1

fff
Preamble

System Basic Components 2

System Prerequisites 3
SINUMERIK
System Limitations 4
SINUMERIK 840D
PCU Retrofit Typical System Overview 5

System Installation 6
Commissioning Manual

System Startup 7
HMI-advanced on IPC <->
HMI-advanced on PCU 8

System Backup / Restore 9

System Maintenance 10

Valid for:

Software:
SINUMERIK
HMI Advanced for Retrofit V7.7
PCU Basesoftware for Retrofit IPC V1.0

03/2020
6FC5253-7BX41-7AG0
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION
indicates that minor personal injury can result if proper precautions are not taken.

NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:

WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Unre- Siemens AG
Division Digital Factory
Document order number: 6FC5253-7BX41-7AG0
Ⓟ 04/2018 Subject to change
Copyright © Siemens AG 2018
All rights reserved
Postfach 32 20
stricted 91050 ERLANGEN
GERMANY

Internal
Table of contents

1 Preamble ................................................................................................................................................ 5
2 System Basic Components ..................................................................................................................... 6
3 System Prerequisites .............................................................................................................................. 7
3.1.1 NCU Hardware ..........................................................................................................................7
3.2 NCU Software ...........................................................................................................................7
3.3 TCU ...........................................................................................................................................8
3.4 Operator Panel ..........................................................................................................................8
4 System Limitations .................................................................................................................................. 9
4.1 Simulation of part programs ......................................................................................................9
4.2 Sinumerik Integrate Products ...................................................................................................9
4.3 MCIS Products ..........................................................................................................................9
4.4 STEP7 on PCU .........................................................................................................................9
4.5 EASY-MASK Applications ........................................................................................................9
4.6 OEM applications ......................................................................................................................9
5 Typical System Overview ...................................................................................................................... 10
5.1 SIN 840D PL ...........................................................................................................................10
5.2 SIN 840D SL with HMI Advanced ...........................................................................................11
6 System Installation ................................................................................................................................ 13
6.1 System Mounting ....................................................................................................................13
6.1.1 Operator Cabinet ....................................................................................................................13
6.1.2 Mounting IPC to OP / TCU .....................................................................................................13
6.1.3 Mounting to DIN-rail ................................................................................................................15
6.1.4 Electrical cabinet .....................................................................................................................16
7 System Start up .................................................................................................................................... 17
8 HMI-advanced on IPC <-> HMI-advanced on PCU ................................................................................ 18
8.1 Booting Sequence ...................................................................................................................18
8.1.1 Normal Startup ........................................................................................................................18
8.1.2 Service System / Backup-Restore ..........................................................................................18
8.1.3 Service Center / Backup/Restore ...........................................................................................19
8.1.4 Setup Booting from USB-stick ................................................................................................20
8.2 Desktop Environment..............................................................................................................21
8.2.1 HMI Adv. shortcut ...................................................................................................................22
8.2.2 HMI Startup .............................................................................................................................22
8.2.3 Ht8TCU ...................................................................................................................................24
8.2.4 TCU Service Center ................................................................................................................25

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Table of contents

8.3 HMI – advanced environment (differences) ........................................................................... 26

8.3.1 Logical drives ......................................................................................................................... 26
8.3.2 Simulation of part programs ................................................................................................... 27
9 System Backup / Restore ...................................................................................................................... 28
10 System Maintenance ............................................................................................................................ 29
10.1 Windows updates ................................................................................................................... 29

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1 Preamble 1
PCU Retrofit for SINUMERIK machine tools is a retrofit solution for SINUMERIK 840D Power Line or SINUMERIK
840D Solution Line in combination with HMI Advanced.
The hard- and software components MMC 103, PCU 50 and HMI Advanced with the old operating systems
Windows 95, NT, XP will be replaced by an IPC 427D with Windows 10 and HMI Advanced for retrofit.
This document describes the configuration and the usage of the PCU retrofit for SINUMERIK solution.
For further information, we refer to the default HMI-Advanced user and installation guide and the manual of the
IPC427D.

NOTICE

- The machine has to be checked for non SINUMERIK standards (like applications from OEMs, system
integrater or solution partner) and the compatibility of the soft- and hardware with the PCU retrofit
solution. Maybe not all specialities are executable with PCU retrofit for SINUMERK.
- Non SINUMERIK applications (OEMs, systemintegrater or solution partner) have to be checked for full
functionality on the new retrofit solution
- check the compatibility of hard- and software of NCU and drive system
- hint the customer to IT security topics
- the provision of a PCU retrofit always have to be implemented by well-educated retrofit specialists
- the IPC have to be mounted in a physical protected cabinet or operator cabinet

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2 System Basic Components 2
The basic required components of PCU-Retrofit are the following:
o IPC 427D with Windows10 (9MC1110-7RF00-0AA0)
o HMI Advanced for Retrofit (6FC5253-7BX41-7AG0) SIN 840D PL and SIN 840D SL
▪ PCU Base for Retrofit V1.0.2005501
▪ HMI Advanced V7.71.20055.01
▪ HMI Advanced V6.5.20550.01 for ShopMill/ShopTurn
o HMI Pro for PCU50 Retrofit (6FC5263-0PY50-0AG0) SIN 840D PL and SIN 840D SL
▪ Runtime version at least V7.03.0.24
▪ System Configuration at least V7.03.00.48

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3 System Prerequisites 3
The applicability of the PCU -> IPC conversion depends on the existing configuration of the
following components:
• NCU hardware
• NCU software
• Operating panel (OP)
• Thin Client Unit (TCU) present in the existing configuration.

If the actual configuration contains incompatible hardware / software, upgrades off one or more
components are required to ensure compatibility with the IPC while maintaining mutual component
compatibility.

3.1.1 NCU Hardware

The following types of SIN840D PL NCU hardware are suitable for usage
• 561.4, 561.5
• 571.4, 571.5, 571.5B
• 572.3, 572.4, 572.5, 572.5B
• 573.2, 573.3, 573.4, 573.5, 573.5B

The following types of SIN840D SL NCU hardware are suitable for usage
• 710.1, 710.2, 710.3 PN
• 720.1, 720.2, 720.2 PN, 720.3 PN, 720.3B PN
• 730.1, 730.2, 730.2 PN, 730.3 PN, 730.3B PN

3.2 NCU Software

The NCU software depends on the HMI-Advanced version used by the system.
For SIN 840D PL NCU :
HMI-advanced 7.6 requires NCU software no older than 6.5
HMI-advanced 6.4 requires NCU software no older than 5.3
For support of 57x.5B NCU software 6.5.27 as minimum is required.

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 For SIN 840D SL NCU :
HMI-advanced requires Sinumerik SL NCU software V2.7 or older
HMI-advanced for Retrofit is released for NC V2.6 and V2.7
and should be compatible to older Version

3.3 TCU
Two types of TCU’s can be used to realize the connection between OP and IPC: TCU30.3 and
TCU20.2.
Hint : The system is optimized for TCU30.3.
If the machine configuration already contains TCU modules (a tool-change station, for
example), all the existing modules must be upgraded to ensure that the new configuration
does not contain a combination of different types of TCU modules.

3.4 Operator Panel

The following OP-types are compatible for IPC if they are used in combination with a suitable
TCU module.
• TCU 20.2 / TCU 30.3
o OP 010, OP 010C, OP010S
o OP 012
o OP 015, OP 015A
Hint : min. resolution for operating WIN10 in Windows-mode is 600x800.
In HMI Advanced mode a resolution off 640x480 can be used.

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4 System Limitations 4
The adapted HMI-advanced version running on the IPC has some limitations in software
functionality compared to the original HMI-advanced PCU version(s)

4.1 Simulation of part programs

Simulation of part programs is no longer available.

4.2 Sinumerik Integrate Products

Sinumerik Integrate (former ePS) products are not supported by Windows 10 and HMI
Advanced for Retrofit.

4.3 MCIS Products

MCIS products are not compatible with Windows 10 and not supported by HMI Advanced for
Retrofit.

4.4 STEP7 on PCU

Older version of STEP7 won’t run on Windows 10. If it is mandatory to run STEP7 on the
machine an update to Step 7 V5.6 is required.

4.5 EASY-MASK Applications

EASY MASK applications can be converted to the new HMI advanced environment.
An installation off Easy-mask is not necessary.
Copy all the EASY-MASK related files and directories from previous system (MMC/PCU)
“ADD_ON”-folder to the new IPC427D “ADD_ON”-folder.

4.6 OEM applications

The compatibility of OEM applications (F:\addon, F:\OEM,…) with the new HMI-advanced
environment depends largely on the compatibility of the application in the Windows 10
environment. In general, if the application can be executed in the Windows 10 environment,
it can also be started by the HMI-advanced for Retrofit system.

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5 Typical System Overview 5
5.1 SIN 840D PL
Fehler! Verweisquelle konnte nicht gefunden werden. shows the connection scheme
between the hardware components of a typical system with an IPC. As we can see on the
picture, the IPC is connected to the SIN 840D PL NC over MPI (Multi-Point interface) and to
the Thin Client Unit over IE(Industrial Ethernet).

Figure 1 System Connection Example SIN840D PL

Figure 2 Network SIN840D PL

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 The HMI network, as shown in Figure 2, is assumed as a physical protected and a secured
network. The company network is assumed as a secured network. (defence in depth)
The firewall settings of the company network are closed by default, no open ports available
(security by default)
Every security change must be validated by customer IT and customer IT security guidelines.

5.2 SIN 840D SL with HMI Advanced

Fehler! Verweisquelle konnte nicht gefunden werden. shows the connection scheme
between the hardware components of a typical system with an IPC. As we can see on the
picture, the IPC is connected to the SIN 840D SL NC over IE(Industrial Ethernet) and to the
Thin Client Unit over IE.

Figure 3 System Connection Example SIN840D SL

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 Figure 4 Network SIN840D SL

The HMI network, as shown in Figure 2Figure 4 is assumed as a physical protected and a
secured network. The company network is assumed as a secured network. (defence in depth)
The firewall settings of the company network are closed by default, no open ports available
(security by default)
Every security change must be validated by customer IT and customer IT security guidelines.

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6 System Installation 6
For the system installation it is necessary to realize the connection between the components as
illustrated on the example in chapter 5.
It is also necessary to provide 24V power supply as well and electrical protection for the IPC and
TCU components

6.1 System Mounting

In general, the IPC + TCU modules can be mounted within the same space of the original
PCU50

6.1.1 Operator Cabinet

If enough space is available, the IPC can be mounted to the back of the operator panel or on a
DIN-rail inside the operator cabinet.
The TCU unit must be mounted on the back of the operator panel.

6.1.2 Mounting IPC to OP / TCU

The IPC unit can be mounted on the back of the OP/TCU using special brackets. In this case
the IPC is located within the same space of the original PCU.

Figure 5 Special Brackets for IPC unit mounting

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 Figure 6 Exploded view mounting

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 Figure 7 IPC unit bracket mounting example

There are two possible mounting positions: left-hand side (regular) and right-hand side
(optimized). When the IPC is mounted on the left-hand side, all the connection of both IPC
and TCU are accessible.
If there is no space for the left-hand side mounting, it is also possible to mount the IPC on the
right-hand side with lower mounting brackets, so the height of the IPC and TCU will equal the
height of a PCU. It must be noted that in this situation the connection of the TCU are not
easily accessible.

6.1.3 Mounting to DIN-rail

If the available space in the operator cabinet only allows the mounting of the IPC to a DIN-rail,
the standard accessories (A5E03833245) can be used for fixing the IPC to the DIN-rail.
In this type of installation, it is also necessary to put in place an Ethernet connection from the
IPC mounted on the DIN-rail towards the Operator Panel (TCU).

Figure 8 IPC unit DIN-rail mounting example

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6.1.4 Electrical cabinet
If there is not enough space available in the operator cabinet, the IPC can be mounted on a
DIN-rail, as book size or wall mount in the electrical cabinet.
The TCU must be mounted on the back of the operator panel.
Similar to the installation inside the operator cabinet an ethernet connection from the IPC
towards the operator panel (TCU) is required.
For mounting the IPC unit to a DIN-rail, the standard IPC mounting accessories
(A5E03833245) can be used.

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7 System Start up 7
The IPC comes pre-loaded with the Windows 10 environment.
Setups for Base Software and HMI Advanced for Retrofit are available on DVD.
The system can be booted directly after the required connections are made.

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8 HMI-advanced on IPC <-> HMI-advanced
on PCU 8
The HMI advanced version running on the IPC is based on the previous HMI advanced version 7.6
SP2 HF12 or HMI advanced version 6.4 SP33 It has some modified features compared to the PCU
version.

8.1 Booting Sequence

8.1.1 Normal Startup

Automatic Sequence:
• BIOS
• Operating System Selection (default: “Sinumerik “)
• Startupmanager
• HMI-advanced startup

8.1.2 Service System / Backup-Restore

The service mode can be activated through the Operating system selection (A), by launching
the “ServiceCenter“ application on the desktop in the Windows 10 environment (B) or using a
USB-Bootstick (Chapter 8.1.4 Setup Bootable USB).
A:
• BIOS
• Operating System Selection: “Booting Service System “
• Service Center is loaded

B:
• Launching the “Service Center“ application in the Windows 10 environment
• Select “Start ServiceSystem”
• Reboot
• BIOS
• ServiceSystem is loaded

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8.1.3 Service Center / Backup/Restore
The ServiceCenter hyperlink will open the Service Center Backup/ Restore tool, from which
Hard disk backups can be created or restored.
Reference:

Figure 9 Service Center Backup/Restore screen

PCU-Base software (IM8),

Chapter: Service and diagnostics

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8.1.4 Setup Booting from USB-stick
The Bios settings menu can be opened by keeping F2 pressed during startup of the IPC.

Figure 10 Bios settings menu

Under the “Boot” tab, the option USB Boot has to be enabled and saved by pressing F10
After closing the Setup Utility the Boot Manager can be opened by pressing “ESC-key” during
startup.

Figure 11 Boot options

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8.2 Desktop Environment
When booting into the desktop environment, a standard Windows 10 environment will be
visible. On the desktop, shortcuts to the HMI-advanced configuration tools are visible.

Figure 12 Windows 10 desktop environment

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8.2.1 HMI Adv. shortcut

HMI Adv. shortcut will start the Sinumerik HMI-Advanced environment as would happen
during a normal IPC boot.

Figure 13 HMI-Advanced environment location

8.2.2 HMI Startup

The HMI StartUp shortcut will open the newly added feature which allows to switch between
the HMI-advanced environment and the desktop environment. The HMI Startup will
automatically be loaded when (re)booting the IPC.
To access the additional functions press “3” while the countdown runs.

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 Figure 15 HMI StartUp loading screen

Figure 14 HMI StartUp initial screen

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 Once the HMI Startup is fully loaded, the following options are available:
• Run HMI Advanced: which will launch / switch back to the HMI-advanced
environment.
• Log Off: which will log off the current windows session
• Show desktop: which will switch to the Windows 10 desktop environment

When switching to the Windows 10 desktop environment, the password of the current
logged in user is required to login to the desktop environment.

Figure 16 Windows login requirement for desktop access

8.2.3 Ht8TCU
Configuration tool for Ht8TCU:
Activation of transfer of an HT8 machine control panel signal
References:
Equipment Manual “Operator components and Networking “
Chapter: Networking

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8.2.4 TCU Service Center

Figure 17 System network center

The shortcut “TCU Service Center” will launch the System network center (SNC.exe), from
which settings can be changed concerning TCU-addresses. For more information please
check the following manual: “Sinumerik 840D Manual Operator components and networking”
chapter 41.1.4

Startup Prio:

Prio 1: reserved for system

Prio 2: default priority
Prio 3: reserved
Prio >= 4: set the startup priority to 4 or higher to give the TCU the focus at startup

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8.3 HMI – advanced environment (differences)

8.3.1 Logical drives

Figure 18 HMI-Advanced Logic drives screen

The first USB stick attached to the system will be mounted to “USB local”. It doesn’t matter if
the USB drive is connected to the TCU or directly to the IPC.
In contrast to HMI-advanced on PCU, all USB media are mapped through a “Local” drive and
not each USB drive is being mapped separately.

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 Figure 19 HMI-Advanced USB-ALL screen

The USB media are accessed through the horizontal softkey “USB-ALL” accessing the currently
connected USB drive.

8.3.2 Simulation of part programs

The simulation of part programs via HMI-Advanced is not available anymore.

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9 System Backup / Restore 9
Backup / restoring the hard drive of the IPC is performed through the ServiceCenter. The procedure
is identical to the PCU50.5

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10 System Maintenance 10
10.1 Windows updates
• Disable Microsoft's Windows Update Service,
• Use an update service that is managed by a service provider that officially offers this ser-
vice for Siemens
Update process must be discussed with customer (schedule, available update-server, lo-
cal WindowsUpdateServer)

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Index

Index
––

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