Benshaw RE-FLASH User Manual

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RSi Series

Drive Re-Flash Tool

Publication #890020-11-00

& Procedure Manual

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Solid State Motor Control

Technology

TRADEMARK NOTICE

Benshaw and are registered trademarks of Benshaw Incorporated.

ModBUS is a registered trademark of Schneider Electric.

Windows 9x, ME, NT, 2000, XP are registered trademarks of Microsoft.

UL is a trademark of Underwriters Laboratories, Incorporated.

TABLE OF CONTENTS

1 INTRODUCTION ....................................... 2

2 REQUIREMENTS ....................................... 4

2.1 Requirements for Re-Flashing Data .............................4

2.1.1 Overview ............................................ 4

2.2 Limits to Upgradability .................................... 4

2.2.1 SX Limits ............................................ 4

2.2.2 GP Limits ............................................ 4

2.2.3 EKP Limits ........................................... 4

2.3 PC Requirements ....................................... 4

2.4 Serial Protocol Conversion .................................. 4

2.5 Software ............................................ 6

3 DRIVE RE-FLASH TOOL................................... 8

3.1 Introduction .......................................... 8

3.2 Installation of the Product Re-flash Tool .......................... 8

3.2.1 Installing the Downloaded DRT ............................... 8

3.2.2 Installing the DRT from CD-ROM .............................. 8

3.3 Operation of Drive Re-flash Tool .............................. 8

3.3.1 The File Menu ......................................... 9

3.3.2 The Product Menu ....................................... 10

3.3.3 The Setup Menu ........................................ 10

3.3.4 The Help Menu ......................................... 11

3.4 The Re-flash Status Panel ................................... 11

3.4.1 The Error Analysis Panel ................................... 11

4 RE-FLASH TOOL CONNECTION .............................14

4.1 Introduction .......................................... 14

4.2 Connections Using the I/O Simulator ............................ 14

4.2.1 Using the I/O Simulator to Re-Flash a Drive ........................ 15

4.3 Connections Using An Inline RS232 to RS485 Converter .................16

4.3.1 Connections Using a Serial converter fromB&BElectronics or Third Party) ......16

4.4 Connections Using A RS422/485 PCMCIA Card ..................... 17

4.4.1 Introduction to Quatech SSP 200/300 RS422/485 PCMCIA card ............. 17

4.4.2 Installation ........................................... 17

4.4.3 Card Configuration ...................................... 18

5 USING THE RE-FLASH TOOL ............................... 20

5.1 Re-flashing the Drive ..................................... 20

5.2 Initiating the Re-flash Operation ............................... 20

5.3 After the Download is Completed ..............................21

5.4 Power Loss During Re-flash Procedure ........................... 21

TABLE OF CONTENTS

6 RE-FLASHING SPECIFIC DRIVES .............................24

6.1 Re-flashing the SX Drive ................................... 24

6.1.1 Placing the SX in Re-flash Mode ............................... 24

6.1.2 Initiating the Re-flash Operation ............................... 24

6.1.3 After the Download is Completed .............................. 25

6.2 Re-flashing the GP General Purpose Microdrive ...................... 25

6.2.1 Placing the GP Micro Drive in Re-flash Mode ........................ 25

6.2.2 Initiating the Re-flash Operation ............................... 26

6.3 Re-flashing the Enhanced Keypad ..............................26

6.3.1 Placing the EKP in Re-flash Mode .............................. 26

6.3.2 Initiating the Re-flash Operation ............................... 26

7 TROUBLESHOOTING .................................... 28

7.1 Advice on Resolving Typical Problems ........................... 28

7.2 How to Check Windows COM Port Settings ........................ 28

8 QUICKSTART GUIDE .................................... 30

8.1 Overview ............................................ 30

8.2 Re-flash Procedure ...................................... 30

9 THIRD PARTY COMM ADAPTERS ............................32

9.1 USB Support for DRT Introduction ............................. 32

9.2 Connectivity Instructions ................................... 32

9.3 B&B Electronics ........................................ 33

9.4 Quatach PCMCIA Card .................................... 33

9.5 Communication Cables .................................... 34

1 INTRODUCTION

1 - INTRODUCTION

Benshaw Services

General Information

RSi Series drives, such as the "SX" Sensorless Vector Drives, the "GP" General Purpose Micro Drive, or the "EKP" Enhanced Keypad may be upgraded via a PC and special software. This is accomplished by using flash memory technology contained in the drive. New software features can be "flashed" into existing products, which allows the product to be upgraded to the newest feature set available.

For those who have extensive experience with flash technology and PCs (or for those who have used the procedure given in this manual on previous occasions), refer to Section 3 of the manual for product-specific instructions an Quick Start, which is a basic outline for re-flashing a drive.

Manual Overview This manual provides information on product, personal computer (PC), and software requirements

to upgrade re-flashable drive products. Connection diagrams for using stock Benshaw Inc. products are also provided, as are detailed instructions for configuring and operating the Drive Re-flash Tool (DRT). This manual assumes that the user has a working knowledge of Microsoft Windows ® operating systems and PC hardware connections. Please refer to Microsoft's documentation for information regarding the operation of the particular Windows system being used. Refer to your PC's documentation for information about your specific hardware configuration.

Related Documents

890020-01 - Hardware User's Manual for the SX AC Inverter.

•

890020-02 - Parameter Configuration Manual for the SX Sensorless Vector Drive.

•

Quick Start Section 7 is a quick start guide that is provided for EXPERIENCED users as an outline for

re-flashing a drive. It provides only the bare essentials for re-flashing a drive. For a detailed procedure use Section 3. The Drive Re-flash Tool (DRT) has a simple user interface. An experienced user may be able to navigate the program without instructions. However, if needed, an overview of the features and function of the DRT is provided in Section 5.

Publication History Please see page 35 of this manual for further information concerning the Publication History.

2 REQUIREMENTS

2 - REQUIREMENTS

2.1 Requirements for Re-Flashing Data

2.1.1

2.2 Limits to Upgradability

2.2.1

Overview

Certain equipment and software requirements are necessary to flash new firmware. This section details the hardware and software requirements for flashing all re-flashable drive products.

SX Limits

Flash upgrades are limited by the age of the SX drive: Models having MCP software versions 3.00 and above can be upgraded to any current version.

To determine the version of MCP software, access the Advance Function Group (AFN) and view the MCP SW Version in parameter AFN 79, AFN 80 or AFN 81 depending on which application software is loaded.

Requirements for Re-flashing

2.2.2

GP Limits

Essentially all production GP drives are compatible with the Product Re-flash Tool. Drives that were provided as beta site drives are not compatible with the tool.

2.2.3

EKP Limits

To be compatible with the Product Re-flash Tool, Enhanced Keypads must have firmware revision 4.0 or greater.

2.3 PC Requirements

The Drive Re-flash Tool (DRT) has been designed to operate under Windows 9x, Windows NT

4.0, Windows ME, and Windows 2000 Windows XP. The following PC hardware requirements are also recommended:

•

Pentium (or equivalent) processor or greater.

•

32 MB (minimum) of RAM.

•

4 MB graphics adapter.

•

RS-232 communications port configurable to either COM1, thru COM8

2.4 Serial Protocol Conversion

Re-flashing is accomplished using RS-485 serial protocol. The standard serial ports provided on PCs use RS-232 protocol. A means of conversion from RS-232 to RS-485 protocol is required for flash upgrading. Benshaw Inc. provides several means for accomplishing this conversion. The operating system of the PC will affect which protocol converter can be used.

2 - REQUIREMENTS

One method is to use the SX I/O Simulator. A 9-pin D-shell Serial Port Extension Cable, used to connect the I/O Simulator to the PC, is required in addition to the I/O Simulator to accomplish communications. These cables are available separately from office supply stores or computer stores. The I/O simulator can ONLY be used if the operating system of the PC is Windows

9X. Refer to note below.

Third-party protocol converters are also available and may be used to flash the product. Note that if you are using Windows NT, Windows ME or Windows 2000 as your operating system, these are the only devices that will ensure successful communication. This is due to the way in which these operating systems handle the serial port. See the note below for the specifications of an acceptable third-party device.

If you use a third-party converter, other than those supplied by Benshaw Inc., you will also need to make a cable to connect the converter to the drive. Connections to the RJ-45 connector on the SX, EKP, or GP drive is shown in Figure 1.

z NOTE: If a third-party device is used. It must be capable of operation with echo disabled. The device must also be capable of automatic (rather than hardware) handshaking. To assure proper handshaking when using Windows NT, Windows 2000 or Windows ME, the transmitter enable must be disabled less than 1 ms after the last bit of the last character of the transmitted message is sent.

B&B Electronics

RS232

Figure 1: RJ-45 Connections for RSi SX EKP Port

Plug (male) Jack (female)

12345678 4

traight-thru

Connection

Pin 1: +24 Vdc Pin 3: SIO+ Pin 6: SIOPin 8: Common

Figure 2: B&B Electronic Cable Connection for RSi SX EKP Port

RS485

Cable WI-400004-00

Cable WI-400002-00

RJ45

2 - REQUIREMENTS

PCMCIA Card RS422/485 interface

Figure 3: PCMCIA Cable Connection for RSi SX EKP Port

RS485

2.5 Software

A copy of the Drive Re-flash Tool (DRT) is required. The tool can be obtained by download from Benshaw's website (www.benshaw.com), or is available on CD-ROM from Benshaw Incorporated. Product upgrade files are also available from either Benshaw's website, or by contacting the factory. The files are supplied as a self-extracting archive, so additional software is not required.

RJ45

Cable WI-400002-00

Cable WI-400003-00

3 DRIVE RE-FLASH TOOL

3 - DRIVE RE-FLASH TOOL

3.1 Introduction

This section provides information on the installation and operation of the Drive Re-flash Tool (DRT).

3.2 Installation of the Product Re-flash Tool

This section describes how to install the DRT, which is obtained either from Benshaw's website or from a CD-ROM obtained from the factory.

Drive Re-flash Tool

3.2.1

3.2.2

Installing the Downloaded DRT

To install the DRT obtained via a download from Benshaw's website, perform the following steps:

1. Download the self-extracting archive.

2. Save the file to a directory on the PC's hard drive or on a network drive.

3. Close all unnecessary programs.

4. Left-click "Start" or the Taskbar, and then choose "Run."

5. Either type the path of the downloaded archive or choose "Browse" and navigate to the file.

6. Select the file and run it.

7. Follow the prompts provided by the Setup file.

Installing the DRT from CD-ROM

To install the DRT from CD, perform the following steps:

1. Insert the CD into the PC's CD drive.

2. Close all unnecessary programs.

3. Left-click "Start" or the Taskbar, and then choose "Run."

4. Use "Browse" to navigate to the CD drive, and then select Disk1.

5. In the Disk1 folder, select Setup.exe and run it.

6. Follow the prompts provided by the Setup file.

3.3 Operation of Drive Re-flash Tool

This section assumes that the DRT was installed using the default path structures. If you have changed the path or the program group in which the program is located, you will have to modify the instructions accordingly. To start the DRT, perform the following steps:

1. Left-click Start on the Windows Taskbar.

2. Navigate to the Programs Folder, and then to a subfolder called "Product Re-flash Tool."

The "Product Re-flash Tool" contains a shortcut to the Product Re-flash Tool. Left-click this shortcut to start the DRT. When the DRT is started, the application will open a window similar to the one shown in Figure 4. When the tool is first used, or if the last mhx (firmware) file was on removable media, the Download button will be colored gray to denote that is not available. The DRT is primarily menu-driven using a conventional Windows Menu bar.

3 - DRIVE RE-FLASH TOOL

Other than the operations on the menu bar, the tool contains only status monitors, summary configuration information, and two buttons. The Download button (shown as active in Figure 4) starts the download process. After Downloading has been started, the Abort button (directly below) becomes active until the download is complete.

Figure 4: Start-up Screen for DRT Software

3.3.1

The File Menu

The file menu offers Open, Close, a History List, and Exit options.

Left-clicking the Open choice will open a dialog box to allow the selection of a firmware file to be downloaded to the drive or EKP. These files have the extension ".mhx" for drives and ".a07" for the EKP.

z NOTE: If the "Product type" selected in the "Product Menus" is not correct for the file attempting to be selected, the correct extension will not be seen.

When a file is selected, it will appear in the Re-flash Configuration section of the DRT window (for example, in Figure 4, the selected file is: E:\My Documents\Products\SX\ MHX Files\Mcp0302.mhx).

Left-clicking on the Close choice will close a file that was opened for downloading. The History List is a list of recently used mhx files. Up to four files will be retained on this list. Selection of a file from the History List is accomplished by left- clicking on the file name, which causes the file to be opened for downloading. When a file is selected, it will appear in the Re-flash Configuration section of the DRT window. Left-clicking on the Exit option will close the DRT application.

3 - DRIVE RE-FLASH TOOL

Table 1: File Name, Extension and Version Definition

Product Firmware File Name Extension Comments

SX Appl and MCP SX xxxxxxxxx .mhx Xxxx is file & version name

EKP EKP xxxxxxxxx .a07 Xxxx is file & version name

GP - Appl GP APPL xxxx .mhx Xxxx is file & version name

GP - FL GP FL xxxxxxx .mhx Xxxx is file & version name

3.3.2 The Product Menu

The DRT must be configured to the correct product type, prior to loading the correct file or attempting a re-flash. The product section will determine what type of file will be searched for when attempting to open a file for download.

3.3.3

The Setup Menu

The Setup Menu provides dialog boxes that are used to change the configuration of the communication aspects of the DRT as well as to enable or disable the Error Analysis panel. Left-clicking on the Communications Properties will display the dialog box shown in Figure 5. The communication port and baud rate can be selected. The default com port is COM1 and the baud rate setting is 38.4k.

Depending on the communication adapter will depend on which communication port should be used. For example; if the I/O simulator is used or the B&B Electronics RS232 to RS485 adapter, Com 1 most likely would be the selection. If a PCMCIA card is used, the most likely COMM 5 and above would be used.

The baud rate normally would be run as high as possible, unless excessive number of communication errors occurs due to interference or hardware performance issues. The baud rate should be lowered to improve performance.

To change the COMM port or baud rate, left-click in the circle to the left of the desired choice, then left-click the "OK" button. To exit the dialog box without changing the setting, left-click the "Cancel" button.

Figure 5: Communication Properties Configuration Screen

3 - DRIVE RE-FLASH TOOL

The amount of time required to re-flash depends on the quality of communications as well as the speed of the PC being used. Approximate times for download completion are:

Baud Rate 4800 9600 19.2k 38.4k

SX -APPL& MCP 32.0 min 16.0 min 8.0 min 4.0 min

EKP 8. min 4.0 min 2.0 min 1.0 min

GP-FL 12.0 min 6.0 min 3.0 min 1.5 min

GP-APPL 16.0 min 8.0 min 4.0 min 2.0 min

3.3.4

The Help Menu

Due to the simplicity of the DRT, context-sensitive help is not available. Opening the Help Menu provides two choice: One choice, Re-flash Manual, opens a copy of this manual in Adobe Acrobat Reader. The other is the "About choice." The About window has a link to Benshaw Inc. home page. Left clicking that link will open the user's default web browser to Benshaw.com.

3.4 The Re-flash Status Panel

As shown in Figure 6, the DRT is not active (that is, the Re-flash Step is indicating Download Inactive). When the tool is activated, the remaining parameters of this panel will update to show the status of the download. A bar graph display of the completion percentage is also shown directly beneath the Re-flash Status panel of the window.

3.4.1

The Error Analysis Panel

The Error Analysis panel is provided as an aid in troubleshooting communications problems. The Error Left-clicking the Error Analysis choice of the Setup menu activates analysis panel. If active, this panel is updated during the download process.

Figure 6: Error Analysis Screen

3 - DRIVE RE-FLASH TOOL

NOTES:

Connectioning the

Re-Flash Tool

4 - RE-FLASH TOOL CONNECTION

4.1 Introduction

There are three possible connection scenarios

I/O Simulator;

•

A third-party device from Benshaw Inc.

•

B&B Electronics, Inline RS232 to RS485 converter PCMCIA card from Quatech SSP 200/300 RS422/485

A third-party device Supplied by the user.

•

4.2 Connections Using the I/O Simulator

Two of the products that can be re-flashed using the DRT, the GP Microdrive and the SX Sensorless Vector Drive. The I/O Simulators contain an RS-232 to RS-485 converter that may be used to re-flash the drive provide the PC operating system is Windows 9x.

This connection method can not be used to re-flash an EKP without adding an external 24V DC power supply and using a custom cable to supply power to the EKP.

Re-flash Tool Connection

To use the I/O Simulator to re-flash a drive you must have a cable to connect the Simulator to the PC. In most cases the required cable will have a 9-pin D-shell male (DB9M) on one end and a 9-pin D-shell female (DB9F) on the other. The cable is wired "straight through" (i.e., pin 1 of the male connects to pin 1 of the female and so on.) Such cables are available from local computer or office stores.

Older computers used 25-pin D-shell (DB25) serial ports. Cables are available that have a 9-pin D-shell (DB9) connector on one end and a 25-pin D-shell (DB25) connector on the other. Adapters are also available to convert between these connectors or to change the gender of the connectors. The cable or the adapters can be purchased for local computer or office stores.

Also, some newer machines may not have serial ports. If the PC has USB ports, a USB to Serial Converter is needed. These devices allow the use of a USB port for the re-flash operation. Examples of these devices include BAFO Technologies BF-810 and the Belkin F5U103. These devices are available from computer stores or online computer peripheral suppliers.

Figure 7: Connections When Using the SX I/O Simulator Pendent

9-Pin D

hell Null Modem Cable to PC RS-232 Port

High-speed Serial Port

9-pin D Shell from Pendent Cable

(normally to high-speed serial port)

4.2.1 Using the I/O Simulator to Re-Flash a Drive

4 - RE-FLASH TOOL CONNECTION

EKP Port

Reflash Cable

PC598 Interface Board

TSP

To connect a protocol converter to a product to be re-flashed follow the procedure below.

1. Locate the serial port or USB port of the PC to be used for the re-flash operation. (Hint: Serial ports are usually on the back of the PC; USB ports can be on the back or front.)

2. If a Serial port is to be used:

•

Connect the Serial port to the 9-pin D-shell (DB9) connector on the side of the I/O Simulator.

3. If a USB port is to be used:

•

Be sure that you have a USB to Serial Converter that is compatible with the operating system you are using.

•

Connect the USB to Serial Converter to the PC.

•

Connect the USB to Serial Converter to the 9-pin D-shell (DB9) connector on the side of the pendant.

4. Connect the flat cable to the top of the Demo pendant.

5. On the drive to be re-flashed:

•

Remove power and wait for the DB Bus to discharge.

•

Remove the terminal access cover.

•

Connect the SX Re-flash cable (that was supplied with the Converter) to the 9-pin D-shell connector that is attached to the drive. (Note: There should be no connection to the

9-pin D-shell (DB9) connector mounted on the TSP is a SX drive.)

•

Connect the RJ45 connector of the SX Re-flash Cable to the RJ45 connector on the TSP board for a SX drive or the ModBUS port of the GP drive.

6. Be sure all unused connections are isolated from any connections in the drive to be re-flashed, then reapply power.

4 - RE-FLASH TOOL CONNECTION

4.3 Connections Using An Inline RS232 to RS485 Converter

4.3.1

Connections Using a Serial converter fromB&BElectronics or Third Party)

The Serial converter from B&B Electronics provide an economical means of converting RS-232 to RS-485 protocol for industrial communication applications such as product re-flash, monitoring, or control. All cables required for flashing new firmware into the SX or GP drive are provided when purchased from Benshaw Inc.

To connect a protocol converter to a product to be re-flashed follow the procedure below.

1. Locate the serial port or USB port of the PC to be used for the re-flash operation. (Hint: Serial ports are usually on the back of the PC; USB ports can be on the back or front.)

2. If a Serial port is to be used:

Connect the serial port to the protocol converter.

•

3. If a USB port is to be used:

Be sure that you have a USB to Serial Converter that is compatible with the operating

•

system you are using. Connect the USB to Serial Converter to the PC.

•

Connect the protocol translator to the USB to Serial Converter.

•

4. Be sure the following settings are selected in the protocol converter:

Echo must be off.

•

Transmission control should be automatic (or timed, as opposed to TE control.)

•

If you are re-flashing an EKP, be sure that the DRV/EKP jumper is in the EKP position.

•

5. Connect the SX Re-flash Cable to the converter. This cable was supplied with the converter if purchased from Benshaw Inc.

6. If you are using a third party translator you will have to make a cable to connect the device to the product being re-flashed. The "product" end must have an RJ45 connector.

7. Connect the remaining RJ45 connector to the product.

•

On a SX Sensorless Vector Drive, connection is to the TSP board. The connector is at the top of the board and slightly right of center.

•

On an SX Sensorless Vector Drive, connection is to the Modbus port. The connector is at the bottom center of the Terminal Strip Processor board.

•

On an Enhanced Keypad (EKP), connection is to the RJ45 connector on the back of the keypad.

8. An external power supply is required when connecting to the EKP, 24 VDC at 50mA.

4 - RE-FLASH TOOL CONNECTION

Figure 8: Connection using inline RS232 to RS485 Converter

In line RS232 to RS485 converter from B&B Electronics

Cable WI-400004-00

USB to RS232

4.4 Connections Using A RS422/485 PCMCIA Card

4.4.1

Introduction to Quatech SSP 200/300 RS422/485 PCMCIA card

Re-Flash Cable WI0400002-00

The PCMCIA card is an excellent way for PC notebooks to obtain an RS485 interface when there is no RS232 port. An alternate method would be to use a USB adapter and an inline RS232 to RS485 interface.

The installation of the PCMCIA card is straight forward. When installed the PC software will activate the plug and play, NEW HARDWARE FOUND. A CD disk is provided with each card. Insert the CD prior to installing the PCMCIA card.

4.4.2

Installation

1. Install the CD that come with the PCMCIA card into the CD Player.

2. Install the PCMCIA into one of the PCMCIA slots in the PC. Sometime the cover for the shot has to be removed first.

3. With the NEWFound Hardware box displayed on the screen select “Install Hardware Driver”.

4. Select “Search for suitable driver for my device”, press NEXT button.

5. Select "CD ROM Drive", press NEXT button.

6. If the CD is the "D" drive, the following file should be selected "d:\serial port adapter\drivers\ Window 2000, XP for PCI, PCMCIA\qserbrd.inf", press NEXT button.

7. A message "Completing the Found NEW Hardware Wizard, press Finish button.

4 - RE-FLASH TOOL CONNECTION

4.4.3 Card Configuration

After installation is complete the card has to be configured to correct operation

1. Select the Windows “START Button”

2. Select “SETTINGS” and Control Panel

3. Select “SYSTEM”, double click

4. System Properties appears

5. Select Hardware tab

6. Select “Device Manager” button

6. In the list of device managers, select “Multi-Port Serial Adapters”

7. Then select “Quatech SSP 200/300 PCMCIA RS422/485 serial adapter” Double Click

8. Select Advance Tab

9. Data Rate to “Auto”

10. RS422/485 A. RS422/485 connector setting, “Loop Back All”

•

B. Receiver Control, “Always Receiving”

•

C. RS422/485 Duplex mode, “AUTO Toggle”, (Changed from Default)

•

D. Select “OK” button

•

11. In the list of device managers, select “Select Ports (COM & LPT)” Communication Ports (COM1)

•

ECP Printer Port (LPT1)

•

Quatech PCMCIA Serial Port (COM5)

•

12. Double click on “Quatech PCMCIA Serial Port (COM5)"

13. Select Port Setting Tab

• Bits per Second: 9600

•

Data Bits: 8

•

Parity: None

•

Stop Bits: 1

•

Flow Control: None

14. Select "Advance" button

Select COM Port Assignment, many PC’s will COM 1-COM 4 “in use” COM 5 is OK to use for the Drive Reflash Tool

15. Exit out of all layers

16. The PCMCIA card is ready to operate.

PCMCIA

Card,

RS422/485

Figure 9: RS422/485 PCMCIA Card

Cable

WI-400003-00

Re-Flash

Cable

WI-400002-00

TSP

EKP Port

5 Using the Re-Flash Tool

5 - USING THE RE-FLASH TOOL

5.1 Re-flashing the Drive

Place the drive in re-flash mode as defined in the following sections.

5.2 Initiating the Re-flash Operation

Left-click on the Download button to start the downloading process. The DRT will now attempt to establish communications with the drive. While this is happening, the download Status is "Synchronizing Baud Rates," and the drive displays will indicate the re-flash is in progress.

The Download Status is "Sending S Record." The bar graph and Re-flash Status panel information are updated to provide an indication of the progress of the download in addition to the quality of communications. If the Error Analysis panel was opened, it will also be updated as the download progresses.

Should it be necessary to abort the process, left-click the Abort button. This action will cause the DRT to display the dialog box shown in Figure 10. Although the download process can be aborted at any time by left-clicking on the Abort button on the DRT, the drive must be completely Re-flashed to be functional because the old firmware was completely erased as part of the process. The download can be continued at any time by restoring the drive to the Re-flash mode and left-clicking the Download button on the DRT. On completion of the download, the DRT will display the message shown in Figure 11. This completes the function of the DRT, and unless one or more additional drives are to be re-flashed with the DRT, it can be closed by either left-clicking the X button in the upper right corner of the window or by selecting Exit from the File menu.

Using the Re-flash Tool

Figure 10: Abort Dialog Box

5 - USING THE RE-FLASH TOOL

Figure 11: Dialog Box for Successful Completion

5.3 After the Download is Completed

After the download is completed, follow the specific instructions for the drive that was re-flashed.

5.4 Power Loss During Re-flash Procedure

The DRT is designed to provide the most reliable operation possible. It uses a checksum mechanism to check for errors during the download process. This data can also be used to restart an aborted download. Even if a power failure would occur to either the PC or the SX (or both), the download could be resumed, when power is restored, without ill effect. If power fails to the PC (and not the drive):

1. When power is restored, restart the PC.

2. When the operating system is loaded, restart the DRT and confirm that your settings are still intact.

3. Left-click download.

If power fails to the drive (and not the PC), when power is restored, if the drive is not in Re-flash mode, re-initialize re-flash.

5 - USING THE RE-FLASH TOOL

NOTES:

Re-Flashing Specific

Drives

6 - RE-FLASHING SPECIFIC DRIVES

This procedure assumes that the Product Re-flash Tool (DRT) is already installed on the PC and that the PC is already connected to the product to be re-flashed. If this is not the case, refer to the section(s) of the manual that describe these operations.

6.1 Re-flashing the SX Drive

6.1.1

Placing the SX in Re-flash Mode

To place an SX drive with an SKP interface in Re-flash Mode, press STOP and MENU at the same time.

z NOTE: If you have difficulty getting the control into the Re-flash Mode, try holding down STOP and then pressing MENU.

The Program LED on the SX's keypad assembly will flash and the display will alternate between the following messages: SX Loader xx.yy

Alternating

Waiting for data and, once data is being received:

¢ > STOP to exit

Re-flashing Specific Drives

z NOTE: xx.yy is the current revision of the flash loader software; it is not related to the revision of the DRT.

At this point in the operation, the drive is volatile; however, the Re-flash procedure can be aborted by pressing STOP on the SX drive's keypad. This will cause the drive to revert to its present firmware.

6.1.2

Initiating the Re-flash Operation

Left-click on the Download button to start the downloading process. The DRT will now attempt to establish communications with the SX drive. While this is happening, the Download Status is "Synchronizing Baud Rates," and the display will change to: Erasing: MCP firmware When the old firmware is erased, the display changes to: Loading: MCPXX.XX.mhx where XX.XX is the revision of the firmware selected. The download of the new software is now in progress.

6 - RE-FLASHING SPECIFIC DRIVES

6.1.3 After the Download is Completed

After the download is completed, press the STOP key on the SX drive's keypad to return to normal operation. The SX will show a fault, either an Active Logic Fault (#43) or a Checksum Fault (#26). Both of these conditions exist simultaneously and must be rectified before the SX drive will be functional. It is recommended that a factory reset be performed at this point. This will reset the checksum fault as well as initialize any new parameter locations in the EEPROM. To perform a factory reset:

1. Press "MENU key and select "AFN Group.

2. Press "DOWN" ¤ arrow once. AFNxx; "Par STO/RCL

3. Press "ENTER" key.

4. Use the "UP" £ arrow to select "Factory Rst".

5. Press the Enter key to accept the change and initialize the reset.

The SX drive is now re-flashed with the desired firmware and is ready for programming or operation. All that remains is to disconnect the re-flash hardware and restore enclosure integrity of the unit. DRT, it can be closed by either left-clicking the X button in the upper right corner of the window or by selecting Exit from the File menu.

To restore the SX drive to service, first disconnect the Re-flash cable. Next, complete any programming changes that are required for the application. Reconnect the Enable (TB4) break apart terminal strip section. Replace the Terminal Access Cover. To ensure the integrity of NEMA 12 models, refer to 890020-01 hardware manual for the proper torque specifications for the terminal access cover screws.

If the SX I/O Simulator was used for the RS-232 to RS-485 conversion, disconnect the Re-flash cable from the 9-pin D-shell connector that is attached to the Interface board and put the cable in a safe place. Next, reconnect the 9-pin D-shell cable to the TSP of the SX I/O Simulator Drive. Now plug the Interface board into the terminal blocks of the SX I/O Simulator Drive. Replace the terminal access cover. Finally, disconnect the pendent form the PC used for Re-flashing.

6.2 Re-flashing the GP General Purpose Microdrive

6.2.1

Placing the GP Micro Drive in Re-flash Mode

Navigate to Fn58 and change the parameter to a value of 99. Exit out by pressing "menu" The GP drive is now in re-flash mode and the display should read C_UP and the WARN LED is lit. Either the Fundamental Layer "GP-FL" (Motor Control) or the Application layer "GP APPL" can be reprogrammed.

6 - RE-FLASHING SPECIFIC DRIVES

6.2.2 Initiating the Re-flash Operation

Click on the PRODUCT menu and select the correct file to be downloaded. Click Download to start the downloading process.

If you are re-flashing the Fundamental Layer, the PROG LED stays on and the FLT LED

•

flashes until the download is complete. If you are re-flashing the Application Layer, the WARN and PROG LEDs stay on and the FLT

•

LED flashes until the download is complete.

The download of the new software is now in progress.

On completion of the download the GP General Purpose Microdrive will return to the normal operating mode.

6.3 Re-flashing the Enhanced Keypad

6.3.1

Placing the EKP in Re-flash Mode

1. If you have not already done so, be sure that the EKP is supplied 24 VDC power

2. The EKP should have power applied. The current revision of the firmware should be showing and a chevron should be going across the screen. (Remember that the current firmware

must be version 4.0 or greater to continue).

3. Press the SHIFT+REV keys and the top line of the EKP will read "EKP Loader 1.0" and the third line will read "Send Firmware."

6.3.2

Initiating the Re-flash Operation

1. Select the file to be downloaded, the left click on the Download button of the PRT.

2. During the downloading process the third line of the keypad should display "Loading:" and the fourth line should be the name of the file being downloaded.

3. When the download is complete the third line of the keypad should display the status of the download. Press ENTER. The introductory EKP screen should reappear with the software version downloaded to the keypad.

4. Remove power from the protocol translator and disconnect all cables.

7 TROUBLESHOOTING

7 - TROUBLESHOOTING

7.1 Advice on Resolving Typical Problems

The following table provides assistance in resolving typical problems.

Symptoms Suggested Remedy

Upon starting, the DRT shows the message "ie_Badid - Specified comport doesn't exist."

DRT Status shows Synchronizing Baud Rates.

Communication hangs (time elapses, no progress, many errors)

The com port setting in Windows is greater than 9, Which is beyond the range of the DRT. To recover, change the resources used by Windows for the comport (that is, make it either Com 1, to Com 8). Exercise care when doing this or a resource conflict may result; it is recommended that this be done only be experienced users.

Check connections. Check that the protocol translator is powered up. Check Com settings: Windows? DRT? Is the SX drive in Re-flash Mode? Try a slower baud rate.

Check connections. Assure protocol translator is still powered up. Abort and try a slower baud rate. Power down the drive for 10 to 15 min. and then star the process over.Reboot the PC to clear all comport setups.

Troubleshooting

7.2 How to Check Windows COM Port Settings

In Windows 9x, Me, 2000:

1. Navigate to Control Panel.

2. Open the System Icon by double-clicking it.

3. Choose the Device Manager tab and select "View by Device Type."

4. Locate the folder "Ports (COM & LPT)."

5. Left-click the plus (+) to open the folder. A listing of Communications ports will appear.

6. Select "Properties" for the port that is to be used.

7. Check the settings against those shown in Table 1 - Settings.

8. Left-click the Advanced button. The FIFO buffer should be enabled, with Receive set for High and Transmit set for Medium.

9. Choose the Resources tab and check the settings against those in Table 2 - Resources.

10. Cancel all dialog boxes to escape or click OK to accept changes.

In Windows NT:

1. Navigate to Control Panel.

2. Open the Ports Icon by double-clicking it.

3. Choose either COM1 to COM8.

4. Left-click the "Settings …" button and check the settings against those in Table 1 - Settings.

5. Left-click Advanced and assure that the COM port number is correct. The Base I/O Address and IRQ are typically at "Default." If the port settings are suspect change them to match those in Table 2 - Resources.

6. The FIFO buffer should be enabled.

7. Cancel all dialog boxes to escape or click OK to accept changes.

8 QUICKSTART GUIDE

8 - QUICKSTART GUIDE

8.1 Overview

This guide is provided for EXPERIENCED users as an outline for Re-flashing a SX drive. It provides only the bare essentials for Re-flashing the drives. For a detailed procedure use Section

3. The Drive Re-flash Tool (DRT) has a simple user interface. An experienced user may be able

to navigate the program without instructions. However, if needed, an overview of the features and function of the DRT is provided in Section 5.

8.2 Re-flash Procedure

1. Determine the type of RS-232 to RS-485 protocol converter to be used. There are three possible options:

A SX I/O Simulator;

•

A third-party device by Benshaw Inc.

•

B&B Inline RS232 to RS485

•

PCMCIA card from Quatech SSP 200/300 RS422/485

•

A third-party device supplied by the user

•

QuickStart Guide

In the case of the SX I/O Simulator, a 9-pin D-shell straight-through cable is required to connect the demo's pendant to the PC. Third-party devices, supplied by Benshaw Inc., the necessary cables are included. For third-party devices supplied by the user, a cable with a RJ45 connector as define in Figure 1 is needed.

2. Procure the Drive Re-flash Tool (DRT), the upgrade file, and the firmware file for the current software revision from Benshaw Inc.. Extract the files and install the DRT and update file on the PC to be used for the installation.

3. Connect the protocol converter to the PC.

4. For SX drives, to which an SKP and EKP are connected, disconnect the EKP and connect the Re-flash cable to the EKP port.

5. Place the SX drive in Re-flash mode by pressing STOP and MENU keys simultaneously from the default or main menu.

6. The following messages will be displayed on the SKP: SX Loader xx.yy

Alternating

Waiting for data and, once data is being received:

¢ > STOP to exit

7. Disconnect the break apart terminal strip section containing the drive enable (EN) terminal. This assures that the drive will not run until programming has been completed.

8. Start the DRT.

9. Select the mhx (firmware) file to be downloaded.

10. Confirm the Re-flash Configuration settings in the Re-flash Configuration panel of the DRT.

11. Left click "Download" to begin.

12. On completion of the download, the DRT can be closed and the Re-flash cable disconnected from the EKP port. If the SX has an EKP, you can re-connect it now.

13. Perform a factory reset of the drive. This will clear any faults that may have occurred. The factory reset "Par STO/RCL" can be found at AFN 84, AFN 85, and AFN 87 depending on the level of application software.

Configure the drive as needed, all previous settings will have been erased. Re-connect the break apart terminal strip(s). Close the drive, taking care to observe any requirements for restoring the enclosure's rating. The procedure is now complete and the SX drive can be restored to service.

Third Party COMM

Adapters

9 - THIRD PARTY COMM ADAPTERS

9.1 USB Support for DRT Introduction

Due to the change in the PC note book, RS232 ports are being replaced with USB ports. To date, no USB converters have been found that directly support RS485. The two defined USP adapters were found to work with the B&B RS232 to RS485 inline converter. These adapters are available on TigerDirect and the purchasing information is as follows for both adapters:

1) Manufacturer: BAFO Technologies Manufacturer Part #: BF-810 Supplier: Tiger Direct Item #: B133-1014

2) Manufacturer: Belkin Manufacturer Part #: F5U103 Supplier: Tiger Direct Item #: B29-5034

9.2 Connectivity Instructions

Connecting either of the two USB devices to a USB port on your computer will activate a plug and play installer for the device. The correct driver must be selected from a CD-ROM provided with each product (Directions are included with the product purchase). When the driver installs, a new COM port will become available that the user can use to access DRT products. The user does not get to choose which COM port number will be added and it may be added from 1 to 8. The output of the USB adapter is a RS232 communication signal. That signal must then be converted to RS485 using a RS232 to RS485 converter.

Third Party COMM Adapters

Adapters were operated on the following systems, Windows 98, Windows 2000, and Windows XP.

Adapter #1: BAFO Technologies

- Works on XP

- Works on 2000

- Does not work on 98

Adapter #2: Belkin

- Works on XP

- Works on 2000

- Works on 98

The Belkin adapter worked in all cases but is 3 times more expensive and is also much larger than the BAFO model. The BAFO model should work on newer computers with 2000/XP, which are the computers most likely not to have serial ports.

9.3 B&B Electronics

The Serial converter fromB&BElectronics provide an economical means of converting RS-232 to RS-485 protocol for industrial communication applications such as product re-flash, monitoring, or control.

The adapter is an inline device, requiring power from the PC RS232 port to power the adapter. The adapter can plug directly into the PC RS232 port. A cable will be required for the RS485 end to be connected to the RSi devices.

Manufacturer Part #: 485FD9R Supplier: B&B Electronics

9.4 Quatach PCMCIA Card

9 - THIRD PARTY COMM ADAPTERS

www.orders@bb-elec.com www.bb-elec.com 815-433-5100

The PCMCIA card when installed will activate the plug and play software, NEW HARDWARE FOUND. A CD disk is provided with each card. The Plug and play software will walk you thru the setup. Refer to section 4.4.1 for specific instructions.

Manufacturer: Qualtech Manufacturer Part #: SSP-200/300 or DSP-200/300, same card Supplier: SuperLogic

www.sales@superlogics.com www.info@superlogics.com 781-893-1600

9 - THIRD PARTY COMM ADAPTERS

9.5 Communication Cables

Communication cables for reflash and Modbus capabilities

WI-400002-00, Cable Part Number

Re-Flash Cable, RJ45 to 9 pin D shell (DB9M)

RJ 45 DB9M SIO+Pin3>-----------------------------Ò Pin 1 SIO + SIO -Pin6>-----------------------------Ò Pin 7 SIO - GNDPin8 >-----------------------------Ò Pin 8 GND

WI-400003-00, Cable Part Number

PCMCIA (DB9M) to Re-Flash Cable (DB9M) or Modbus, Adapter Cable

DB9M (Connects to PCMCIA) DB9F DATA OUT + Pin 2 > -----------------------Ò Pin 1 SIO + DATA IN + Pin 4 >-----

DATA OUT - Pin 7 > -----------------------Ò Pin 7 SIO DATA IN - Pin 8 >-----

GNDPin3> -----------------------------Ò Pin 8 GND

WI-400004-00, Cable Part Number

In line converter (DB9F) to Re-Flash Cable (DB9M) or Modbus, Adapter Cable

DB9M (Connects to In Line Converter) DB9F DATA OUT + Pin 2 > -----------------------Ò Pin 1 SIO + DATA In - Pin 7 >--------------------------Ò Pin 7 SIO GNDPin4> -----------------------------Ò Pin 8 GND

Revision History;

Revision Date ECO#

01 29/08/03 Initial Release

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Benshaw RE-FLASH User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual