Procedure to Upgrade from SYSCON+ to SYSCON2 and Implement Release 5.0 in a Working Maxum Network Access Unit (NAU)

Transcription

1 to Upgrade from SYSCON+ to SYSCON2 and Implement Release 5.0 in a Working Maxum Network Access Unit (NAU) Difficulty Level: High Estimated time to execute: 2 Hours Revision History Issue Date Reason /15/09 First Draft Based on IP /23/10 Lab tested and released SYSCON+ to SYSCON2 1 IP-0006

2 1.0 Description This document describes the procedure to replace an original version SYSCON+ with a SYSCON2 and to install and activate release 5.0 software in a Network Access Unit. This procedure involves replacement of the original SYSCON+ with the SYSCON2 boards. A retrofit kit (part number A5E ) is required for this procedure. Depending on the existing configuration some parts in this kit may not be required. This kit contains the following items. Description Quantity SYSCON2 (consisting of an SIB with CAC3 installed on it) 1 Cables for SYSCON communication and debug ports (short) 2 Cables for SYSCON communication and debug ports (long) 3 Computer bracket with three DB-9 connectors (for COM and Debug) 1 Ethernet Switch Board with 1 ft Ethernet cable 1 New HMI Interface Cable 1 Filter for HMI Ribbon Cable and Double-sided tape for installing Filter 1 Miscellaneous Labels 1 RS-485 Adapter Cable 1 Note: The above list is included for reference only and is not intended to be all inclusive. For a complete list with part numbers, refer to the packing list sent with the kit. Also required is a tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers. Warning: Full safety precautions must be followed throughout all sections of this procedure to prevent possible injury, equipment damage, or death. Verify that the area is clear of flammable gases and vapors and that appropriate authorization is obtained to do the work (hot work permits). Warning: This upgrade must be done with the approval of the local authority having jurisdiction. SYSCON+ to SYSCON2 2 IP-0006

3 2.0 Prerequisites This procedure must be performed by a user who has detailed knowledge of the Maxum and the NAU. This includes detailed knowledge of the hardware, operation, and database setup of the device. In addition, the user should have sufficient computer skills to be able to install and operate the new software. If a customer does not have the knowledge required for this procedure, then it is highly recommended that Siemens Field Service personnel be contracted to assist. A tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers is required to perform this procedure 3.0 Upgrade System Manager This section covers upgrading of the Maxum System Manager software to various workstations. This is required for proper communication with the new Maxum II software Release 5.0. This section is not required if the software was installed previously. System Manager Upgrade 1. To upgrade the System Manager software, insert the Maxum System Manager installation disk. The installation program will launch automatically (if it does not run automatically, execute the setup.exe file on the disk). 2. Follow the directions given by the installation tool to upgrade to the new software. You may accept the defaults by clicking "Next" as needed in the installation windows. 3. Repeat the installation for all computers that you wish to upgrade. SYSCON+ to SYSCON2 3 IP-0006

4 4.0 Installation of New SYSCON2 and Upgrade to Release 5.0 This section covers replacement of SYSCON+ with SYSCON2 and upgrading of the NAU software version. Note: All figures are located at the end of this document. 1. Verify that the IP addresses (IP address, IP mask, and router address) of the NAU are available as they will be needed in order to configure the new SYSCON2. 2. Using System Manager, save the existing database of the NAU to the hard drive of the Workstation. From the System Manager software choose: System > Unit Backup / Restore Choose the desired NAU Enter the desired file name for the backup file Select the Backup the Analyzer button in the window Result: The.amd database file is saved to the hard drive of the PC. SYSCON+ to SYSCON2 4 IP-0006

5 3. Updating the Database to Rel 5.0 A new function in Maxum Utilities, DBConverter, is used to update the NAU database from older software versions to software Release 5.0. Note: Details and instructions for running DBConverter can be accessed by opening the DBConverter help file from the Maxum Reference Help File. DBConverter Help may also be assessed from the DBConverter window. This step will use DBConverter to create a new database file for use in loading the NAU later in this procedure. Perform the following to convert the database to Release 5.0. Start Maxum System Manager and access the analyzer. Open Maxum Utilities using the Tools menu in System Manager. Start DBConverter by selecting the Loader menu in Maxum Utilities. Under the Source File section In the DBConverter window choose Database File. This will cause a Select File button to appear. Hit the Select File button. Select the.amd database file that was saved at the beginning of this procedure. The Target File part of the window will now be populated. When the target file selection appears, choose Database File From the drop down menu select software version 5.0 for the target. Select Start in the DBConverter window. Either choose the default name offered or enter a desired new name of the output.amd file (do not overwrite an existing file). Press Save. The conversion will begin and the progress will be shown in the DBConverter window. Note that a comparison log file is available that shows if there were any errors with the conversion. Contact Siemens support if there are errors (not warnings) with the database conversion. After conversion is complete, close the DBConverter window. SYSCON+ to SYSCON2 5 IP-0006

6 4. Shut down power to the NAU. 5. Original SYSCON+: Use the following steps to remove the SYSCON+ from the NAU. Unplug all cables from the SYSCON+ board, including cables connecting both externally to the NAU and internally within the NAU. Make note of cable plug in locations, and label the cables if necessary to insure they can be reconnected correctly later. If it is not already disconnected, unplug the power cord from the NAU at that power supply end. Completely remove the HMI cable. Because the SYSCON2 connector for this cable is different, the cable will be replaced with a new one from the upgrade kit. Remove the screws that secure all plug-in boards to the SYSCON tray, including the debug/reset connector hardware that occupies one of the slots. If a CAN expansion motherboard is installed in the other half of the NAU, it is not necessary to remove those plug-in boards. Make note of the plug in locations for all boards and then unplug them and set them aside in a static protected location. Remove the power supply by loosening the three nuts that secure the power supply and then lifting it out of the NAU. Using a 2.5mm hex wrench, remove all six (6) screws that connect the SYSCON+ to the assembly. There are screws at each corner and two in the middle of the board. Remove the SYSCON+. SYSCON+ to SYSCON2 6 IP-0006

7 6. New SYSCON2: Use the following steps to install the new SYSCON2 into the NAU. Insert the new SYSCON2. Using a 2.5mm hex wrench, install all six (6) screws that connect the SYSCON2 to the assembly. There are screws in the same locations as the SYSCON+. Using a 3/16 nut driver or wrench, remove the existing RS232 and RS485 connectors from the assembly. Using the 3/16 nut driver or wrench, install the two new RS232/RS485 connector cables (short) onto the assembly. Plug the connectors into the SYSCON2. The top connector is Serial 1 and connects to the position labeled Serial 1 on the SYSCON2. The bottom connector is Serial 2 and connects to the position labeled Serial 2. Refer to figure 2 for plug in locations. From the kit, install the bracket that is equipped with 3 DB-9 connectors into slot 2 of the assembly. If slot 2 was previously already occupied by a board, the position where the previous debug/reset hardware was located may be used. For the three connectors (long cables) of the bracket, Serial 3 is on top, Serial 4 is in the middle, and Debug is on the bottom. Plug the connectors into the SYSCON2 board in their proper locations, referring to figure 2 for plug-in locations. Apply the debug/serial connector labels from the kit next to the bracket as shown in figure 3. For SYSCON+, the NAU SYSCON assembly is equipped with an opening for the Ethernet connection. For the SYSCON2, this location is used for the Reset switch. The upgrade kit contains a small, rigid label that is used to label the new Reset switch. Apply the reset label over the Ethernet opening as shown in figure 3. Be sure to carefully align the hole on the label with the Reset switch on the SYSCON2. Reinstall the power supply and tighten the 3 nuts that secure it to the NAU. Do not connect the power cord at this time. SYSCON+ to SYSCON2 7 IP-0006

8 CAUTION: To support backwards compatibility of peripheral boards, the board slots in the SYSCON2 are not keyed. In the following step DO NOT install any boards that are not approved for use by Siemens into the SYSCON2. Doing so may damage the board, the SYSCON2, or both. All boards received from Siemens for use with the SYSCON+ are approved for use with the SYSCON2. Boards not supplied by Siemens are not approved. 7. New SYSCON2: Reinstall boards that were installed in the old SYSCON+ (e.g. CAN boards, Fiber Optic Converter boards, etc.) in the new SYSCON2. Note: Any board equipped in slot 5 (which has a different type of connector) is NOT to be reinstalled. Boards that plug into this slot in the SYSCON+ are not required in the SYSCON2. The upgrade kit should include an Ethernet switch board. Install this board in the slot 5 of the new SYSCON2. SYSCON+ to SYSCON2 8 IP-0006

9 8. New SYSCON2: Re-connect all cables to the new SYSCON. Refer to Figures 2 and 3. Install the new HMI to SYSCON2 cable. A 1 ft long RJ-45 Ethernet cable is included in the kit. Install this cable between the internal RJ-45 connector on the Ethernet Switch Board and the RJ-45 connector on the CAC3. Refer to figures 2 and 3 for the proper CAC3 connection (labeled 10BaseT external). Notes on Serial Ports and other connections: 1. The pinout for the serial ports, when configured for RS-485 operation, is different between the SYSCON+ and SYSCON2. Also, the RS-485 connection is now a male connector. There is an adapter cable supplied with the upgrade kit that is used to adapt an existing RS-485 cable to the SYSCON2. If an RS-485 cable is equipped, install the adapter cable at this time. 2. In Release 5.0 software all serial ports may be configured as either RS-232 or RS-485. However, Serial 1 on the SYSCON2 is hardcoded to always operate as Modbus (Serial 2 may be used to operate as a printer connection). If there is an RS-485 Modbus connection on the SYSCON+, the cable must be moved to Serial 1. Also, any non-modbus cable in the RS-232 connector must be moved to Serial 2. Note that if this configuration exists, the software will be automatically changed by the DBConverter program to match. 3. The external RJ-45 Ethernet connection is now located on the Ethernet Switch board which is located in the slot 5 of the assembly. The existing Ethernet cable can be plugged into any location in the Ethernet Switch. 9. A filter must be added to the HMI ribbon cable to prevent interference. This filter is included in the upgrade kit. Some NAUs may already have the filter installed. If it is not already installed, install the filter at this time as shown in Figure Reconnect the power cord and apply power to the NAU. SYSCON+ to SYSCON2 9 IP-0006

10 11. From the physical HMI on the NAU, set the IP addresses for the new SYSCON2. This will allow the System Manager software to communicate with the device so that the updated database may be loaded. The HMI software in Release 5.0 is slightly different from the software in prior releases. However, the path for setting IP addresses is the same. From the Configure Menu choose System Setup. Then choose the IP SET INFO softkey and modify the IP address, the IP mask, and the Router IP address to match the desired settings that were noted earlier in this procedure. CAUTION: In the following step, verify that the CORRECT analyzer is downloaded. Loading the wrong analyzer will lead to loss of data. 12. Load New SYSCON2 with Converted Database: Open System Manager and choose the System menu and then Unit Backup / Restore. In the Backup/Restore window, select the NAU to be upgraded. Choose the 7file name for the AMD file that was created by DBConverter earlier in this procedure. Enter the super login ID and the password for that ID. Select Restore the analyzer. A warning message will appear indicating that all of the current data on the device will be destroyed and it will be rebooted. Verify that the CORRECT device is chosen and hit Yes to continue. The database will load and reset automatically. Perform a startup of all hardware in accordance with all standard safety procedures. 13. Verify the operation of any I/O that is configured in the NAU, including any remote I/O for the NAU that is configured in other devices. Note that some modification of the I/O datatype and scaling may be necessary in order for the I/O to function as desired. SYSCON+ to SYSCON2 10 IP-0006

11 14. Check the operation of the following (if equipped): 1. System Manager connection to the NAU via Ethernet 2. Maintenance Panel on the NAU 3. Verify any equipped I/O is functioning as expected 4. MaxBasic Programs (run each manually, if feasible) 5. Any other communication links that may exist (e.g. Modbus, printer). 15. Verify that the there is not a purge alarm on the device (purge bypass should be used and function correctly on the NAU). 16. Perform any other system checks that may be needed. 17. The following steps must be taken to allow for the unlikely event of a fallback to the old hardware. 1. A copy of the original AMD file must be saved. This file should be stored in a safe location to prevent it from being accidentally deleted. 2. The original SYSCON+ board should remain on site in a protected location to prevent damage. Any additional hardware that was removed as part of the upgrade should remain with the original SYSCON+ board. The original SYSCON+ and the other hardware must NOT be used as spares or replacements in any other device. 3. On a piece of paper, make notes indicating which boards were installed in which slots in the original SYSCON+ configuration. Store this information with the original SYSCON+. 4. All other kit hardware should remain with the original SYSCON+. This hardware and information should be saved for at least one month to ensure that no problems arise with the new device. If a problem arises, do not attempt to fall back without the advice and assistance of Siemens support. If a fallback becomes necessary, Siemens support will provide a fallback procedure. SYSCON+ to SYSCON2 11 IP-0006

12 5.0 Figures Reset SIMM 80 #2 Flash/SRAM SIMM 80 #1 Flash/DRAM SIMM 72 Maintenance Panel Display CAN Direct 5 CAN Direct 4 CAN Direct 3 CAN Direct 2 Power Purge RS 232/485 Internal Bus Not Used Not Used SYSCON Debug CAN Direct 1 AT Bus PCI Slot 4 10Base2 CAN Bus PCI Slot 3 PCI Slot 2 PCI Slot 1 I/O Terminal Blocks 10BaseT Figure 1 SYSCON+ Connections SYSCON+ to SYSCON2 12 IP-0006

13 Figure 2 SYSCON2 Board Connections SYSCON+ to SYSCON2 13 IP-0006

14 Figure 3 NAU Labels and Connections Figure 4 Application of Filter for HMI Ribbon Cable SYSCON+ to SYSCON2 14 IP-0006