Executing Part Programs from CF Card on SINUMERIK 810D

1. System Overview: 810D Storage Architecture

The SINUMERIK 810D is a compact modular CNC platform that integrates the NCK (Numerical Control Kernel), PLC, drive modules, and operator panel into a single coordinated chassis. Unlike its larger sibling the 840D, the 810D condenses the CCU (Compact Control Unit) and operator interface into one physical unit while still separating the HMI runtime environment from the NCK runtime. This separation drives a fundamental fact that catches most first-time users: the storage slots visible on the 810D hardware are not interchangeable. A CF card inserted into the wrong slot boots HMI upgrade media, not part programs. Executing a part program directly from removable media therefore requires the engineer to first identify the correct physical slot, the correct logical channel, and the correct boot mode before any file transfer can succeed.

Three storage surfaces matter for part program execution on the 810D:

• CCU slot — Compact Flash / PCMCIA slot on the CCU710 or CCU720 module itself. This is the slot the NCK uses to load part programs and machine data at boot.
• PCU slot — PCMCIA slot on the front of the PCU (Panel Control Unit) or PCU20 operator panel. Used by the Windows-based HMI runtime for HMI upgrades, option enabling, and file service to the HMI partition.
• MMC slot — the legacy designation for the operator-panel-mounted slot on the HMI Advanced side. Identical electrically to the PCU slot for practical purposes.

2. Identifying the Active Boot Slot (CCU vs PCU vs MMC)

The 810D hardware variants place the CF/PCMCIA receptacle in one of three locations. Before any card preparation begins, locate the slot by following the operator panel cable back to the CCU module. The CCU slot is mechanically identical to a Type II PCMCIA slot (68-pin) and accepts both legacy linear PCMCIA SRAM cards and CF-to-PCMCIA adapters.

Two visual cues confirm the CCU slot: it is recessed behind a small plastic door with a push-eject button, and the slot is electrically inside the NCK domain — meaning that a card inserted while the control is powered does not appear as a drive letter on the HMI. This NCK-local access is precisely what makes direct part program execution possible.

3. PCMCIA Hardware: Adapters, Card Types, and Compatibility

The 810D predates native CF card support, so a compact-flash card must be presented to the control as a PCMCIA-ATA device. This is achieved with a passive Type II PCMCIA-to-CF adapter — a flat sled with a 50-pin CF socket on one side and a 68-pin PCMCIA plug on the other. Field experience shows that adapters with the IDEC “Hitachi” or SanDisk branding are the most reliable; generic adapters often fail to enumerate under the 810D NCK boot ROM.

4. HCS Mode: What It Is and When to Use It

HCS stands for HMI Compact Storage, a Siemens-defined mode in which the PCMCIA card is treated as the boot-time source for NCK and PLC data. When the control is configured to boot from HCS, the NCK reads the entire persistent machine state from the card at power-up: NCK machine data, PLC program, drive parameters, compensation tables, and any part programs located in the part-program root.

Two HCS variants exist:

1. HCS boot (full) — card contains a complete NCK image including the PLC project. Used to clone one machine onto another, or to recover from a corrupted NCK.
2. HCS part program only — card contains part programs and work offsets only; NCK reads its machine data from internal Flash. This is the mode you want for routine shop-floor distribution of programs.

The distinction is configured in the NCK via machine data MD11200 (default file extension for part programs) and the HMI startup sequence. Operators can verify the active HCS state at boot by watching the seven-segment display on the CCU: a steady dot indicates the NCK is reading the card, a flashing dot indicates a card error or no card present.

5. Part Program File Types and Directory Layout

The 810D uses a strict file-type convention enforced by the NCK. Programs that omit the correct extension are ignored by the part-program manager even if they are syntactically valid DIN/ISO code.

The on-card directory layout for HCS mode looks like this when the card is mounted on a Windows PC:

\ (card root)
  \NCK\                 (NCK runtime files; do not edit)
    \MMC\               (legacy MMC runtime; not used on 810D)
  \HMI\                 (HMI runtime files; option bits)
  \DH\                  (drive data files; .ACX, .BEF)
  \DP\                  (PROFIBUS configuration)
  \PLC\                 (PLC project sources)
  \PROGRAMS\            (user part programs)
    \SHAFT_001.MPF
    \SHAFT_001.WPD\
      \DRILL_45.SPF
      \DRILL_46.SPF
  \ARCHIVE\             (NCK archives, .ARC files)
  \DIAG\                (service log output, optional)

6. Preparing a PCMCIA/CF Card for 810D Use

Card preparation is the single most common failure point. The 810D is unforgiving about partition type, block size, and file-system cluster alignment. Follow this sequence exactly when commissioning a new card.

1. Insert the CF card into a USB reader on a Windows PC. Back up any existing contents; the card will be repartitioned.
2. Open Disk Management (diskmgmt.msc). Delete all existing partitions on the card.
3. Create a new primary partition spanning 100% of the card. File system: FAT16 for cards up to 2 GB, FAT for cards up to 32 MB. Avoid FAT32 — older CCU boot ROMs do not recognize it.
4. Set the allocation unit size to 4 KB (or 2 KB for cards < 32 MB). Do not use the default Windows 64 KB cluster size; the NCK boot loader cannot read files written with very large clusters on cards above 1 GB.
5. Apply the format. Verify the volume label is empty — the 810D HMI has a known issue where a labeled volume confuses the HCS boot path.
6. Insert the CF card into the PCMCIA adapter. Eject safely from Windows.
7. With the 810D powered down, insert the adapter into the CCU slot only. Do not insert while powered unless you are running a live HCS service; a hot-insert in HCS boot mode can cause NCK alarm 4100.

7. Loading Part Programs onto the Card

Two practical methods exist: write to the card on a Windows PC and walk it to the machine, or use the 810D's own services interface to copy programs over the network. The PC method is faster for large libraries; the network method is preferred when the same card must remain in the machine for runtime.

7.1 PC-Based Method (Direct Write)

1. Insert the prepared card in the USB reader.
2. Create the \PROGRAMS\ folder on the card root.
3. Copy your .MPF, .SPF, and .WPD files into \PROGRAMS\ using Windows Explorer. Verify the file extensions are uppercase — DIN/ISO programs written with lowercase .mpf are accepted by some 810D firmware versions and rejected by others.
4. Eject the card safely.
5. Insert into the 810D CCU slot. Power on.

7.2 Network-Based Method (RCS / DNC)

1. Connect the 810D to a Windows PC running RCS Commander or any DNC server (e.g., Predator DNC, CIMCO). The 810D exposes a port 21 FTP service on the HMI side and an SMB share on the operator network.
2. From the HMI, navigate to Services → Network → CF Card. If the card is mounted in the CCU slot, the HMI shows it as the logical drive /card (or C: on HMI Advanced).
3. Drag-and-drop .MPF/.SPF files from the network share to the card root. The HMI prompts for a “copy to active runtime” confirmation; answer Yes.

8. Executing Part Programs from the Card

Once the card is mounted, the part program manager on the HMI lists every .MPF and .SPF on the card. Execution follows the standard SINUMERIK selection sequence:

1. On the HMI, press Program Manager (or navigate Startup → Programs on legacy HMI).
2. The left pane shows the active sources: NCK, CF Card, Network. Select CF Card.
3. Browse to the program: e.g., /card/PROGRAMS/SHAFT_001.MPF. The path syntax is fixed by the NCK and uses forward slashes; Windows backslashes fail silently.
4. Press Select. The program loads into the NCK interpreter. The active program name appears in the channel status line at the top of the HMI.
5. Press NC Start to begin execution. To execute in single-block mode, enable SBK on the operator panel first.

For automated job shops that want a specific .MPF to load on power-up, set the NCK boot program via:

• HMI path: Startup → NCK → Boot Program → /card/PROGRAMS/AUTO.MPF
• Equivalent machine data: MD20150 $MN_DEFAULT_GCODE_FILE (file name) and MD20160 $MN_GCODE_MODE (mode bits; bit 4 = boot from card).

9. Backing Up NCK, PLC, and Drive Data to the Card

The CCU slot also supports a complete NCK image archive, useful when commissioning a new machine or recovering from a failed upgrade. The archive is a single .ARC file written to the card root.

1. Insert the card in the CCU slot.
2. From the HMI: Startup → Archive → Create.
3. Select scope: NCK + PLC + Drives + HMI (or any subset).
4. Select destination: CF Card (CCU).
5. Choose file name: BACKUP_2024-11-15.ARC.
6. Press Start. The archive takes 60–300 seconds depending on the option bit count and drive parameter set.

To restore:

1. Power down the 810D.
2. Insert the card containing the .ARC into the CCU slot.
3. Power on while holding the HMI soft key Startup (or use the CCU rotary switch to position 1 = “Boot from card”).
4. Select Restore from CF Card. The control prompts for confirmation; answer Yes.

The Siemens SINUMERIK 840D/810D ManualTurn application documentation describes how the same card layout is used by the installation tool to stage NCK and PLC data, which is useful as a reference for naming conventions and the expected directory tree even when not using ManualTurn itself.

10. Troubleshooting Matrix

11. Verification and Commissioning Checklist

Run this sequence after every card preparation to confirm a clean configuration before moving to production.

1. Insert the card in the CCU slot. Power on the 810D.
2. Confirm the seven-segment CCU display shows a steady dot (card read) and the HMI reaches the operator menu within 45 seconds.
3. Open Program Manager → CF Card. Confirm every expected .MPF/.SPF is listed with the correct file size.
4. Select a test program, simulate if the machine supports it (key switch in Simulation), and verify the dry run completes without alarm.
5. Run a real cut on a scrap part. Confirm the program ends with M30 and the channel status returns to Reset.
6. Power down, remove the card, power up without the card. Confirm the control still boots to operator mode (HCS boot = “programs only”) and the previously selected program is in the channel history.
7. Re-insert the card, confirm the boot picks up the card-resident program automatically if MD20160 boot bit is set.
8. Label the card with the part number, revision, and date. Store in an ESD bag in a controlled environment; CF cards tolerate 0–70 °C but degrade faster above 50 °C in shop-floor cabinets.

12. Frequently Asked Questions