Resolving Siemens Sinumerik Alarm 700100 SHOPMILL ASUP Error

1. Problem Overview

On a Deckel Maho DMU 35 (or any Siemens 840D/840D sl/810D machine equipped with the SHOPMILL conversational programming option) that has been physically relocated, it is common to see the following failure mode after the control boots from a fresh installation or a complete archive restore:

• The operator area is limited to ISO mode; no SHOPMILL softkey is visible in the horizontal softkey bar.
• The alarm line and alarm log show 700100 FM error Shopmill ASUP run-up (or variants such as 700100 FM SHOPMILL asup start).
• Selecting or executing a previously created *.MPF / Shopmill program raises "Shopmill program not executable as not tested by shopmill."

Alarm 700100 belongs to the family of FM (Function Module) start-up errors. It is raised by the SHOPMILL FM when the asynchronous subroutine (ASUP) _N_SHOPMILL_INI or the related path-initialization program is not found, is empty, or returns an error during NCK run-up. Without successful run-up, the HMI suppresses the SHOPMILL softkey because the corresponding operating-area plugin cannot bind to a valid NC environment.

2. Affected Hardware and Software

3. Root Cause Analysis

The most probable root cause sequence on a relocated machine where all three archives (NC, PLC, MMC/PCU) were reloaded is one or more of the following:

1. SHOPMILL option/license mismatch. The NCK was flashed with NC archive data that does not contain the SHOPMILL option bit, while the HMI image still expects the SHOPMILL operating area. The HMI hides the softkey because FB/FC checks on the option status return a non-enabled state.
2. Missing or corrupted ASUP _N_SHOPMILL_INI. The Shopmill FM in NCK run-up schedules this ASUP. If the file is missing, empty, or has its PROT attribute stripped, the FM aborts and raises 700100.
3. Wrong initial-program path configuration. Machine data MD11620 MN_PROG_EVENT_NAME or MD20150 GCODE_TAB / MD20152 PROTOCOL_RESET was overwritten by a default archive that points the reset path to _N_CMA_DIR instead of _N_SHOPMILL_DIR.
4. PLC interface not aligned with HMI expectations. The PLC backup restored a different interface byte (e.g., DB19.DBB0 series "Shopmill active") than the HMI is currently expecting after the restore.
5. "Not tested by Shopmill" secondary alarm. Programs created on this machine carry the SHOPMILL identifier in their _N_[name]_MPF header. When the Shopmill FM cannot initialize, the test-bench signature is invalidated and the program is rejected as untrusted.

4. Pre-Restoration Verification

Before any further reload, capture the current state for comparison with the pre-relocation backup:

1. From the HMI, go to Commissioning > HMI > System Data and export the active HMI configuration.
2. From the HMI, go to Commissioning > NC > NCK and run Archive NCK to a USB stick or network share. Verify the resulting .arc file size is non-trivial (> 1 MB for typical 840D installations).
3. From the PLC, in STEP7 / TIA, upload the current S7 program and compare it to the previously backed-up S7 program (block checksums). Look at DB19 and DB21–DB30 in particular.
4. Run pi pi_test from the HMI Service > PLC menu and capture any non-zero return values.
5. On the PCU, run the HMI service menu (password SUNRISE → access level Manufacturer) and inspect C:\Program Files\Siemens\Automation\HMI for the presence of the shopmill plugin directory.

5. Confirming the SHOPMILL Option State

On the HMI, navigate to Commissioning > NC > Options and read the option list. SHOPMILL is reported as ShopMill (or legacy ManualTurn / ShopMill 4-axis / 5-axis depending on the build).

• If the option shows Set but the softkey is missing, the problem is in the HMI binding (continue to Section 7).
• If the option shows Not set, the NCK is missing the SHOPMILL enable. The license key may have been lost during NCK flash/restore.

For license re-installation, transfer the original license CF card image (lic_D... files) back to the CF card slot on the NCU using a card reader and reboot the NCK. License files are stored under /card/license/ and are matched to the NCU serial number; if the NCU was replaced during the move, you must request a re-issued license from Siemens with the new CF card number.

6. Restoring the SHOPMILL NC Data and ASUP Files

The Shopmill FM expects a specific set of files under _N_SHOPMILL_DIR on the CF card. After a full reload these must be present:

To verify presence from the HMI service area:

1. Open Commissioning > NC > File System.
2. Drill into /_N_SHOPMILL_DIR.
3. Confirm the files above are listed with a non-zero size. Empty files are a symptom of a corrupted archive restore.

If files are missing, restore them from the .arc archive: copy them to a USB stick, then from Commissioning > NC > Read In Archive, select the arcview tool and extract the Shopmill directory. Always reload archives with the control in Reset and the NCK in Run-up hold state, then perform an NCK reset.

7. Re-Enabling the Shopmill Softkey

The horizontal softkey bar is generated by the HMI operating-area configuration. On HMI Advanced the file is slpmconfig.ini and the relevant section is:

[Shopmill]
Visible = 1
Position = 6
Menu = menu_shopmill.com
PasswordLevel = 1

On HMI Embedded the file is operate.com / easyScreensConfiguration.xml. The shopmill softkey is bound to the Shopmill area and is hidden when the option returns disabled or the ASUP has not yet returned RET successfully.

1. Edit slpmconfig.ini on the PCU and confirm Visible = 1 for the Shopmill area.
2. Re-import the file via Service > HMI > Reload Configuration or restart the HMI process.
3. If the softkey still does not appear, use the HMI configurator (Siemens HMI Pro / Operate) to drag the Shopmill tile into the softkey bar. Save the project and reload.

8. Correcting ASUP and Reset Configuration

The 700100 FM error typically points to a misconfiguration of the path reset or the PROG_EVENT handler that SHOPMILL uses to chain into its ASUPs. Check the following machine data:

Reload the original values from the pre-relocation archive. If you do not have an MD list, ask the machine OEM (in this case Gildemeister / DMG) for the .tea text file of the MD exports. Apply the values, then perform an NCK reset followed by a controlled run-up.

9. PLC Interface Verification (DB19)

The PLC communicates Shopmill state to the NCK and HMI primarily through DB19:

Cross-check the values online in STEP7 / TIA against the default project. If DBX0.7 is forced to 0 by the PLC, the HMI will not display the softkey regardless of the NC option. In that case the PLC archive was loaded from a different machine build and needs to be re-flashed with the correct FB100/FC100/FC101 blocks.

10. Resolving the "Not Tested by Shopmill" Message

This message is raised by the Shopmill FM when it opens a program whose header was generated by Shopmill but is not in the current "trusted" set, typically because the FM aborted at run-up. After the fixes in Sections 6 and 8 are applied and a successful NCK run-up has been observed, the next time the HMI opens any Shopmill program it will re-test and re-sign it. Manually trigger this by:

1. Select the program in the program manager.
2. Open the Tools > Shopmill > Test Program menu item (if available, otherwise choose the softkey Test).
3. Wait for the cycle verification to complete. The header will be updated and the message disappears for that program.

If the test fails on a specific cycle, the cycle itself (e.g. CYCLE71 face milling) is throwing an error; resolve the cycle call first, then re-test.

11. Step-by-Step Recovery Procedure

1. Backup current (degraded) state: NC archive, HMI service backup, PLC upload. Do not overwrite the known-good pre-relocation backup.
2. Verify SHOPMILL option in NC options. If not set, reinstall license from the original CF card image.
3. Restore the SHOPMILL directory (_N_SHOPMILL_DIR) from the pre-relocation NC archive.
4. Re-import the correct slpmconfig.ini / operate.com from the pre-relocation HMI backup.
5. Apply the correct MD values for MD20150, MD20152, MD11620, MD11630, MD20140, MD20144.
6. Re-flash PLC with the correct project, paying attention to FB100/FC100/FC101 and DB19.
7. Power-cycle the NCK and PCU (in that order: NCK first, then PCU).
8. Boot into HMI, confirm alarm 700100 is cleared.
9. Confirm SHOPMILL softkey is visible and selecting it loads the SHOPMILL operating area.
10. Re-test one existing program to clear the "not tested by Shopmill" message.
11. Run a dry-run (rapid at 0%, then incremental feed) on a known program to verify the cycle chain works end-to-end.

12. Verification Checklist

• Alarm 700100 is no longer in the active alarm list after NCK run-up.
• SHOPMILL softkey appears in the horizontal softkey bar at the expected position.
• Selecting the softkey opens the SHOPMILL operating area and lists the configured tools.
• Opening a previous *.MPF does not raise "not tested by Shopmill".
• Creating a new Shopmill program generates a valid *.MPF with the SHOPMILL header.
• Dry-run with rapid override 0% confirms tool-path display and no NCK start disables.
• PLC interface DB19.DBX0.7 = 1, DB19.DBB4 = 3 when Shopmill is active.
• License state in Commissioning > NC > Options shows ShopMill = Set.

13. Common Pitfalls and Field Notes

• Loading a general 840D archive (e.g. for a different machine class) will overwrite the _N_SHOPMILL_DIR with default content that is incompatible with the OEM cycles on the DMU 35. Always load the matching .arc.
• If the PCU was replaced with a different model (e.g. from PCU 50 to PCU 50.3), the HMI image must match. Mismatched images cause the SHOPMILL plugin to be missing, which the HMI handles by hiding the softkey silently.
• Card-reader writes to the CF card must use a Siemens-approved format. A vanilla FAT32 formated card can leave lic_* files unreadable, which the NCK then interprets as "no license".
• After any NCK reset, allow at least 60 s for all ASUPs and the Shopmill FM to finish. A premature keypress on a softkey during this window can lock the HMI.
• The alarm 700100 description text in the HMI is sometimes truncated; the full text is "FM error: Shopmill ASUP run-up" and the remedy hint is "load _N_SHOPMILL_INI".

14. FAQ