Rockwell Automation 1747-OS302 User Manual

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Installation Instructions

SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade

Introduction

Enclosed in this package is a firmware/operating system upgrade for your SLC 5/03 or SLC 5/04 processor. Take anti-static precautions when upgrading the firmware.

ATTENTION

The Flash EPROMs are electrostatic sensitive devices. Do not handle without proper grounding precautions. Do not install PROM with power applied to the SLC 5/03 or SLC 5/04 processor.

If you upgrade an SLC 5/03 or SLC 5/04 processor, you receive anomaly fixes as well as added functionality. During the upgrade, the ladder logic program inside the processor is erased. Therefore, the first step in upgrading the firmware/operating system is to save the processor’s ladder logic program.

This product is CE compliant for all applicable directives when product or packaging is marked.

Installation Procedure

1 Publication 1747-IN007C-EN-P - October 2002

Follow these instructions carefully. Refer to page 3 for component placement information.

1. Save the current user program to your hard drive using your

programming software, to a memory module, or to a 1747-PSD Program Storage Device.

IMPORTANT

2. Remove the communication cable between the processor and

your programming terminal.

The user program is cleared as part of the firmware/operating system upgrade process. You must restore your program after loading the upgrade. Also, all communication ports are returned to the default parameters.

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2 SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade

3. Remove power from the chassis containing the processor.

ATTENTION

Do not remove the processor from the SLC 500 chassis until all power is removed from the SLC 500 power supply.

4. Remove the processor from the chassis.

5. Plug the firmware/operating system upgrade pack into the

memory module socket.

6. Move the operating system write-protect jumper (J4) to the

unprotected, or program, position.

IMPORTANT

Jumper J4, located in the bottom right corner of the motherboard, provides write protection from any download of a new operating system. The

“out of the box” position of this jumper is “PROTECT,” or write protect. Without the

jumper, the processors are write protected.

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Catalog and Serial Number Label

SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade 3

Figure 1 Component Placement Information

Place the firmware upgrade label here.

The SLC 5/03 and SLC 5/04 processors are

protected

from the firmware download when jumper J4 is in this position:

The SLC 5/03 and SLC 5/04 processors accept the firmware download when jumper J4 is in this position:

SLC 500 PROCESSOR UNIT

CAT

SERIAL NO.

SER

FAC

PROC. REV.

PLACE FRN UPGRADE LABEL HERE

OPERATING SYSTEM INFO

OS #

SER

FRN

WHITE

RED

BATTERY

PROTECT

PROGRAM

CURRENT REQUIREMENTS: 1A @ 5 VDC

LISTED IND. CONT. EQ.

FOR HAZ. LOC. A196

CLASS 1, GROUPS A, B, C AND D, DIV OPERATING TEMPERATURE CODE T3C

Daughter Board

Mother Board

Firmware Upgrade/Memory

Jumper J4

Module Socket

7. Firmly seat the processor back into the chassis.

8. Apply power to the chassis containing the processor while

watching the LED display. All the LEDs should turn on and then turn off. The download process of the firmware takes up to 2.5 minutes. While the download is in progress, the RUN and FLT LEDs remain off. The other four LEDs – RS232, DH485 (DH+ on the SLC 5/04), FORCE, and BATT – turn on and off in a walking bit sequence. If the download is successful, these four LEDs remain on together. If the FLT LED turns on and a combination of LEDs flash on and off indicating an error condition, refer to the troubleshooting information on page 4.

200mA @ 24 VDC

. 2

MADE IN USA

9. After completing the download, remove power from the chassis

containing the processor.

ATTENTION

Do not remove the processor from the SLC 500 chassis until all power is removed from the SLC 500 power supply.

10. Remove the processor from the chassis.

11. Carefully remove the firmware upgrade pack and place it in the

anti-static packaging it was shipped in.

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4 SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade

12. Move the operating system write-protect jumper (J4) back to the

protected position (see diagram on page 3).

IMPORTANT

13. Apply the enclosed firmware upgrade label to the processor

nameplate.

14. Firmly seat the processor back into the chassis.

15. Attach the communication cable between the processor and

your programming terminal.

16. Apply power to the chassis containing the processor while

watching the LED display. All the LEDs should flash on and then turn off except for the FLT LED which should remaining flashing. If the FLT LED turns on and a combination of LEDs flash on and off indicating an error condition, refer to the troubleshooting information in this document.

Failure to return the J4 jumper to the protected position results in an error (0x3D Hex) on the power cycle following the download of a valid program to the processor. This error condition prevents the module from going to run and causes Channel 0 communication settings to return to their defaults. To properly clear the error, place the J4 jumper in the protected position, and then re-download a valid user program to the processor.

Identifying Processor Errors While Downloading Firmware

Publication 1747-IN007C-EN-P - October 2002

17. Restore your program.

The download process of the firmware/operating system takes up to

2.5 minutes. While the download is in progress, the RUN and FLT LEDs remain off. The other four LEDs – RS232, DH485 (DH+ on the SLC 5/04), FORCE, and BATT – turn on and off in a walking bit sequence. If the download is successful, these four LEDs remain on together.

If the download is not successful, the FLT LED turns on and a combination of LEDs flash on and off indicating an error condition. The following LED diagrams and tables provide information regarding error messages, possible cause(s) for the error, and recommended action(s) to take to resolve the error.

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SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade 5

If the LED’s indicate:

POWER

If the LED’s indicate:

POWER

If the LED’s indicate:

POWER

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Fatal Hardware Error

Probable Cause Recommended Action

Major hardware failure due to noise, improper grounding, or poor power source.

Cycle power and see if the error repeats itself. If the error clears, you should be able to download the firmware. If the error persists, contact your Rockwell Automation representative.

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Corrupted Operating System Memory Module

Probable Cause Recommended Action

The operating system on the Flash EPROM is corrupt.

Cycle power and see if the error repeats itself. If the error persists, either contact your Rockwell Automation representative for a new operating system upgrade cartridge, or download the old operating system, if available.

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Flash EPROM Failure

Probable Cause Recommended Action

The processor flash EPROM is corrupt.

Cycle power and see if the error repeats itself. If the error clears, you should be able to download the firmware. If the error persists, contact your Rockwell Automation representative.

POWER

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Corrupt or Missing

Probable Cause Recommended Action

The operating system is missing or has been corrupted.

If the LED’s indicate:

Operating System

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF.

Indicates the LED is ON.

(1) The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor.

Cycle power. If error clears, you should be able to download the firmware. If the error persists, contact your Rockwell Automation representative for a new operating system.

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6 SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade

If the LED’s indicate:

POWER

If the LED’s indicate:

POWER

If the LED’s indicate:

POWER

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Downloadable Operating

Probable Cause Recommended Action

Failure during transmission of

Download the operating system.

downloadable operating system.

System Failure

(1)

The Following

RUN

FLT

BATT

(1)

FORCE

DH485

RS232

Error Exists

Incompatible Platform

The Following

RUN

FLT

BATT

FORCE

DH485

RS232

Error Exists

Memory Write Protected

Probable Cause Recommended Action

The upgrade of the operating system is incompatible with the processor hardware.

Use an operating system that is compatible with your processor hardware.

Probable Cause Recommended Action

An attempt was made to download the operating system onto write-protected memory.

Change the J4 jumper of the SLC 5/03 and SLC 5/04 processors to the program position.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF.

Indicates the LED is ON.

(1) The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor.

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SLC 5/03™ and SLC 5/04™ Processors Firmware/Operating System Upgrade 7

If the LED’s indicate:

POWER

If the LED’s indicate:

POWER

(1)

The Following

Probable Cause Recommended Action

Error Exists

RUN

FLT

BATT

FORCE

DH485

RS232

NVRAM error Major hardware failure due to

noise, improper grounding, or poor power source.

Cycle power and see if the error repeats itself. If the error clears, you should be able to download the firmware. If the error persists, contact your Rockwell Automation representative.

(1)

RUN

FLT

BATT

FORCE

DH485

RS232

The Following Error Exists

Hardware Watchdog Time-out

Probable Cause Recommended Action

Major hardware failure due to noise, improper grounding, or poor power source.

Cycle power and see if the error repeats itself. If the error clears, you should be able to download the firmware. If the error persists, contact your Rockwell Automation representative.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF.

Indicates the LED is ON.

(1) The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor.

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Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://support.rockwellautomation.com find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect Support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://support.rockwellautomation.com

, you can

Installation Assistance

If you experience a problem with a hardware module within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your module up and running.

United States 1.440.646.3223

Monday – Friday, 8am – 5pm EST

Outside United States

Please contact your local Rockwell Automation representative for any technical support issues.

New Product Satisfaction Return

Rockwell tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning, it may need to be returned.

United States Contact your distributor. You must provide a Customer Support case

number (see phone number above to obtain one) to your distributor in order to complete the return process.

Outside United States

Please contact your local Rockwell Automation representative for return procedure.

Publication 1747-IN007C-EN-P - October 2002 21 PN 40071-093-01(3)