Allen-Bradley Enhanced PLC-5 Installation Instructions Manual

Brand: Allen-Bradley

Model: Enhanced PLC-5

Type: Installation Instructions Manual

This manual is also suitable for

1 Publication 1785-IN022C-EN-P - September 2005

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 Kit

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, 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.

Locate Your Controller’s

Update Procedure in this

Document

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.

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

Publication 1785-IN022C-EN-P - September 2005

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.

Publication 1785-IN022C-EN-P - September 2005

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

Publication 1785-IN022C-EN-P - September 2005

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

Important Considerations for CL I, Div. 2 Installations

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

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.

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

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.

Publication 1785-IN022C-EN-P - September 2005

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

Publication 1785-IN022C-EN-P - September 2005

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

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.

ATTENTION

Failure to follow these procedures exactly or to

cause an interruption during them may result in

an inoperable controller.

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Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 7

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.

Allen-Bradley Motors

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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.

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.

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Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 9

4. Remove power from the controller.

5. Remove the controller from the chassis.

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 440-646-3223.

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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

Step 4 - Install the New Firmware EPROMS

Note: Do not reinstall the controller 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 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

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.

U18*

U61*

U70*

Replace the

U61 and U70

EPROMS*

If applicable,

replace the U18

EPROM*

(if applicable)

U5*

U31*

U7 or U12*

Replace the

U5 and U31

EPROMS on the

circuit board*

If applicable,

Remove communication card

replace the U7

or U12 EPROM

(if applicable)

on the

communication

card*

Publication 1785-IN022C-EN-P - September 2005

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 11

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 controller).

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 controller into the chassis.

2. Apply power to the controller.

3. After powerup, check the status of the controller:

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 D

ETHERNET PLC-5/40 PROCESSOR

MADE IN USA

PART NO. 96215074 A01

BACKPLANE CURRENT

REQUIREMENTS

3.3A AT 5VDC

SERIES

F/W REV

Q.2

FIRMWARE UPGRADE

CAT. NO.

1785-L40E

SERIES REV.

DG.2

Place new label over

previous label or below

entire product label.

If: Then:

PROC LED is solid red and CH1A DH+

LED is flashing green

Update is complete. Proceed to the next

step.

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

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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:

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.

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

Publication 1785-IN022C-EN-P - September 2005

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

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.

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.

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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

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.

ATTENTION

Failure to follow these procedures exactly or to

cause an interruption during them may result in

an inoperable controller.

Publication 1785-IN022C-EN-P - September 2005

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 15

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.

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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

3D - Select the firmware revision.

Click Next.

Select the correct update revision.

Click Finish.

3E - Verify the update.

Click Next.

Click Get Info to verify the

programmable controller

you are updating.

3C - Select the serial port of the computer to

which you connected the 1784-CP10 or -CP11

cable.

Select COM1 or COM2.

Publication 1785-IN022C-EN-P - September 2005

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 17

4. Remove power from the controller.

5. Remove the controller from the chassis.

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.

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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

Step 4 - Install the New Firmware EPROM

(if applicable)

Note: Do not reinstall the controller until you complete the next step.

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.

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.

U7 or U12

If applicable, replace

the U7 or U12 EPROM

on the

Remove communication card

communication card*

(if applicable)*

Publication 1785-IN022C-EN-P - September 2005

Firmware Update Instructions for Ethernet, Enhanced and ControlNet PLC-5 Programmable Controllers 19

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 controller).

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 controller into the chassis.

2. Apply power to the controller.

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 D

ETHERNET PLC-5/40 PROCESSOR

MADE IN USA

PART NO. 96215074 A01

BACKPLANE CURRENT

REQUIREMENTS

3.3A AT 5VDC

SERIES

F/W REV

Q.2

FIRMWARE UPGRADE

CAT. NO.

1785-L40E

SERIES REV.

DG.2

Place new label over

previous label or below

entire product label.

Allen-Bradley Motors

Publication 1785-IN022C-EN-P - September 2005

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

3. In ControlFLASH:

4. After powerup, check the status of the controller:

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.

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.

At the “Cycle Power” prompt, click OK

If: Then:

PROC LED is solid red and CH1A DH+ LED

is flashing 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 440.646.3223. Send controller

in for repair.

PROC LED is flashing red and green Repeat the ControlFLASH procedure

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Allen-Bradley Enhanced PLC-5 Installation Instructions Manual

Brand: Allen-Bradley

Model: Enhanced PLC-5

Type: Installation Instructions Manual

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