Rockwell Automation 1757-SWKIT4000 User Manual

ProcessLogix R400.0 Installation and Upgrade Guide
1757-SWKIT4000
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 these products must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. In no event will Allen-Bradley be responsible or liable for indirect or consequential damage resulting from the use or application of these products.
Any illustrations, charts, sample programs, and layout examples shown in this publication 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 liability (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 publication, notes may be used to make you aware of safety considerations. The following annotations and their accompanying statements help you to identify a potential hazard, avoid a potential hazard, and recognize the consequences of a potential hazard:
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.
!
IMPORTANT
Allen-Bradley is a trademark of Rockwell Automation
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Support

Before you contact Rockwell Automation for technical assistance, we suggest you please review the t roubles hooting inf ormation contained in this publication first.
If the problem persists, call your local Rockwell Automation representative or contact Rockwell Automation in one of the following ways:
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Your Questions or Comments on this Manual

If you find a problem with this manual, please notify us of it on the enclosed How Are We Doing form.

Table of Contents

Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . 3
Your Questions or Comments on this Manual . . . . . . . . . . 3
Preface
ProcessLogix R400.0 Installation Introduction
Our Assumptions About Readers . . . . . . . . . . . . . . . . . . . . P-1
Starting Conditions and Assumptions . . . . . . . . . . . . . . P-1
Minimum Hardware Requirements. . . . . . . . . . . . . . . . . . . P-3
Rockwell Automation Technical Support . . . . . . . . . . . . . . P-4
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-4
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-4
Your Questions or Comments about This Manual . . . . . P-4
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5
Terms and Type Representations . . . . . . . . . . . . . . . . . P-5
Contents of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
ProcessLogix Online User Documentation/Knowledge
Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
ProcessLogix R400.0 Installation and Upgrade Guide. . . P-7
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . P-8
Chapter 1
Operating System Support. . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ProcessLogix Component Configuration Table. . . . . . . . 1-1
Operating System Options. . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ProcessLogix Server Supported Installations . . . . . . . . . . . . 1-1
Clean Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Upgrade from ProcessLogix R320.0 Server
Currently Running Windows NT 4.0 Workstation. . . 1-2
Re-Deployment Options. . . . . . . . . . . . . . . . . . . . . . . . 1-2
ProcessLogix Client Supported Installations . . . . . . . . . . . . 1-3
Clean Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Upgrade: Currently Running Windows NT 4.0 Workstation
with ProcessLogix Client Software . . . . . . . . . . . . . . . . 1-3
i Publication 1757-IN040B-EN-P - March 2002
Table of Contents ii
Operating System Installation Procedures
Chapter 2
Clean System Windows 2000 Server Installation . . . . . . . . . 2-1
Installing Windows 2000 Server on a New System. . . . . 2-1
Starting the Windows 2000 Server Installation . . . . . . . . 2-2
Starting the Installation from the Boot Floppies. . . . . . . 2-4
Starting the Installation from the CD-ROM. . . . . . . . . . . 2-4
Completing the Windows 2000 Server Installation . . . . . 2-5
Clean System Windows 2000 Professional Installation. . . . . 2-10
Starting the Windows 2000 Professional Installation. . . . 2-10
Creating Boot Floppies. . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Starting the Installation from the Boot Floppies. . . . . . . 2-12
Starting the Installation from the CD-ROM. . . . . . . . . . . 2-12
Completing the Windows 2000 Professional Installation. 2-13
Installing Service Pack 2 for Windows 2000 . . . . . . . . 2-17
Checking for Windows 2000 Service Pack 2 . . . . . . . . . 2-17
Installing Windows 2000 Service Pack 2 . . . . . . . . . . . . 2-18
Installing Internet Explorer 5.5 SP1 . . . . . . . . . . . . . . . . . . 2-19
Checking the Internet Explorer Version. . . . . . . . . . . . . 2-19
Upgrading Internet Explorer 5.5 SP1. . . . . . . . . . . . . . . 2-20
Installing Adobe Acrobat Reader 4.05. . . . . . . . . . . . . . . . . 2-22
Additional Operating System Customization Procedures . . . 2-22
Adjusting the Video Settings. . . . . . . . . . . . . . . . . . . . . 2-23
Setting Up Additional Drivers . . . . . . . . . . . . . . . . . . . . 2-24
Third Party Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Other Required System Settings . . . . . . . . . . . . . . . . . . 2-24
Creating an Emergency Repair Disk. . . . . . . . . . . . . . . . . . 2-25
Creating the ProcessLogix User Accounts . . . . . . . . . . . . . . 2-26
Creating the ps_user and erserver accounts. . . . . . . . . . 2-26
Logging on with the ps_user account . . . . . . . . . . . . . . 2-27
Clean System Windows NT 4.0 Workstation Installation . . . 2-28
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Starting the Windows NT Installation . . . . . . . . . . . . . . 2-29
Setting Up Windows NT. . . . . . . . . . . . . . . . . . . . . . . . 2-30
Installing TCP/IP Networking Software . . . . . . . . . . . . . 2-31
Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . 2-34
Setting Up the Display Driver. . . . . . . . . . . . . . . . . . . . 2-35
Completing Installation . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Installing Service Pack 6a for Windows NT 4.0 . . . . . . . 2-35
Setting Up Additional Drivers after the
Service Pack Installation . . . . . . . . . . . . . . . . . . . . . 2-37
Configuring System Properties . . . . . . . . . . . . . . . . . . . 2-38
Converting to NTFS after Installing Windows NT. . . . . . 2-39
Creating the ps_user Account. . . . . . . . . . . . . . . . . . . . 2-39
Installing Internet Explorer 5.5 SP 1 . . . . . . . . . . . . . . . 2-39
Checking Required System Settings . . . . . . . . . . . . . . . . . . 2-40
Creating an Emergency Repair Disk. . . . . . . . . . . . . . . . . . 2-41
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ProcessLogix Server Installation Procedures
Table of Contents iii
Chapter 3
Installing ProcessLogix Software on a Clean PC . . . . . . . . . 3-1
Installing Server Software. . . . . . . . . . . . . . . . . . . . . . . 3-2
Installing SQL Server . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing Knowledge Builder . . . . . . . . . . . . . . . . . . . . 3-4
Installing RSLinx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing Engineering Tools . . . . . . . . . . . . . . . . . . . . . 3-5
Installing PsAxCtl Document EXE . . . . . . . . . . . . . . . . . 3-6
Installing the ProcessLogix Server. . . . . . . . . . . . . . . . . 3-6
Adding PCIC Hardware Device Drivers . . . . . . . . . . . . . . . 3-10
Moving the RSLinx Activation File . . . . . . . . . . . . . . . . . . . 3-10
About the Activation File . . . . . . . . . . . . . . . . . . . . . . . 3-10
Determining the Current RSLinx Version. . . . . . . . . . . . 3-11
Installing the Activation File . . . . . . . . . . . . . . . . . . . . . 3-12
Configuring RSLinx Drivers for
ControlNet Supervisory Network . . . . . . . . . . . . . . . . 3-13
Updating the 1784-PCIC Firmware . . . . . . . . . . . . . . . . 3-15
Configuring RSLinx Drivers for
Ethernet Supervisory Network . . . . . . . . . . . . . . . . . . 3-18
Completing the ProcessLogix R400.0
Install on a Redundant Server Pair . . . . . . . . . . . . . . . 3-19
Completing the ProcessLogix R400.0
Install on a Non-Redundant Server. . . . . . . . . . . . . . . 3-20
Upgrading Hardware Component Firmware . . . . . . . . . 3-20
Checking Control Builder Operation and Logging On . . 3-20 Backing Up a ProcessLogix Server Hard Drive to Tape . 3-20
Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 3-21
ProcessLogix Server Upgrade Procedures
Chapter 4
Preparing for a ProcessLogix Software Upgrade . . . . . . . . . 4-1
Things to consider before upgrading . . . . . . . . . . . . . . 4-1
Networking the R320.0 and R400.0 Servers . . . . . . . . . . 4-1
Upgrade Procedures for ProcessLogix R320.0 Servers . . . . . 4-3
Backing Up a ProcessLogix R320.0 Server to Tape. . . . . 4-3
Exporting the Engineering Repository Database . . . . . . 4-4
Saving Important Data . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Exporting the ProcessLogix Server Database . . . . . . . . . 4-6
Removing the RSLinx Software Activation File. . . . . . . . 4-7
Restoring the Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Restoring other ProcessLogix Data . . . . . . . . . . . . . . . . 4-8
Restarting SERVERB and synchronizing. . . . . . . . . . . . . 4-8
Synchronizing Server Databases on Redundant Servers . 4-9
Importing the ProcessLogix Server Points Database. . . . 4-10
Importing the Engineering Database. . . . . . . . . . . . . . . 4-11
Upgrading Hardware Component Firmware . . . . . . . . . 4-12
Backing Up a ProcessLogix Server Hard Drive to Tape . 4-13
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Table of Contents iv
ProcessLogix Client Installation and Upgrade Procedures
Chapter 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Operating System Support. . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Windows 2000 Professional . . . . . . . . . . . . . . . . . . . . . 5-2
Windows NT 4.0 Workstation. . . . . . . . . . . . . . . . . . . . 5-3
Pre-work for systems with ProcessLogix R320.0 . . . . . . . . . 5-5
Saving Important Data . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Removing Selected Components. . . . . . . . . . . . . . . . . . 5-7
Cleaning Up the Registry . . . . . . . . . . . . . . . . . . . . . . . 5-9
Upgrading the Windows NT 4.0 Workstation
Operating System to Windows 2000 Professional . . . . . 5-10
Installing Windows 2000 Service Pack 2 . . . . . . . . . . . . 5-12
Installing Internet Explorer 5.5 SP1. . . . . . . . . . . . . . . . 5-12
Installing ProcessLogix R400.0 Client Software. . . . . . . . 5-12
Updating the Windows NT 4.0 Workstation Operating System for R400.0 Software 5-12
Checking for Windows NT 4.0 Service Pack 6a . . . . . . . 5-13
Installing Service Pack 6a for Windows NT 4.0 . . . . . . . 5-13
Installing MDAC 2.5 Service Pack 1. . . . . . . . . . . . . . . . 5-14
Recording the NT System Path Value . . . . . . . . . . . . . . 5-15
Installing Windows Installer . . . . . . . . . . . . . . . . . . . . . 5-15
Verifying the NT System Path Value . . . . . . . . . . . . . . . 5-15
Installing Internet Explorer 5.5 SP1. . . . . . . . . . . . . . . . 5-16
Updating the ActiveX Support Files. . . . . . . . . . . . . . . . 5-17
Replacing MFC42.dll . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Installing ProcessLogix R400.0 Client Software. . . . . . . . 5-17
Installing ProcessLogix R400.0 Client Software . . . . . . . . . . 5-18
Installing Knowledge Builder . . . . . . . . . . . . . . . . . . . . 5-19
Installing the ProcessLogix Client Software . . . . . . . . . . 5-20
Verifying ProcessLogix Client Installation . . . . . . . . . . . . . . 5-23
Restoring the Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Setting Up a Station With a Non-redundant Server. . . . . 5-24
Setting Up a Station With a Redundant Server Pair. . . . . 5-25
Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 5-27
Checking Control Builder Operation and Logging On
(Engineering Workstation Only) . . . . . . . . . . . . . . . 5-28
Generic Comm Layer Settings
(Engineering Workstation Only) . . . . . . . . . . . . . . . 5-28
Publication 1757-IN040B-EN-P - March 2002
Additional Redundant Server Procedures
Table of Contents v
Chapter 6
Adding Redundancy to R400.0
Non-Redundant Server Systems . . . . . . . . . . . . . . . . . 6-1
Changing the Computer Name on a ProcessLogix Server 6-1
Completing the ProcessLogix R400.0
Setup on a Redundant Server Pair . . . . . . . . . . . . . . . 6-1
Changing Hosts File Entries . . . . . . . . . . . . . . . . . . . . . 6-1
Changing TCP/IP address on a Secondary Server
(SERVERB) Node . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Changing the ProcessLogix License. . . . . . . . . . . . . . . . 6-4
Setting up Primary Server (SERVERA) node 6-6
Making Redundant Hardware File Entries . . . . . . . . . . . 6-6
Configuring the Time Service . . . . . . . . . . . . . . . . . . . . 6-8
Setting Up Secondary Server (SERVERB) Node . . . . . . . . . . 6-10
Making Redundant Hardware File Entries . . . . . . . . . . . 6-10
Configuring the Time Service . . . . . . . . . . . . . . . . . . . . 6-10
Confirming Data Link is Available. . . . . . . . . . . . . . . . . 6-10
Configuring Stations in Quick Builder (on SERVERA) . . . . . 6-11
Synchronizing Server Databases on Redundant Server . . 6-13
Confirming Databases are Synchronized . . . . . . . . . . . . 6-13
Setting up the Redundant ERDB . . . . . . . . . . . . . . . . . . 6-15
Setting Up Station on SERVERB . . . . . . . . . . . . . . . . . . . . . 6-16
Setting Up Station on SERVERA . . . . . . . . . . . . . . . . . . . . . 6-18
Restarting Redundant Servers. . . . . . . . . . . . . . . . . . . . . . . 6-21
Synchronizing Other Files . . . . . . . . . . . . . . . . . . . . . . 6-22
Upgrading Hardware Component Firmware . . . . . . . . . . . . 6-22
Checking Control Builder Operation and Logging On . . 6-23 Backing Up a ProcessLogix Server Hard Drive to Tape . 6-23
Creating an Emergency Repair Disk . . . . . . . . . . . . . . . 6-23
Firmware Maintenance Procedures
Chapter 7
1784-PCIC Driver and Firmware Installation . . . . . . . . . . . . 7-1
Install Hardware Device Drivers . . . . . . . . . . . . . . . . . . 7-1
Verify the 1784-PCIC Driver Version . . . . . . . . . . . . . . . 7-2
Updating the 1784-PCIC Firmware . . . . . . . . . . . . . . . . 7-2
Upgrading Hardware Component Firmware . . . . . . . . . . . . 7-4
About Firmware Upgrades . . . . . . . . . . . . . . . . . . . . . . 7-4
Firmware Revision Level Reference. . . . . . . . . . . . . . . . 7-5
Important Usage Considerations . . . . . . . . . . . . . . . . . . 7-7
Loading 1757-PLX52, TC-MUX021, or 1757-FIM Boot
and Personality Images. . . . . . . . . . . . . . . . . . . . . . 7-9
Updating Firmware in CNB, ENET, IOM, SRM, PIM
or ControlNet Adapter . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Setting CNB Module NUT Timing . . . . . . . . . . . . . . . . . 7-14
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Table of Contents vi
Supplementary Procedures
Chapter 8
Stopping ProcessLogix Applications and Services . . . . . . . . 8-1
Stopping the ProcessLogix Server . . . . . . . . . . . . . . . . . 8-2
Shut Down SQL Server Services . . . . . . . . . . . . . . . . . . 8-2
Stop RSLinx Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Stopping NI-FBUS and Excel . . . . . . . . . . . . . . . . . . . . 8-4
Launching ProcessLogix Knowledge Builder. . . . . . . . . . . . 8-4
SQL Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
SQL Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Cancelling a Software Component Installation . . . . . . . . . . 8-5
Replacing and Repairing Removing ProcessLogix Software
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SQL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
RSLinx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Manual System Backup/Restore Procedures . . . . . . . . . . . . 8-7
Backing Up a ProcessLogix R400.0 Server to Tape. . . . . 8-7
Restoring a ProcessLogix Server System
From a Backup Tape . . . . . . . . . . . . . . . . . . . . . . . 8-7
Using Network Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
About Network Tools. . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Usage guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Online help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Making First Time Network Tools Settings. . . . . . . . . . . 8-9
Installing and Running VirusScan with ProcessLogix. . . . . . 8-14
About VirusScan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Removing Existing VirusScan NT Program. . . . . . . . . . . 8-14
Installing VirusScan NT and Configuring Directories
for Scan Exclusion . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Changing the Computer Name on a ProcessLogix Server . . 8-16
Saving Important Data . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Shut Down ProcessLogix Server . . . . . . . . . . . . . . . . . . 8-18
Shut Down SQL Server Services . . . . . . . . . . . . . . . . . . 8-18
Removal of Selected Components. . . . . . . . . . . . . . . . . 8-19
Changing the PC Name . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Reinstalling Components . . . . . . . . . . . . . . . . . . . . . . . 8-23
Restoring the Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Changing the Computer Name on a ProcessLogix Client. . . 8-27
Changing the Computer Name on a
Windows NT 4.0 Client. . . . . . . . . . . . . . . . . . . . . . 8-27
Changing the Computer Name on a
Windows 2000 Client . . . . . . . . . . . . . . . . . . . . . . . 8-27
Procedure for Configuring a ProcessLogix Client . . . . . . 8-28
Adding 1757-PLX52 Controller Redundancy to R400.0
Non-Redundant 1757-PLX52 Controller Configurations . . . . 8-28
Deleting a Non-Redundant 1757-PLX52 and
Unassigning its Contents . . . . . . . . . . . . . . . . . . . . 8-29
Publication 1757-IN040B-EN-P - March 2002
PC Performance for Proc es s Logix Systems
Table of Contents vii
Installing and connecting Redundant
Chassis Pair (RCP) Hardware . . . . . . . . . . . . . . . . . 8-30
Updating Firmware Revision Levels . . . . . . . . . . . . . . . 8-31
Creating a Redundant 1757-PLX52 . . . . . . . . . . . . . . . . 8-31
Installing Knowledge Builder on a
Non-ProcessLogix System . . . . . . . . . . . . . . . . . . . . . 8-32
Removing Knowledge Builder . . . . . . . . . . . . . . . . . . . 8-32
Installing Service Pack 2 for Windows 2000. . . . . . . . . . 8-33
Installing Internet Explorer 5.5 SP1. . . . . . . . . . . . . . . . 8-33
Installing MDAC2.5 SP1 . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Installing Knowledge Builder . . . . . . . . . . . . . . . . . . . . 8-34
Chapter 9
ProcessLogix Performance Features . . . . . . . . . . . . . . . . . . 9-3
PC Qualification/Installation Services . . . . . . . . . . . . . . 9-3
Redundant Networking . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Server Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Multi-User/Location Control Builder . . . . . . . . . . . . . . . 9-5
Multiple Clients/Stations. . . . . . . . . . . . . . . . . . . . . . . . 9-5
Integrated Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Operating System Tuning . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Service/Kernel Tuning . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Disk Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
File System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
File System Defragmentation . . . . . . . . . . . . . . . . . . . . 9-10
Defragmenting the Disk . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Memory and Swapfile . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Client/Station Memory Settings . . . . . . . . . . . . . . . . . . . 9-13
Servers with 128 MB of Physical RAM or Less.. . . . . . . . 9-13
Servers with 256 MB of Physical RAM or More. . . . . . . . 9-13
Adjusting Swapfile Size on Windows 2000 . . . . . . . . . . 9-14
Network Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Management of Traffic . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Benefits from other Network Services . . . . . . . . . . . . . . 9-17
System Usage 9-17
Topology Related Settings . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Physical Location of the Systems. . . . . . . . . . . . . . . . . . 9-18
Physical location of the Components . . . . . . . . . . . . . . 9-19
Service Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Network Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
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Table of Contents viii
New Functions and Features
Chapter 10
Enhanced Foundation Fieldbus Support. . . . . . . . . . . . . . . 10-1
Profibus DP Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
SST-PFBCLX PROFIBUS Interface Module . . . . . . . . . . . 10-2
SST-PFBCLX Module Characteristics . . . . . . . . . . . . . . . 10-2
Functional Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
SST-PFBCLX / PROFIBUS Network Configuration . . . . . 10-4
ProcessLogix Block Architecture. . . . . . . . . . . . . . . . . . 10-4
Limitations and Exclusions . . . . . . . . . . . . . . . . . . . . . . 10-5
Control Builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Match Dialog Support UCD Tab . . . . . . . . . . . . . . . . . . 10-5
CM Chart Visualization. . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Delta Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Naming Convention Change. . . . . . . . . . . . . . . . . . . . . 10-6
CEE Function Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Four New Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
PUSH Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Engineering Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Displaying Infinity and Handling for Online Changes . 10-11
Block Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Update to Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Refresh Template Capability for FLM. . . . . . . . . . . . . . 10-11
Windows 2000 Platform and Tools. . . . . . . . . . . . . . . . . . 10-11
Series C and D CNBs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Server 10-12
Updated Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
HMIWeb Runtime Browser. . . . . . . . . . . . . . . . . . . . . 10-14
HMIWeb Display Builder . . . . . . . . . . . . . . . . . . . . . . 10-15
Updated Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Server Scripting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Updated Display Builder . . . . . . . . . . . . . . . . . . . . . . 10-17
Updated Quick Builder . . . . . . . . . . . . . . . . . . . . . . . 10-17
Updated OPC Support . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Enhanced Area Assignment Support . . . . . . . . . . . . . . 10-18
Updated Alarm Pager Support . . . . . . . . . . . . . . . . . . 10-19
History Archiving Manager. . . . . . . . . . . . . . . . . . . . . 10-19
Updated Universal Modbus Support . . . . . . . . . . . . . . 10-19
Modbus TCP Support. . . . . . . . . . . . . . . . . . . . . . . . . 10-19
User Defined Data Formats . . . . . . . . . . . . . . . . . . . . 10-20
Application Development. . . . . . . . . . . . . . . . . . . . . . 10-20
Diagnostic Improvements. . . . . . . . . . . . . . . . . . . . . . 10-21
Updated Alarming Support. . . . . . . . . . . . . . . . . . . . . 10-21
Windows 2000 Support . . . . . . . . . . . . . . . . . . . . . . . 10-21
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
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Performance and Capacity Specifications
Table of Contents ix
Chapter 11
PC Platform Requirements. . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Summary of R400.0 Enhancements to ProcessLogix System
Capacity & Performance. . . . . . . . . . . . . . . . . . . . . . . . 11-2
Server Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Platform System Configuration Definitions . . . . . . . . . . 11-3
Station/Engineering Client Requirements. . . . . . . . . . . . 11-5
ProcessLogix Server Platform Requirements. . . . . . . . . . 11-6
Application Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
User Interface Capacity and Performance. . . . . . . . . . . . . . 11-9
Control Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Server Redundancy 11-11 Server Notifications 11-11
Communications Capacity and Performance. . . . . . . . . . . 11-12
System Communications Load Philosophy
and Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
System Communications Limits. . . . . . . . . . . . . . . . . . 11-15
Controller Communications . . . . . . . . . . . . . . . . . . . . 11-16
Client/Server Communication Capacity . . . . . . . . . . . . 11-18
Controller Notifications . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
Controller Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
I/O Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
PROFIBUS DP Topology Specifications. . . . . . . . . . . . 11-21
ProcessLogix/PROFIBUS Interface
Topology Specifications . . . . . . . . . . . . . . . . . . . . 11-21
FIM Performance Limits. . . . . . . . . . . . . . . . . . . . . . . . . . 11-23
I/O Module Sample Periods . . . . . . . . . . . . . . . . . . . . 11-25
I/O Network Configuration Rules . . . . . . . . . . . . . . . 11-25
1757-PLX52 Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
Major ProcessLogix Software Components
Chapter 12
Major ProcessLogix FTW Software Revisions . . . . . . . . . 12-1
Major ProcessLogix Server Software Revisions. . . . . . . . 12-2
Embedded Software Components. . . . . . . . . . . . . . . . . 12-3
External, Third Party Qualified Software Components . . 12-5
Miscellaneous SCADA Component Revisions. . . . . . . . . 12-7
Controller, Communication & I/O Firmware . . . . . . . . . 12-7
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Table of Contents x
Publication 1757-IN040B-EN-P - March 2002

Preface

Our Assumptions About Readers

Before configuring a ProcessLogix R400.0 systrem you MUST:
Be familar with navigating and running applications in a
Microsoft Windows NT/2000 environm ent.
Have some experience in loading software applications on a
personnal computer (PC).
Be familar with ProcessLogix hardware components.
Be familar with ControlNet configuration.
Be trained on ProcessLogix R400.0, including Control Buil der
and Server components.
If applicable to your system, you must also have appropriate
training on other Rockwell Automation products such as
ControlLogix and RSNetworks.
ATTENTION
!
If you have not received ProcessLogix R400.0 training 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.
Contact your local sales offfice for more information about training schedules and available trained personnel.

Starting Conditions and Assumptions

You have the following items on hand:
ProcessLogix R400.0 Software Change Note is incorporated into
this Installation and Upgrade Guide: Chapter 10, New Functions
and Features and Chapter 11, Performance and Capacity
Specifications.
ProcessLogix R400.0 System Software CD 1 containing process
software such as SQL.
ProcessLogix R400.0 Syst em Software CD 2 containing
ProcessLogix applications software.
Proc essLogix R400.0 Knowledge Build er CD containing the latest
version of the online documentation.
1 Publication 1757-IN040B- EN-P - March 2002
Preface 2
Windows 2000 Server CD (Microsoft CD, including boot
diskettes).
RSLinx OEM Master (Activation) Disk.
The Factory CD containing default system drivers for backup
purposes only. Please contact Rockwell Automation Technical
Support before using this CD. This CD is only supplied with new
ProcessLogix R400.0 servers.
You must be certain that your PC meets the minimum hardware requirements for a ProcessLogix Server or ProcessLogix Client.
ProcessLogix Servers require a Windows 2000 Server operating
system. See Table 11.C on page 11-6 to review the minimum
platform requirements for the ProcessLogix Serve r.
ProcessLogix Client Stations require either a Windows 2000 or
Windows NT 4.0 operating sys tem. See T ab le 11.B on page 11-5
to review the minimum platform requirements for a
ProcessLogix Client.
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Preface 3

Minimum Hardware Requirements

ProcessLogix R400.0 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.
Refer to Table P.1: Supported Hardware for ProcessLogix R400.0 on page P-3 to review the hardware requirements for a new R400.0 ProcessLogix Server. See Table 11.B on page 11-5 and Table 11.C on page 11-6. for minimum hardware requirements for upgrading an existing system to R400.0.
Only the hardware listed in
Table P.1 below is supported for ProcessLogix R400.0 Servers. Upgrading from R320.0 requires new hardware.
Table P.1: Supported Hardware for ProcessLogix R400.0
Component Description
Base Dell PowerEdge 1400 Processor 1 GHz/133 256K Cache, Pentium III Mouse Logitec System Mouse Keyboard Quietkey 104-Key, 6 Pin System RAM 384MB, DIMM, 133MHz 16x72, 168 CD-ROM 20/48X Black, Compact Disk Drive, IDE Floppy Drive 1.44MB, F3, NEC P 1400 Hard Drive 18GB 10K, 68P Tape Drive 20/40G, Tape Backup Unit, Power Vault 100T, DD54 Network Intel Pro 100 Plus, NIC I/O Expansion 6 PCI Operating System Microsoft Windows 2000 Server, 5 Client Access Licenses, NTFS,
All hardware component drivers
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Preface 4

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 Prod uct Support

Contact your loca l Ro ckwell Automation r e pr e s en ta t iv e 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 Automation 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 and open to
http://www.ab.com/mem/technotes/techmain.html http://support. automation.rockwell.com

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 How Are We Doing Form, at the back of this manual. This form is also available in Knowledge Builder.
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, Inc. Automation Control and Information Group Technical Communication 1 Allen-Bradley Drive Mayfield Heights, OH 44124-6118
Publication 1757-IN040B-EN-P - March 2002
Preface 5

Conventions

Terms 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 FileNew to start new drawing.
Key in this path location >D:\setup.exe<.
Publication 1757-IN040B-EN-P - March 2002
Preface 6

Contents of Release

The following software and documentation components are included in the ProcessLogix R400.0 Software/documentation kit (1757-SWKIT4000).
Release Component s Catalog and part numbers
ProcessLogix R400.0 CD 1 and CD 2
ProcessLogix Engineering Tools ProcessLogix Server Software RSLinx 2.3
ProcessLogix Knowledge Builder CD 1757-SWKIT4000
ProcessLogix R400.0 Documentation Set Including:
The ProcessLogix R400.0 Installation and Upgrade Guide
1757-SWKIT4000 CD 1 957555-50
CD 2 95760375
957555-41 957555-51
1757-IN040B-EN-P 957678-48

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. Most of the documents may also b e ordered individually through Rockwell Automation in print format, visit us at: www.theautomationbookstore.com
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 access process relevant information and references.
References to Knowledge Builder throughout this document are illustrated as:
Navigate in Knowledge Builder to Ethernet Implementation
ConfigurationSetting Up Drivers and IP Addresses for
Guide
more information.
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Preface 7

ProcessLogix R400.0 Installation and Upgrade Guide

The ProcessLogix R400.0 Installation and Upgrade Guide is shipped with a ProcessLogix system and provides:
procedures for upgrading an R320.0 system to R400.0
procedures for updating the firmware to R400.0 levels
procedures for installing the software on a clean PC
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 but are now provided in this guide:
descriptions of new features and functions
descriptions of performance and capacity specifications
listings of major ProcessLogix software components
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Preface 8

Acronyms and Abbreviations

AI AO
Analog Output
CB
Control Builder
CCL — Control Component Library
CD
Compact Disc
CDA CD-ROM CEE
Control Execution Environment
CM
Control Module
1756-CNB or CNB CPM CPU DI
Digital Input
Analog Input
Control Data Access
Compact Disc Read Only Memory
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
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 VGA WINS
Serial Interface Module
Transmission Control Protocol/Internet Protocol
Video Graphics Array
Windows Internet Name Service
System Redundancy Module
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Chapter
1
ProcessLogix R400.0 Installation Introduction

Operating System Support

Operating System Options

ProcessLogix Component Configuration Table

The following table shows the supported operating systems for ProcessLogix.
Table 1.A ProcessLogix Component Configuration Ta ble
ProcessLogix NT 4.0 Windows 2000
Workstation Server Professional Server
Server Client
The hardware platform and all devices contained within it designated for running the ProcessLogix R400.0 Software should be evaluated for compatibility with the Window s 2000 operating system.
Systems designated to run Pro cessLogix R400.0 Server software shou ld be Server Class and certified to run the Windows 2000 Serve r Operating System.
✔✔✔✔
Systems designated to run Pro cessLogix R400.0 Clien t Software should be W orkstation/Desktop Class and certified to run the Windows NT4.0 Workstation or Windows 2000 Professional Operating System.
To check to see which certifications your computer and hardware components have, consult the Microsoft Hardware Compatibility List
http://www.microsoft.com/windows2000/upgrade/compat/default.asp
at:
Review the scenarios below for your curren t operating system installation and upgrade options.

ProcessLogix Server Supported Installations

IMPORTANT
1 Publication 1757-IN040B-EN-P - March 2002
A PCIC card must already be installed in the ProcessLogix Server(s).
1-2 ProcessLogix R400.0 Installation Introduction
IMPORTANT
If you plan to use Microsoft Excel Data Exchange, Microsoft Excel 2000 must be installed before installing ProcessLogix.

Clean Install

The Clean Install is a clean machine installed with ProcessLogix R400.0 Server software. That is, the installation begins with formatting the hard disk and installing Windows 2000 Server. Refer to Installing ProcessLogix Software on a Clean PC on page 3-1.

Upgrade from ProcessLogix R320.0 Server Currently Running Windows NT 4.0 Workstation

ATTENTION
Upgrading to ProcessLogix R400.0 Server requires that the system be running Windows 2000 Server.
!
IMPORTANT
ProcessLogix R400.0 requires that you replace your current installation with new hardware and operating software for the Server.
After using the techniques outlined in Saving Important Data on page 4-5 to back up all data or trans fe r th e da ta to anothe r sy s tem , r efe r to Installing ProcessLogix Software on a Clean PC on page 3-1.

Re-Deployment Options

After using the techniques outlined in Saving Important Data on page 4-5 to back up all data or trans fe r th e da ta to anothe r sy s tem , the system can be setup to be used as an R400.0 Client. Follow the instructions in Installing ProcessLogix R400.0 Client Software on page 5-18.
You must upgrade to Rockwell Automation recommended hardware specifications to be eligible for Rockwell Automation Technical support. ProcessLogix R400.0 installations onto R320.0 hardware specifications is not supported.
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ProcessLogix R400.0 Insta llation Introduction 1-3

ProcessLogix Client Supported Installations

Clean Install

If you have a new client system, refer to ProcessLogix Client Installation and Upgrade Procedures on page 5-1.
A clean install is not required for upgrading R320.0 Client software to R400.0. If performing this option, backup all the data on the system, then follow the instructions in Saving Important Data on page 5-6.

Upgrade: Currently Running Windows NT 4.0 Workstation with ProcessLogix Clie nt Software

Upgrading the operating system is not required for ProcessLogix Client software. If your R320.0 system utilized the Windows NT 4.0 Workstation software on a certified system, you have the option of performing an operating system upgrade to Windows 2000 Professional. Refer to Upgrading the Windows NT 4.0 Workstation Operating System to Windows 2000 Professional on page 5-10.
After the operating system upgrade, it is required to upgrade the ProcessLogix Client software to the R400.0 Version.
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1-4 ProcessLogix R400.0 Installation Introduction
Publication 1757-IN040B-EN-P - March 2002
Chapter
2
Operating System Installation Procedures

Clean System Windows 2000 Server Installation

ATTENTION
!
IMPORTANT
These installation scenarios use a “clean” PC installation method in which all data on the system will be removed/erased. This is an irrecoverable action. All data must be first “backed up” or transferred to another system before proceeding.
R400.0 ProcessLogix Servers require the Windows 2000 Server operating system.
R400.0 ProcessLogix Client Stations may use Windows 2000 Professional, Windows 2000 Server, Windows NT 4.0 Workstation, or Windows NT 4.0 Server operating systems.
If you purchased a new ProcessLogix R400.0 Server from Rockwell Automation, the operating system has already been installed. Do not try to reinstall it.
Other Windows 2000 Installation Methods:
Unattended Installation
Remote Installation Services
Over the Network Installation
SysPrep
Systems Management Server
Consult the Microso f t Docu mentati on s et incl ud ed w ith t he Ope rating System for these methods.

Installing Windows 2000 Server on a New System

Y o u must install W indows 2000 Server on your s ystem bef ore you can install or run the ProcessLogix R400.0 software. The current required Operating System components are Windows 2 000 Server with Windows 2000 Service Pack 2 applied and Internet Explorer 5.5 Service Pack 1. The Windows 2000 Server software, Service Packs, and Internet Explorer are licensed products of Microsoft Co rporation.
1 Publication 1757-IN040B-EN-P - March 2002
2-2 Operating System Installation Procedures
Copies of the Service Packs and Internet Explorer are included on the ProcessLogix software CD for your convenience.
The following instructions guide you through the installation of Windows 2000 Server:

Starting the Windows 2000 Server Installation

Creating the Boot Floppies (i f necessary)
Perform the installation using one of the following methods:
Starting the installation from the Boot FloppiesStarting the installation from the CD-ROM
Starting the Windows 2000 Server Installation
This procedure assumes:
All network cards are installed in the PC and they are set to the
correct IRQs.
All supporting ProcessLogix system hardware is installed and
connected to the PC.
The PC meets specified hardware and software requirements.
Navigate in Knowledge Builder to Server and Client Installation
Hardware and Software Requirements for more
Guide
information.
All manufacturers related driver diskettes are available to
complete the installation.
If you received your PC from the manufacturer with Windows 2000 Server pre-installed, skip to Installing Service Pack 2 for Windows 2000 on page 2-17.
ATTENTION
Consult the PC Manufacturer for any specialized instructions/procedures related to the installation of the Microsoft Windows 2000 Server operating system.
Publication 1757-IN040B-EN-P - March 2002
!
This procedure lists only the generic installation procedure. It does not contain any special instructions for any manufacturer specific driver installation requirements.
Operating System Instal lation Procedures 2-3
Creating Boot Floppies
If your system does not support booting from a CD-ROM, follow these instructions to create the required Boot Floppies. Otherwise, skip to Starting the Installation from the CD-ROM on page 2-4.
IMPORTANT
You will need:
4 blank 3.5” 1.44 Mb (High Density) Floppy Disks
1.44 MB Floppy Drive
CD-ROM Drive
DOS or Windows based Operating System with access to
CD-ROM and floppy devices.
1. Insert the Windows 2000 Server CD into the CD-ROM drive.
2. Click Start
3. Key in this command in the Open entry field:
>cmd< and click OK to open the DOS window.
If your installation requires additional Drivers to be installed for access to the Hard Disk Controller , Disk Device, or CD-ROM, it may be necessary to start the installation via the Boot Floppies. (Even if your system supports booting off of a CD-R OM.).
Run.
4. At the DOS prompt, key in: >D:< and press Enter.
5. Key in this command:
>cd bootdisk< and press Enter.
6. Key in this command:
>makeboot< and press Enter.
7. Enter the letter of your floppy disk drive. >A<
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2-4 Operating System Installation Procedures
8. Follow the on-screen prompts for inserting, labeling, and
creating the four floppy disks.
IMPORTANT
9. When all the boot floppies have been made, shut down the PC.
Server Boot floppies and Professional Boot floppies are different.

Starting the Installation from the Boot Floppies

1. With the PCs’ power off, ins ert the dis ke tte tit led W indow s 2000
Setup Boot Disk into the floppy disk drive.
2. Turn on the PC.
3. Insert the Microsoft Windows 2000 Server CD into the CD-ROM
drive.
4. Follow the on-screen prompts to remove and insert the
Windows 2000 Se rver Setup Disk s 2, 3, and 4 when inst ructed to do so.
5. Continue with Completing the Windows 2000 Server Installation
on page 2-5.
Publication 1757-IN040B-EN-P - March 2002

Starting the Installation from the CD-ROM

1. Turn on the PC.
2. Insert the Microsoft Windows 2000 Server CD into the CD-ROM
drive.
3. When prompted, enter into the computer’s BIOS setup program.
4. Verify that the Boot Priority has the CD-ROM de vice listed first.
(Before the floppy or hard disk devices.)
5. Exit the BIOS and save the setting.
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