Rockwell Automation 1757-SWKIT3200 User Manual

ProcessLogix R320.0 Installation and Upgrade Guide

1757-SWKIT3200

Installation Instructions

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets al l performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liabilit y (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Allen-Bradley is a trademark of Rockwell Automation.

Identifies information that is critical for successful application and understanding of the product.

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

• EN 50081-2 EMC — Generic Emission Standard, Part 2 —

Industrial Environment

• EN 50082-2 EMC — Generic Immunity Standard, Part 2 —

Industrial Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage, by applying the safety requirements of EN 61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests. For specific information required by EN 61131-2, see the appropriate sections in this publication, as well as the Allen-Bradley publication Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . ii

European Communities (EC) Directive Compliance . . . . . . . iii

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Preface

Our Assumptions About Readers . . . . . . . . . . . . . . . . . . . . P-1

Starting Conditions and Assumptions . . . . . . . . . . . . . . P-1

Minimum Hardware Requirements. . . . . . . . . . . . . . . . . . . P-2

Rockwell Automation Technical Support . . . . . . . . . . . . . . P-3

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3

Your Questions or Comments about This Manual . . . . . P-3

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4

Terms and Type Representations . . . . . . . . . . . . . . . . . P-4

Related Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

ProcessLogix R320.0 Installation and Upgrade Guide. . . P-5

ProcessLogix Online User Documentation/Knowledge

Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6

Contents of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . P-7

Chapter 1

Preparing for a ProcessLogix Software Upgrade . . . . . . . . . 1-1

Things to consider before upgrading . . . . . . . . . . . . . . 1-1

Saving Current Controller Data (optional) . . . . . . . . . . . 1-3

Determining Your Hard Drive Free Space Requirements 1-4

Backing Up a ProcessLogix Server to Tape . . . . . . . . . . 1-6

Stopping ProcessLogix Applications and Services . . . . . . . . 1-8

Installing Service Pack 6a for Windows NT 4.0. . . . . . . . . . 1-11

Installing Internet Explorer 5.01. . . . . . . . . . . . . . . . . . . . . 1-12

Upgrading Data Access Components . . . . . . . . . . . . . . . . . 1-13

Uninstalling ProcessLogix Knowledge Builder Software . . . 1-14

Recording the NT System Path Value . . . . . . . . . . . . . . 1-14

Uninstall Knowledge Builder . . . . . . . . . . . . . . . . . . . . 1-14

Verifying the NT System Path Value . . . . . . . . . . . . . . . 1-15

Uninstalling Adobe Acrobat Reader 3.01 . . . . . . . . . . . . 1-15

Installing ProcessLogix Knowledge Builder Software . . . . . 1-16

Removing the 9904/1784-KTCX15 Card

and Installing the 1784-PCIC Card . . . . . . . . . . . . . . . . . 1-18

Upgrading ProcessLogix Software

on a Non-redundant Server Only. . . . . . . . . . . . . . . . . . . 1-19

About Upgrading Software on the Server . . . . . . . . . . . 1-19

Installing Server Software. . . . . . . . . . . . . . . . . . . . . . . 1-20

Installing RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Installing Engineering Tools . . . . . . . . . . . . . . . . . . . . . 1-22

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Migrating the ERDB. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Installing the ProcessLogix Server . . . . . . . . . . . . . . . . 1-23

Setting Up User Accounts . . . . . . . . . . . . . . . . . . . . . . 1-25

Moving the RSLinx Activation File. . . . . . . . . . . . . . . . . . . 1-26

About the Activation File. . . . . . . . . . . . . . . . . . . . . . . 1-26

Determining the Current RSLinx Version . . . . . . . . . . . 1-26

Installing the Activation File. . . . . . . . . . . . . . . . . . . . . 1-27

Configuring RSLinx Drivers for ControlNet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . . . 1-29

Updating the 1784-PCIC Card Firmware . . . . . . . . . . . . 1-30

Re-installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . 1-34

Updating the 1784-PCIC Network Address . . . . . . . . . . 1-36

Configuring RSLinx Drivers for Ethernet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

Upgrading Hardware Component Firmware . . . . . . . . . . . 1-39

Making Post ProcessLogix Software Installation

Checks for a Non-redundant Server . . . . . . . . . . . . . . . . 1-39

Things to check after the upgrade . . . . . . . . . . . . . . . . 1-39

Reconfiguring Other RSLinx Clients . . . . . . . . . . . . . . . 1-40

Reloading the 1757-PLX52 Database. . . . . . . . . . . . . . . 1-40

Initiating Redundant Controller Switchover. . . . . . . . . . 1-41

Enabling the ProcessLogix OPC Server. . . . . . . . . . . . . 1-42

Backing up a ProcessLogix Server to Tape . . . . . . . . . . 1-43

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 1-43

Upgrading ProcessLogix Software

on a Redundant Server Pair. . . . . . . . . . . . . . . . . . . . . . 1-45

About Upgrading Software on the Server . . . . . . . . . . . 1-45

Installing Server Software . . . . . . . . . . . . . . . . . . . . . . 1-47

Installing RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Installing Engineering Tools . . . . . . . . . . . . . . . . . . . . 1-50

Migrating the ERDB (on SERVERB only). . . . . . . . . . . . 1-50

Installing the ProcessLogix Server . . . . . . . . . . . . . . . . 1-51

Setting Up User Accounts . . . . . . . . . . . . . . . . . . . . . . 1-52

Configuring RSLinx Drivers for ControlNet

Supervisory Network . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . . . 1-54

Updating the 1784-PCIC Card Firmware . . . . . . . . . . . . 1-55

Re-installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . 1-55

Configuring the ControlNet Supervisory Network. . . . . . . . 1-57

Updating the 1784-PCIC Network Address . . . . . . . . . . 1-58

Configuring RSLinx Drivers for Ethernet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

Upgrading Hardware Component Firmware . . . . . . . . . . . 1-61

Making Post ProcessLogix Software Installation

Checks for a Redundant Server Pair. . . . . . . . . . . . . . . . 1-62

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Things to Check after the Upgrade. . . . . . . . . . . . . . . . 1-62

Creating the Secondary ERDB . . . . . . . . . . . . . . . . . . . 1-62

Synchronizing ERDB on Redundant Servers . . . . . . . . . 1-63

Setting Up Station on SERVERB . . . . . . . . . . . . . . . . . . 1-64

Setting Up Station on SERVERA . . . . . . . . . . . . . . . . . . 1-67

Synchronizing Server Databases on Redundant Servers . 1-71

Synchronizing Other Files . . . . . . . . . . . . . . . . . . . . . . 1-72

Reconfiguring Other RSLinx Clients . . . . . . . . . . . . . . . 1-72

Reloading the 1757-PLX52 Database. . . . . . . . . . . . . . . 1-72

Initiating Redundant Controller Switchover. . . . . . . . . . 1-72

Enabling the ProcessLogix OPC Server . . . . . . . . . . . . . 1-72

Backing up a ProcessLogix Server to Tape . . . . . . . . . . 1-72

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 1-72

Installing ProcessLogix Client Software . . . . . . . . . . . . . . . 1-73

Configuring an Operator Workstation . . . . . . . . . . . . . . . . 1-73

Installing Service Pack 6a for Windows NT 4.0 . . . . . . . 1-74

Installing Internet Explorer 5.01 . . . . . . . . . . . . . . . . . . 1-74

Upgrading Data Access Components . . . . . . . . . . . . . . 1-74

Uninstalling ProcessLogix Knowledge Builder Software. 1-74

Installing ProcessLogix Knowledge Builder Software. . . 1-74

Installing ProcessLogix Operator Workstation Software . 1-74

Configuring an Engineering Workstation . . . . . . . . . . . . . . 1-78

Installing Service Pack 6a for Windows NT 4.0 . . . . . . . 1-78

Installing Internet Explorer 5.01 . . . . . . . . . . . . . . . . . . 1-78

Upgrading Data Access Components . . . . . . . . . . . . . . 1-78

Uninstalling ProcessLogix Knowledge Builder Software. 1-78

Installing ProcessLogix Knowledge Builder Software. . . 1-78

Installing ProcessLogix Engineering

Workstation Software . . . . . . . . . . . . . . . . . . . . . . . . 1-79

Verifying ProcessLogix Client Installation. . . . . . . . . . . . . . 1-83

Things To Consider After The Installation. . . . . . . . . . . 1-83

Setting Up a ProcessLogix Client

With a Non-redundant Server . . . . . . . . . . . . . . . . . . 1-84

Setting Up a ProcessLogix Client

With Redundant Servers . . . . . . . . . . . . . . . . . . . . . . 1-86

Checking Control Builder Operation and Logging On . . 1-89

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 1-89

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Chapter 2

Upgrading Hardware Component Firmware . . . . . . . . . . . . 2-1

About firmware upgrades . . . . . . . . . . . . . . . . . . . . . . . 2-1

Firmware revision level reference . . . . . . . . . . . . . . . . . 2-2

Important Usage Considerations . . . . . . . . . . . . . . . . . . 2-4

Updating the 1784-PCIC Card Firmware . . . . . . . . . . . . . 2-5

Loading 1757-PLX52 and TC-MUX021

Boot and Personality Images . . . . . . . . . . . . . . . . . . . 2-10

Updating Firmware in CNB, ENET, IOM, SRM, PIM

or ControlNet Adapter. . . . . . . . . . . . . . . . . . . . . . . . 2-15

Setting CNB Module NUT Timing. . . . . . . . . . . . . . . . . 2-16

Chapter 3

Installing Windows NT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Starting the Windows NT Installation . . . . . . . . . . . . . . . 3-2

Setting Up Windows NT . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Installing TCP/IP Networking Software. . . . . . . . . . . . . . 3-5

Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . 3-8

Setting Up the Display Driver . . . . . . . . . . . . . . . . . . . . 3-9

Completing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Installing Service Pack 6a for Windows NT 4.0. . . . . . . . 3-9

Setting Up Additional Drivers after

the Service Pack Installation . . . . . . . . . . . . . . . . . . . 3-10

Configuring System Properties . . . . . . . . . . . . . . . . . . . 3-11

Converting to NTFS after Installing Windows NT . . . . . 3-12

Creating the plx_user Account. . . . . . . . . . . . . . . . . . . 3-12

Installing Internet Explorer 5.01. . . . . . . . . . . . . . . . . . 3-12

Upgrading Data Access Components . . . . . . . . . . . . . . 3-12

Checking Required System Settings. . . . . . . . . . . . . . . . . . 3-13

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . . . 3-14

Installing ProcessLogix Knowledge Builder Software . . . . . 3-15

Installing the 1784-PCIC Card . . . . . . . . . . . . . . . . . . . . . . 3-15

Installing ProcessLogix Software on a Clean PC . . . . . . . . . 3-16

Installing Server Software . . . . . . . . . . . . . . . . . . . . . . 3-17

Installing RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Installing Engineering Tools . . . . . . . . . . . . . . . . . . . . 3-19

Installing the ProcessLogix Server . . . . . . . . . . . . . . . . 3-19

Setting up User Accounts. . . . . . . . . . . . . . . . . . . . . . . 3-23

Completing ProcessLogix Install

on a Non-Redundant Server . . . . . . . . . . . . . . . . . . . . 3-23

Configuring RSLinx Drivers for ControlNet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . . . 3-25

Updating the 1784-PCIC Card Firmware . . . . . . . . . . . 3-26

Re-installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . 3-30

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Configuring the ControlNet Supervisory Network . . . . . 3-31

Updating the 1784-PCIC Network Address . . . . . . . . . . 3-32

Configuring RSLinx Drivers for Ethernet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Upgrading Hardware Component Firmware. . . . . . . . . . . . 3-34

Making Post ProcessLogix Software Installation

Checks for a Non-redundant Server . . . . . . . . . . . . . . . . 3-34

Checking Control Builder Operation and Logging On . . 3-34

Enabling the ProcessLogix OPC Server . . . . . . . . . . . . . 3-34

Backing Up a ProcessLogix Server Hard Drive to Tape . 3-34

Creating the Emergency Repair Disk . . . . . . . . . . . . . . 3-35

Installing ProcessLogix Client Software on a Clean PC . . . . 3-35

Checking Required System Settings . . . . . . . . . . . . . . . 3-35

Installing ProcessLogix Client software . . . . . . . . . . . . . 3-35

Verifying ProcessLogix Client Installation. . . . . . . . . . . . . . 3-36

Setting Up a ProcessLogix Client

with a Non-redundant Server . . . . . . . . . . . . . . . . . . 3-36

Setting up a ProcessLogix Client

with Redundant Servers . . . . . . . . . . . . . . . . . . . . . . 3-36

Checking Control Builder Operation and Logging On . . 3-36

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 3-36

Chapter 4

Completing ProcessLogix Install on a Redundant Server Pair and Adding Redundancy to R320.0

Non-Redundant Server Systems . . . . . . . . . . . . . . . . . . . . 4-1

Changing Hosts File Entries . . . . . . . . . . . . . . . . . . . . . . 4-1

Changing TCP/IP address on a Secondary

Server (SERVERB) Node . . . . . . . . . . . . . . . . . . . . . . . 4-4

Changing the Computer Name. . . . . . . . . . . . . . . . . . . . 4-5

Updating the Registry . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Changing the ProcessLogix License . . . . . . . . . . . . . . . . 4-6

Re-installing ProcessLogix Engineering Tools . . . . . . . . . 4-6

Configuring RSLinx Drivers for ControlNet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Installing the 1784-PCIC Driver . . . . . . . . . . . . . . . . . . . 4-9

Updating the 1784-PCIC Card Firmware . . . . . . . . . . . . 4-10

Configuring the ControlNet Supervisory Network . . . . . 4-10

Updating the 1784-PCIC Network Address . . . . . . . . . . 4-11

Configuring RSLinx Drivers for Ethernet

Supervisory Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Restarting Redundant Servers . . . . . . . . . . . . . . . . . . . . . . 4-13

Setting up Secondary Server (SERVERB) node . . . . . . . . . . 4-13

Setting Up Primary Server (SERVERA) Node. . . . . . . . . . . . 4-19

Upgrading Hardware Component Firmware. . . . . . . . . . . . 4-20

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Making Post ProcessLogix Software Installation

Checks for a Redundant Server Pair. . . . . . . . . . . . . . . . 4-20

Synchronizing ERDB on Redundant Servers . . . . . . . . . 4-20

Synchronizing Server Databases on Redundant Servers. 4-20

Synchronizing Other Files . . . . . . . . . . . . . . . . . . . . . . 4-21

Checking Control Builder Operation and Logging On. . 4-21

Enabling the ProcessLogix OPC Server. . . . . . . . . . . . . 4-21

Backing Up a ProcessLogix Server to Tape. . . . . . . . . . 4-21

Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 4-21

Chapter 5

Launching ProcessLogix Knowledge Builder . . . . . . . . . . . . 5-1

Cancelling a Software Component Installation . . . . . . . . . . . 5-1

Removing ProcessLogix Software Components . . . . . . . . . . 5-1

Uninstalling ProcessLogix Knowledge Builder Software . 5-2

Removing the ProcessLogix Server. . . . . . . . . . . . . . . . . 5-2

Removing ProcessLogix Client Software . . . . . . . . . . . . . 5-3

Removing Engineering Tools. . . . . . . . . . . . . . . . . . . . . 5-3

Removing RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Upgrading an Engineering Database to R320.0. . . . . . . . . . . 5-7

Recovering from Failure of an Automatic

ER Database Migration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Manual System Backup/Restore Procedures. . . . . . . . . . . . 5-10

Backing Up a ProcessLogix Server to Tape. . . . . . . . . . 5-10

Restoring a ProcessLogix Server System

From a Backup Tape . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Using Network Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

About Network Tools . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Usage guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Making First Time Network Tools Settings . . . . . . . . . . 5-15

Installing and Running VirusScan with ProcessLogix . . . . . 5-20

About VirusScan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Removing Existing VirusScan NT Program . . . . . . . . . . 5-20

Installing VirusScan NT and Configuring Directories

for Scan Exclusion . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Changing the Computer Name . . . . . . . . . . . . . . . . . . . . . 5-22

Procedure for Configuring a Non-redundant Server . . . 5-22

Procedure for Configuring a ProcessLogix Client . . . . . 5-23

Adding 1757-PLX52 Controller Redundancy to R320.0 Non-Redundant 1757-PLX52 Controller Configurations . . 5-23

Deleting a Non-Redundant 1757-PLX52

and Unassigning its Contents . . . . . . . . . . . . . . . . . . 5-23

Installing and connecting Redundant Chassis

Pair (RCP) hardware . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Checking firmware revision levels . . . . . . . . . . . . . . . . 5-26

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Creating a Redundant 1757-PLX52 . . . . . . . . . . . . . . . . 5-26

Setting Up User Accounts . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Creating the plx_user Account . . . . . . . . . . . . . . . . . . . 5-27

Setting up erserver and/or mngr user accounts. . . . . . . 5-28

Setting Up User Accounts to Logon as a Service . . . . . . 5-28

Setting up mngr Account on a ProcessLogix Server

to Logon as a Batch Job . . . . . . . . . . . . . . . . . . . . . . 5-29

Chapter 6

ProcessLogix System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Ethernet Supervisory Network . . . . . . . . . . . . . . . . . . . . 6-1

CCL Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Controller & I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Expanded ControlNet Interoperability . . . . . . . . . . . . . . 6-2

1794 FLEX I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Common SCM’s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

10 1757-PLX52s per Server. . . . . . . . . . . . . . . . . . . . . . . 6-3

1784-PCIC Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Control Builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chart Visualization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Printing Enhancements . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Data Base Import/Export. . . . . . . . . . . . . . . . . . . . . . . . 6-5

CB Change Journaling . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Engineering Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Network Diagnostic Manager. . . . . . . . . . . . . . . . . . . . . 6-6

Interrupt Usage Note. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

20 Stations per Server (NT Server) . . . . . . . . . . . . . . . . . 6-8

FSC (Fail Safe Controller) Ethernet . . . . . . . . . . . . . . . . . 6-9

Support for Windows NT v4.0 Service Pack 6a . . . . . . . . 6-9

Support for Internet Explorer v5.01 . . . . . . . . . . . . . . . . 6-9

New Station and Display Builder . . . . . . . . . . . . . . . . . . 6-9

New Quick Builder . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Bristol Babcock OpenBSI Interface. . . . . . . . . . . . . . . . 6-11

Additional Modicon Data Formats . . . . . . . . . . . . . . . . 6-11

Modbus Plus SA85 Adapter Selectable for a Channel. . . 6-12

Support for Siemens S5 TF Driver v5.2 . . . . . . . . . . . . . 6-14

Support for the 1784-PCIC card

on Allen-Bradley SCADA channels . . . . . . . . . . . . . . 6-14

Support for Redundant PLC-5 Controllers on ControlNet 6-15

Improved Industrial Shape Files. . . . . . . . . . . . . . . . . . 6-18

Alarm Pager support for UCP Protocols . . . . . . . . . . . . 6-19

Optional Failover of Redundant Servers On Process

Controller Communications Subsystem Failure. . . . . . 6-19

Station Object Model Extensions . . . . . . . . . . . . . . . . . 6-20

RSLinx 2.2 Service Pack 1 . . . . . . . . . . . . . . . . . . . . . . 6-20

New Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

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Table of Contents viii

Chapter 7

PC/NT Platform Requirements . . . . . . . . . . . . . . . . . . . . . . 7-1

Server Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Platform System Configuration Definitions . . . . . . . . . . . 7-2

User Interface Capacity and Performance . . . . . . . . . . . . . . 7-9

Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Server Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Server Notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Communications Capacity and Performance . . . . . . . . . . . 7-11

Controller Communications . . . . . . . . . . . . . . . . . . . . . 7-11

Client/Server Communication Capacity. . . . . . . . . . . . . 7-12

Controller Notifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Controller Redundancy. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

I/O Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Input Module Sample Periods . . . . . . . . . . . . . . . . . . . 7-15

Output Module Sample Periods . . . . . . . . . . . . . . . . . . 7-15

I/O Network Configuration Rules . . . . . . . . . . . . . . . . 7-16

1757-PLX52 Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Engineering Tools Resources. . . . . . . . . . . . . . . . . . . . 7-20

Chapter 8

Major ProcessLogix FTW Software Revisions . . . . . . . . . 8-1

Major ProcessLogix Server Software Revisions . . . . . . . . 8-2

Embedded Software Components . . . . . . . . . . . . . . . . . 8-3

External, Third Party Qualified Software Components. . . 8-5

Miscellaneous SCADA Component Revisions . . . . . . . . . 8-7

Controller/Communication/I/O Firmware. . . . . . . . . . . . 8-7

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Preface

Our Assumptions About Readers

We assume that you are familiar with navigating and running applications in a Microsoft Windows NT environment. Y ou have some experience in loading software applications on a personal computer and are somewhat familiar with ProcessLogix hardware components as well as the Control Builder application. If you have no software loading experience and are not familiar with ProcessLogix hardware components and Control Builder, we recommend that you find someone who does have experience to assist you in loading the ProcessLogix software and making hardware and firmware changes in associated ProcessLogix hardware components.

Starting Conditions and Assumptions

You have the following items on hand:

• ProcessLogix R320.0 Software Ch ange Not e is now incorporated

into the Installation and Upgrade Guide. Refer to Chapters 5, 6, and 7 in this publication.

• ProcessLogix R320.0 compact disc (CD) containing all

ProcessLogix software components

• ProcessLogix R320.0 Kno wledge Builder CD containing the lat est

version of the online documentation

• Windows NT 4.0 Workstation CD (Microsoft CD, including boot

diskettes)

• RSLinx OEM Master (Activation) Disk

• Your PC meets the minimum hardware requirements for a

ProcessLogix Server or ProcessLogix Client.

1 Publication 1757-IN032B-EN-P - April 2001

Preface 2

Minimum Hardware Requirements

ProcessLogix Server Software must be installed on a PC that is specifically qualified. Use of any other PC variations will render the standard warranty and support agreement null and void .

IMPORTANT

End users purchasing ProcessLogix 1757-PLXSYS KIT are not eligible for the standard 90 day technical support, unless the software is installed by personnel trained specifically for ProcessLogix installation.

Please refer to the table below to review the hardware requirements for a new R320.0 ProcessLogix server or client system. ProcessLogix Clients require a Windows NT operating system to support the multiple-user configuration nodes architecture that is possible with R320.0 ProcessLogix systems See Table 7.C on page 7-4 for minimum hardware requirements for upgrading an existing system to R320.0.

Component Description

Base Dell OptiPlex GX200 Processor 800Mhz,Pentium III, 133Mhz Front Side Bus Integrated Functions 4X AGP Video w/8MB of Memory

Audio, 512KB Cache 10/100 NIC Mouse Microsoft Intellimouse Keyboard Quietkey Spacesaver 104-Key, US System RAM 256MB, ECC PC700, 1 RIMM CD-ROM 40X SCSI Floppy Drive 1.44MB, 3.5" SCSI Controller Adaptec 29160N Controller Hard Drive 9.1GB Minimum U2W, 10,000 RPM, SCSI

GX1/M, w/T erm inated Cabl e Tape Drive 10/20 G, SCSI, TR-5, Tape Backup Unit Network Integrated 3COM

3C90SC with 1 RJ45 connector I/O Expansion 5 PCI, 2 ISA/PCI shared slots Software Microsoft Windows NT4.0 (Service Pack 6a), NTFS

All hardware component drivers

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Preface 3

Rockwell Automation Technical Support

Rockwell Automation offers support services worldwide, with over 75 sales/support offices, 512 authorized distributors, and 260 authorized systems integrators located throughout the United States alone, plus Rockwell Automation representatives in every major country in the world.

Local Product Support

Contact your local Rockwell Automation representative for:

• sales and order support

• product technical training

• warranty support

• support service agreements

Technical Product Assistance

If you need to contact Rockwell Automation for technical assistance, first call your local Rockwell Auto mation representative, then:

• Network Pre-sales Hotline, 440.646.3638 (3NET)

• Post-sales Technical Support, 440.646.5800

• Web Links

http://www.ab.com — as a registered member, open to http://www.ab.com/mem/technotes/techmain.html

Your Questions or Comments about This Manual

If you find a problem or have a comment about this manual, please notify us of it on the enclosed Publication Problem Report (at the back of this manual).

If you have any suggestions about how we can make this manual more useful to you, please contact us at the following address:

Rockwell Automation, Allen-Bradley Company, Inc. Control and Information Group Technical Communication 1 Allen-Bradley Drive Mayfield Heights, OH 44124-6118

Publication 1757-IN032B-EN-P - April 2001

Preface 4

Conventions

Term s and Type Representations

The following table summarizes the terms and type representation conventions used in this Guide.

Term/Type Representation

click, click on, click [button name]

double-click Click left mouse button twice in

drag Press and hold left mouse button

right-click Click right mouse button once.

select click to highlight a menu item or

<F1> Keys to be pressed are shown in

Meaning Example

Click left mouse button once. (Assumes cursor is positioned on object or selection.)

quick succession. (Assumes cursor is positioned on object or selection.)

while dragging cursor to new screen location and then release the button. (Assumes cursor is positioned on object or selection to be moved.)

(Assumes cursor is positioned on object or selection.)

list choice, or click on a button.

angle brackets.

Click Browse.

Double-click the Station icon.

Drag the PID function block onto the Control Drawing.

Right-click the AND function block.

Select Configure Allen-Bradley drivers from the list box.

Press <F1> to view the online Help.

<Ctrl>+<C> Keys to be pressed together are

shown with a plus sign.

⇒New

File

>D:\setup.exe< Data to be keyed in at prompt or in

Shows menu selection as menu name followed by menu selection.

an entry field.

Press <Ctrl>+<C> to close the window.

Click File⇒New to start new drawing.

Key in this path location >D:\setup.exe<.

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Preface 5

Contents of Release

The following software and documentation components are included in the ProcessLogix R320.0 Software/documentation kit (1757-SWKIT3200).

Release Component s Catalog and part numbers

ProcessLogix CD

ProcessLogix Engineering Tools ProcessLogix Server Software RSLinx 2.2

ProcessLogix Knowledge Builder CD 1757-SWKIT3200

ProcessLogix R320.0 Installation and Upgrade Guide

1757-SWKIT3200 957445-88

957536-40 1757-IN032B-EN-P

957536-31

Publication 1757-IN032B-EN-P - April 2001

Acronyms and Abbreviations

AI — AO

— Analog Output

— Control Builder

CCL — Control Component Library

— Compact Disc

CDA CD-ROM CEE CM

— Control Module

1756-CNB or CNB CPM CPU DI

— Digital Input

Analog Input

— Control Data Access

— Compact Disc Read Only Memory

— Control Execution Environment

— ControlNet Bridge module

— Control Processor Module

— Central Processing Unit

LAN

— Local Area Network

LED

— Light Emitting Diode

MAC

— Media Access Control

— Megabytes

NTFS

— Windows NT File System

NUT

— Network Update Time

NTFS

— Windows NT File System

NUT

— Network Update Time

ODBC

— Open Database Communications

OEM

— Original Equipment Manufacturer

— Personal Computer

1784-PCIC or PCIC 1757-PIM

— Pulse Input Module

— PCI ControlNet Interface Module

Preface 7

DNS

— Domain Name System

— Digital Output

DOS

— Disk Operating System

— Engineering Repository

ERDB

— Engineering Repository Database

— Function Block

FSC

— Fail Safe Controller

HTML

— HyperText Markup Language

I/O

— Input/Output

IOM

— Input/Output Module

IRQ

— Interrupt Request

ISA

— Industry-Standard Architecture

PLC

— Programmable Logic Controller

RAM

— Random Access Memory

RCP

— Redundant Chassis Pair

RTU

— Remote Terminal Unit

SCADA

— Supervisory Control and Data Access

SCM

— Sequential Control Module

SCSI

— Small Computer System Interface

1757-SRM or SRM TC-MUX01 TCP/IP

— Transmission Control Protocol/Internet Protocol

VGA

— Video Graphics Array

WINS

— Windows Internet Name Service

— System Redundancy Module

— Serial Interface Module

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Preface 8

Publication 1757-IN032B-EN-P - April 2001

Preparing for a ProcessLogix Software Upgrade

Chapter

System Software Upgrade Procedures

ATTENTION

This section assumes that you are currently running ProcessLogix software version R300.1 or 310.0 and Service Pack 5 for Windows NT 4.0. The tasks associated with upgrading from an earlier release are beyond the scope of this docu ment.

If you are migrating a system from R300.0 or earlier, you must upgrade to R300.1 or R310.0 before proceeding with the R320.0 upgrade.

Refer to the documentation supplied with R300 .1 or R310.0 ProcessLogix software for instructions on upgrading from an earlier release to R300.1 or R310.0.

• Refer to Installing ProcessLogix Client Software on page 1-73 to

upgrade the Client software on a networked ProcessLogix Client system.

• Refer to Full PC Software Installation Procedures on page 3-1 to

install ProcessLogix software on a clean PC.

Things to consider before upgrading

ATTENTION

Be certain that your process is off control before you begin any upgrade procedure. This means the 1757-PLX52 should be in the Idle state.

ATTENTION

Before upgrading to this release, be certain that the ProcessLogix user accounts exist and are set up correctly. Refer to Setting Up User Accounts on page 5-27.

1 Publication 1757-I N0 32B-EN-P - April 2001

1-2 System Software Upgrade Procedures

The following table summarizes some upgrade related functions that you should consider before upgrading the existing system to R320.0.

Consider this: Because:

New license with R320.0 ProcessLogix software

Localization • The localization of an existing system is lost during an

Save Controller Data • This updates the database with current Controller data.

Back Up R300.0 Server Data

• Your existing R300.1 or 310.0 license will not work with R320.0.

• Be certain that you have the R320.0 license numbers on hand before starting the software installation.

upgrade.

• Before starting an upgrade, be certain that you have the localization toolkit in your language for R320.0.

• Remove the current localization update using the Control Panel Add/Remove Programs function.

• Select R200 Language Update to change the language for the Control Builder application back to the default of US English.

• This is recommended if you plan to make a backup of your current database.

• Refer to Saving Current Controller Data (optional) on page 1-3.

• This provides a path for recovering your current system as a standard precaution.

• Refer to Installing Service Pack 6a for Windows NT 4.0 on page 1-11.

Have at least 400MB of Free Disk Space

• This allows sufficient disk space to automatically backup selected system data during the installation process.

• Refer to Determining Your Hard Drive Free Space Requirements on page 1-4.

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System Software Upgrade Pr ocedures 1-3

Saving Current Controller Data (optional)

IMPORTANT

While not required, we suggest that you use this procedure to update the ERDB with the most current Controller data before the upgrade. This procedure assumes that the Control Builder (CB) application is running and communicating with 1757-P LX52 Controllers in your ProcessLogix system.

1. If Control Builder isn’t running, start it.

2. Close any open Control Module and/or Sequential Control

Module.

3. For a system with redundant ProcessLogix Servers, be certain that

the databases are synchronized. Refer to Synchronizing ERDB on Redundant Servers on page 1-63.

4. In Monitoring tab, click the plus s ign in the t ree root path t o the

CPM icon for the controller to display the CEE fo lder icon.

5. Click the CEE folder icon. Click Tools

and then click Continue to upload the existing controller database. This may take considerable time to complete, depending on the

amount of CM/SCMs (and their number of FBs and/or number of Steps/Transitions) currently assigned to this CEE.

If you have redundant Servers, you only need to perform this procedure on the SERVERB node.

⇒Upload with Contents

6. Click the CEE folder icon. Click Tools

Project) and then click Continue to save the existing controller database.

This may take considerable time to complete, depending on the amount of CM/SCMs (and their number of FBs and/or number of Steps/Transitions) currently assigned to this CEE.

7. Repeat Step 4 to Step 6 for each controller (CPM icon) in your

system.

8. In preparation for the software upgrade, inactivate the CMs, SCMs,

and IOMs, and put the CEE in its Idle mode.

9. Close Control Builder.

⇒Update with Contents (to

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1-4 System Software Upgrade Procedures

TIP

W e recommend that you make a backup copy of your erdb_a.mdb database after you save th e curr en t controller data. The default direct ory location for the erdb_a.mdb database is:

C:\Honeywell\TPS50\System\ER. W e recommend that you create a new folder in the C:

directory for this purpose and then rename the database after it is copied to the folder.

For example, you could name the folder erbackup and rename the file erdb_a_bu.mdb to readily identify this as the backup database copy.

Determining Your Hard Drive Free Space Requirements

A base requirement for ProcessLogix software releases is that they fit on older PCs having 4 GB hard drives. This means that the R320.0 rele ase needs to fit within a 4 GB partition, regardless of the overall size of the hard drive. For example, if your PC has an 8 GB hard drive partitioned into two 4 GB partitions, then all ProcessLogix applications and the entire operating system (the swap file, Service Pack 6a, etc.) will reside on the C: partition, while the other partition will be empty.

This means you must provide sufficient space on the C: partition before you begin an upgrade, or the upgrade will fail at several points due to insufficient disk space. The software installation routine requires additional disk space to automatically back up selected system data during the installation process.

ATTENTION

We recommend that you have free space equal to at least 1.5 times the size of your C:\Honeywel l directory and its subdirectories (minimum of 400 MB) before you begin an upg rade.

Use the following steps to compute the minimum free space requirements for your PC.

1. Open Windows NT Explorer.

2. Right-click the C:\Honeywell folder in the left pane and click

Properties. W ait until the Size number stops updating.

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System Software Upgrade Pr ocedures 1-5

3. Take this number and multiply it by 1.5 to find your free space

requirements. If the result is le ss than 400 MB, make the result 400 MB. Click Cance l to clos e th e H one y we l l Properties dialog box .

EXAMPLE

In the following example, the C:\Honeywell tree size is 458 MB. Multiplying 458 MB by 1.5 results in 687 MB. This means you would need at least 687 MB of free disk space before beginning your upgrade.

4. In Windows NT Explorer, right-click the (C:) drive icon in the left

pane and click properties. Check the free space size listed for the C drive in the open dialog box. Click Cancel to close the dialog box. If there is not enough free disk space, refer to the following paragraph for suggestions on how to increase it.

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1-6 System Software Upgrade Procedures

What should you do if you do not meet the recommended memory requirements:

If you do not me et the minimum free disk space requirement, you can try one or more of the follow ing actions to increase your free disk space:

• Compact the ERD B ( Use the Db Adm i n uti lit y :

⇒Programs⇒ProcessLogix Engineering Tools⇒

Start DBADMIN

• Remove old error logs in directory C:\ErrorHandling,

• Remove old backups you have of the ERDB.

• Remove the Service Pack Uninstall directory C:\WINNT\

$NtServicePackUninstall$.

• Move any of your application files not residing in the

C:\Honeywell tree to the oth er partition, if you have another partition.

⇒Tools⇒Compact Database.)

Backing Up a P r ocessLogix Server to Tape

Use the following procedure to back up your current ProcessLogix Server data to tape.

1. If the Server to be backed up is a member of a redundant Server

pair, synchronize the ER and Server databases.

a. Refer to Synchronizing ERDB on Redundant Servers on

page 1-63.

b. Refer to Synchronizing Server Databases on Redundant

Servers on page 1-71.

ATTENTION

2. Insert a tape into the PC’s tape drive.

Before continuing, you MUST exit all ProcessLogix applications and stop all ProcessLogix services.

Refer to Stopping ProcessLogix Applications and Services on page 1-8.

Publication 1757-IN032B-EN-P - April 2001

Wait for the tape to mount (stop making noise).

3. Click Start

⇒Run.

System Software Upgrade Pr ocedures 1-7

4. Key in this command in the Open entry field:

>cmd<

and click OK to open the DOS window.

5. At the DOS prompt, key in this command:

>fullbkup<

and press >Enter<

This initiates some file copying and then the backup dialog box appears. No further interaction is needed until the backup completes. This process may take considerable ti me to complete, depending on the Server.

TIP

For more information on backup procedures, refer to the Windows documentation and/or online help that accompanied your system.

TIP

You may see errors such as: “file xxx skipped”. These errors are normal and will not affect the validity of your backup tape.

6. When the backup completes, remove the backup tape from the tape

drive.

7. Exit the DOS window.

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1-8 System Software Upgrade Procedures

Stopping ProcessLogix Applications and Services

ATTENTION

Before installing or uninstalling any software component, you MUST exit all ProcessLogix applications and stop all ProcessLogix services.

IMPORTANT

Use the following procedure to exit all ProcessLogix applications and stop all ProcessLogix services.

1. Exit all running ProcessLogix applications, such as Control Builder,

Station, and Network Tools (NTOOLS).

2. Stop the following ProcessLogix services through the Services icon

in Control Panel. When finished, close the Services dialog box.

TIP

• ProcessLogix ER Replicator (redundant SERVERB node only)

• ProcessLogix ER Server

• ProcessLogix System Repository

• ProcessLogix Control Data Access Server

If you have redundant servers, you must complete this procedure on the SERVERB node first. Then complete the entire procedure again for the SERVERA node.

Some software services may interact. For example, stopping the ProcessLogix System Repository automatically stops the ProcessLogix Control Data Access Server, if it is running.

Observe the on-screen prompts for details.

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System Software Upgrade Pr ocedures 1-9

3. Click Start⇒Programs⇒ProcessLogix Server⇒Start-Stop

ProcessLogix Server to call up the ProcessLogix Server dialog box.

TIP

To display the “Full Mode” version of the ProcessLogix Server dialog box, click the icon on the left of the title bar and click Advanced

⇒Full Mode.

A checkmark will now appear in front of the Full Mode selection to show that it is active.

a. With the Full Mode version of the dial og box act ive, cl ick the

Database Unloaded option.

b. Click Yes to confirm the action and wait for the Server to

change its state.

c. Close the ProcessLogix Server dialog box.

4. Click Start

⇒Programs⇒Rockw e ll Software⇒RSLinx⇒RSLinx

Service Control Panel to call up the RSLinx Service Control dialog box.

a. Click Stop.

TIP

The ProcessLogix Control Data Acces s Server service must be stopped before you can stop RSLinx through its control panel.

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1-10 System Software Upgrade Procedures

b. Wait for the message RSLinx Service is not running to appear.

Close the dialog box.

5. Skip to Step 9 if NI-FBUS is not running. Otherwise, close the

NI-FBUS configurator.

6. Wait until the FCS shutdown window disappears before

proceeding.

7. Right-click the NI-FBUS 2.3 icon in the taskbar and select Open.

8. Close the NI-FBUS window and click Yes to confirm.

9. Right-click an open space in the taskbar and click Task Manager to

open the Windows NT Task Manager window.

10. Click the Processes tab, scroll through the list box and select any

process with the Image Name of EXCEL.EXE.

11. Click End Process.

12. Close Task Manager.

Stopping the 1784-PCIC(S) devices

After you have installed the 1784-PCIC card and installed the ProcessLogix R320.0 sof tware, use the foll owing procedure to st op the PCIC(S) devices.

13. Click Start

14. Double-click the Devices icon.

⇒Settings⇒Control Panel.

Publication 1757-IN032B-EN-P - April 2001

15. Select the A-B Virtual Backplane device driver.

16. Click Stop.

17. Click OK to also stop the A-B 1784-PCIC(S) device driver.

18. Close the Devices dialog box.

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