share name including "_" does not work.
ERLde70178 Image change blocked until TC is accepted.
ERLde70316 SW upgrade: OEM data are not saved.

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ERLde70774 Error while printing image using Ctrl P or via automatic test machine.
ERLde71416 Start-up, NC: Yes/No vertical softkeys transposed on query
MGLdm00945 R&D: Zoom will be deselected once the simulation is exited.
MGLdm00976 R&D: With polar coordinate programming an already closed contour will not be detected
by the geometry processor (GP).

For 06.05.52.00

HMI Embedded and JobShop:

1. Exception during processing of RS-232-C (V.24):
Solution to avoid the problem: RS-232-C changed from fast domain service to standard domain service
2. Display MDs 9460 and 9464:
Lower limit of display MD 9464 reduced from 60200 to 51200; additionally, default display MD 9464 set
to 102400 and MD 9460 bit 7 set to 1
3. New display MD 9890 ST_USER_CLASS_MEAS_T_CAL:
New display MD 9890 ST_USER_CLASS_MEAS_T_CAL implemented
4. New display MD 9747 CMM_ENABLE_MEAS_AUTO:
New display MD 9747 CMM_ENABLE_MEAS_AUTO implemented
5. Mold making programs:
String search in mold making programs caused the user interface to freeze
6. S3D:
S3D: A short data stream interrupt causes a simulation interrupt
7. Spindle performance display:
The spindle performance display was improved and implemented according to DD:
For this function, a new configuring element PROGRESSBAR_BAR_ADV was implemented; it is
described in DD and is to be included in the Planning Guide.
8. TOOLMAN:
TOOLMAN: Suppressing the "Relocate" function will also suppress the "Load" softkey.
9. Cycles:
Measuring cycles 06.03.24 and standard cycles 06.05.14.00 integrated
ERLde57250 SI: User agreement for more than 5 axes
ERLde68261 Network execution: Highly sporadic crash
ERLde72375 ToDo 9614: Unable to enter a lead for the tap
ERLde72511 Network/execution from external source: Sporadic output of error 14601
ERLde72539 Diagnostic/operational messages: Not displayed in list
ERLde72890 "L" is automatically inserted after search function.
ERLde72904 ToDo 8512: Messages are not displayed with scroll function
MGLdm01037 R&D: HMI Emb. exception on task change during editing
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MGLdm01046 ToDo 9639: R&D: Simultaneous recording in G700 too small by 25.4

For 06.05.53.00
HMI Embedded and JobShop:
1. Teleservice:
When the mmcr.exe was called via a file with a directory name containing blank spaces, this file was not
parsed correctly.
2. Cycles version screen:
Gray font for Details softkey in the Cycles version screen was not correct
3. Teleservice:
Error on IP address generation when the RCS was called via a file.
4. 2D simulation:
In the broken-line graphics, not all dimension lines and values of coordination systems pointing downwards
were correctly displayed.
5. DDIR:
DDIR: Extcall. Specification of percentage (%) of external program that has already been executed or loaded
to the NC.
6. ToolMan:
(ToDo 9805): ToolMan: Line break was not correct in OEM softkey display
7. G code online help:
G code online help does not function correctly
ERLde68094 ‘Grid’ table element is not displayed clearly
ERLde72141 Grid: Changing column properties does not function
ERLde72600 MDI/TEACH: No entry possible after 36 NC blocks
ERLde72825 Grid: Focus control does not function
ERLde73961 Extremely slow display generation for remote diagnostics via OP15
ERLde74840 Diagnostics/action log: No alarm number + wrong time
ERLde75133 Remote diagnostics RCS Viewer config does not always become active
ERLde75421 Parameters/user data: Sporadic exception
MGLdm01071 R&D: Hidden program can be edited

For 06.05.54.00

ERLde72137 Load Mask" is not supported within an open mask

For 06.05.55.00
ERLde80105 BIOS change because of new PCU20 with 333MHz
TOOLMAN When the channel is changed it is possible that the tool offsets are copied by mistake from
Tool list - Details to another channel
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ERLde77404 Sporadic exception on keyswitch 6 in MDI mode

ERLde80793 Service/Upgrate archive: read in drive data is not possible
ERLde80836 Networkmanager:Exeption PCU20 at access to network drive.

For 06.05.56.00
ERLde57510 SD: Setting data 42940 and 42950 are not effective
MGLdm01353 R&D: The files Drehen.ini etc. cannot be found
ToDo 7790 StonPC: Simulation: second start does not work
ToDo 10542 Online help in G code programs does not work
ToDo 10555 In override positions <=80%, the simulation does not come to an end
ToDo 10518 New display MD 9708 $MM_CMM_INDEX_SPINDLE_2
ERLde82161 MGL +/- key without a function
ToDo No 10715 Minimum value of the display MD 9708 for SM 6.4 and SM 7.1 at 0
When copying parts of the input field to another input field (via CTRL-C, CTRL-V), the contents of
the target field are destroyed
New display MDs 9778 and 9779

For 06.05.57

MGLdm01244 Block search during execution from external source

MGLdm01249 R&D: No display after block search without calculation
without Increase upper limit of MDs 9706 and 9707 from 3 to 6
ERLde80356 Machine/MDA: Display of last block after reset
ToDo Nr 10715 Set minimum value of display MD 9708 for SM 6.4 and SM 7.1 to 0
MGLdm01302 Make the display machine data 'AMD 9206 -
$MM_USER_CLASS_WRITE_TOA_SUPVIS' known to HMI Embedded
060556-30 When copying parts of a text field to another text field (by means of CTRL-C,
CTRL-V), the contents of the target field are destructed
ERLde79068 With the 'Copy and Paste' function, it may be possible that a sentence is doubled
MGLdm01350 Wrong cursor position after insertion of a tool in DIN and return to open G code
program
CHMdc08248 Special characters for engraving cycle incomplete.
SR-206337182 Crash in HMI Embedded
ERLde57510 Too many tool parameters: setting data 42940 and 42950 have no effect
ERLde81658 Reach Out not possible via CF card

For 06.05.57

MGLdm01244 Block search during execution from external source

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MGLdm01249 R&D: No display after block search without calculation

without Increase upper limit of MDs 9706 and 9707 from 3 to 6
ERLde80356 Machine/MDA: Display of last block after reset
ToDo Nr 10715 Set minimum value of display MD 9708 for SM 6.4 and SM 7.1 to 0
MGLdm01302 Make the display machine data 'AMD 9206 -
$MM_USER_CLASS_WRITE_TOA_SUPVIS' known to HMI Embedded
060556-30 When copying parts of a text field to another text field (by means of CTRL-C,
CTRL-V), the contents of the target field are destructed
ERLde79068 With the 'Copy and Paste' function, it may be possible that a sentence is doubled
MGLdm01350 Wrong cursor position after insertion of a tool in DIN and return to open G code
program
CHMdc08248 Special characters for engraving cycle incomplete.
SR-206337182 Crash in HMI Embedded
ERLde57510 Too many tool parameters: setting data 42940 and 42950 have no effect
ERLde81658 Reach Out not possible via CF card

For 06.05.59.00
AP00306410 Controlling the focus of Wizzard Grid, problems with row, collumn and value
AP00301508 Problems with more than 700 part programs in one directory
AP00343259 Problems with nck upgrade archives

New functions:
Extended trip recorder

For 06.05.60
AP00359868 Trip recorder / settings: No file size limitation for PCU20
AP00350356 Trip recorder: Power On directly leads to Exception
AP00347893 Trip recorder: Exeption in BA-Auto + offset block, cannot always be reproduced

For 06.05.61
ToDo 10818 Tool management: Exception when reading in tool data,
MGLdm01418 Overwriting tool
ToDo 10857 Tool management: Without TO_OPTION_MASK, bit 2 the OEM tool data are
MGLdm01443 not read
ToDo 10823 When changing the ini files, index 0 is not accepted for the OEM tool parameters
(change under TO)

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For 06.05.62
AP00361676 Trip recorder: Exeption after generation of crash data

For 06.05.63
Trip recorder can be switched off completely

For 06.05.64
AP00371726 ShopMill editor: Problem when deleting first program line with backspace

For 06.05.65
AP00375024 PI services TMFDPL and TMPOSM do not work

For 06.05.66
ToDo 11101 Tool management: When more than 354 tools are created, not all the tools are
displayed in TOOLMAN any longer
AP00388241 Make program path pollable when selecting “External program”
AP00413456 NC errors are displayed without a number in the second channel
ToDo 11128 Expansion of the s3d log to include the variable mode of tool life monitoring

For 06.05.68
AP00375024 PI services TMFDPL and TMPOSM do not work

For 06.05.70

AP00433021 Wizard: No values from /Tool/Find/resultToolNr

ToDo 11283 Tool management: Loop at initialization of columns uses loop index type UWORD. The loop
runs backwards to -1 -> Exception.

AP00355858
ToDo 11230 "Tool management: 'Multiple creation, loading, deleting of tools without corresponding
acknowledgement leads to diverse anomalies, depending on the ShopMill/NC version used'"

AP00455794
ToDo 11231 Tool management: No tools can be loaded into the grippers. The magazine number cannot be
entered.

For 06.05.71
AP00370313 Alarm 16420 due to mutilation of the free G code line in the basic program

AP00563402 HMI exception when executing from external source without

doubling of G code lines in the editor

For 06.05.72
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AP00554686 RS-232-C settings are being reset

For 06.05.74
AP00528880 WIZ_DATA.COM is becoming larger

06.05.75
SZ status 06.05.23.00
AP00522129 3D simulation: Interface signal DB19.DBX20.6 is not received.
AP00615477 Standard display MDs after metric / inch changeover
AP00611819 3D simulation: Sporadic exception
AP00641105 Exception when opening own screen forms
Without Error when searching/replacing in the Editor

For 06.05.76
AP00697935 HMI emb Editor problem after program change and search/replace, re-number

For 06.05.77
Debugs for JobShop:
AP00621136: Tool manager: Display problem for tool wear
AP00612983: No graphic display (dotted-line graphics) of program blocks for SM/ST

For 06.05.78
AP00738596: User messages are not correctly displayed if there is more than one message number
Debugs for JobShop:
AP00732486: Loading/unloading tools. Sporadic message: "Please wait: Tool manager is being updated.
AP00697952: Unmachined part definition in inches: Incorrect scaling in X and Y in the simulation
AP00603651: The free G code line is corrupted in the GP

For 06.05.80.01
AP01089152: CF cards do no longer function
The software release contains a new Bios version (V 2.0). With it, alll Siemens SINUMERIK 1GB CF cards
will now be supported.

5. How to integrate user ramp-up screens

Install the system software on a PC and change to the Explorer after

installation (standard path: HMI_0_2\BIN\640); then copy the desired screens
(256 colors, LOGO_OEM.BMP or OEM_*.BMP)to the directory of the relevant
resolution (BIN\640, BIN\800 and BIN\1024). Copy batch file OEM_BMP.BAT from
directory tools\oem_bmp of the delivered CD to the specified directories and
start it in all three directories.
Continue with the usual installation procedure and generate an ABB file.
Notice: the user ramp-up screen must be named LOGO_OEM.BMP.

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6. How to use Compact Flash Cards

Versions 06.02.35, 06.03.01 and higher:

ABB file "\PCU_20.ABB” generated with system and application disks, can be
transferred directly to the Compact Flash Card.
For example:
- With a PG or notebook via PCMCIA and customary Compact Flash Adapter.
- With a customary USB card reader supporting CF cards.
- Through an existing network connection by using the function Copy + Paste in
the Programming area.

Secondary conditions:

An 8MB image requires a Compact Flash Card of at least 16MB, while a 16MB image
requires a Compact Flash Card of at least 32MB. The image "\PCU_20.ABB” must be
available in the root directory of the Compact Flash Card.

The Compact Flash Cards (empty cards) with 32MB (6FC5313-1AG00-0AA0) and 64MB
(6FC5313-2AG00-0AA0) are available for operation with the operator component
SINUMERIK PCU 20.
Adapter for CF cards (customary); for example see:
www.sandisk.com/retail/pca.asp

The PCU 20 software is updated as usual:

1. Switch off the PCU 20

2. Insert the previously created Compact Flash into the PCU 20
3. Switch on the PCU 20; press key “6” in the update menu for ramp-up
4. Press the key sequence "0" "0" or "-" (i.e. with/without configuration data)
and burn the image to the internal EPROM of the PCU 20.
5. The PCU 20 will now automatically boot with the new software version.

Note:
The Compact Flash Card can be inserted into the PCU 20 only by using a (customary)
CF-PCMCIA adapter.

7. Supplementary conditions

Due to error MGLdm01069, files are not displayed in the Program operating area.

After the software upgrade of the PCU 20 with CF card and ABB file, hieroglyphics
are sporadically displayed in the "IBN\Logische Laufwerke\Dateitypen"
("Startup\Logic_drives\File_types") menu.
This setting acts as a filter in the Program operating area and files are not
displayed.

Remedy:
In case of updates with Compact Flash (all versions) and updates with linear flash
up to version 6.4.8, please check the IBN\Logische Laufwerke\Dateitypen
("Startup\Logic_drives\File_types") in the operating area and delete, if necessary.

USB keyboard on face side of operator panel is not hot-plug capable.

System software does not support mouse (USB).

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If you change or replace the hard key configuration (keys.ini file) in the
configuration files, all INI files indicated in that file will be listed and you
can change and replace them; however, these data will not automatically be
entered in the image. This has to be done explicitly when installing the system
software by clicking “Insert files”.
The functionality "overstore" (OP-mode AUTO or MDA) requires at least 3KB free
NCU memory

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