Allen-Bradley 1785-L11B User manual

For A-B Internal Use Only Publication 1785-6.2 March 1998

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... Use this manual if you are responsible for performing a flash

firmware upgrade to a flash-based PLC-5®processor.

This Manual Describes... This manual describes how to use the PLC-5 programmable

controller flash tool to upgrade these products:

• series E and later Enhanced PLC-5 processors

• series E and later Ethernet®PLC-5 processors

• 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.

For more information about: Read this publication: Publication number:

EnhancedPLC-5 processors Enhancedand Ethernet PLC-5 Programmable

Controllers User Manual 1785-6.5.12

Ethernet PLC-5 processors

ControlNet 1.0 or 1.25 PLC-5 processors ControlNet PLC-5 Programmable Controllers

User Manual 1785-6.5.14

ControlNet 1.5 PLC-5 processors ControlNet PLC-5 Programmable Controllers

Phase 1.5 User Manual 1785-6.5.22

Allen-Bradley Automation

Publication 1785-6.2 March 1998 For A-B Internal Use Only

Before You Begin... 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

You will copy the flash files to your hard drive.

Using the Flash Tool To successfully use the flash tool, you need to complete seven steps:

1. Prepare the PLC-5 processor.

2. Install the flash tool.

3. Perform the firmware upgrade.

4. Apply the firmware revision label.

5. Update the communication plug firmware, if necessary.

6. Reconnect the PLC-5 processor.

7. Uninstall the flash tool.

!ATTENTION: You must install and run the PLC-5

flashtoolonacomputerbootedupinDOS6.22orlater.

Do not usea DOS window running under Windows

95 or Windows NT.

!ATTENTION: Pay strict attention to the flash tool

procedure. Failuretofollowthisprocedureexactlymay

result in an inoperable processor.

For A-B Internal Use Only Publication 1785-6.2 March 1998

Step 1 - Preparing the PLC-5 Processor

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.

ATTENTION: You must save the processor memory

to your hard disk or to an EEPROM. If you do not, the

PLC-5 user memory will be lost because the flash

procedure erases processor memory.

Allen-Bradley Automation

Publication 1785-6.2 March 1998 For A-B Internal Use Only

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

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 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

Step 3 - Performing the Flash Upgrade

Follow these steps to upgrade the processor firmware.

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 .

!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.

!ATTENTION: Do not interrupt the flash download

process by disturbing the processor or computer.

Failure to do so may result in an inoperable processor.

Return

For A-B Internal Use Only Publication 1785-6.2 March 1998

3. Select the appropriate script file by moving the cursor to the file name and

pressing . Script files are named as follows:

Lwwx_yz.ini

4. On your computer, select the communication port (COM1 or COM2) by

moving the cursor to select the port and pressing .

5. Make sure you have established a connection. This could take about

60 seconds.

Where: Represents:

11, 20, 26, 30, 40, 46, 60, 80, or 86

dependingon what flash upgrade you are

trying to download to the processor.

the type of flash upgrade to download:

• B (for Enhanced)

• L (for Extended-local I/O)

• C (for ControlNet 1.0 or 1.25)

• E (for Ethernet)

• C15 (for ControlNet 1.5)

the series of the flash upgrade to download

(see the disk label)

the revision of the flash upgrade to download

(see the disk label)

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.

Return

Allen-Bradley Automation

Publication 1785-6.2 March 1998 For A-B Internal Use Only

If you received an error:

When the flash download begins:

• the processor’s COMM LED blinks green

• the processor’s PROC LED blinks red/green

• a percent complete status (0 - 100) appears in the middle

of the screen that indicates how much of the flash update

is complete

6. 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.

If you received this error: Do this:

Processor not connected. a. Make sure the keyswitch is in Program

mode.

b. Make sure the processor power is on.

c. Check the serial cable.

d. Verify the COM port being used bythe

computer.

e. Return to item 3, step 3 on page 5 and

repeat this section.

Target processor does

not match script file. a. Check the name of the script file.

b. Make sure you are connected to the correct

type and series of processor.

c. Return to item 3, step 3 on page 5 and

repeat this section.

Firmware series stated

in script file does not

match PLC.

a. Make sure you are connected to the correct

type and series of processor.

b. Return toitem 3, step 3 on page 5 and

repeat this section.

No script files found. a. 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.

b. Make sure you selected the catalog number

of the flash upgrade you want to

download to the processor on the flash

upgrade catalog number selection

screen. Do not select the catalognumber

of the processor you currently have.

c. Return to item 3, step 3 on page 5 and

repeat this section.

For A-B Internal Use Only Publication 1785-6.2 March 1998

7. When the flash update is complete, cycle power to the processor.

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 back 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.

If the processor powers up with the: Do this:

PROC LED solid red andCH1A DH+ LED

blinking green (normally) continue with the item 8, step 3 that

follows this table.

PROC LED flashing red/green

(flash mode) Return to item 3, step 3 on page 5 and

repeat this section.

If you have repeated this item more

than 3 times, send the processor to

Allen-Bradley repair services.

PROC LED solid red and CH1A DH+

LED off

CAT. NO. REV.

1785-L40B E A01

PLC-5/40 PROCESSOR

MADE IN USA

PART NO. 96215074 A01

BACKPLANE CURRENT

REQUIREMENTS

3.3A AT 5VDC

Series E PLC-5 Processor Series C or Series D PLC-5 Processor

SERIES

F/W REV

FIRMWARE UPGRADE

CAT. NO.

1785-L40B

SERIES REV.

41022

41023

Allen-Bradley Automation

Publication 1785-6.2 March 1998 For A-B Internal Use Only

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.

1. Make sure you have already removed the battery cover and

disconnected the battery and disconnected any cables attached to

the processor.

!ATTENTION: Printed circuit board components can

be damaged during routine handling and installation.

Follow these precautions to reduce static electricity

discharges before you upgrade the processor firmware.

• Handle the printed circuit board by the case or

carrier without touching the pins or the edge

connector.

• Use a static-free workstation.

• Connect the static-free workstation to ground

through a minimum 200K ohm resistance.

• Wear a grounded, conductive wrist strap with a

minimum 200K ohm resistance.

• Ground all tools before you begin to upgrade the

firmware.

• Control the relative humidity of the installation

area. Ideal conditions are 40-60% relative

humidity.

For A-B Internal Use Only Publication 1785-6.2 March 1998

2. Do one of the following:

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.)

If you have a: Do this:

PLC-5/11, or -5/20 type processor a. Remove the four screws thathold the right side

plastic cover.

b. Remove the cover.

c. Remove the two large screws and washers located in the

middle of the exposed circuit board.

d. 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.

Noticethedirectioninwhichthebatterycableiswrapped

around the nearby standoff.

e. Disconnect the wires leading from the battery to the

stake pins on the exposed circuit board.

f. Disconnect the wires leading from the keyswitch 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.

U18

PROM

1785-L11, -5/20 board

41024

Allen-Bradley Automation

Publication 1785-6.2 March 1998

Supersedes Publication 1785-6.2 June 1997

Publication 1785-6.2-RN2 July 1997

955131-61

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 \flash

2. Delete all files within that directory by typing:

del *.*

3. Change to the root directory by typing:

cd\

4. Remove the flash directory by typing:

rd flash

PLC-5and ControlNetare 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.

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