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Problem uploading pcp file to sinumerik 810t

Created by: ticko at: 2/4/2012 10:07 PM (32 Replies)

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2/4/2012 10:07 PM	Rate (0)
ticko Posts: 7 Rating: (0)	Hello, I have a CNC machine with Sinumerik 810t GA3, which had bad batteries and data were lost. I have a backup of TEA1, TEA2, PCP and PCA. I replaced the batteries and followed instructions how to upload data, but i have the following problem. I successfully uploaded TEA1 and TEA2 files. But when i want to upload PCP file, the transmission is interrupted after a few bytes transferred (195 bytes). It happens every time. I also tryed slower speeds (300), and the transmission stoped after 73 bytes. If i try to upload other files it works. The problem is only with PCP data. Does anybody have a clue, what could be wrong? Thank you. Regards, Matic
ticko Posts: 7 Rating: (0)
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2/5/2012 7:57 PM	Rate (0)
Pee El Sea Gold Member Joined: 1/19/2008 Last visit: 9/3/2025 Posts: 998 Rating: (65)	Hi, Are you loading it in initial clear mode ?. Pee

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2/6/2012 9:49 PM	Rate (0)
ticko Posts: 7 Rating: (0)	Yes, I am doing it in initial clear mode. I was following the manual from Siemens about reloading machine data. As I have read inthis thread,it might be corrupted PCP file... Any suggestions?
ticko Posts: 7 Rating: (0)
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2/7/2012 8:57 AM	Rate (0)
Pee El Sea Gold Member Joined: 1/19/2008 Last visit: 9/3/2025 Posts: 998 Rating: (65)	Hi, If you look at the file in a text editor it should obviously start with %PCP and then long lines of code such as D80230A1 etc etc. It is a hex code dump of the plc. Upload it if your not sure and I'll have a look This file usually goes in OK it's the alarm text file that everybody has problems with. Pee

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2/8/2012 4:19 PM	Rate (0)
rezahashemi Posts: 10 Rating: (0)	Dear ticko could you send me pcp file?
rezahashemi Posts: 10 Rating: (0)
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2/10/2012 11:56 AM	Rate (0)
ticko Posts: 7 Rating: (0)	Hi, file starts with '% P C P' and not with '%PCP'. See the attachment. Do you think this is the problem? Regards, Matic Attachment SPT.zip (1116 Downloads)
ticko Posts: 7 Rating: (0)
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2/13/2012 10:18 PM	Rate (0)
Jefke Advanced Member Joined: 9/15/2009 Last visit: 9/15/2025 Posts: 25 Rating: (0)	are you using XP? I expierienced many problems with PC(or PG)with XP. With a PC with WIN98 never problems (only for PCP, other serial transmission under XP is no problem)

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2/13/2012 10:38 PM	Rate (0)
ticko Posts: 7 Rating: (0)	Hi, yes I tried both, Win XP and 98. In XP i also had problems with TEA1 and TEA2 which didn't upload completely. Then I switched to Win 98, TEA1 and TEA2 were uploaded without problems but PCP data not. Then i tought it it must be a communication problem, so i tried few different connection parameters. I set lower baud rate on both PC and CNC, all without success. PCP data transfer stops after few bytes transmitted. But i can transmit cnc programs and other data without problems via RS232, so i think the problem is not computer or OS related. Regards, Matic
ticko Posts: 7 Rating: (0)
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4/16/2014 7:33 AM	Rate (0)
Primoz12 Posts: 1 Rating: (0)	I have exactly the same problem with my Siemens 810m GA2. I have been trying several different things, but after 2688bytes siemens stop receiving file containing %PCP parameters. If I furter press start transmit button, the transmission is continued, not as pcp parameters but in a separate file. I dont know if it is even possible to transmit his.
Primoz12 Posts: 1 Rating: (0)
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4/16/2014 4:20 PM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Primoz12 I have exactly the same problem with my Siemens 810m GA2. I have been trying several different things, but after 2688bytes siemens stop receiving file containing %PCP parameters. If I furter press start transmit button, the transmission is continued, not as pcp parameters but in a separate file. I dont know if it is even possible to transmit his. Hello, Try clearing the NC and PLC by pressing the eye button softkey and check. Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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5/18/2014 2:52 AM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Has anyone found a sollutionto the above mentioned problem? Same goes for my 810M GA2, TEA1 and TEA2, no problem, the PCP file starts, but stops at about 220 bytes (sometimes some more, sometimes less) Mine stopped working at turn on one day, only able to start in initial mode and giving PLC alarm Batteriealarm, machine ende and the second one is PLC Stop. Should the NC be able to start up with only the TEA1 and TEA2 files loaded (probably giving an error regarding no PLC program or connection or so?) Thank you all very much for the help I allready had from here!!!! Bart
Primotechnics Posts: 10 Rating: (1)
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5/18/2014 10:33 PM	Rate (0)
Pee Ell Sea Posts: 672 Rating: (57)	Hi, From initial clear mode if you clear mc data, plc data, plc program, asm, and load standard mc data, plc data, and standard plc program your system should run OK. (only the system not the machine). Then load your backup data. Pee
Pee Ell Sea Posts: 672 Rating: (57)
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5/18/2014 11:36 PM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Pee, Thanks for the reply. I thought it worked that way, mine doesn't start up at all. If I power up I only get the initial screen where you can select MC, and NC data, load the standard one, and load data from and to the machine. If I clear all the data and format the memory, the free space stays the same so I suspect I can't get in the initial clear mode, I can't get at the screen were you are supossed to enter 1111 and the eyeball key. Any suggestions are (very) welcome. Bart
Primotechnics Posts: 10 Rating: (1)
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5/20/2014 8:05 PM	Rate (0)
Ekalavya Posts: 2964 Rating: (484)	Primotechnics Pee, Thanks for the reply. I thought it worked that way, mine doesn't start up at all. If I power up I only get the initial screen where you can select MC, and NC data, load the standard one, and load data from and to the machine. If I clear all the data and format the memory, the free space stays the same so I suspect I can't get in the initial clear mode, I can't get at the screen were you are supossed to enter 1111 and the eyeball key. Any suggestions are (very) welcome. Bart Hello, May be useful check this link /tf/WW/en/Posts/50916 Regards, Prakash
Ekalavya Posts: 2964 Rating: (484)
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5/21/2014 12:51 AM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Prakash, Thanks for the help, but I found that tread and the file to reload. Everything works exactly as described in the PDF, only, when I reset everything, mine doesn't start up in "normal" mode again, it only works in initial clear mode. So I can't give the 1111 code and enter, and then when powering up pushing the eyeball button. Any info would be greatly appreciated! Gr Bart
Primotechnics Posts: 10 Rating: (1)
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5/24/2014 12:53 AM	Rate (1)
Primotechnics Posts: 10 Rating: (1)	Hello everyone, Just letting people know what I found out solving my problem: First I kept getting battery alarm even after changing the battery at the back of the NC (screen) After reading through the whole manual 810_GA1_Installation_Instructions (Found here, thx!!) I figured it could be a dead battery off the Ram memory card. Removed the card, measured the voltage...0.3V instead of 3.6 V. Changed the battery although Siemens says changing the complete ram memory plate (but my whallet dissagreed), and YES I finally got rid off the alarm #6 battery alarm, and I could power up (although the machine wasn't working yet) Followed the instructions in 810 reload (see attachment) which are vvery detailed and correct. And yes, I could start up, only to find out I couldn't move the axes because I kept getting alarms 1720,1721 and 1722 (and some more) saying arbeitsfeldfehler (or something like that). Found out I needed to input the "size" off the working area in the setting data and sub menu axial. You fill in the values you can find in the TEA1 file under 2280,2281,2282 and 2283 (which is your machines travel in 0.001mm + 1mm) at the max values but you should wright these as negative numbers, so 550 mm travel is -551000 (in my case). The max travel is 1mm or fill in 1000 (again you can find the values in the TEA1 file on your PC or in the NC-MD daten in the NC.) Now you should be good to go (mine's not yet because I can't get the 4th axe to move so can't learn the machine it's reference points...) Hope this helps someone some day, Thanks all!! Bart Attachment 810_820 reload.pdf (602 Downloads)
Primotechnics Posts: 10 Rating: (1)
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6/3/2014 6:09 AM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Hello I have the same problem with communication. I ve put down baudrate at 1200 and transfer goes to end. But in my backup floppy I didnt find file %TEA1. I dont know what is the ASM file, must have function because is the biggest size In attachment is the backup floppy If someone have time and is willing to help me please give to me explanation of files especially the ASM file Thanks in advance Attachment My sinumerik Floppy 820.zip (688 Downloads)

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6/3/2014 8:25 AM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, From what I've learn't so far, there doesn't seem to be a TEA1 file in yours, it should have the title %TEA1 and end with M02, and has N numbers with values. % T E A 1 N 0 =0 N 1 =500 N 2 =0 N 3 =500 N 4 =0 N 5 =100 N 6 =0 N 7 =100 . . . N10923 =0 N10924 =0 N10925 =0 N10926 =0 N10960 =0 N10961 =0 N10962 =0 N10963 =0 N10964 =0 N10965 =0 N10966 =0 M02 Hope this helps. What make model of machine is it? Maybe you can get it from the manufacturer? Gr Bart
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6/4/2014 10:23 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Thanks on yours help but WHAT NOW??? Tell me is it possible to aks SIEMENS for that file? Do they have database for all products? I have other original diskette. After all Ive find the Disk reader but its not possible to read the contents. Thanks Blagoja Sotirovski Ohrid, Republic of Macedonia Attachment Disk original.pdf (678 Downloads)

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6/5/2014 12:32 PM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, Depends on the manufacturer off the machine, but those will probably be in Step 5, the program which you then need to read and upload the file to the machine. Siemens just has the standard software for the 810 (which will probably still be in the memory) but it won't make your machine work. You need the files supplied by the manufacturer. Maybe there are some hidden papertapes somewwhere in the machine, and you can find someone with a tape reader to put them in? (I did ;-) So you can try to find somebody who has the same machine and therefore (probably) the same TEA files, you can download it from his machine (but if you have no experience that's risky) or maybe he hs backups from his machine. Or maybe you can find a printed version and if you have the patience input them manually (good luck on that ;-) Gr Bart
Primotechnics Posts: 10 Rating: (1)	Last edited by: Primotechnics at: 6/5/2014 12:32 PM
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6/6/2014 2:40 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	thanks a lot I agree all thay you say. I hope Im not bore, and disturbing you. I ve learned a lot in this case and as I can take this conclusion: 1.%TEA 1 file contains the machine data sholud be put at NC *this file I miss so is it possible to start PLC without file??? 2.%TEA2 file contains the machine data sholud be put at PLC 3.%PCP -PLC program 4.%PCA - NC Alarms explanation. Without this file the CNC will work giving alarms but there will be not explanation after Alarm number. In attacment are alarms at CNC. The main problem is that PLC is in STOP mode- not working. Thanks for help Attachment 820 Alarms.pdf (695 Downloads)

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6/6/2014 7:08 PM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, You've got it wright. Without the TEA1 the machine won't work. The PLC stop alarm is the most important for the machine, but the second one (#11) is why the PLC is in stop mode. At siemens they state: REason : UMS declared unvalid Explanation : UMS ram not loaded or empty UMS not defined : - UMS (RAM) overturned - UMS (EEPROM) empty Wrong UMS inserted Error when linking Remedy : Insert correct UMS (not in your case I think) Reload UMS (RAM) I think that's your problem. Good luck!! Bart
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6/7/2014 3:38 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Hello Bart Thanks a lot for ev,ry thing Today I had a little time to work with Sinumerk and I discover that The ASM file at Floppy is UMS memory. I ve put asm file in initial clear mode and restart CNC but not working . The plc is still in stop mode. In the NC there 's tea1 file I dont know does modified after battery failrue !!! I discovered that at CNC you can do backup at this : 1. NC MD - %TEA1 2.PLC MD- % TEA2 3.UMS PLC- PLC RAM 4.PLC PG - PLC PROGRAM I will send tou you theese files because are at my desktop PC. I ve downoaded sucessfully ram and program but afterthat made backup but believe to me the files are different so that make me suspect in my work. Still I'm gratefull to YOURS and EVERYONE 's help have a good day

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6/8/2014 4:11 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	So At the end I didnt find solution yet but I have concrete conclutoins: If I want to make backup i will take the following files: 1.NC MD => % TEA1 the file Im still missing. without this file I get allarm nr. 11 wrong UMS identifier. Still I dont know wht exactly to do because I dont understand explanations. If I clear nc system bit 5015.6 then the allarm wil dissapear. I dont know is it right ??? 2.PLC MD=>%TEA2 3.PLC PRG=>%PCP EMPTY After battery failrue. If I Put PCP file from FDD => Sinumerik(PLC) then I will get alarm message nr 3 PLC STOP mode. 4.UMS DAT=>%ASM the think that confusing me most!!! I ve tried to put ASM file contained in the backup floppy disk in Initial clear mode and in normal data input/ output mode withot results. I dont understand that because if You take backup file from Sinumerik normally is that file could be downloaded in Sinumerik to restore machine So please anyone can help me with any information I will be gratefull. At the attachment are files I downoaded from sinumerik to my PC. Thanks Attachment MY Sinumerik backup.zip (777 Downloads)

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6/8/2014 7:55 PM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, I've looked at the files you've attached and I do see the TEA1 file (NC-MD). And also the TEA2 file is there and looks ok as does the PCP. If you have these 3 files, the machine should work, unless you have a hardware problem. So normally, you erase everything in initial clear mode, then you install TEA1 en 2, then format user memory (If I'm not mistaking) and then you install the PCP file. Then the machine should be working. I still don't know what the ASM file is. I've only limited knowledge off the Sinumerik due to a problem with my own machine. But from what I've found you only need those 3. The following PCA file is only the alarm text, but not necesary, the system will still show the alarm numbers. So follow the intructions off the 810-820 reload file (see before) and you should be able to make the machine work (don't worry about the ASM file) Gr Bart
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6/8/2014 8:37 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Hello Bart The TEA1 file is the file Ive dovnloaded from NC. Probably is standard siemens file after clearing NC MD and restart the system. I dont know how to explain that in the attachment are files downloaded from the machine after battery failrue. So there is no option to bakup alarms file or I dont know how to do that.. Bart thanks to you for yours advices, I m electrical engineer at maintenance, so if you need any help Im willing to give to you At the end I m asking anyone can explain %ASM file. (whats function ???) Thanks

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6/17/2014 6:29 AM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	hello one more time I'm asking all members willing to help to me about my CNC Sinumerik 820 to explai to me what is meaning(function) of UMS. Exactly I'm able to make backup of UMS but I dont know what with this file? Is it possible lost %TEA1 file to take from UMS in attachment??? It is impossible to download to my sinumerik !!! And another quetion what I need to do to make "Load plcprogram" steakers appear at initial clear mode. Thanks in advance Attachment 820 Data output.pdf (677 Downloads)

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6/17/2014 1:53 PM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, Sorry, but mine doesn't even hve the UMS-Dat transfer possibility. I don't know if it is possible to upload or download. What I have learned, you need first TEA1 then TEA2, reformat, then PCP, then the machine should work, the other files are there for extra features, PCA will show what a certain alarm number means and so on, but the machine can work without all these. Only TEA 1 and 2 and PCP are necasary. Good luck! Bart
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6/17/2014 10:26 PM	Rate (0)
Pee Ell Sea Posts: 672 Rating: (57)	HI, UMS or ASM is a means to customise the displays and also to store fixed cycles and commissioning data. The UMS if programmed was usually blown onto eprom so tea1 and tea2 and pcp could be loaded directly from the initial start area. I would guess it cannot be loaded via serial port because it is an eprom based ulility and no ram exists to load it into. The UMS backup that you probably have is the standard Siemems version. The programming kit to produce a UMS on an 820/810 control was many times the cost of the control so very very few controls have this option. Pee
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6/18/2014 8:37 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Thanks on Your's help Still I need the TEA1 file. I've downloaded in sinumerik similar TEA1 file and after that Ive changed some bits 5000 ... in NC MD area and PLC go into RUN Mode(start working) but there is alot of things dont work. My intention was how to re commision CNC with UMS ??? Is it possible??? I mean the original TEA1 file is impossible to find. All the best,
	Last edited by: socaoh at: 6/22/2014 1:40 AM Last edited by: socaoh at: 6/22/2014 1:39 AM
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6/26/2014 8:41 PM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Hello Finaly Ive do recommisioning CNC lathe. The owner buy from Germany files needed (%TEA1....) but I suspect that tea1 is original to that machine because the working area was not correct. Exactly I think that they send from smaller similar cnc lathe. I ve change some NC MD data and solve that but I dont know is it necessery to reference toolbox because I have this message at PDF attachment. Especially I'm gratefull to Primotechnics who did giving me advices all the time. Thanks Attachment Reference.pdf (805 Downloads)

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6/27/2014 1:42 AM	Rate (0)
Primotechnics Posts: 10 Rating: (1)	Hi, Thanks, your very welcome! I don't think this i a rel problem you have. The reference points are reached, and the machine should work, correct? Off course it will display a incorrect value when moving the axes to a certain point, but that can be changed. Maybe you should check NC-MD 240*maybe these are set incorrectly? Seethe attached file, maybe that can help. I guess yours is GA3? Gr Bart Attachment 338_810_820_GA3_Installation_Instructions.pdf (695 Downloads)
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6/29/2014 8:38 AM	Rate (0)
socaoh Experienced Member Joined: 3/28/2014 Last visit: 8/27/2025 Posts: 82 Rating: (0)	Hello. One more time Im GRATEFULL to Primotechics on his help all the time. Im electrical engineer at Sector to Maintenance and Energy in production company in Ohrid, Macedonia. If You have any needs Im willing to give you help back. The CNC is not mine but of my friend so Ive learned a lot of Sinumerik, but at the end I think I have the latest problem: Alarm message: 1120 Clamping monitoring Cause :• Incorrect position feedback polarity • Mechanically clamped axis forced out of position • Fault at control device (actuator), tacho-generator, motor, mechanical components or NC measuring-circuit hardware Scan: • At rest • During clamping • During deceleration Effect: • NC START disabled • Setpoint 0 • Servo enable cancelled after time in MD 156 has expired • Follow-up mode Explanation: • During positioning the following error could not be reduced more rapidly than the time input in MD 156 • During clamping the limit specified in MD 212* was exceeded Remedy: • MD212* (clamping tolerance) must be greater than MD 204* (exact stop limit coarse). • MD156 (servo enable cutoff delay) must be such that the following error can be suppressed within this time *So spindle start and after few second stop * All other functions working well Thanks

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