TCsi - Create My Config Expert Software Upgrade

TC820LTYsi → Proceed to Step 4

TC820si → Check PLC Version

Go to [Diagnostics] → [Version]

If PLC user program version is 01.XX.XX, the machine has Old-PLC.

Proceed to Step 2

If PLC user program version is 05.XX.XX, the machine has New-PLC.

Proceed to Step 4

Step 2 is required only if TC820si has Old-PLC i.e. PLC user program version 01.xx.xx.

Set Manufacture Password.

Go to [Setup] → [Mach. Data] → [General MD].

Press [Search] and enter 11230

Select the 11230 variable and ensure Bit 0 is deselected.

Go to [Setup] → [System Data] → [NC data] → [NC active data] → [Measure system error compensation].

Click on Measure system error comp axis 2 then press [Copy].

At the top of the directory, find your USB location and press [Paste]. The file on the USB stick will appear as AX2_EEC.ini.

Step 3 is required only if TC820si has Old-PLC i.e. PLC user program version 01.xx.xx.

Use a computer to open the AX2_EEC.ini file.

Rename AX2_EEC.ini to AX3_EEC.ini.

This adjustment is necessary because the Z-Axis is moving from Axis 2 to Axis 3.

Open the file in Notepad.

Press Ctrl + H to open the "Replace" function.

In "Find," type AX2; in "Replace with," type AX3. Click Replace All to update all instances of "AX2" to "AX3" in the file.

Save the file. It will be used later.

Start with a clean USB drive.

There should be no files on the USB stick other than the deployment '.usz' file. The machine upgrade may fail if the deployment file is not copied to a blank USB.

Locate the master deployment file stored on SharePoint:

TCsi

Engineering will release a new deployment file (.usz) to fix bugs and add new features, so the version on the hyperlink may differ from the one shown in the picture.

Copy the ".usz" file to your USB drive.

Set Manufacture Password.

To set Machine Identification: Go to [Setup] → [Machine Data] → [General MD] → [Search].

Enter 17400 and press [Input], then confirm the parameter matches the machine type.

TC820si

TC820LTYsi

After updating 17400[0], press Reset (po) to apply changes.

Set Manufacture Password.

To set Date and Time: Go to [Setup] → [HMI] → [Date time].

Verify date and time.

If necessary, adjust the time: Update to the correct time, then click [Accept] and [OK].

Close the machine door.

Go to [Machine]→ [TSM] → [Select Tool] → Select Tool 1 and press [Cycle Start].

This will move the turret to Position 1

Go to [Tool List] (Left vertical, second button from top) and verify the turret position is at Tool 1.

The Machine should be on Position 1 matching the Tool List Position 1.

Go to [Machine] and verify that the measurement is in inch at the position banner.

If you need to change the measurement to inch: Go to [Settings] → [Page 2], then press [Changeover inch].

Confirm the machine is now set to [inch].

Press [E-Stop].

Go to [Setup] → [2nd Page] → [Setup Archive] → [All data of this machine] → [Ok]

(1) Make sure all boxes are checked.

(2) Select the [Archive name] data field. Name the file: Backup_NPDHS-YYYY-MM-DD_BEFORE_UPGRADE. Press [OK].

Note: YYYY-MM-DD is the current date (e.g., June 26, 2023, is written as 2023-06-26 in the archive name).

The default storage path should be [Archives/Manufacturer]. If the storage path is anything other than the default, change it by pressing [Change storage path] → [Archive/Manufacturer] → [OK].

This screen will also give you the option to save the archive to either USB port.

Power off machine. Remove pendant rear cover. Insert USB with the .usz file at the rear of the pendant below the switch. Move the switch from [RUN] to [Stop]. Power up machine. Click the down arrow and select one:

TC820si_New PLC — Select if Step 1 showed 05.XX.XX, pick New PLC, TC820si_Old PLC — Select if Step 1 showed 01.XX.XX, pick Old PLC, TC820si_44_NewPLC — Select if King Rich serial number on the electrical cabinet door is STA60044 or higher.

TC820LTYsi — Select if upgrading a TC820LTYsi machine, TC820LTYsi_14 — Select if King Rich serial number on the electrical cabinet door is STP60014 or higher.

It is extremely important to select the correct option. If the wrong option is chosen, you’ll need to load the original archive saved in Step 9 and repeat the upgrade process.

After selecting the correct option, press [Next]. The upgrade will take approximately 20-25 minutes if only the deployment file is applied. However, if the CNC software upgrade is also included, the process will take around 45-50 minutes. When the upgrade is complete, press [OK].

If the popup window showing "Package Execution has been Completed" did not appear, or if you see a "Package Canceled" message in red at the top of the screen, then the expert deployment was not executed successfully. Please contact customer support for assistance.

From the rear of the pendant, remove the USB. Set the switch to [Run] while the machine is still powered. The machine interior lights will light up after this is done.

If the switch is not set to [Run], the machine will not start in the run state, and an additional power cycle will be required.

Power cycle machine.

Set Manufacturers Password.

Verify date and time. Go to [Setup] → [HMI] → [Date time]. Adjust if necessary.

Go to [Machine] → [TSM] and verify that the TSM screen displays Position 1.

Go to [Tool List] and verify the turret position is at Tool 1.

Steps 12 through 17 are required only if the user selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

Step 12 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

Enter Manufacturer Password.

Go to [Setup] → [Mach. Data] → [Axis MD] → [Select Axis] → [AX3:MZ1].

Press [Search] and enter 32700[0] and press [Input].

Set 32700[0] parameter from 1 to 0.

Press [Set MD active (cf)].

Step 13 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

Go to [Setup] → [System Data] → USB location of AX3_EEC.ini from Step 3.

Press [Activate] on the right hand side.

Go to [Setup] → [Mach. Data] → [Axis MD] → [Select Axis] → [AX3:MZ1].

Press [Search] and enter 32700[0] and press [Input].

Set 32700[0] parameter from 0 to 1.

Press [Set MD active (cf)].

Step 14 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

TC820si Old PLC (01.XX.XX) will need options enabled after Expert Deployment Upgrade. Determine which options the current machine has enabled.

Go to [Setup] → [Machine Data] → [General MD] → [Search].

If Parts Catcher is installed:

Set 14512[8] bit 0 = 0

Set 14512[38] bit 0 = 1

If an option is not active, set the relevant bit to 0.

Step 15 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

If Chip Washdown is installed:

Set 14512[40] bit 1 = 1

If High-Pressure Coolant Pump is installed:

Set 14512[40] bit 2 = 1

If an option is not active, set the relevant bit to 0.

Step 16 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

If Oil Skimmer is installed:

Set 14512[2] bit 0 = 0

Set 14512[2] bit 1 = 0

Set 14510[22] = 0

Set 14512[23] = 0

14512[25] Select Bit 0, Bit 2, Bit 7 to set variable to 85H

If an option is not active, set the relevant bit to 0.

Step 17 is required only if the user has selected TC820si OldPLC (01.XX.XX) from the dropdown menu in Step 10.

Verify If an option is not active, the relevant bit is set to 0.

Verify all installed options are functioning.

If an option is not working, check that the option bits in the previous steps are set correctly.

If the option bits are set correctly but the option still does not work, contact TRAK Customer Support.

If an alarm is active regarding an option that is NOT installed, contact TRAK Customer Support.

Go to [Setup] → [2nd Page] → [Setup Archive] → [All data of this machine].

(1) Make sure all five components are selected with a check box.

(2) Select the [Archive name] data field. Name the file: Backup_NPDHS-YYYY-MM-DD_AFTER_UPGRADE. Press [OK].

After deployment, the contents of the USB are displayed here, with the HTML file highlighted.

Open the HTML file listed on the USB either on the Siemens control or by opening it in a browser on a computer.

It is important to look towards the bottom of the file checking for the [errors] and [faults] fields. They should be [0] otherwise report to Engineering.

When the machine leaves the factory, the directory will be created in the machine config folder; FST's loading files only need to locate it by serial number.

TC820si Configs

TC820LTYsi Configs

Create a new directory within the correct machine folder named ExpertDeployment_Date

Replace Date with the deployment date (e.g., ExpertDeployment_31NOV24).

Copy the five items to new folder: (1) Complete MAID directory with four files, (2) HTML file, (3 ) Text document, (4) Archived file saved at the end of step 9. (5) Archived file saved at the end of step 18.

Please load all five Items to the folder.

If you have trouble finding the correct location for the files, please contact customer support for assistance.