Allen-Bradley Motors

Installation Instructions Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Purpose Firmware Update Kit Contents Hardware and Software Requirements This document describes how to update firmware on your Ethernet, Enhanced, or ControlNet PLC-5 programmable controller. 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 Your computer must meet the following requirements to perform the firmware update: at least a 486 processor Windows 95, Windows 98, or Windows NT, or later, operating system at least 16 Mbytes of available memory To perform Ethernet Series C, or later, 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 controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. Locate Your Controller s Update Procedure in this Document To update the firmware on this controller: Go to this page: Ethernet PLC-5, Series C and D 4 Ethernet PLC-5, Series E or Later 13 Enhanced PLC-5, Series A thru D 21 Enhanced PLC-5, Series E or Later 25 ControlNet PLC-5, All Series 33 Allen-Bradley Motors 1

2 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual, when necessary we use notes to make you aware of safety considerations. 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. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence SHOCK HAZARD Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present. BURN HAZARD Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be dangerous temperatures.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3 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. 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 programmable controller. Allen-Bradley Motors

4 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Important Considerations for CL I, Div. 2 Installations 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. Ethernet PLC-5 Programmable Controllers - 1785-L20E - 1785-L40E - 1785-L80E Series 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 ATTENTION You must save the controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. 1. Save the controller s processor memory to your hard disk or to an EEPROM. 2. Remove power from the controller. 3. Remove the controller battery cover and disconnect the battery. 4. Remove the controller from the chassis.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 5 5. Locate and document the controller s hardware Ethernet address. The address is on the circuit board label toward the back of the controller. 6. If applicable, disconnect the coprocessor or Ethernet Interface sidecar module. 7. Reinstall the controller into the chassis. 8. Apply power to the controller. 9. Through the Ethernet port, use either a switch, hub or crossover cable to connect the computer to the controller. Make sure the TCP/IP is configured and running on the personal computer. 10. Assign the controller s IP address by going online with the controller via DH+ or serially. Use the channel configuration screen to configure the IP address for Channel 2 (uncheck the BOOTP enabled box). 11. Turn the controller keyswitch to PROGRAM mode. Allen-Bradley Motors

6 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 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 ATTENTION Failure to follow these procedures exactly or to cause an interruption during them may result in an inoperable controller. 1. If you have not already done so, connect the computer to the controller through the Ethernet channel: use either a switch, hub or crossover cable to connect the computer to the controller 2. Close all applications including RSLinx.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 7 3. Start ControlFLASH: 3A - Start the ControlFLASH software. Click Next. 3B - Select the appropriate PLC-5 Programmable Controller catalog number. Use the cursor to highlight the PLC-5 type Click Next. Allen-Bradley Motors

8 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3C - Enter the Ethernet IP address of the PLC-5 you are updating. Click Get Info to verify the programmable controller you are updating. Click OK. 3D - Select the firmware revision. Select the correct update revision. Click Next. 3E - Verify the update. Click Finish.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 9 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. 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 440-646-3223. 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. 4. Remove power from the controller. 5. Remove the controller from the chassis. Allen-Bradley Motors

10 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 4 - Install the New Firmware EPROMS On the Ethernet PLC-5, Series C and D: 1785-L20E programmable controller Replace the U61 and U70 EPROMS* If applicable, replace the U18 EPROM* U18* (if applicable) U61* U70* 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 controller by reversing steps 1 thru 4. 1785-L40E and -L80E programmable controllers 1. On the front of the controller, remove the 2 hex nuts on Channel 0. 2. Remove the screw on the communication card and gently pull the card out of the Replace the U5 and U31 EPROMS on the circuit board* If applicable, replace the U7 or U12 EPROM on the communication card* U5* U31* U7 or U12* (if applicable) Remove communication card controller. 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 controller by reversing steps 1 thru 5. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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. Note: Do not reinstall the controller until you complete the next step.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 11 Step 5 - Apply the Firmware Revision Label 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. 1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of controller). Make certain to place the label so that the current series and revision information is clearly visible. CAT. NO. REV. 1785-L40E C D ETHERNET PLC-5/40 PROCESSOR MADE IN USA PART NO. 96215074 A01 BACKPLANE CURRENT REQUIREMENTS 3.3A AT 5VDC F/W REV Q.2 SERIES C FIRMWARE UPGRADE CAT. NO. 1785-L40E SERIES REV. D G.2 Place new label over previous label or below entire product label. Step 6 - Complete the Firmware Update 1. Install the controller into the chassis. 2. Apply power to the controller. 3. After powerup, check the status of the controller: If: PROC LED is solid red and CH1A DH+ LED is flashing green PROC LED is solid red but the CH1A DH+ LED is not flashing green PROC LED is flashing red and green Then: Update is complete. Proceed to the next step. 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). Repeat the ControlFLASH procedure Allen-Bradley Motors

12 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 4. Since you removed the controller 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 controller 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 controller 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: At the Cycle Power prompt, click OK The update process is now complete. The Status windows displays the result of the update. If an error occurs, it is displayed in this window. If an error occurs, click View Log to see specific error information. Click OK. 6. When the update is successful: restore all connections to the controller 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 440.646.3223.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 13 Ethernet PLC-5 Programmable Controllers - 1785-L20E - 1785-L40E - 1785-L80E Series E or Later To update these series of Ethernet PLC-5 programmable controller firmware, you must first use ControlFLASH and then if applicable, replace EPROMS. To start this firmware update, follow these steps: Step 1 - Prepare the PLC-5 Programmable Controller ATTENTION You must save the controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. 1. Save the controller s processor memory to your hard disk or to an EEPROM. 2. Disconnect all cables (serial, DH+, ControlNet, Ethernet, etc.) from the controller. 3. Remove power from the controller and remove it from the chassis. 4. Remove the controller battery cover and disconnect the battery. This resets the serial port to its default configuration so that the controller and ControlFLASH can communicate. 5. If applicable, disconnect the coprocessor or Ethernet Interface sidecar module. 6. Verify that the serial port DIP switches are set for RS-232. 7. Reinstall the controller and apply power. 8. Turn the controller keyswitch to PROGRAM mode. Allen-Bradley Motors

14 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 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 ATTENTION Failure to follow these procedures exactly or to cause an interruption during them may result in an inoperable controller. 1. Connect the computer to the controller using a 1784-CP10 or -CP11 cable between the computer and Channel 0 of the controller 2. Close all applications including RSLinx.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 15 3. Start ControlFLASH: 3A - Start the ControlFLASH software. Click Next. 3B - Select the appropriate PLC-5 Programmable Controller catalog number. Use the cursor to highlight the PLC-5 type Click Next. Allen-Bradley Motors

16 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3C - Select the serial port of the computer to which you connected the 1784-CP10 or -CP11 cable. Select COM1 or COM2. Click Get Info to verify the programmable controller you are updating. Click Next. 3D - Select the firmware revision. Select the correct update revision. Click Next. 3E - Verify the update. Click Finish.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 17 3F - Start the firmware update. Click Yes. The progress indicator shows how much of the update has been performed. Important: This update will take approximately 13 minutes to complete. 3G - 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: 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. These procedures are detailed on the following pages. 4. Remove power from the controller. 5. Remove the controller from the chassis. Allen-Bradley Motors

18 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 4 - Install the New Firmware EPROM (if applicable) On the Ethernet PLC-5 Programmable Controller, Series E or Later: Do this: 1785-20E, -L40E and -L80E programmable controllers 1. On the front of the controller, 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. If applicable, replace the U7 or U12 EPROM on the communication card* U7 or U12 (if applicable)* Remove communication card 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 controller by reversing steps 1 thru 6. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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. Note: Do not reinstall the controller until you complete the next step.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 19 Step 5 - Apply the Firmware Revision Label 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. 1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of controller). Make certain to place the label so that the current series and revision information is clearly visible. CAT. NO. REV. 1785-L40E C D ETHERNET PLC-5/40 PROCESSOR MADE IN USA PART NO. 96215074 A01 BACKPLANE CURRENT REQUIREMENTS 3.3A AT 5VDC F/W REV Q.2 SERIES C FIRMWARE UPGRADE CAT. NO. 1785-L40E SERIES REV. D G.2 Place new label over previous label or below entire product label. Step 6 - Complete the Firmware Update 1. Install the controller into the chassis. 2. Apply power to the controller. Allen-Bradley Motors

20 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3. In ControlFLASH: At the Cycle Power prompt, click OK The update process is now complete. If an error occurs, click View Log to see specific error information (see the table below). The Status windows displays the result of the update. If an error occurs, it is displayed in this window. Click OK. 4. After powerup, check the status of the controller: If: PROC LED is solid red and CH1A DH+ LED is flashing green PROC LED is flashing red. CH1A is not flashing green PROC LED is flashing red and green Then: Update is complete. Proceed to Step 5 below. Call Rockwell Automation Technical Support at 440.646.3223. Send controller in for repair. Repeat the ControlFLASH procedure 5. When the update is successful: restore all connections to the controller 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 440.646.3223.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 21 Enhanced PLC-5 Programmable Controllers - Series A thru D To update these series of Enhanced PLC-5 firmware, you must replace the applicable EEPROMS. To start this firmware update, follow these steps: Step 1 - Prepare the PLC-5 Programmable Controller ATTENTION You must save the controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. 1. Save the controller s processor memory to your hard disk or to an EEPROM. 2. Disconnect all cables (serial, DH+, ControlNet, Ethernet, etc.) from the controller. 3. Remove power from the controller and remove it from the chassis. 4. Remove the controller battery cover and disconnect the battery. 5. If applicable, disconnect the coprocessor or Ethernet Interface sidecar module. Allen-Bradley Motors

22 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 2 - Install the New Firmware EPROMS 1. Disassemble the controller to begin the EPROM replacement: On the Enhanced PLC-5 Programmable Controllers, Series A thru D: 1785--L11B, -L20B and -L26B programmable controllers Replace the U61 and U70 EPROMS* If applicable, replace the U18 EPROM* U18* (if applicable) U61* U70* 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 controller by reversing steps 1 thru 4. On the Enhanced PLC-5 Programmable Controllers, Series A thru D: Do this: 1785-L30B programmable controller 1. On the front of the controller, remove the 2 hex nuts on Channel 0. 2. Remove the screw on the communication card and remove the card. Replace the U5 and U31 EPROMS on the circuit board* If applicable, replace the U7 or U12 EPROM on the communication card* U5* U31* U7 or U12 (if applicable) Remove 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 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 controller by reversing steps 1 thru 6. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 23 On the Enhanced PLC-5 Programmable Controllers, Series A thru D: 1785-L40B, -L46B, -L60B, -L80B and -L86B programmable controllers Replace the U5 and U31 EPROMS on the circuit board* Replace the U7 or U12 EPROM on the chassis communication card (if applicable)* U5* U31* U12* U7* Replace the firmware EPROM on the chassis circuit board (if applicable)* Replace the U12 EPROM on the circuit board communication card* PLC-5 Chassis Do this: 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 EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS. 10. See the figure to the left for the numbers and locations of the EPROMS. 11. Reassemble the controller by reversing steps 1 thru 8. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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. Allen-Bradley Motors

24 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 4 - Apply the Firmware Revision Label 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. 1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of controller). Make certain to place the label so that the current series and revision information is clearly visible. CAT. NO. REV. 1785-L40E C D ETHERNET PLC-5/40 PROCESSOR MADE IN USA PART NO. 96215074 A01 BACKPLANE CURRENT REQUIREMENTS 3.3A AT 5VDC F/W REV Q.2 SERIES C FIRMWARE UPGRADE CAT. NO. 1785-L40E SERIES REV. D G.2 Place new label over previous label or below entire product label. Step 5 - Complete the Firmware Update 1. Install the controller into the chassis. 2. Reconnect any cables. 3. Apply power to the controller. 4. After powerup, check the status of the controller: If: 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 Then: Update is complete. Proceed to Step 5 below. 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).

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 25 5. When the update is successful: restore all connections to the controller 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 440.646.3223. Enhanced PLC-5 Programmable Controllers - 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: Step 1 - Prepare the PLC-5 Programmable Controller ATTENTION You must save the controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. 1. Save the controller s processor memory to your hard disk or to an EEPROM. 2. Disconnect all cables (serial, DH+, ControlNet, Ethernet, etc.) from the controller. 3. Remove power from the controller and remove it from the chassis. 4. Remove the controller battery cover and disconnect the battery. This resets the serial port to its default configuration so that the controller and ControlFLASH can communicate. 5. If applicable, disconnect the coprocessor or Ethernet Interface sidecar module. 6. Verify that the serial port DIP switches are set for RS-232. 7. Reinstall the controller and apply power. 8. Turn the controller keyswitch to PROGRAM mode. Allen-Bradley Motors

26 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 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 ATTENTION Failure to follow these procedures exactly or to cause an interruption during them may result in an inoperable controller. 1. Connect the computer to the controller using a 1784-CP10 or -CP11 cable between the computer and Channel 0 of the controller 2. Close all applications including RSLinx.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 27 3. Start ControlFLASH: 3A - Start the ControlFLASH software. Click Next. 3B - Select the appropriate PLC-5 Programmable Controller catalog number. Use the cursor to highlight the PLC-5 type Click Next. Allen-Bradley Motors

28 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3C - Select the serial port of the computer to which you connected the 1784-CP10 or -CP11 cable. Select COM1 or COM2. Click Get Info to verify the programmable controller you are updating. Click Next. 3D - Select the firmware revision. Select the correct update revision. Click Next. 3E - Verify the update. Click Finish.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 29 3F - Start the firmware update. Click Yes. The progress indicator shows how much of the update has been performed. Important: This update will take approximately 8 or 9 minutes to complete. 3G - 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: 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. These procedures are detailed on the following pages. 4. Remove power from the controller. 5. Remove the controller from the chassis. Allen-Bradley Motors

30 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 4 - Install the New Firmware EPROMS (if applicable) 1. Disassemble the controller to begin the EPROM replacement: On the Enhanced PLC-5 Programmable Controllers, Series E or later: If applicable, replace the U18 EPROM* U18* (if applicable) 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 controller by reversing steps 1 thru 4. 1785-L30B, -L40B, -L46B, -L60B, -L80B and -L86B programmable controllers Replace the U7 or U12 EPROM on the chassis communication card (if applicable)* U12* U7* PLC-5 Chassis Replace the U12 EPROM on the circuit board communication card* 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 EPROMS one at a time, taking note of the location number and the orientation of the notch in each of the EPROMS. 10. See the figure to the left for the numbers and locations of the EPROMS. 11. Reassemble the controller by reversing steps 1 thru 8. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 31 Step 5 - Apply the Firmware Revision Label 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. 1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of controller). Make certain to place the label so that the current series and revision information is clearly visible. CAT. NO. REV. 1785-L40E C D ETHERNET PLC-5/40 PROCESSOR MADE IN USA PART NO. 96215074 A01 BACKPLANE CURRENT REQUIREMENTS 3.3A AT 5VDC F/W REV Q.2 SERIES C FIRMWARE UPGRADE CAT. NO. 1785-L40E SERIES REV. D G.2 Place new label over previous label or below entire product label. Allen-Bradley Motors

32 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 6 - Complete the Firmware Update 1. Install the controller into the chassis. 2. Apply power to the controller 3. In ControlFLASH: At the Cycle Power prompt, click OK The update process is now complete. If an error occurs, click View Log to see specific error information (see the table below). The Status windows displays the result of the update. If an error occurs, it is displayed in this window. Click OK. 4. After powerup, check the status of the controller: If: PROC LED is solid red and CH1A DH+ LED is flashing green PROC LED is solid red but the CH1A DH+ LED is not flashing green PROC LED is flashing red. CH1A is not flashing green Then: Update is complete. Proceed to Step 5 below. 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). Call Rockwell Automation Technical Support at 440.646.3223. Send controller in for repair. 5. When the update is successful: restore all connections to the controller 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 440.646.3223.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 33 ControlNet PLC-5 Programmable Controllers - 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: Step 1 - Prepare the PLC-5 Programmable Controller ATTENTION You must save the controller s processor memory to your hard disk or to an EEPROM. If you do not, the controller s user memory will be lost because the firmware update procedure erases memory. 1. Save the controller s processor memory to your hard disk or to an EEPROM. 2. Disconnect all cables (serial, DH+, ControlNet, Ethernet, etc.) from the controller. 3. Remove power from the controller and remove it from the chassis. 4. Remove the controller battery cover and disconnect the battery. This resets the serial port to its default configuration so that the controller and ControlFLASH can communicate. 5. If applicable, disconnect the coprocessor or Ethernet Interface sidecar module. 6. Verify that the serial port DIP switches are set for RS-232. 7. Reinstall the controller and apply power. 8. Turn the controller keyswitch to PROGRAM mode. Allen-Bradley Motors

34 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 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 ATTENTION Failure to follow these procedures exactly or to cause an interruption during them may result in an inoperable controller. 1. Connect the computer to the controller using a 1784-CP10 or -CP11 cable between the computer and Channel 0 of the controller 2. Close all applications including RSLinx.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 35 3. Start ControlFLASH: 3A - Start the ControlFLASH software. Click Next. 3B - Select the appropriate PLC-5 Programmable Controller catalog number. Use the cursor to highlight the PLC-5 type Click Next. Allen-Bradley Motors

36 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 3C - Select the serial port of the computer to which you connected the 1784-CP10 or -CP11 cable. Select COM1 or COM2. Click Get Info to verify the programmable controller you are updating. Click Next. 3D - Select the firmware revision. Select the correct update revision. Click Next. 3E - Verify the update. Click Finish.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 37 3F - Start the firmware update. Click Yes. The progress indicator shows how much of the update has been performed. Important: This update will take approximately 13 minutes to complete. 3G - 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: 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. These procedures are detailed on the following pages. 4. Remove power from the controller. 5. Remove the controller from the chassis. Allen-Bradley Motors

38 Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers Step 4 - Install the New Firmware EPROMS (if applicable) On the ControlNet PLC-5 Programmable Controllers, Series C and D: 1785-L20C, -L40C, -L60C, -L80C, -L20C15, -L40C15, -L60C15, and L80C15 programmable controllers Do this: 1. On the front of the controller, remove the screw on the communication card. 2. Gently pull the communication card out of the controller 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 controller by reversing steps 1 thru 3. U7 or U12* Remove communication card On the ControlNet PLC-5 Programmable Controllers, Series E and F: Do this: 1785-L20C, -L40C, -L80C, -L20C15, -L40C15 and L80C15 programmable controllers 1. On the front of the controller, 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 U7 or U12 the backplane edge connector away from the (if applicable)* 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 Remove communication card the EPROM. 9. Reassemble the controller by reversing steps 1 thru 6. * EPROM numbers may vary and their locations shown in these illustrations are approximate. Your series and revision of controller 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. Note: Do not reinstall the controller until you complete the next step.

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 39 Step 5 - Apply the Firmware Revision Label 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. 1. Apply the new firmware revision label on or below the existing product identification label (depending on the series and revision of controller). Make certain to place the label so that the current series and revision information is clearly visible. CAT. NO. REV. 1785-L40E C D ETHERNET PLC-5/40 PROCESSOR MADE IN USA PART NO. 96215074 A01 BACKPLANE CURRENT REQUIREMENTS 3.3A AT 5VDC F/W REV Q.2 SERIES C FIRMWARE UPGRADE CAT. NO. 1785-L40E SERIES REV. D G.2 Place new label over previous label or below entire product label. Step 6 - Complete the Firmware Update 1. Install the controller into the chassis. 2. Apply power to the controller. 3. In ControlFLASH: At the Cycle Power prompt, click OK The update process is now complete. The Status windows displays the result of the update. If an error occurs, it is displayed in this window. If an error occurs, click View Log to see specific error information (see the table on the next page). Click OK. Allen-Bradley Motors

4. After powerup, check the status of the controller: If: PROC LED is solid red and CH1A DH+ LED is blinking green PROC LED is flashing red. CH1A is not flashing green PROC LED is flashing red and green You get a PLC Mismatch error: Incorrect Selection of PLC Device You get an Error Reading Serial Number: Invalid Serial Number Then: Update is complete. Proceed to Step 5 below. Call Rockwell Automation Technical Support at 440.646.3223. Send controller in for repair. Repeat the ControlFLASH procedure The controller you selected and the controller you are trying to update are different. Repeat the procedure and select the correct controller. The PLC-5 programmable controller was previously updated incorrectly. Send it in for repair. 5. When the update is successful: restore all connections to the controller 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 440.646.3223. PLC-5, ControlNet, Allen-Bradley, DH+, PLC-5/20, -5/20C, -5/30, -5/40, -5/40C, -5/60, -5/80, -5/80C, -5/20E, -5/40E, -5/80E, and RSLinx are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. 40 PN 957899-47 Supersedes Publication 1785-IN022B-EN-P - November 2002 Copyright 2005 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.