1785-6.2, PLC-5 Programmable Controller Flash Tool, User Manual
Contents
1. Spain Sweden Sentzarland Taiwan Thailand Trinidad Tunisia Turkey United Arab Emirates Lintied Kingdom United States Uruguay Wenezuela Reclowell Adomation Heariquartar 1201 South Sarii Stmet Miwauker Wi Seid LGA Tak 1 414 Seen Faw 1 414 Sad Rockwell Aulomation Berapaan Headquarters SAW avarus Hermann Debroudaan 46 1160 Bruset Belgium Tal et 2663 08 D Fa 2 2 663 06 a Rockwell Automation Asia Poofia Headquarters 27F Citoorp Conine 18 Whitfield Rood Couse Bay Hong Kong Tet B50 2587 4763 For Bii 2608 1646 Publication 1785 6 2 March 1998 955131 61 Supersedes Publication 1785 6 2 June 1997 A 5 Publication 1785 6 2 RN2 July 1997 1998 Rockwell International All Rights Reserved Printed in USA2. before you upgrade the processor firmware e Handle the printed circuit board by the case or catrier without touching the pins or the edge connector e Use a static free workstation e Connect the static free workstation to ground through a minimum 200K ohm resistance e Wear a grounded conductive wrist strap with a minimum 200K ohm resistance e Ground all tools before you begin to upgrade the firmware e Control the relative humidity of the installation area Ideal conditions are 40 60 relative humidity 1 Make sure you have already removed the battery cover and disconnected the battery and disconnected any cables attached to the processor For A B Internal Use Only 2 Do one of the following If you have a PLC 5 11 or 5 20 type processor U18 PROM 1785 L11 5 20 board 41024 Do this a Remove the four screws that hold the right side plastic cover Remove the cover Remove the two large screws and washers located in the middle of the exposed circuit board Separate the two processor boards by pulling the exposed circuit board at the backplane edge connector away from the metal cover as you would open a book Notice the direction in which the battery cable is wrapped around the nearby standoff Disconnect the wires leading from the battery to the stake pins on the exposed circuit board Disconnect the wires leading from the keyswitch
3. flash upgrade catalog number selection screen Do not select the catalog number of the processor you currently have Return to item 3 step 3 on page 5 and repeat this section When the flash download begins e the processor s COMM LED blinks green e the processor s PROC LED blinks red green e apercent complete status 0 100 appears in the middle of the screen that indicates how much of the flash update is complete Wait for the flash update to complete The upgrade should take about 5 minutes to complete When the download is complete the status bar will be at 100 and the screen will display this message Processors Flash Update Completed Press Any Key to Continue For A B Internal Use Only 7 When the flash update is complete cycle power to the processor If the processor powers up with the Do this PROC LED solid red and CH1A DH LED continue with the item 8 step 3 that blinking green normally follows this table PROC LED flashing red green Return to item 3 step 3 on page 5 and flash mode repeat this section PROC LED solid red and CH1A DH If you have repeated this item more LED off than 3 times send the processor to Allen Bradley repair services 8 Disconnect the serial cable that you used to perform the flash upgrade Step 4 Applying the Firmware Revision Label Important It is important to apply this label to your processor to ensure you receive the correct version b
4. B Use This Manual If This Manual Describes For more information about User Manual PLC 5 Programmable Controller Flash Tool Catalog Number 1785 L11B L20B L20C L20C15 L20E L26B L30B L40B L40C L40C15 L40E L40L L46B L46C15 L60B L60C L60C15 L60L L80B L80C L80C15 L80E L86B Use this manual if you are responsible for performing a flash firmware upgrade to a flash based PLC 5 processor This manual describes how to use the PLC 5 programmable controller flash tool to upgrade these products e series E and later Enhanced PLC 5 processors series E and later Ethernet PLC 5 processors e series C and later ControlNet PLC 5 processors This manual also describes what to do if the flash upgrade does not complete successfully The following publications contain additional information about Allen Bradley PLC 5 processor products To obtain copies contact your local Allen Bradley office or distributor Read this publication Publication number Enhanced PLC 5 processors Enhanced and Ethernet PLC 5 Programmable 1785 6 5 12 Ethernet PLC 5 processors Contollers User Manual ControlNet 1 0 or 1 25 PLC 5 processors ControlNet PLC 5 Programmable Controllers 1785 6 5 14 User Manual ControlNet 1 5 PLC 5 processors ControlNet PLC 5 Programmable Controllers 1785 6 5 22 Phase 1 5 User Manual Publication 1785 6 2 March 1998 For A B Internal Use Only 2 Before You Be
5. ack if you send it in for repair 1 Turn off power to the processor 2 Remove the processor from the chassis 3 Apply the new firmware revision label in the space indicated by dotted lines on the product identification label The following figure shows where to place the label on a series E PLC 5 processors and on older PLC 5 processors Series E PLC 5 Processor Series C or Series D PLC 5 Processor CAT NO REV 1785 L40B E A01 CAT NU 1785 L406 PLC 5 40 PROCESSOR PLE 5 40 CONTROLMET PROCESSOR MODULE it zE Mis Allen Bradley s4 CLIDV2 YA LISTED WHEN G GP A B C D U le TEMP CODE K USTED SYSTEM SEE DATA SHEET FOR INSTALLATION DETAILS FIRMWARE UPGRADE MADEINUSA OOOO pan CAT NO PART NO 96215074 A01 Sore a lt 1785 L40B SERIES REV E B eS a ee HIJE EITRI Wiigi SCE GPRM TEN ASP EN A DERRE bi BACKPLANE CURRENT bt REQUIREMENTS i 5 EAA ARANEGI 3 3A AT 5VDC EEA An 14 aa a a a 41023 1785 La0cih H L 41022 For A B Internal Use Only Publication 1785 6 2 March 1998 Publication 1785 6 2 March 1998 Step 5 Updating the Communication Plug Firmware If you received communication plug PROM s with your order you need to update your PROM s to complete the flash upgrade ATTENTION Printed circuit board components can be damaged during routine handling and installation Follow these precautions to reduce static electricity discharges
6. ctory by typing cd 4 Remove the flash directory by typing rd flash PLC 5 and ControlNet are trademarks of Allen Bradley Inc a Rockwell International Company Ethernet is a registered trademark of DEC Intel and Xerox Corporation Windows Windows 95 and Windows NT are registered trademarks of Microsoft in the U S and other countries a Rockwell onain Rockwell Aulomation helps ila cualomers pecahe a superar rolum an Pair ineasimanl by bringing ether adia brands in ustia aulomaton crealing a broad spectum of aasy bo integrale wadua These ara supporied by local technical resources available worldwide a global network of syalem solutions peowiders and the advanced technology mesouroes of Rockwell Worldwide representation ae eh ie EM Argenting Agscrala Austria Bahrain Beigigm Bolivia Breed Bulgaria Canada Chile Ching People s Republic of Colombia Gosia Fipa Gronia Cypris Grech Aapubic Danmark Dominican Rapuble Eouiinr Boypl El Galada Finland France Gerry Ghana Grassi Gualesala Honduras Heng Kong Hungary kaang india Indonesia Iran Ireland paa ly Jamaica Japan Jordan Kpa Kuwat Lebanon Macau Waka Malla Meco Morogoro The Mineriands New Zealand Nigarla Norway Oman Fakisian Panama Peru Poilppines Poland Portugal Puaro Picy Qaiar Aomania Russia Saud Arabia Singapore Slovaka Slovenia South Aica Rapublic of
7. drive by typing copy a c flash 4 On the programming terminal change to the following directory containing the firmware files by typing cd c flash mf Step 3 Performing the Flash Upgrade Follow these steps to upgrade the processor firmware ATTENTION Do not interrupt the flash download process by disturbing the processor or computer Failure to do so may result in an inoperable processor 1 Enter this command flash5 The flash upgrade catalog number selection screen appears 2 Use the arrow keys to move the cursor to the catalog number of the flash upgrade you want to download to the processor and press m Publication 1785 6 2 March 1998 For A B Internal Use Only 5 3 Select the appropriate script file by moving the cursor to the file name and pressing 15 Script files are named as follows Lwwx_yz ini Where Represents ww 11 20 26 30 40 46 60 80 or 86 depending on what flash upgrade you are trying to download to the processor x the type of flash upgrade to download B for Enhanced L for Extended local 1 0 C for ControlNet 1 0 or 1 25 E for Ethernet C15 for ControlNet 1 5 y the series of the flash upgrade to download see the disk label z the revision of the flash upgrade to download see the disk label 4 On your computer select the communication port COM1 or COM2 by moving the cursor to select the port and pressing 5 5 Make s
8. gin Using the Flash Tool Publication 1785 6 2 March 1998 Gathering What You Need Gather the following items before you begin using the flash upgrade Items marked with an asterisk are included in the flash tool package you ordered flash firmware upgrade tool disk PLC 5 processor whose firmware you want to update with chassis and power supply personal computer with PLC 5 programming software installed shielded serial cable 1784 CP10 or 1784 CP11 this manual firmware revision label plug PROM s if you require a plug PROM firmware update Running the Software ATTENTION You must install and run the PLC 5 flash tool on a computer booted up in DOS 6 22 or later Do not use a DOS window running under Windows 95 or Windows NT You will copy the flash files to your hard drive To successfully use the flash tool you need to complete seven steps wot Nn 2G os Gs OS ATTENTION Pay strict attention to the flash tool procedure Failure to follow this procedure exactly may result in an inoperable processor Prepare the PLC 5 processor Install the flash tool Perform the firmware upgrade Apply the firmware revision label Update the communication plug firmware if necessary Reconnect the PLC 5 processor Uninstall the flash tool For A B Internal Use Only Step 1 Preparing the PLC 5 Processor ATTENTION You must save the processor memory to your hard disk or to an EEPROM If you do not t
9. he PLC 5 user memory will be lost because the flash procedure erases processor memory 1 Save processor memory to your hard disk or to an EEPROM using your PLC 5 programming software 2 Remove the processor battery cover and disconnect the battery This resets the serial port to its default configuration so that the PLC 5 processor and the flash tool can communicate 3 Turn off processor power 4 Disconnect all cables serial DH ControlNet Ethernet etc from the processor 5 Disconnect the coprocessor or PLC 5 Ethernet Interface module if one is connected 6 Turn the processor keyswitch to Program mode 7 Turn on processor power 8 Attach the shielded serial cable 1784 CP10 or 1784 CP11 between channel 0 on the PLC 5 processor and the serial port on the computer For A B Internal Use Only Publication 1785 6 2 March 1998 Step 2 Installing the Flash Tool 1 Boot the computer in DOS 6 22 or later Do not use a DOS window running under Windows 95 or Windows NT Verify that there is a DOS prompt on the screen 2 Create the following directory on the programming terminal s hard drive by typing md c flash eD ATTENTION Make sure you install this application on the hard drive Do not attempt to run it from the floppy disk it will not work 3 Place the flash firmware upgrade tool diskette in the a drive of the programming terminal Copy the files from this diskette to the programming terminal hard
10. to the stake pins on the exposed circuit board See the figure at the left for the location of the communication plug PROM Series D and earlier PLC 5 40C 5 60C or 5 80C processor Remove the phillips head screw near the channel 1B LED and gently remove the channel 1 communication plug Be aware that the memory grounding clip may move or drop off from the cover mounting tab 3 Remove the PROM observing the orientation of the PROM notch Replace the plug PROM checking to see that the PROM notch is correctly oriented 4 Reassemble and power up the processor Step 6 Reconnecting the PLC 5 Processor 1 Reconnect the battery any cables and coprocessor or PLC 5 Ethernet Interface module 2 Reload your program and make certain that it runs properly If you have any questions call technical support at 440 646 6800 For A B Internal Use Only Publication 1785 6 2 March 1998 10 Step 7 Uninstalling the Flash Tool We recommend that you remove the flash tool directory and all of the files it contains Follow these steps to uninstall the flash tool Important Make sure you are in the flash directory that you created on the hard drive so that you do not accidentally delete the wrong files 1 On the programming terminal change to the directory containing the firmware files by typing cd asn peng 2 Delete all files within that directory by typing ger eal lt a 3 Change to the root dire
11. ure you have established a connection This could take about 60 seconds If you The screen displays established a connection information about the target processor The processor s PROC LED flashes red green did not establish a connection an error message See the following table For A B Internal Use Only Publication 1785 6 2 March 1998 Publication 1785 6 2 March 1998 If you received an error If you received this error Processor not connected Do this a Make sure the keyswitch is in Program mode Make sure the processor power is on Check the serial cable Verify the COM port being used by the computer Return to item 3 step 3 on page 5 and repeat this section Target processor does not match script file Check the name of the script file Make sure you are connected to the correct type and series of processor Return to item 3 step 3 on page 5 and repeat this section Firmware series stated in script file does not match PLC Make sure you are connected to the correct type and series of processor Return to item 3 step 3 on page 5 and repeat this section No script files found Make sure you copied all files from the firmware upgrade diskette to the c flash hard drive directory as described in item 2 step 2 on page 4 Make sure you selected the catalog number of the flash upgrade you want to download to the processor on the
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