plcAndLcuSwappingOut
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1. PC TCP INSTALL ADDED LINE S END rem rem RECHNER CP581 rem set path C cp581 path set temp C dos set cp580 C cp581 cp580d msg mode com1 9600 n 8 1 p rem mode Iptl com1 rem CPHTB Treiber laden Ih cphtb ssnr24 resync rem CPHTB Treiber entfernen rem cphtb u rem CPMASS Treiber laden rem lh cpmass rem rem OPTION VIRTUELLES LAUFWERK E rem rem SSREMOTE installieren binaere Speicherung Ih sSremote e rem SSREMOTE installieren Formatierte Speicherung aller rem S5 Datenbausteine aller CPUs rem Ih sSremotf e F ALLFORM FMT rem SSREMOTE entfernen rem sSremote u rem Kommando Interpreter laden rem cpshell rem echo on C CD cd Iculab delay 10 inicom2 mainl goto ENDE ENDE Note June 5 2002 The size ofthe LCU labtest program mainl exe is 120 800 bytes The size ofthe LCU operational program also mainl exe is 131 974 bytes To file LCUSETUP From Jon Hagen Date 6 17 03 Subject Bios for CP581 Pentium silicon disk still w o files Reference Section 3 8 of Siemens Simatic CP581 User Manual MAIN F2 to enter setup System time System date Legacy Diskette A Legacy Diskette B gt Primary Master gt Primary Slave gt Keyboard Features Boot Sequence System Memory Extended memory Main Submenus Primary Master Mode Auto HH MM SS space bar increments key decrements MM DD YY 1 4MB 1 25MB 3 1 2 Disa2. arrow on the side of the module B Install the PLC on the platform 1 At the platform turn the system off and replace the the PLC with the spare The PLC or its left side in the case of the double wide PLC 1 goes into the second slot from the left side of the card cage 2 Power up the system 3 Perform an overall reset on the PLC to load the contents of the FLASH module into the RAM This is done as follows using the switches on the front of the PLC 4 Put the run stop switch in the STOP position 5 Hold the reset switch DOWN 6 Toggle the run stop switch twice i e from STOP to RUN to STOP to RUN to STOP 7 Hold the reset switch UP 8 Place the run stop switch in the RUN position 9 Place the reset switch in its center position The PLC should now be running but it needs to be synchronized with LCU A synchronous start must be done as follows 10 Power the system off 11 Power the system back on after about one minute things should be running normally 2 Procedure for Replacing the LCU in the Vertex Pointing System on the Platform A Test the Spare LCU in the digital lab Note first that the LCU is actually a package consisting from left to right of the CP581 computer the floppy hard disk drive unit the IRIG time card and the 3COM Ethernet card The spare LCU and spare PLC are normally kept in a test rack in the digital lab running synchronized lab test versions of their programs Turn on the monitor if not
3. connector During this time the Jump counter at the top of the screen will accumulate a few counts If you disconnect the IRIG cable the NoSig counter will become active ater a few seconds It will stop counting a few seconds after the cable has been replaced B Install the LCU on the platform 4 Take the prepared spare to the the platform Power the system down and replace the the LCU with the spare The left hand side of the LCU package goes into the seventh slot from the left of the card cage Getting the package to fully engage the backplane sockets is quite difficult the connectors have little self alignment ability You must feel the package push into place both top and bottom Try to get you hands into the card cage so that you can exert pressure with your thumbs at both the top and bottom of the package 5 Power the system up The LCU and PCU should boot up and synchronize without the need of any keyboard intervention leaving the system operating normally Check the LCU screen to see that the positions and time are displayed correctly 3 Procedure for Replacing the PLC in the test rack in the digital lab 1 Turn off the rack using the power switch on the outlet box under the keyboard 2 Install the lab test version FLASH memory module in the PLC which is to be the spare 3 Plug this PLC into the crate in the test rack The PLC or its left hand side in the case of the double wide PLC no 1 goes into the second slo
4. 60 IDPORT 0x150 rem SET PATH C PCTCP PATH rem C PCTCP PCTCPP INI is parameter file with platform ip address SET PCTCP C PCTCP PCTCPP INI C PCTCP ETHDRV rem PC TCP INSTALL ADDED LINE S END rem rem RECHNER CP581 rem set path C cp581 path set temp C dos set cp580 C cp581 cp580d msg mode com1 9600 n 8 1 p rem mode Iptl com1 rem CPHTB Treiber laden Ih cphtb ssnr24 resync rem CPHTB Treiber entfernen rem cphtb u rem CPMASS Treiber laden rem Ih cpmass rem rem OPTION VIRTUELLES LAUFWERK E rem rem SSREMOTE installieren binaere Speicherung Ih sSremote e rem SSREMOTE installieren Formatierte Speicherung aller rem S5 Datenbausteine aller CPUs rem Ih s5remotf e F ALLFORM FMT rem SSREMOTE entfernen rem sSremote u rem Kommando Interpreter laden rem cpshell rem cd cd LAN echo on delay 10 inicom2 mainl goto ENDE LAB C DOS SMARTDRV EXE ECHO OFF PROMPT p g PATH C DOS C LAN C DOS SET TEMP C DOS MODE CON CODEPAGE PREPARE 437 C DOS EGA CPI MODE CON CODEPAGE SELECT 437 KEYB US C DOS KEYBOARD SYS C cd LAN rem PC TCP INSTALL ADDED LINE S BEGIN rem Driver Software der EtherLink Karte C nwclient driver 3c5x9pd 0x60 IDPORT 0x150 rem SET PATH C PCTCP PATH rem C PCTCP PCTCPL INI is parameter file with labtest ip address SET PCTCP C PCTCP PCTCPL INI C PCTCP ETHDRV rem
5. E X C800 DFFF i e000 e7ff noems DOS HIGH rem COUNTRY 001 437 C DOS COUNTRY SYS DEVICE C DOS DISPLAY SYS CON EGA 1 FILES 30 rem BUFFERS 10 0 buffers 20 0 LASTDRIVE H MENU menuitem PLAT OPERATIONAL PLATFORM PROGRAM default menuitem DOS DOS CAUTION NOT FOR UPSTAIRS USE menuitem LAB LABTEST CAUTION NOT FOR UPSTAIRS USE menudefault LAN 15 PLAT DEVICE C DOS ANSLSYS DOS DEVICE C DOS ANSLSYS LAB DEVICE C DOS ANSLSYS APPENDIX 3 AUTOEXEC BAT ON SILICON DISK echo off rem edited by jon hagen May 22 2002 echo on goto Kconfig rem note that following line is never executed initcmos c cmos ini DOS c DOS SMARTDRV EXE ECHO On PROMPT p g PATH c DOS C NORTON MODE CON CODEPAGE PREPARE 437 C DOS EGA CPI MODE CON CODEPAGE SELECT 437 KEYB US C DOS KEYBOARD SYS rem INITIALIZE C COMPILER SETTINGS SET PATH C C600 BINB C C600 BIN C DOS C PCTCP PATH SET LIB C DEVKIT NETMSC6 0 C C600 LIB SET INCLUDE C DEVKIT INCLUDE C C600 INCLUDE SET HELPFILES C C600 HELP HLP SET INIT C C600 INIT SET TMP C C600 TMP NC GOTO ENDE PLAT C DOS SMARTDRV EXE ECHO OFF PROMPT p g PATH C DOS C LAN SET TEMP C DOS MODE CON CODEPAGE PREPARE 437 C DOS EGA CPI MODE CON CODEPAGE SELECT 437 KEYB US C DOS KEYBOARD SYS C cd LAN rem PC TCP INSTALL ADDED LINE S BEGIN rem Driver Software der EtherLink Karte C nwclient driver 3c5x9pd 0x
6. To file From Jon Hagen Date May22 Aug 21 2002 Subject VERTEX SYSTEM PLC and LCU Replacement Procedures 1 Procedure for Replacing the PLC on the Platform A Test the spare PLC in the digital lab The spare PLC and spare LCU are normally kept in a test rack in the digital lab running the lab test versions of their programs Turn on the monitor if not already on and observe that the spare PLC and LCU are operating properly each should have only its green run light lit and the monitor should be displaying slowly incrementing CH and GREG positions and a steadily increasing time the format is seconds past midnight If the rack was turned off turn it on by lifting the power switch on the outlet box under the keyboard When prompted type 3 enter to select the labtest version of the program If the system does not come up properly refer below to Procedure for Replacing the PLC in the Test Rack in the Digital Lab If the rack was already turned on and operating properly it is a good idea to cycle its power anyway to see that the PLC and LCU boot up properly When you are satisfied that the spare PLC is working and booting 1 Turn the rack off using the power switch on the outlet box under the keyboard 2 Pull the lab test FLASH memory module out of the PLC 3 Plug in the working program FLASH memory module This module is kept in a small cardboard box on top of the crate just above the PLC Note the this side up
7. already on and observe that the spare PLC and LCU are operating properly each should have its green run light lit and the monitor should be displaying the blue pointing system display with slowly incrementing CH and GREG positions and a steadily increasing time seconds past midnight None of the four IRIG card errors displayed in black and white at the top of the screen should be incrementing If the rack is turned off tun it on by lifting the power switch on the outlet box under the keyboard Watch the screen and press 3 return when prompted to activate the lab test version of the program In about one minute the test system should be operating as described above If not the PLC may need resetting refer below to Procedure for Replacing the PLC in the Test Rack in the Digital Lab If the rack was already on it is a good idea to cycle the power anyway to be sure that the LCU and PLC boot up properly To test the ETHERNET card first get a DOS prompt by typing the password VERTEX maybe twice from the Lab Test display screen Then ping Nevis by typing PINGTEST return A successful ping is indicated by a screen of status data response time etc You can get back into Labtest using the standard CTL ALT DEL reboot and then typing 3 return for labtest when prompted When the display is back to normal note that the time may be in error for several seconds while the IRIG card acquires the code supplied to its front panel BNC
8. bled 8455 MB None A then C 640 kB 31744 k key toggles this through Auto User and None Auto yields 17475 cylinders 15 yeads 63 sectors max capacity 8455 MB LBA mode control enabled Primary Slave Mode Auto yields LBA mode control enabled Keyboard Features Numblock Auto key toggles S5 INTERFACE S5 Interface Disabled Page Frames Enabled Frames 4 Mode Paged Page Number 0 Base 00h 244 V O Pointer Disabled Range P PERIPHERIE Base FX Pointer Read Disabled gt S5 Communications Flags S5 Interface Submenu 0 S5 Communication Flags all set to Disabled
9. cursor arrives at USR1 Backspace to clear this field and type the word NONE Then hit TAB until the cursor arrives at OK More NONE s will appear as if no disk at all has been installed but in fact the silicon disk will become the C drive Hit RETURN and proceed through EXIT and SAVE You should also turn off the yellow check mark auto In another field of the setup menu be sure that num lock is disabled CONFIG SYS and AUTOEXEC BAT When the system boots up using CONFIG SYS and AUTOEXEC BAT it displays a menu with three options PLATFORM the operational program LABTEST the test program kept running in the designated spare LCU in the digital lab test rack and DOS for development debugging etc PLATFORM is the default option to boot up the LCU on the platform card cage it is not even necessary to plug in the keyboard the operational program will by default start itself PLATFORM is the only option that should be used on the platform The enabled AUTOEXEC BAT hard disk version or silicon disk version starts the desired program operating version of the program or labtest version of the program or DOS from the enabled drive It also sets up the Ehthernet link with the appropriate ip address by using different versions of the parameter file PCTCP INI APPENDIX 2 CONFIG SYS ON SILICON DISK rem DEVICE C DOS SETVER EXE DEVICE C DOS HIMEM SYS TESTMEM OFF m 2 rem DEVICE C DOS EMM386 EX
10. ds for the first 5 seconds or so while the card is synchronizing with the data on the IRIG cable The program 630DEMO 2 provides other tests of the card APPENDIX 1 PLATFORM AND LABTEST PROGRAMS DISKS AND FILES The LCU contains both a rotating hard disk and fixed silicon disk non volatile silicon RAM Both the hard disk and the silicon disk contain the operating version and the lab test version of the program so we have the option of running from either disk Normally we will chose to boot and run from the silicon disk which with no moving parts should be more reliable than the hard drive which rotates continuously and must eventually fail In order to boot and run from the silicon disk we use the setup program to tell the bios to ignore the hard disk completely as if it does not exist With this setup the silicon disk automatically becomes the C drive and there is no D drive During program development we set the bios up to recognize the hard disk it becomes C and silicon disk becomes D In this standard pc mode we load programs on the silicon disk by writing to D But in the silicon disk only mode these programs are then accessed from C As a result all the disk references and path statements in the config sys and autoexec bat files are to the C drive These boot programs exist both on the silicon disk and on the hard drive and are virtually identical they make references only to the C drive If the silicon dis
11. k were to fail we can run the setup program to restore the hard disk With the hard drive is operational the LCU will then boot and run either version of the program ignoring the silicon disk If you want to see whether the hard disk or the silicon disk is currently enabled get to the C prompt in DOS and type DIR to display the size of the C drive The silicon disk is about 2MB while the hard disk is about 2GB If both the silicon disk and the hard disk fail we could possibly run from the A drive This option seems unlikely and we have not prepared a bootable floppy containing the programs and configuration files needed for platform and or labtest operation RUNNING SET UP TO ENABLE THE HARD DISK OR SILICON DISK The boot sequence provides you with a brief prompt at which you hit CNT ALT ESC to enter the set up program You can boot by cycling the power or by using CNT ALT DEL The latter however is locked out when the LCU program is running in which case you can type the password VERTEX and the LCU will revert to DOS with CNT ALT DEL enabled Once you have the setup program menu on the screen scroll down to AT Hard Disk and hit RETURN The cursor will now be on AUTO ALL DRIVES Select this option by hitting RETURN if you want to enable the hard drive Then simply tab to OK hit RETURN and proceed through EXIT and SAVE If you want to disable the hard drive ie enable only the silicon disk hit TAB until the
12. rd 2 Plug the LCU package which is to be the spare into the rack The left hand side of the LCU package goes into the seventh slot from the left of the card cage Getting the package to fully engage the backplane sockets is quite difficult the connectors have little or no self alignment ability You must feel the package both top and bottom push into place Try to get you hands into the card cage so that you can exert pressure with your thumbs at both the top and bottom of the package 3 Perform the tests describe above in 2A until you are satisfied that the test system is operating properly Note The black and white counter data at the top of the screen monitors four IRIG errors TmOut time out indicates that the IRIG card did not respond when addressed BadDat indicates bad data values such as a BCD 7 8 or 9 in the tens of minutes field Jump indicates that successive time readings had values too far apart and NoSig indicates that the card is not syncing to the IRIG cable There are also two stand alone programs to test the IRIG card Get into DOS while booting or by typing VERTEX while the test system is running Go to the root directory and then to the directory BC630AT Run the program 630DEMO1 It will ask for the card s base address Enter 0 The base address is 200H It will then display the time in days of the year hours minutes and seconds The display will read zeros except for the sub secon
13. t from the left of the card cage 4 Turn on the rack using the power switch on the outlet box under the keyboard 5 Perform an overall reset on the PLC to load the contents of the FLASH module into the PLC s RAM This is done as follows using the switches on the PLC 6 Put the run stop switch in the STOP position 7 Hold the reset switch DOWN 8 Toggle the run stop switch twice i e from STOP to RUN to STOP to RUN to STOP 9 Hold the reset switch UP 10 Place the run stop switch in the RUN position 11 Place the reset switch in its center position The PLC will now be loaded and running but it needs to be synchronized with LCU A synchronous start must be done as follows 12 Turn off the test rack using the power switch on the outlet box under the keyboard 13 Turn the rack back on When prompted type 3 enter to select the labtest version of the LCU program After about one minute things should be running normally Both the PLC and LCU should have only the green RUN light lit and the monitor should be displaying slowly incrementing CH and GREG positions The time should be steadily incrementing 4 Procedure for Replacing the LCU in the test rack in the digital lab Note that the LCU is actually a package consisting from left to right of the CP581 computer the floppy hard disk drive unit the IRIG time card and the 3COM ethernet card 1 Turn off the rack using the power switch on the outlet box under the keyboa
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plcAndLcuSwappingOut