Sinumerik 840D sl: Tool Management INSTALLATION ERROR Recovery

Problem Summary

The Sinumerik 840D sl Tool Management screen returns an "INSTALLATION ERROR" dialog when the operator navigates to the tool list under the PARAMETER operating area. The fault follows manual edits to magazine-count machine data and persists even after the values are reverted to their previous state, blocking all access to magazine configuration, tool loading, and tool unloading functions. Tool-list shortcuts, the magazine list view, and OEM-supplied tool-management soft keys all refuse to open. A subsequent NC POWER ON re-raises a PLC alarm indicating that the PLC can no longer read the magazine data block from the NCK. The system is functional mechanically but cannot run a part program because the tool-change handshake cannot be established.

Affected System, Controller, and Software

The fault applies to:

• Controller: Sinumerik 840D sl (NCU 710.x / 720.x / 730.x with PLC 317-2DP / 150)
• HMI: Sinumerik Operate (PCU 50.5 / IPC / TCU) on the active operating area
• Tool Management: TM 2.x / TM 4.x active configuration (OEM-framed screen)
• Typical versions: SW 4.5 SP2 through SW 4.94 / 5.21 (HMI-PRO, HMI-ADV)

The error string "INSTALLATION ERROR" originates from the Tool Management runtime when it cannot bind the magazine-table data block (DB 9x) to the requested OEM frame. Refer to the Sinumerik 840D sl Tool Management (FBWsl) Function Manual for the OEM frame binding logic and the corresponding data-block map.

Root Cause: MM-Type Machine Data Modification Without Archive Cycle

The triggering event in nearly every reported case is direct editing of a memory-layout machine data whose name begins with $MN_MM_NUM_.... The most common offending MDs are listed below.

These MDs control the static memory map of the NCK. Changing the number of magazines, magazine locations, or TO units forces the NCK to relocate internal data blocks and invalidate any tool-management configuration that was previously bound to the old layout. The system does not gracefully migrate the running tool list; it expects the operator (or the OEM commissioning engineer) to perform a full NC archive cycle before and after such a change.

Why Editing MD 18084 ($MN_MM_NUM_MAGAZINE) Is Especially Sensitive

MD 18084 ($MN_MM_NUM_MAGAZINE) defines how many magazine data records the NCK reserves in its internal image. The OEM commissioning sets this value to match the physical magazine count (chain, revolver, pick-up, gantry loaders). Lowering the value from 4 to 3 (or any other reduction) shrinks the internal magazine table and orphans any magazine whose index now exceeds the new count. Raising it without first confirming that the PLC and DB 9x map are scaled to the new count produces the same orphaning effect on the PLC side.

The $MN_MM_NUM_MAGAZINE value must satisfy the inequality:

$MN_MM_NUM_MAGAZINE ≥ configured magazine count (physical + virtual)

Additional constraints enforced by the NCK:

• MD 18084 ≥ 1 (always)
• MD 18084 ≤ MD 18085 (magazines cannot exceed partial-tool capacity)
• MD 18084 × (locations per magazine) ≤ MD 18086
• MD 18084 ≤ MD 18088 × 2 (each TOA supports two magazines)

See the Sinumerik 840D sl Machine Data List for full bit/scalar definitions and interdependencies. Any change to MD 18084 is a POWER ON active MD.

Related Alarm and Status Indicators

When the Tool Management runtime cannot bind the magazine table, the NCK and PLC raise the following alarms. Treat all of them as secondary symptoms confirming the same root cause.

Alarm codes are documented in the Sinumerik 840D sl Diagnostics Manual. Use the alarm history (Diagnostics → Alarm Log → Selection) to confirm the originating channel and clear/save state.

Protection-Level Configuration for Tool Management

The follow-up question in most service tickets is: "How do I allow the operator to edit tool geometry via key switch position 2?" The protection level for the Tool Management operating area is governed by two machine data:

Siemens access levels map to the key switch as follows:

To allow the operator to load geometry with key-switch position 2, set:

$MN_ACCESS_TM_MAG_PLACES = 4
$MN_ACCESS_WRITE_TM = 4

Changes to access MDs are RESET-active, not POWER ON-active, so they take effect immediately without a re-archive cycle. Document the change in the machine data sheet before issuing an NC archive so the new level persists. Reference: Sinumerik Operate Programming Manual, chapter "Tool Management Operating Area".

Mandatory Preconditions Before Any MM-Type MD Edit

Any edit to $MN_MM_NUM_... must follow the order below. Skipping a step is what causes the INSTALLATION ERROR.

1. Switch to Service operating area (key switch position 3 or OEM password).
2. Open Commissioning → Data Management.
3. Create a backup of the active NC, PLC, HMI, and compensation data (*.arc) plus an Option-checked archive including compensation data and drive data.
4. Verify the archive file is non-zero size and stored on a CF card, USB, or network share that is not the active card.
5. Edit the $MN_MM_NUM_... MD in the expert list (only after the archive is confirmed).
6. Save the modified MD list to CF/USB (DO NOT perform POWER OFF yet).
7. Create a fresh NC archive that includes the new MM layout plus compensation data.
8. Reload that freshly created archive immediately. The reload is what writes the new layout into the active NCK SRAM.
9. Perform a controlled POWER ON (NCK reset) only after the reload reports success.

Solution: NC Archive Recovery Procedure

The corrective procedure re-establishes the previous magazine layout by loading an archive captured before the failed edit. Use the OEM commissioning backup if no service backup exists.

Step 1 - Reach the Service Operating Area

• On the HMI, press the Menu Select key or click the menu icon at the top left.
• Navigate to Service (password: OEM-supplied service password, or rotate key switch to position 3 / OEM).
• If the Service area is greyed out, the access level is below the OEM setting. Move the key switch or enter the access password via Menu → Log On → Password.

Step 2 - Open the Data Manager

• In the Service area, select Data Manager.
• The default tree shows the local drives:

/card/user/sinumerik/
/card/oem/sinumerik/
/card/active
/card/oem/...

• Navigate into /card/user/sinumerik/archive/ (or the OEM-supplied path: /card/oem/sinumerik/archive/). All NC archives (*.arc) and PLC archives (*.arc) are stored here.

Step 3 - Identify the Correct Archive

• Sort by date, take the most recent archive before the failed MM edit.
• Each archive is named with the date-time stamp and a suffix: _NC.ARC, _PLC.ARC, _HMI.ARC, or a combined *.ARC with the option bits set.
• Confirm with the OEM that the archive matches the active machine serial number. Loading the wrong archive overwrites machine-specific compensation data and PLC commissioning values.

Step 4 - Reload the NC Archive

1. Highlight the _NC.ARC file.
2. Select the soft key Load (or right-click → Load).
3. Confirm the dialog "Load NC archive? Existing data will be overwritten."
4. The HMI shows progress and the NCK performs a controlled reset. Do not interrupt power.
5. When the dialog returns to the operating area, the NCK is back on the saved layout.

Step 5 - Reload the PLC Archive (If Available)

1. Highlight the _PLC.ARC file in the same folder.
2. Select Load. Confirm the prompt.
3. The PLC goes to STOP during the load and returns to RUN when the dialog closes.

Step 6 - Verify and Power Cycle

1. Open Diagnostics → Alarm Log and clear the residual alarms.
2. Navigate to Parameter → Tool List. The INSTALLATION ERROR dialog must be gone and the configured magazine list must appear.
3. Perform a controlled POWER OFF / POWER ON of the NCU only (not the line voltage) so the new archive becomes the boot default.
4. After POWER ON, verify the tool list opens and a dry-run M6 (tool change) executes without alarm.

Verification and Commissioning Checks

After the archive reload, confirm the following before releasing the machine for production:

Field-Proven Caveats and Best Practices

Lessons gathered from service tickets where the INSTALLATION ERROR was observed on Sinumerik 840D sl machines.

• Never trust "undo the value". Reverting the MD value in the expert list does not roll back the internal block map. A full archive cycle is mandatory.
• Do not run a part program between edit and archive reload. The operator that powers off mid-cycle is the most common cause of persistent PLC "cannot read data" alarms.
• Distinguish NC vs PLC archives. An NC archive restores NC-side machine data, compensation, and tool tables. A PLC archive restores DB 9x / FB 36 / FB 39 tool-change blocks. Both must be consistent with the mechanical configuration.
• Keep the OEM commissioning archive as the gold copy. Store it on a USB stick labelled with the machine serial and version. Do not overwrite it with later service backups.
• Document every $MN_MM_NUM_... edit in the machine data sheet. Include the date, reason, old value, new value, and the two archive filenames (before and after).
• Cross-check $MN_MM_NUM_MAGAZINE against PLC variables. In the PLC, magazine count is mirrored in DB 9x DW 0 (number_of_magazines). A mismatch raises PLC alarm 802102 on next boot.
• Verify HMI-PRO option bitmap. Tool Management requires HMI option bit OP 6 / OP 31 enabled (depends on SW version). An accidental loss of the bit presents as INSTALLATION ERROR even though the NCK data is correct. Check via Commissioning → HMI → Licenses.
• Backup the active card before loading an archive. If the wrong archive is loaded, the previous active image can be restored from /card/active (only if not overwritten).

Preventive Procedure Before Modifying Any $MN_MM_NUM_... MD

1. Obtain written authorization from the OEM / control engineer.
2. Schedule the work during a planned production stop.
3. Back up NC + PLC + HMI + Compensation to USB (option bits all set).
4. Verify the backup file size > 0 and can be opened in another HMI for sanity check.
5. Edit the MD in the expert list.
6. Save the modified MD list to USB.
7. Create a fresh NC archive (with Compensation option enabled).
8. Reload that archive immediately.
9. POWER OFF / POWER ON only after the reload dialog closes successfully.
10. Verify tool management, dry-run M6, alarm log, and protection levels before releasing the machine.

Alternative Recovery: When No Backup Is Available

If no NC archive exists and the OEM backup was never made, recovery becomes manual:

1. Document the current MD values of 18084, 18085, 18086, 18088, 18100, 18102.
2. Set MD 18084, 18085, 18086, 18088, 18100 to the documented "safe" values that match the physical configuration:

$MN_MM_NUM_MAGAZINE = physical magazine count + 1 (one buffer)
$MN_MM_NUM_MAGAZINE_LOCATION = sum of all location counts
$MN_MM_NUM_PART_TOOL = 60 (default, sufficient for 1 magazine)
$MN_MM_NUM_TOA = number of channels + 1

3. Save the MD list.
4. Create an NC archive (with compensation).
5. Reload the archive.
6. POWER ON.

If the machine was never commissioned and the tool list was always empty, the machine may come back with an empty tool table that needs to be re-populated from the OEM commissioning sheet. Contact the OEM for the original tool list (often supplied as a PDF plus an .INI).

OEM Frame Loading Errors vs Tool Management Installation Errors

The string "INSTALLATION ERROR" can appear for two distinct reasons that look similar but require different fixes.

If the HMI is stuck at "Loading OEM Frame" instead of allowing you to reach the Service area, recovery must be done via network (VNC / SSH / WinSCP) or by booting from a rescue image on a CF card. Document this with the OEM before opening the HMI for any future intervention.