Firmware Update Instructions for Ethernet, … · Publication 1785-IN022B-EN-P - November 2002 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable

Installation Instructions

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers

Purpose This document describes how to update firmware on your Ethernet™,

Enhanced or ControlNet™ PLC-5® programmable controller.

Firmware Update Contents Depending on your requirements, the firmware update kit may contain:

• ControlFLASH software with the firmware update

• these installation instructions

• applicable firmware release notes

• a firmware revision label

• firmware EPROMS, if applicable

Hardware and Software Requirements

Your computer must meet the following requirements to perform the firmware update:

• at least a 486 processor

• Windows® 95, Windows 98, or Windows NT® operating system

• at least 16 Mbytes of available memory

• for ControlNet phases 1.0 and 1.25, a computer booted with DOS 6.22 or later

To perform Ethernet Series C and D firmware updates, you will need a Network Interface Card and a switch, Ethernet hub or crossover cable.

To perform other updates, you need a shielded serial cable, either 1784-CP10 or 1784-CP11.

ATTENTION

!You must save the PLC-5 processor memory to your hard disk or to an EEPROM. If you do not, the PLC-5 user memory will be lost because the firmware update procedure erases memory.

1 Publication 1785-IN022B-EN-P - November 2002

2 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers

Locate Your Update Procedure in this Document

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 Rockwell Automation 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, Rockwell Automation 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 Rockwell Automation 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:

To Update the Firmware on this PLC-5: Go to this page to begin:Ethernet PLC-5, Series C and D 4Ethernet PLC-5, Series E or later 13Enhanced PLC-5, Series A thru D 21Enhanced PLC-5, Series E or Later 25ControlNet PLC-5, All Series 33

WARNING

!Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

Publication 1785-IN022B-EN-P - November 2002

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3

ATTENTION

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

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

ATTENTION

!This version of ControlFLASH is only suitable for this firmware update. Do not use this version of ControlFLASH to update firmware on any other PLC-5.

ATTENTION

!Preventing Electrostatic Discharge

This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment:

• Touch a grounded object to discharge potential static.

• Wear an approved grounding wrist strap.

• Do not touch connectors or pins on component boards.

• Do not touch circuit components inside the equipment.

• If available, use a static-safe workstation.

• When not in use, store the equipment in appropriate static-safe packaging.



Important Considerations for CL I, Div. 2 Installations

Ethernet PLC-5- 1785-L20E- 1785-L40E- 1785-L80ESeries C and D

To update these series of Ethernet PLC-5 firmware, you must first use ControlFLASH through the Ethernet channel, and then replace the applicable EPROMS. To start this firmware update, follow these steps:

Step 1 - Prepare the PLC-5 Programmable Controller

WARNING

!When you connect or disconnect the battery, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

• For safety information on the handling of lithium batteries, including handling and disposal of leaking batteries, refer to Guidelines for Handling Lithium Batteries, publication AG-5.4

• Store batteries in a cool, dry environment. We recommend 25° C with 40% or 60% relative humidity. You may store batteries up to 30 days between -45° - 85° C, such as during transportation. To avoid possible leakage, do not store batteries above 60° C for more than 30 days.

WARNING

!When you install or remove the module with power applied, or you connect or disconnect the serial cable with power applied to this programmable controller or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

ATTENTION




1. Save the PLC-5 processor memory to your hard disk or to an EEPROM.

2. Remove power from the PLC-5.

3. Remove the PLC-5 battery cover and disconnect the battery.

4. Remove the PLC-5 from the chassis.

5. Locate and document the PLC-5 hardware Ethernet address.The address is on the circuit board label toward the back of the PLC-5.

6. If applicable, disconnect the coprocessor or PLC-5 Ethernet Interface sidecar module.

7. Reinstall the PLC-5 into the chassis.

8. Apply power to the PLC-5.

9. Through the Ethernet port, use either a switch, hub or crossover cable to connect the computer to the PLC-5.

10. Make sure the TCP/IP is loaded and running on the personal computer.

11. Make certain the computer’s Ethernet IP address and subnet mask (for example, 255.255.255.0 for Class C) is entered.The PLC-5 should have an IP address with the same first three octets as the computer’s Ethernet network interface address.

If it doesn’t, then you can assign the IP either by going online

with the PLC-5 over DH+™ or serially, and configuring the IP address for Channel 2 via the channel configuration screen (uncheck the BOOTP enabled box). Or, by setting up a BOOTP server with this module’s assigned IP address.

12. Turn the PLC-5 keyswitch to PROGRAM mode.



Step 2 - Install the ControlFLASH Software

1. Insert the ControlFLASH disk into the floppy drive of your computer.

2. Browse the A: drive and select the setup.exe program.

3. If you have an earlier version of ControlFLASH installed, we recommend to install this version into the same directory.

4. Follow the Setup Wizard as it guides you through the installation process.

Step 3 - Perform the ControlFLASH Update

1. If you have not already done so, connect the computer to the PLC-5 through the Ethernet channel:

– use either a switch, hub or crossover cable to connect the computer to the PLC-5

2. Close all applications including RSLinx™.

ATTENTION

!Failure to follow these procedures exactly or to cause an interruption during them may result in an inoperable PLC-5.



3. Start ControlFLASH:

3A - Start the ControlFLASH software.

3B - Select the appropriate PLC-5 Programmable Controller catalog number.

Click Next.

Use the cursor to highlight the PLC-5 type

Click Next.



3C - Enter the Ethernet IP address of the PLC-5 you are updating.

3D - Select the firmware revision.

Click OK.

Select the correct update revision.

Click Finish.

3E - Verify the update.

Click Next.

Click Get Info to verify the programmable controller you are updating.





3F - Start the firmware update.

Click Yes.

The progress indicator shows how much of the update has been performed.

Important: This update can take up to two minutes to complete.

3H - Follow the power cycle instructions during and after the update process.

When the update is complete, the software will prompt you to cycle power.

Important: Do not click OK until you complete the next three steps: - “Install the New Firmware EPROMS” - “Apply the Firmware Revision Label” - “Complete the Firmware Update”

These procedures are detailed on the following pages.

3G - Check the STAT LED on the PLC-5. If it is flashing green, the ControlFLASH update was successful - continue to step 3H. If the STAT LED is not flashing green, the update was not successful - call Rockwell Automation Technical Support at 440-646-5800.



Step 4 - Install the New Firmware EPROMS

Note: Do not reinstall the PLC-5 until you complete the next step.

On the Ethernet PLC-5, Series C and D: Do this:

1785-L20E programmable controller 1. Remove the four screws that hold the right side plastic cover.2. Remove the cover.3. Remove the two large screws and washers located in the center of the exposed circuit board.4. Carefully 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.5. Remove and replace the firmware EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS. 6. See the figure to the left for the numbers and locations of the EPROMS.7. Reassemble the PLC-5 by reversing steps 1 thru 4.

1785-L40E and -L80E programmable controllers 1. On the front of the PLC-5, remove the 2 hex nuts on Channel 0.2. Remove the screw on the communication card and gently pull the card out of the PLC-5. 3. Remove the four screws that hold the right side plastic cover and remove the cover.4. Remove the two large screws and washers located in the center of the exposed circuit board.5. Carefully 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.6. Remove and replace the firmware EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS.7. See the figure to the left for the numbers and locations of the EPROMS.8. Reassemble the PLC-5 by reversing steps 1 thru 5.

* EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of PLC-5 and firmware may be different. Make certain the EPROM numbers from your firmware update match the numbers on their respective circuit boards and communication cards.

U18*

U61*

U70*

Replace theU61 and U70EPROMS*

If applicable,replace the U18EPROM*

(if applicable)

U5*

U31*U7 or U12*

Replace theU5 and U31EPROMS on thecircuit board*

If applicable,

Remove communication card

replace the U7or U12 EPROM

(if applicable)

on the communicationcard*



Step 5 - Apply the Firmware Revision Label

1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of PLC-5). Make certain to place the label so that the current series and revision information is clearly visible.

Step 6 - Complete the Firmware Update

1. Install the PLC-5 into the chassis.


3. After powerup, check the status of the PLC-5:

IMPORTANT It is important to apply this label to your programmable controller to ensure you receive the correct version back if you send it in for repair.

CAT. NO. REV.1785-L40E C DETHERNET PLC-5/40 PROCESSOR

MADE IN USAPART NO. 96215074 A01

BACKPLANE CURRENT REQUIREMENTS3.3A AT 5VDC

SERIESC

F/W REVQ.2

FIRMWARE UPGRADECAT. NO.1785-L40ESERIES REV.D G.2

Place new label overprevious label or belowentire product label.

If: Then:

PROC LED is solid red and CH1A DH+ LED is flashing green

Update is complete. Proceed to Step 4.

PROC LED is solid red but the CH1A DH+ LED is not flashing green

Make certain that all new EPROMS are properly installed (notches on circuit board and EPROMS match, there are no bent pins, EPROMS are installed in the correct location).

PROC LED is flashing red and green Repeat the ControlFLASH procedure



4. Since you removed the PLC-5 from the chassis, you must reenter the computer’s Ethernet IP address and subnet mask (for example, 255.255.255.0 for Class C).The PLC-5 should have an IP address with the same first three octets as the computer’s Ethernet network interface address.

If it doesn’t, then you can assign the IP either by going online with the PLC-5 over DH+ or serially, and configuring the IP address for Channel 2 via the channel configuration screen (uncheck the BOOTP enabled box). Or, by setting up a BOOTP server with this module’s assigned IP address.

5. In ControlFLASH:

6. When the update is successful:

– restore all connections to the PLC-5

– download the program back into memory and make certain that it runs properly

Your firmware update is complete. If you have any questions, call Rockwell Automation Technical Support at 440.646.5800.

Click OK.

The update process is now complete.

If an error occurs, click View Log to see specific error information.

The Status windows displays the result of the update. If an error occurs, it is displayed in this window.

At the “Cycle Power” prompt, click OK



Ethernet PLC-5- 1785-L20E- 1785-L40E- 1785-L80ESeries E or Later

To update these series of Ethernet PLC-5 firmware, you must first use ControlFLASH and then if applicable, replace EPROMS. To start this firmware update, follow these steps:



2. Disconnect all cables (serial, DH+, ControlNet, Ethernet, etc.) from the PLC-5.

3. Remove power from the PLC-5 and remove it from the chassis.

4. Remove the PLC-5 battery cover and disconnect the battery. This resets the serial port to its default configuration so that the PLC-5 and ControlFLASH can communicate.


6. Verify that the serial port DIP switches are set for RS-232.

7. Reinstall the PLC-5 and apply power.


ATTENTION










1. Connect the computer to the PLC-5 using a 1784-CP10 or -CP11 cable between the computer and Channel 0 of the PLC-5

2. Close all applications including RSLinx.

ATTENTION







Click Next.


Click Next.




Click Next.


Click Finish.


Click Next.


3C - Select the serial port of the computer to which you connected the 1784-CP10 or -CP11 cable.

Select COM1 or COM2.






Click Yes.


Important: This update will take approximately 13 minutes to complete.

3G - Follow the power cycle instructions during and after the update process.


Important: If you are updating the firmware EPROM on the communication card, you must first complete the next three steps: - “Install the New Firmware EPROMS” - “Apply the Firmware Revision Label” - “Complete the Firmware Update”

If you are not updating the firmware EPROM on the communication card, skip to step 5 “Apply the Firmware Revision Label”.




Step 4 - Install the New Firmware EPROM(if applicable)


On the Ethernet PLC-5, Series E or Later: Do this:

1785-20E, -L40E and -L80E programmable controllers 1. On the front of the PLC-5, remove the 2 hex nuts on Channel 0.2. Remove the screw on the communication card.3. Remove the four screws that hold the right side plastic cover and remove the cover.4. Remove the two large screws and washers located in the center of the exposed circuit board.5. Carefully 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.6. Gently pull the communication card off of the circuit board. 7. Remove and replace the U7 or U12 firmware EPROM, taking note of the location number and the orientation of the notch on the EPROM.8. See the figure to the left for the number and location of the EPROM.9. Reassemble the PLC-5 by reversing steps 1 thru 6.


U7 or U12

If applicable, replacethe U7 or U12 EPROMon the


communication card*(if applicable)*












SERIESC

F/W REVQ.2





3. In ControlFLASH:






Click OK.

The update process is now complete. If an error occurs, click View Log to see specific error information (see the table below).



If: Then:


Update is complete. Proceed to Step 5 below.

PROC LED is flashing red. CH1A is not flashing green

Call Rockwell Automation Technical Support at 440.646.5800. Send PLC-5 in for repair.




Enhanced PLC-5- Series A thru D

To update these series of Enhanced PLC-5 firmware, you must replace the applicable EPROMS. To start this firmware update, follow these steps:





4. Remove the PLC-5 battery cover and disconnect the battery.


ATTENTION




Step 2 - Install the New Firmware EPROMS

1. Disassemble the PLC-5 to begin the EPROM replacement:

On the Enhanced PLC-5, Series A thru D: Do this:

1785--L11B, -L20B and -L26B programmable controllers 1. Remove the four screws that hold the right side plastic cover.2. Remove the cover.3. Remove the two large screws and washers located in the center of the exposed circuit board.4. Carefully 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.5. Remove and replace the firmware EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS. 6. See the figure to the left for the numbers and locations of the EPROMS.7. Reassemble the PLC-5 by reversing steps 1 thru 4.


1785-L30B programmable controller 1. On the front of the PLC-5, remove the 2 hex nuts on Channel 0.2. Remove the screw on the communication card and remove the card.3. Remove the four screws that hold the right side plastic cover and remove the cover.4. Remove the two large screws and washers located in the center of the exposed circuit board.5. Carefully 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.6. Gently pull the communication card off of the circuit board. 7. Remove and replace the firmware EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS.8. See the figure to the left for the numbers and locations of the EPROMS.9. Reassemble the PLC-5 by reversing steps 1 thru 6.


U18* (if applicable)

U61*

U70*

Replace theU61 and U70EPROMS*

If applicable,replace the U18EPROM*

U5*

U31*U7 or U12

Replace theU5 and U31EPROMS on thecircuit board*

If applicable, replacethe U7 or U12 EPROMon the


(if applicable)

communication card*




1785-L40B, -L46B, -L60B, -L80B and -L86B programmable controllers 1. Remove the four screws that hold the right side plastic cover.2. Remove the cover and remove the communication cards.3. Remove the two large screws and washers located in the middle of the exposed circuit board.4. 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.5. Notice the direction in which the battery cable is wrapped around the nearby standoff.6. Disconnect the wires leading from the battery to the stake pins on the exposed circuit board.7. Disconnect the wires leading from the keyswitch to the stake pins on the exposed circuit board.8. Remove both communication cards.9. Remove and replace the firmware EPROMSone at a time, taking note of the locationnumber and the orientation of the notch ineach of the EPROMS.10. See the figure to the left for the numbersand locations of the EPROMS.11. Reassemble the PLC-5 by reversing steps 1 thru 8.


U5*

U31* U12*

Replace the U5 and

Replace the U12 EPROM on the circuit

on the circuit board*

PLC-5 Chassis

Replace the firmware EPROM on the chassis

U7*

Replace the U7 or U12 EPROMthe chassis communication

card

board communication card*

on (if applicable)*

circuit board (if applicable)*

U31 EPROMS







2. Reconnect any cables.









SERIESC

F/W REVQ.2



If: Then:

PROC LED is solid red and CH1A DH+ LED is blinking green


PROC LED is solid red but the CH1A DH+ LED is not blinking green






Enhanced PLC-5 - Series E or Later

To update these series of Enhanced PLC-5 firmware, you must first use ControlFLASH and then if applicable, replace EPROMS. To start this firmware update, follow these steps:










ATTENTION












ATTENTION







Click Next.


Click Next.





Click Next.



Click Finish.


Click Next.






Step 4 - Install the New Firmware EPROMS (if applicable)

1. Disassemble the PLC-5 to begin the EPROM replacement:


Click Yes.


Important: This update will take approximately 8 or 9 minutes to complete.









On the Enhanced PLC-5, Series E or later: Do this:

1. Remove the four screws that hold the right side plastic cover.2. Remove the cover.3. Remove the two large screws and washers located in the center of the exposed circuit board.4. Carefully 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.5. Remove and replace the firmware EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS. 6. See the figure to the left for the numbers and locations of the EPROMS.7. Reassemble the PLC-5 by reversing steps 1 thru 4.

1785-L30B, -L40B, -L46B, -L60B, -L80B and -L86B programmable controllers 1. Remove the four screws that hold the right side plastic cover.2. Remove the cover.3. Remove the two large screws and washers located in the middle of the exposed circuit board.4. 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.5. Notice the direction in which the battery cable is wrapped around the nearby standoff.6. Disconnect the wires leading from the battery to the stake pins on the exposed circuit board.7. Disconnect the wires leading from the keyswitch to the stake pins on the exposed circuit board.8. Remove both communication cards.9. Remove and replace the firmware EPROMSone at a time, taking note of the locationnumber and the orientation of the notch ineach of the EPROMS.10. See the figure to the left for the numbersand locations of the EPROMS.11. Reassemble the PLC-5 by reversing steps 1 thru 8.


U18* (if applicable)If applicable,replace the U18EPROM*

U12*

Replace the U12 EPROM on the circuit

PLC-5 Chassis

U7*

Replace the U7 or U12 EPROMthe chassis communication

card

board communication card*

on (if applicable)*








SERIESC

F/W REVQ.2







2. Apply power to the PLC-5

3. .In ControlFLASH:






Click OK.

The update process is now complete. If an error occurs, click View Log to see specific error information (see the table below).



If: Then:



PROC LED is solid red but the CH1A DH+ LED is not flashing green


PROC LED is flashing red. CH1A is not flashing green

Call Rockwell Automation Technical Support at 440.646.5800. Send PLC-5 in for repair.



ControlNet PLC-5 - All Series

To update these series of ControlNet PLC-5 firmware, you must first use ControlFLASH and then if applicable, replace EPROMS. To start this firmware update, follow these steps:










ATTENTION












ATTENTION







Click Next.


Click Next.





Click Next.



Click Finish.


Click Next.







Click Yes.


Important: This update will take approximately 13 minutes to complete.








Step 4 - Install the New Firmware EPROMS (if applicable)


On the ControlNet PLC-5, Series C and D: Do this:

1785-L20C, -L40C, -L60C, -L80C, -L20C15, -L40C15, -L60C15, and L80C15 programmable controllers

1. On the front of the PLC-5, remove the screw on the communication card.2. Gently pull the communication card out of the PLC-5 chassis. 3. Remove and replace the U7 or U12 EPROM, taking note of the location number and the orientation of the notch in the EPROM.4. See the figure to the left for the location of the EPROM.9. Reassemble the PLC-5 by reversing steps 1 thru 3.

On the ControlNet PLC-5, Series E and F: Do this:

1785-L20C, -L40C, -L80C, -L20C15, -L40C15 and L80C15 programmable controllers 1. On the front of the PLC-5, remove the 2 hex nuts on Channel 0.2. Remove the screw on the communication card.3. Remove the four screws that hold the right side plastic cover and remove the cover.4. Remove the two large screws and washers located in the center of the exposed circuit board.5. Carefully 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.6. Gently pull the communication card off of the circuit board. 7. Remove and replace the U7 or U12 EPROM, taking note of the location number and the orientation of the notch in the EPROM.8. See the figure to the left for the location of the EPROM.9. Reassemble the PLC-5 by reversing steps 1 thru 6.


U7 or U12*


U7 or U12


(if applicable)*








3. In ControlFLASH:





SERIESC

F/W REVQ.2



Click OK.

The update process is now complete. If an error occurs, click View Log to see specific error information (see the table on the next page).









PLC-5 is a registered trademark of Rockwell Automation, Inc.Allen-Bradley, DH+, PLC-5/20, -5/20C, 5/30, -5/40, -5/40C, -5/60, -5/80, -5/80C, -5/20E, -5/40E, and -5/80E and RSLinx are trademarks of Rockwell Automation, Inc.ControlNet is a trademark of ControlNet International, Limited.Ethernet is a registered trademark of DEC, Intel and Xerox corporationsWindows and Windows NT are trademarks of Microsoft Corporation.

If: Then:

PROC LED is solid red and CH1A DH+ LED is blinking green Update is complete. Proceed to Step 5 below.

PROC LED is flashing red. CH1A is not flashing green Call Rockwell Automation Technical Support at 440.646.5800. Send PLC-5 in for repair.


You get a PLC Mismatch error: Incorrect Selection of PLC Device The PLC-5 you selected and the PLC-5 you are trying to update are different. Repeat the procedure and select the correct PLC-5.

You get an Error Reading Serial Number: Invalid Serial Number The PLC-5 programmable controller was previously updated incorrectly. Send it in for repair.

Publication 1785-IN022B-EN-P - November 2002 40 PN 957345-77Supersedes Publication 1785-5.22 - June 1999 Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Documents

Firmware Update Instructions for Ethernet, … · Publication 1785-IN022B-EN-P - November 2002 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable