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.
Table of Contents
Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . ii
European Communities (EC) Directive Compliance . . . . . . . iii
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.
1Publication 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.
ComponentDescription
BaseDell OptiPlex GX200
Processor800Mhz,Pentium III, 133Mhz Front Side Bus
Integrated Functions4X AGP Video w/8MB of Memory
Audio, 512KB Cache 10/100 NIC
MouseMicrosoft Intellimouse
KeyboardQuietkey Spacesaver 104-Key, US
System RAM256MB, ECC PC700, 1 RIMM
CD-ROM40X SCSI
Floppy Drive1.44MB, 3.5"
SCSI ControllerAdaptec 29160N Controller
Hard Drive9.1GB Minimum U2W, 10,000 RPM, SCSI
GX1/M, w/T erm inated Cabl e
Tape Drive10/20 G, SCSI, TR-5, Tape Backup Unit
NetworkIntegrated 3COM
3C90SC with 1 RJ45 connector
I/O Expansion5 PCI, 2 ISA/PCI shared slots
SoftwareMicrosoft Windows NT4.0 (Service Pack 6a), NTFS
All hardware component drivers
Publication 1757-IN032B-EN-P - April 2001
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-clickClick left mouse button twice in
dragPress and hold left mouse button
right-clickClick right mouse button once.
selectclick to highlight a menu item or
<F1>Keys to be pressed are shown in
MeaningExample
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<.
Publication 1757-IN032B-EN-P - April 2001
Preface 5
Related Documents
The following is a list of the printed documents that ship with a
ProcessLogix system. These documents complement the Knowledge Builder online user documentation and are listed in the suggested reading
order.
ProcessLogix R320.0 Installation and Upgrade Guide
The ProcessLogix R320.0 Installation and Upgrade Guide provides:
• procedures for upgrading a system to R320.0
• procedures for updating the firmware to R320.0 levels
• procedures for installing the software on a clean personal
computer
• procedures for tasks associated with migrating to redundant
Server and/or redundant Controller architecture.
The following items used to be included in the SCN Software Change
Notice in previous releases:
• descriptions of new features and functions
• descriptions of performance and capacity specifications
• listings of major ProcessLogix software components
Publication 1757-IN032B-EN-P - April 2001
Preface 6
ProcessLogix Online User Documentation/Knowledge Builder
ProcessLogix online user documen tati on is included with yo ur
ProcessLogix system in browser format through the Knowledge Builder. The same documents may also be ordered individually
through Rockwell Automation in print format.
Knowledge Builder provides the user with task-based documentation
within the Server and Client stations and may be accessed while using
any of ProcessLogix’s software programs. Knowledge Builder’s internal
links and search functions allow the user to quickly access process
relevant information and references.
References to Knowledge Builder throughout this document are
illustrated as:
Navigate in Knowledge Builder to Ethernet Implementation
⇒Configuration⇒Setting Up Drivers and IP Addresses for more
Guide
information.
Contents of Release
The following software and documentation components are included
in the ProcessLogix R320.0 Software/documentation kit
(1757-SWKIT3200).
Release Component sCatalog and part numbers
ProcessLogix CD
ProcessLogix Engineering Tools
ProcessLogix Server Software
RSLinx 2.2
ProcessLogix Knowledge Builder CD1757-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
CB
— Control Builder
CCL — Control Component Library
CD
— 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
MB
— 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
PC
— Personal Computer
1784-PCIC or PCIC
1757-PIM
— Pulse Input Module
— PCI ControlNet Interface Module
Preface 7
DNS
— Domain Name System
DO
— Digital Output
DOS
— Disk Operating System
ER
— Engineering Repository
ERDB
— Engineering Repository Database
FB
— 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
Publication 1757-IN032B-EN-P - April 2001
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.
1
• 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.
!
1Publication 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.
Publication 1757-IN032B-EN-P - April 2001
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
Publication 1757-IN032B-EN-P - April 2001
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.
Publication 1757-IN032B-EN-P - April 2001
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.
Publication 1757-IN032B-EN-P - April 2001
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.
Publication 1757-IN032B-EN-P - April 2001
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.
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.
Publication 1757-IN032B-EN-P - April 2001
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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