2330002-DCS-0001, Rev 7 PDF

Honeywell
Experion PKS Server & Station

Installation and Backup Procedures
for
OneSteel Whyalla Steelworks
Blast Furnace Capital and Reline

Projects
Industrial Automation
and Control
Quality Endorsed
Company
ISO 9001 Lic. No. QEC0170

Standards Australia
OneSteel Whyalla Server & Station Installation & Backup Procedures

Blast Furnace Capital and Reline Projects Document: 2330002-DCS-0001
Project No: 2330002 Page 1 of 92 Rev 67, 25-Aug15-Dec-04
Honeywell
This document and any Honeywell documents, software, code and/or drawings
referenced herein, contain proprietary information and intellectual property of
Honeywell Limited. Information contained and referenced herein is to be used
solely for the purpose submitted, and no part of such information or its contents shall
be reproduced, published or disclosed to a third party without the express permission
of Honeywell Limited. The customer may copy and distribute the information
internally in a printed format on paper but in no other format with the sole exception
of electronic copies of software for archival purposes.
Honeywell Signed: Date:

Checked by: Mike Smith
Honeywell Signed: Date:

Approved by:
OneSteel Signed: Date:

Approved by:

Honeywell
Formatted
Revision Status
Revision Date Prepared By Description
A 21st Aug 2003 S.Allen / Initial Customer Review

S.Peake
0 16-Jan-04 S.Peake Server Backup/Restore Procedures
added & Station Installation updated.
1 25-Mar-04 S.Peake Updated “Considerations for putting
server online”.
Added Alarm/Event Printer
Configuration.
Updated Patch installations.
2 20-Apr-04 S.Peake More detail added to Section 5 to
address CSC comments.
Microsoft patch installation moved to
section 4.7.4
3 03-June-04 S.Allen Added installation of Experion Patch
5, Patch 9 and Events Patch, and an
amendment to the restoration of
displays.
4 16-June-04 S.Allen Added Tape Backup setup to Server
Restore Procedure and added registry
change to Station Configuration.
5 28-Jun-04 S.Allen Added some extra comments to the
Station Configuration section &
added set up of an alarm & event
printer on EXP_OPS2 to the Server
Replacement procedure.
6 25-Aug-04 S.Allen Updated with Patched installed
during July & August visits
7 15-Dec-04 S.Peake Updated with OPC Server, backup
strategy and station configuration
changes.
Notes:
 Modifications after Rev 0 will be indicated by a revision change bar in the left
hand side margin and coloured text.

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Table of Contents
1. Introduction....................................................................................................... 978
1.1. Purpose of document ............................................................................... 978
1.2. Scope of document ................................................................................... 978
1.3. Reference Documents .............................................................................. 978
1.4. Definitions & Abbreviations ............................................................... 11910
2. Station Installation and Configuration ...................................................... 121011
2.1. Pre-installation Requirements .......................................................... 121011
2.2. Install Experion PKS Process Client ................................................ 121011
2.3. Install Updated HMIWeb Components ........................................... 131112
2.3.1. FTE & Network Settings ............................................................. 151314
2.4. Configure Operating System Software ............................................ 161415
2.4.1. Network Setup Wizard ................................................................. 161415
2.4.2. Verify Workgroup and shares ...................................................... 181617
2.4.3. Set the logon to Classic Logon Authentication............................ 191718
2.4.4. Change Internet Explorer Security Settings ................................. 201819
2.4.5. Disable Windows Automatic Update........................................... 211920
2.4.6. Password on the mngr account .................................................... 222021
2.4.7. Deny local logon for service user accounts ................................. 232122
2.4.8. Enable Time Synchronisation to Server ...................................... 232122
2.4.9. Prevent the monitor from being switched off after idle time ....... 252324
2.4.10. Change BIOS settings for Auto Power On .................................. 252324
2.4.11. Install Microsoft Windows Patches ............................................. 262425
2.5. Configure Stations ............................................................................. 262425
2.5.1. Share Abstract Directory and setup file replication ..................... 292728
2.5.2. Create oper and elec accounts and set group membership .......... 323031
2.5.3. Automatic Logon for Oper account (Operator Stations Only) .... 353334
2.5.4. Batch files for Automatic Station Start-up for Operator Account
(Operator Stations Only) .............................................................................. 373536
2.5.5. Alarm Sound (for Operator Stations only)................................... 373536
2.5.6. QuickBuilder Patch (Windows XP only). ................................... 393738
2.6. Additional Software Installations ..................................................... 403839
2.6.1. RSLogix Programming Software ................................................. 403839
2.6.2. Inoculate Anti-Virus Software ..................................................... 403839
2.6.3. Install the CD Writer Software. ................................................... 403839
2.6.4. Printer Configuration ................................................................... 403839

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2.6.5. Alarm Printer Configuration (EXP_OPS1 only) ......................... 403839
2.7. Group Policy Setup for Stations ....................................................... 424041
3. Server Backup ............................................................................................. 504849
3.1. Daily backup strategy ........................................................................ 504849
3.1.1. Backup Batch Files on Servers .................................................... 514950
3.2. Weekly Backup Strategy ................................................................... 545152
3.3. Engineering Configuration Backup ................................................. 555152
3.3.1. Backup Procedure ............................................................................ 5552
3.3.2. Restoring files from Engineering Backup.................................... 595556
4. Experion PKS Server Restore Procedure................................................... 605657
4.1. Hardware Configuration ................................................................... 605657
4.2. Install Windows 2000 Server SP3 Operating System ..................... 615758
4.3. Install Experion PKS Server Software ............................................ 635960
4.4. Install Fault Tolerant Ethernet Drivers ........................................... 656162
4.5. Configure Users.................................................................................. 666263
4.6. Configure Server & File System ....................................................... 676364
4.7. Apply patches and install tools ......................................................... 686465
4.7.1. Apply the event database table lock patch: .................................. 686465
4.7.2. Update the HMIWeb applications to R3.0 Build 471 .................. 686465
4.7.3. Apply server synchronization efficiency patch: .......................... 696465
4.7.4. Apply the Microsoft patches: ....................................................... 706667
4.7.5. Install & Configure Anti-virus software .......................................... 7167
4.8. Load Onesteel Whyalla Blast Furnace Configuration ................... 726869
4.8.1. Abstract Directory (Custom displays) ......................................... 726869
4.8.2. History Archives .......................................................................... 726869
4.8.3. Server Database ........................................................................... 726869
4.8.4. Engineering Repository ............................................................... 747071
4.8.5. Events Database ........................................................................... 767273
4.8.6. QuickBuilder Database ................................................................ 767273
4.8.7. Station Configurations ................................................................. 777374
4.8.8. User Directory.............................................................................. 777374
4.8.9. Individual restore of server configuration components ............... 777374
4.9. Configure Backup utilities on Server ............................................... 787475
5. Putting spare server online ......................................................................... 867778
5.1. Actions prior to connection on the plant network .......................... 867778
5.1.1. Power down Plant Server and Power-up Replacement................ 867778
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5.1.2. Stop Experion PKS Server services ............................................. 867778
5.1.3. Set the time on the Server ............................................................ 867778
5.2. Activities during connection of replacement server ....................... 867778
5.2.1. Ensure ControlNet Cables are correctly connected ..................... 867778
5.2.2. Ensure FTE Cables are correctly connected ................................ 867778
5.2.3. Check Network configuration and operation ............................... 877879
5.3. Activities after connection of the replacement Server .................... 877879
5.3.1. Synchronising Time between Servers (A or B) ........................... 877879
5.3.2. Configuring Alarm Event Printer on Server (A or B).................. 887980
5.3.3. Engineering Database Considerations ......................................... 887980
5.3.4. Synchronise Servers ..................................................................... 898081
5.3.5. Check logs.................................................................................... 898081
5.4. Check functions on replaced Server................................................. 908182
5.4.1. Abstract replication ...................................................................... 908182
5.4.2. VNC ............................................................................................. 908182
5.4.3. RSLinx ......................................................................................... 908182
5.4.4. Check Experion PKS Services ..................................................... 908182
5.5. Activities when replacement server is running as primary ........... 918182
5.5.1. DSA.............................................................................................. 918283
5.5.2. Server Scripts (FTE Alarms) ....................................................... 918283
5.5.3. Point communications.................................................................. 918283
5.5.4. Check Logs .................................................................................. 928384
5.6. Post-replacement tasks ...................................................................... 928384
5.6.1. Backup batch file ......................................................................... 928384

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1. Introduction
1.1. Purpose of document
This set of procedures outlines the steps required to install and configure both the
stations and servers at the Onesteel Whyalla Blast Furnace. Specifically the
procedures cover the Microsoft Windows XP Operating System and Experion PKS
R101 Client software required for an operator or maintenance stations, and the
backup, restore and install procedures for the Microsoft Windows 2000 Server
Operating System and Experion PKS R101 Server Software on the Servers.
1.2. Scope of document

This document is limited in scope to the installation of the servers and the operator
and maintenance stations at the Onesteel Whyalla Blast Furnace. It assumes the
station installations are to be performed on a Dell Precision 340 Workstation with two
Intel Pro/1000 XT network adapters installed, while the Server installation is to be
performed on two identical Dell PowerEdge 2600 Servers, each with two Intel
Pro/100S Desktop network adapters installed. This document also outlines the
backup and recovery procedures for the redundant Experion PKS R101 Process
Servers.
1.3. Reference Documents
Document Source Reference

Blast Furnace Replacement of Tosdic –247+ Honeywell QM0202705 Rev 8.
Distributed Control System Proposal.
Functional Specification Honeywell 2330002_006 Rev 2
Knowledge Builder PKS version 4.1 Honeywell 51153500-101
(CD Media with Experion PKS R101 Media)
Experion PKS R101 Software Installation & Honeywell EP-DCSX31-101
Upgrade Guide (SIUG)
Experion PKS R101 Software Change Notice Honeywell R101 ePKS Ship SCN v2.4
(SCN)
Fault Tolerant Ethernet Planning, Installation Honeywell fe05-110
and Service Guide (for FTE R110)
Network Configuration Spreadsheet Honeywell 2330002-DCS-0002
Operator Entry Panel Installation Instructions Honeywell Doc: 51199191
Software Change Notice: Station & HMIWeb Honeywell HMIWeb R3[1].0.454.471 for
Display Builder R3.0 Build 471 R101 Server SCN.pdf
Software Change Notice: Release 101 Patch 5 Honeywell R101 Patch5 SCNv8.pdf
Software Change Notice: Release 101 Patch 9 Honeywell R101 Patch 9 SCN v2.pdf
Software Change Notice: Release 101 Patch Honeywell R101 Patch 10 SCN.pdf
10

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Document Source Reference
Software Change Notice: Event Subsystem Honeywell EventSubsystemUpdateSCN.pdf
Software Update

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1.4. Definitions & Abbreviations
DSA Distributed Server Architecture

EPKS Experion PKS Process Control System
ERDB Engineering Repository Database (C200 Controller Configuration)
KB Knowledge Builder PKS „online‟ documentation
FTE Fault Tolerant Ethernet
HMI Human Machine Interface
NIC PC Network Interface Card
OEP Operator Entry Panel (Honeywell custom keyboard)
OS Operating System. Typically Microsoft Windows Operating System.
PC Personal Computer
PCIC PCI Bus ControlNet Interface Card for PC‟s
Station Experion PKS application used for viewing process conditions
SIUG Experion PKS Software Installation and Upgrade Guide
SCN Experion PKS Software Change Notice
W2K Microsoft Windows 2000 Operating System

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2. Station Installation and Configuration

Both the Operator and Maintenance Stations have the same base Experion PKS R101
Client Software loaded. The Maintenance Stations only differ from the Operator
Stations in the following details:
 a PCIC card is installed for a direct connection to the ControlNet
 RSLogix and RSNetworx are installed on the PC for programming the
ControlLogix PLC‟s.
 The station does not automatically log in to the oper account when powered up.
2.1. Pre-installation Requirements

The following items are required in order to complete the installation of an operator
station:
 Experion PKS R101 Installation CD‟s
o Base Software CD
o Support Software CD
o Knowledge Builder CD
o Application Software CD
o Common Components Software CD v141.3
 Dell provided CD‟s
o Windows XP SP1 Installation CD

o Intel Pro/1000 XT Drivers CD
o Roxio Easy CD Creator Installation CD
 Experion PKS R101 Software Installation & Upgrade Guide (SIUG)
 FTE R110 Planning, Installation and Service Guide
 This installation procedure
 Network Configuration Worksheet
 Passwords for „ps_user‟ and csc administration accounts
 Password for Experion PKS „mngr‟ user account password
The following additional items are required in order to complete the installation of a
maintenance station:
 Rockwell RSLogix5000 Install and Master Disk
 Rockwell RSNetworx for ControlNet Installation and Master Disk
2.2. Install Experion PKS Process Client

The standard Experion PKS R101 Process client should first be installed as per the
checklist on page 72 of the E-PKS R101 SIUG. Note this checklist includes the
installation of:
 Windows XP operating system

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 Intel Pro/1000 XT NIC Drivers
 Fault Tolerant Ethernet (see section below for FTE settings)
The following install steps in the checklist can be ignored as they are not required or
licensed for this installation:
 Add computer to domain (all PC‟s are in the EXPERIONPKS workgroup)
 Microsoft Excel is not required on the Operator or Maintenance Stations,

although it may be installed as per CSC policies.
 Serial Adapters are not required.
 Integrated Operator Keyboard
 Video Capture Card
NOTE: Operator Entry Panels have been purchased for stations in the Control Room
(EXP_OPS1, EXP_OPS2 & EXP_MNT1). The installation instructions for these are
contained in a separate document as listed in the reference documents.
When the Experion PKS client components are selected the following items should be
installed:
 HMIWeb Display Builder & Station
 Quickbuilder
 Display Builder
 System Displays
 Standard Displays
2.3. Install FTE Components not installed during FTE Software

Procedure
Follow the FTE software Install procedure (Section 4.3 in the “FTE Planning,
Installation & Service Guide”, fe05-110) to install the FTE components that were not
installed initially.
HCI Runtime
FTE Status Server
System Management Runtime
When complete restart the Station.
Open the FTE Status Display (Start – Programs – Honeywell TPS – FTE Status
Display) and connect to Localhost, verify all the FTE nodes on the network are shown
and are “OK”.
Note that if it is not possible to put the station on the FTE network it may be
necessary to put a crossover cable between the two network ports to prevent problems
when re-booting the station.
2.4. Install Updated HMIWeb Components

Update the Station and HMIWeb Display Builder applications to R3.0 Build 471 by
following the instructions in Section 5.2 “Client Installation for Existing Clients” of
the Software Change Notice for the Release

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Note the required installation file “HMIWeb_R3_0_454_471_for_R101_Server.exe”
can be found in the StationConfig directory on either server, which is a backed up
directory.
2.5. Install Experion Patch 5

Install the Experion Release 101.0 Patch 5 by following the instructions in Section
4.2.1 “Copy and Unzip the Patch Installer” and then 4.2.3 “Installing R101.0 Patch 5
in Process Client” of the Software Change Notice for Patch 5.
Note the required Installation file “EPKS R101.0 Post Release Patch 5.zip” and the
Software Change Notice can be found in the Program Files\Honeywell\Experion
PKS\Server\User\Patches directory on either server, which is a backed up directory.

Note the required Installation file “R101_Patch9.zip” and the Software Change Notice
can be found in the Program Files\Honeywell\Experion PKS\Server\User\Patches
directory on either server, which is a backed up directory.

Note the required Installation file “R101_Patch10.zip” and the Software Change
Notice can be found in the Program Files\Honeywell\Experion
2.8. Install Events Subsystem Update

Install the Experion Release 101.0 Events Subsystem update by following the
instructions in Section 5.2 “Client Installation” of the Software Change Notice for the
Events Subsystem update.
Note the required Installation file “eventupdate.PKS.101.exe” and the Software

Change Notice can be found in the Program Files\Honeywell\Experion

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2.8.1. FTE & Network Settings

Note that the applicable IP address configuration and network patching for each of the
PC‟s and Servers in the system are defined in the Network Configuration Spreadsheet
(document 2330002-DCS-0002).
When naming the Network Connections the following convention has been used on
each PC:
“FTE OWBF Yellow” for the Yellow connection
“FTE OWBF Green” for the Green connection
The table below outlines the FTE specific settings for each Station and/or Server.
Selected Adapters Select both “Yellow” and “Green”

Adapters.
Device Index EXP_SVRA 1
EXP_SVRB 2
EXP_OPS1 3
EXP_OPS2 4
EXP_OPS3 5
EXP_OPS4 6
EXP_MNT1 7
EXP_MNT2 8
EXP_MNT3 9
EXP_MNT4 10
EXP_MNT5 11
Interval 500 ms
Disjoin Multiplier 3
Max FTE Nodes 511
Multicast Address 224.66.11.99
UDP Source Port 47837
UDP Destination Port 51966
Max Routing Hops 64

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2.9. Configure Operating System Software
2.9.1. Network Setup Wizard

Run the Network Setup Wizard to configure this computer as operating on a network
without an internet connection.
i. While logged on as Administrator or ps_user, run the Network Setup
wizard from “Network Connections” selection under Settings.
ii. Click „Next‟ on the welcome screen

iii. Click „Next‟ on the “Before you continue…” screen.
iv. If presented with a disconnected hardware warning check the “Ignore
disconnected hardware” checkbox and click „Next‟.
v. From the first set of choices to select your connection, select “Other” and
click „Next‟.
vi. Select the choice “This computer belongs to a network without an Internet
connection” and click „Next‟.
vii. Select “Let me choose the connections” and click „Next‟
viii. Uncheck ALL connections listed to prevent any network connections
being bridged, and click „Next‟.

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ix. Provide a computer description such as “Experion PKS Operator Station

1” and ensure the Computer name is that listed in the Network
Configuration Spreadsheet (2330002-DCS-0002). Click „Next‟ to
continue.
x. Enter a workgroup name of EXPERIONPKS and Click „Next‟ to

continue.
xi. Review the Settings and click „Next‟.
xii. Once the settings have been applied select “Just finish the wizard” and
click „Next‟.
xiii. Click „Finish‟ and then re-boot the PC if requested to do so.

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2.9.2. Verify Workgroup and shares
i. Click Start – Settings – Control Panel – System.
ii. Click the “Computer Name” Tab
iii. Verify that the Workgroup = EXPERIONPKS
iv. If workgroup is incorrect, Click “Change..” and type in correct workgroup.
Click “ok”.
v. Click “OK” and exit Control panel.

vi. Open Windows Explorer.
vii. Verify that C:\Program Files\Honeywell\PST_Server and C:\Program
File\Honeywell\Experion PKS\Engineering Tools are shared.

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2.9.3. Set the logon to Classic Logon Authentication

i. From the Administrative Tools in the Control Panel open “Local Security
Policies”.
ii. Select the Local Policies > Security Options
iii. Scroll down to the Network access: Sharing and security model for local
accounts and double-click to change the setting.
iv. Change the setting to “Classic-local users authenticate as themselves”.

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2.9.4. Change Internet Explorer Security Settings
v. Logon as ps_user.
vi. Open Internet Explorer; go to Tools – Internet Options.
vii. Select the Security Tab.
viii. Select “Trusted Sites”
ix. Click “Sites”

x. In the box “Add this Web site to the zone:” type http://EXP_SVRA
xi. Deselect the “Require server verification (https:) for all sites in this zone.
xii. Then click “Add”
xiii. Repeat for http://EXP_SVRB

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xiv. Click “OK” then “OK” again and close Internet Explorer.
2.9.5. Disable Windows Automatic Update.

i. Go to Start – Settings – Control Panel – Internet Options.
ii. Go to the Advanced Tab and Ensure that the “Automatically check for Internet
Explorer Updates” is unchecked. Then close the Internet Options Dialog.
iii. From Control Panel go to System then the Automatic Updates Tab.
iv. Ensure that the “Keep my computer up to date” check box is unchecked.
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v. Close System dialog and control panel.
2.9.6. Password on the mngr account

i. Logon as mngr (the default password is mngr123)
ii. Press CTL-Alt-Del then Change Password.
iii. Type in the old password then the new password that must be the same as the
PlantScape System “mngr” user account password (not the CSC administration
account).
iv. Click Log Off…
v. Log back on as ps_user

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2.9.7. Deny local logon for service user accounts

.
i. Open the Administrative Tools from the Control Panel

ii. Open the Local Security Policies
iii. Select Local Policies > User Rights Assignment in the Security Settings tree
iv. Double click on the Deny Logon Locally
v. On the Properties page click “Add User or Group”
vi. In the text box enter “erserver; mngr” and click „Check Names‟..Both the local
mngr and erserver accounts should be underlined.
vii. Click OK on the Specify Users and Groups window.
viii. Click OK on the Deny Logon Locally Properties window.
2.9.8. Enable Time Synchronisation to Server

i. Open a command prompt (Start – Run – cmd)
ii. Type the following commands: C:\>w32tm /config /syncfromflags:manual
/manualpeerlist:EXP_SVRA
iii. Then: C:\>w32tm /config /update

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iv. To check the commands have worked, double click on the time on the taskbar.
Go to the Internet Time Tab and verify that the time was successfully
synchronized with EXP_SVRA.

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2.9.9. Prevent the monitor from being switched off after idle time
This prevents the monitors being switched off automatically by the PC after 20mins
(default) idle time.
v. Open the Display Control Panel
vi. Click the “Power…” button to open the power settings
vii. Ensure all the Settings are set to “Never” for the „Home/Office Desk‟ power
scheme.
viii. Click OK to close the Power Options Window

ix. Click OK to close the Display Properties Window.
x. Repeat these steps after the oper account is created in 2.10.2 when logged in as
oper.
2.9.10. Change BIOS settings for Auto Power On

This setting ensures the Stations power on automatically after a power failure.
xi. Restart the PC from the Start > Shutdown menu
xii. While the Power On Test is still running press the F2 function key to enter the
BIOS setup
xiii. Use the Down Arrow to select “AC Power Recovery”
xiv. Press the Space bar until the “AC Power Recovery” is set to ON
xv. Press the Esc key
xvi. Select “Save Changes and Exit” and press Enter. The PC will then re-boot.

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2.9.11. Install Microsoft Windows Patches
Knowledge
Install Order MS Fix Comments
Base Article
1 MS03-039 KB824146
2 MS03-041 KB823182
3 MS03-043 KB828035
4 MS04-003 KB832483
5 MS04-004 KB832894
6 MS04-007 KB828028
** Check Add/Remove programs as may have
been installed by prior installations ** (Win2K
Pre-SP4 Hotfix Q322913 Only)
** Check Add/Remove programs as may have
been installed by prior installations ** (Win2K
SP4 Hotfix Q815021 Only)
2.10. Configure Stations

i. Map a drive to EXP_SVRA\c$ or obtain a copy of the A server backup.
ii. On EXP_SVRA there is a directory C:\StationConfig in which resides the
master copies of the files required for configuring the station connections.

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iii. Copy station.ini from the StationConfig folder to C:\WINDOWS on the Station
PC.
iv. Copy stn1_script.txt (and stn2_script.txt if configuring a station for a dual
operating screen) into the C:\Program Files\Honeywell\Experion
PKS\Client\Station directory on the Station PC. No longer required.
v. Copy default2.stb into the C:\Program Files\Honeywell\Experion
PKS\Client\System\R100 directory on the Station PC. This file defines the
toolbar, menus and keyboard configuration for station.
vi. Copy default.stn and backup.stn (and default2.stn and backup2.stn for
EXP_OPS1 &, EXP_OPS2, EXP_OPS3 and EXP_MNT4) to the C:\Program
Files\Honeywell\Experion PKS\Client\Station directory on the Station PC .
These files define the station connection, display directories and sound
configuration.
vii. Copy the “hosts” file into the WINDOWS\SYSTEM32\DRIVERS\ETC folder,
replacing the existing file.
viii. Open Station, if a dialog box comes up with all stations busy click ok. Go to
Station, Connect. Select Default, click edit Connection.

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ix. Select either Static Station or rotary station and enter the appropriate station
number as per the table below for the station that is being installed.

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Computer Name Computer Location Filenames Station Station
type Number
EXP_SVRA Experion PKS Server A Default.stn Rotary N/A
Backup.stn
EXP_SVRB Experion PKS Server B Default.stn Rotary N/A
Backup.stn
EXP_OPS1 (Dual Operations Control Room Default.stn Static 1
Screen: Screen1) Operator Station 1, Screen 1 Backup.stn
EXP_OPS1 (Dual Operations Control Room Default2.stn Static 2
Screen: Screen 2) Operator Station 1, Screen 2 Backup2.stn
Screen: Screen 2) Operator Station 2, Screen 2 Backup2.stn

Screen: Screen2) Operator Station 3, Screen 2 Backup2.stn
EXP_OPS4 IEC Switch Room Operator Default.stn Static 6
Station Backup.stn
EXP_MNT1 Operations Control Room Default.stn Static 7
Maint. Station. Backup.stn
EXP_MNT2 IEC Switch Room Maint. Default.stn Static 8
Station. Backup.stn
EXP_MNT3 BiStat WTP Maintenance Default.stn Static 9
Station Backup.stn
EXP_MNT4 (Dual BiStat Maintenance Station, Default.stn Static 10
Screen: Screen1) Screen 1 Backup.stn
EXP_MNT4 (Dual WTP BiStat Maintenance Default2.stn Static 1013
Screen: Screen2) Station, Screen 2 Backup2.stn
EXP_MNT5 Compressor Substation Maint. Default.stn Rotary 11
Station Backup.stn
x. Click save and repeat for the backup station (note: Use the same static station
number/rotary station selection).
2.10.1. Share Abstract Directory and setup file replication

i. Open Windows Explorer. Go to C:\Program Files\Honeywell\Experion
PKS\Client.
ii. Create a new folder Abstract

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iii. Right Click Abstract, go to Properties, go to the Sharing Tab and select “Share
this folder on the network” (The default name should be Abstract – keep this).
iv. Set permissions for EVERYONE to read, and Honeywell Administrators &
Administrators to Modify, Read & Write.
v. Set Security to provide the mngr account with Full Control of the abstract
directory.
vi. Click Apply, and then close the dialog box.

vii. Open Station; go to Configure – System Hardware – File Replication.

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viii. Click on the Abstract Replication.
ix. Under “Destination”, add the Computer name to the list of Specific PCs.

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x. Click Save.
xi. If you wish the abstract to be copied across immediately then click “Replicate
Now”. After some time a report should be presented indicating which files
were copied from the server to each configured station PC,
xii. Delete the file sysdtldaca.dsp from the …client\system\R101 directory. (There
is a modified version of this file in the Non-Standard system display directory
in the Abstract directory.)
2.10.2. Create oper, elec and csc accounts and set group membership
i. Right Click “My Computer”, Select Manage.
ii. Select System Tools – Local Users and Groups – Users.
iii. Right Click and select “New User…”

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iv. In the form enter Username = Oper, Full Name – Experion PKS Operator,
Password = oper.
v. Deselect “User must change password at next login”
vi. Select “Password never expires” and “User cannot change password”.
vii. Click “Create” then click “Close”.

viii. Right Click oper account and select “Properties”.
ix. Click on “Member Of” Tab then click “Add..”

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x. Click “Advanced…”
xi. Click “Find Now..”
xii. Select Engineers then “OK”.
xiii. Click “Advanced..” then Find Now..” again and select “Engineering Repository
Users” then “OK”. Click ok.

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xiv. Click “Apply” then “ok”.

xv. Repeat these steps for the elec account for maintenance and electrical staff.
xvi. Repeat these steps for the csc account except it should only be joined to the
Administrators group.
2.10.3. Automatic Logon for Oper account (Operator Stations Only)

This task is applicable only to the EXP_OPS1, EXP_OPS2, EXP_OPS3 and
EXP_OPS4 stations.
i. Click Start – Run – type “regedit”
ii. Navigate to HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows
NT\CurrentVersion\Winlogon
iii. Change AutoAdminLogon to 1. (Double click to change value).

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iv. Change DefaultUserName to oper.
v. Change DefaultPassword to oper.
vi. Restart computer to ensure the station is automatically logged in with the oper
account.
vii. Change the oper account settings to classic Windows settings: Right Click Start
– Properties, Select Classic Start Menu. Click Apply then ok.
viii. Right click on the desktop – click properties – on the themes tab, in the Theme
drop-down box select Windows Classic. Click Apply then ok.

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2.10.4. Batch files for Automatic Station Start-up for Operator
Account (Operator Stations Only)
This task is applicable only to the EXP_OPS1, EXP_OPS2, EXP_OPS3 and
EXP_OPS4 stations.
i. Open Windows Explorer and map a drive to EXP_SVRA (deselect Reconnect
at logon) and logon as ps_user. (or alternatively source the files from a backup
of the EXP_SVRA server).
ii. Copy the start_station.bat (and start_station2.bat for EXP_OPS1, & EXP_OPS2
& EXP_OPS3) from the \\EXP_SVRA\StationConfig\ folder.
Right click the start button, go to “Explore” (alternatively navigate to C:\Documents
and Settings\oper\Start Menu\), then navigate to Programs\Start Up and paste the .bat
files that were copied from the StationConfig folder on EXP_SVRA.
iii. Log Off oper and log back on to ensure that this works (station should start up
immediately).
Formatted: Bullets and Numbering
iv. Shortcuts to the same batch files should be placed in the C:\Documents and
Settings\oper\Desktop folder to provide targets for the operator to restart the
Station if it „crashes‟ for any reason. Log on as the oper and ensure the
shortcuts appear on the correct screen for each station application.
2.10.5. Alarm Sound (for EXP_OPS1, EXP_OPS2 and EXP_OPS4)

i. Open Station; go to Configure – System Hardware – Stations.
ii. Select the Station used by the Operator Station.
iii. On the General tab ensure that the under the “Audible Alarm/Station Failure
Alarm” ensure that the “Activate for HIGH priority alarms” and “Activate for
URGENT priority alarms” checkboxes are checked.
NOTE: The configuration of the sounds used for each of the High and Urgent alarms
is contained within the .stn file (The properties for this are viewed from Station by
going to Station – Connect; then select a connection, click Edit Connection… and go
to the “Sounds Tab”.

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At the time of writing the sounds being used on the stations are:
…\Experion PKS\station\CitectAlarm.wav for Urgent Priority
…\Experion PKS\station\ding.wav for High Priority
No sound for Low Priority
The required .wav files are available on the C:\StationConfig directory on the A
server and should be placed in the indicated directories above on each station.
Also the properties for the audible alarms are configured on a Server Wide
basis. To view the details from Station go to Configure – System
Hardware – Server Wide Settings, then the Alarm/Event Options Tab. (For
the Audible Alarm to work the “Audible Active time” must be greater than
zero.
Note also that for Station STNOPS1_S2 that an Alarm/Event Printer should be
assigned to \\EXP_OPS1\ALMEVENT1 to print LOW, HIGH & URGENT Alarms,
and Operator Changes. This should be visible in the station configuration for
STN_OPS1_S2.

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2.10.6. QuickBuilder Patch (Windows XP only).

Note: When you click the column headings in the standard Experion PKS R101
Quickbuilder running on Windows XP to sort the column, all the columns become
grey and a restart of quickbuilder is required. The patch below rectifies this but
should ONLY BE INSTALLED ON WINDOWS XP stations.
i. Copy the Zip file “QBSelectorMKII_ISR43696_For_QB2.10.484.zip” from the

\\EXP_SVRA\StationConfig\QuickBuilderPatchXPOnly directory.
ii. Follow the instructions in the Readme file contained within the zip file to install
the update.

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2.11. Additional Software Installations
2.11.1. RSLogix Programming Software

For maintenance stations, RSLinx v2.4.1, RSLogix 5000 v11, RSNetworx for
ControlNet and RSNetworx for DeviceNet may be installed as per Rockwell
Installation Instructions.
2.11.2. Inoculate Anti-Virus Software

E-Trust Inoculate Anti-Virus Software is to be installed on each operator and
maintenance station PC, as per standard CSC practice on the Onesteel Site.
2.11.3. Install the CD Writer Software.

All operator and Maintenance Station PC‟s have been supplied with CDR/W drives.
i. Insert the “For Installing/Reinstalling Roxio Easy CD Creator 5.2 Basic CD”.
ii. Follow the installation prompts that automatically appear when the CD is
inserted. (Alternatively double click the setup.exe on the CD). All defaults are
acceptable.
2.11.4. Printer Configuration

Select Run… from the Windows Start Menu
Type \\exp_mnt1 and press enter
Double-click on the HP LaserJet Printer to install the printer on this machine
Check that the Printer is selected as the default printer from Settings > Printers
Check that A4 is selected as the paper size in both the properties of the Printer and the
Printing Preferences for the Printer.
From Station set the margins to the smallest allowed from Action > Page Setup menu.
Print a test page from station to ensure the printer is setup correctly.
2.11.5. Alarm Printer Configuration (EXP_OPS1 OPS2 & EXP_OPS2

MNT1 only)
Plug in the Epson LQ-2080 ESC/P 2 printer to the parallel port.
The station will auto-recognise the printer and install the required drivers.
Start > Settings > Printers
Select the new printer, right-click and select Properties
Name the printer ALMEVENT1.
Under the “Sharing” tab select “Shared As:” and type ALMEVENT1 as the share
name.
Click OK.
(Note: The printer is set up on EXP_OPS2 MNT1 as a backup only in the event of the
failure of EXP_OPS1 OPS2 so the printer will not be physically connected).
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2.11.6. Charging Printer Configuration (EXP_OPS3 only)
Plug in the Epson LQ-2080 ESC/P 2 printer to the parallel port.
The station will auto-recognise the printer and install the required drivers.
Start > Settings > Printers
Select the new printer, right-click and select Properties
Name the printer CHARGING_PRINTER
Under the “Sharing” tab select “Shared As:” and type CHARGING_PRINTER as the
share name.
Click OK.
2.12. Registry Setting Change

The following change needs to be made on all the Stations and Servers to enable some
graphics to be viewed correctly.
1. Log onto the Server/Station with administrator rights.
2. Open the Registry Editor by Start – Run – regedit
3. Browse to HKEY_CLASSES_ROOT\CLSID\{0D43FE01-F093-11CF-8940-
00A0C9054228}
4. Right-click and select New – Key
5. Rename the new key “Implemented Categories”
6. Under “Implemented Categories”, right click and select New-Key
7. Rename the new key {7DD95801-9882-11CF-9FA9-00AA006C42C4}
8. Repeat steps 5 & 6 and rename the new key {7DD95802-9882-11CF-9FA9-
00AA006C42C4}.
9. The final configuration should look like the screenshot below. Close the
Registry editor.

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2.13. Group Policy Setup for Stations

Due to the restrictions imposed by the Group Policy setup on the stations it is
recommended that this configuration be done as the last step in the configuration of
the station, after the correct operation of the station has been confirmed.
1. Ensure you are logged on the ps_user administrator.

2. From Windows Explorer choose Tools > Folder Options
3. From the View tab select to show hidden files and folders.
4. Navigate to the C:\Windows\System32 directory
5. Make a copy of the GroupPolicy directory as a backup.
6. Right-click on the GroupPolicy Directory and select Properties.
7. On the Security Tab ensure the following users/groups are present in the
access list and leave the properties window open:
a. Administrator
b. Csc
c. Ps_user
d. Elec
e. Oper
8. Set the security for the Administrator, CSC, and elec accounts as below:
9. Click on the “Advanced…” Button.

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10. Check the “Reset permissions on all child objects and enable propogation of
inheritable permissions” checkbox.
11. Click “Apply”
12. From the Start menu select Run…

13. Type “gpedit.msc” and [Enter]
14. Enter the security settings as per the following tables:
User Configuration > Administrative Templates > Start Menu and Taskbar
Setting State
Remove user's folders from the Start Menu Enabled
Remove links and access to Windows Update Enabled
Remove common program groups from Start Menu Enabled
Remove My Documents icon from Start Menu Enabled
Remove Documents menu from Start Menu Enabled
Remove programs on Settings menu Not Configured
Remove Network Connections from Start Menu Enabled
Remove Favorites menu from Start Menu Enabled
Remove Search menu from Start Menu Enabled
Remove Help menu from Start Menu NEnabled
Remove Run menu from Start Menu Enabled
Remove My Pictures icon from Start Menu Enabled
Remove My Music icon from Start Menu Enabled
Remove My Network Places icon from Start Menu Enabled
Add Logoff to the Start Menu Enabled
Remove Logoff on the Start Menu Not configured
Remove and prevent access to the Shut Down command Not configured
Remove Drag-and-drop context menus on the Start Menu Enabled
Prevent changes to Taskbar and Start Menu Settings Enabled
Remove access to the context menus for the taskbar Enabled
Do not keep history of recently opened documents Enabled
Clear history of recently opened documents on exit Enabled
Turn off personalized menus Enabled
Turn off user tracking Not configured
Add "Run in Separate Memory Space" check box to Run dialog box Not configured

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Setting State
Do not use the search-based method when resolving shell shortcuts Not configured
Do not use the tracking-based method when resolving shell shortcuts Not configured
Gray unavailable Windows Installer programs Start Menu shortcuts Enabled
Prevent grouping of taskbar items Not configured
Turn off notification area cleanup Not configurede
Lock the Taskbar Not configured
Force classic Start Menu Enabled
Remove Balloon Tips on Start Menu items Not configured
Remove pinned programs list from the Start Menu Not configured
Remove frequent programs list from the Start Menu Enabled
Remove All Programs list from the Start menu Enabled
Remove and disable the Turn Off Computer button Not configured
Remove the "Undock PC" button from the Start Menu Enabled
Remove user name from Start Menu Not configured
Remove Clock from the system notification area Not configured
Hide the notification area Not configured
Do not display any custom toolbars in the taskbar Enabled

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User Configuration > Administrative Templates > Desktop
Setting State
Hide and disable all items on the desktop Not configured
Remove My Documents icon on the desktop Enabled
Remove My Computer icon on the desktop Enabled
Remove Recycle Bin icon from desktop Enabled
Remove Properties from the My Documents context menu Not configured
Remove Properties from the My Computer context menu Not configured
Remove Properties from the Recycle Bin context menu Not configured
Hide My Network Places icon on desktop Enabled
Hide Internet Explorer icon on desktop Enabled
Do not add shares of recently opened documents to My Network Places Enabled
Prohibit user from changing My Documents path Enabled
Prevent adding, dragging, dropping and closing the Taskbar's toolbars Enabled
Prohibit adjusting desktop toolbars Enabled
Don't save settings at exit Enabled
Remove the Desktop Cleanup Wizard Enabled
User Configuration > Administrative Templates > System
Setting State
Don't display the Getting Started welcome screen at logon Not configured
Century interpretation for Year 2000 Not configured
Configure driver search locations Not configured
Code signing for device drivers Not configured
Custom user interface Not configured
Prevent access to the command prompt Enabled **
Prevent access to registry editing tools Enabled
Run only allowed Windows applications Not configured
Don't run specified Windows applications Not configured
Turn off Autoplay Enabled
Restrict these programs from being launched from Help Not configured
Download missing COM components Not configured
Windows Automatic Updates Disabled

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** See below for settings to ensure logon batch files may run.
User Configuration > Administrative Templates > Windows Components >

Windows Explorer
Setting State
Removes the Folder Options menu item from the Tools menu Not Configured
Remove File menu from Windows Explorer Enabled
Remove "Map Network Drive" and "Disconnect Network Drive" Enabled
Remove Search button from Windows Explorer Enabled
Remove Windows Explorer's default context menu Enabled
Hides the Manage item on the Windows Explorer context menu Enabled
Allow only per user or approved shell extensions Not configured
Do not track Shell shortcuts during roaming Not configured
Hide these specified drives in My Computer Enabled **
Prevent access to drives from My Computer Enabled
Remove Hardware tab Not configured
Remove DFS tab Not configured
Remove Security tab Not configured

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Setting State
Remove UI to change menu animation setting Not configured
Remove UI to change keyboard navigation indicator setting Not configured
No "Computers Near Me" in My Network Places Enabled
No "Entire Network" in My Network Places Enabled
Maximum number of recent documents Not configured
Do not request alternate credentials Not configured
Request credentials for network installations Not configured
Remove CD Burning features Enabled
Do not move deleted files to the Recycle Bin Not configured
Display confirmation dialog when deleting files Not configured
Maximum allowed Recycle Bin size Not configured
Remove Shared Documents from My Computer Not configured
Turn off caching of thumbnail pictures Not configured
** Screenshot below shows setting for Hide Drives:

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User Configuration > Administrative Templates > Windows Components >
Windows Update
Setting State
Remove access to use all Windows Update featues Enabled
15. Minimise all items on the desktop (windows key + M) to show the properties
window for the GroupPolicy folder. Set the security for all accounts except
the oper account as below:
For the oper account set the security as:

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16. Click on the “Advanced…” Button.

17. Check the “Reset permissions on all child objects and enable propogation of
inheritable permissions” checkbox.
18. Click “Apply”
19. The settings may then be tested by logging off the ps_user account and
logging back on as oper. All functions indicated in the tables should be
disabled for the oper account.
20. Logging back on as ps_user should provide the normal windows interface. If
this is not the case log on as the Administrator account, take ownership of the
Group Policy Folder and restore the backed up group policy folder.

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3. Server Backup
3.1. Daily backup strategy
The daily backup is an automated backup run by CSC over the network (ie. through
the DSA routers) to backup the server data on their central backup server. This has
been tested to ensure there are no bandwidth problems which could affect the DSA
transfers. The "D:\ExperionBackup" directory on each of the A and B Experion PKS
Servers is copied to CSC's backup facilities. To ensure the contents of this directory
are kept up to date with sufficient data to restore any component of the configuration
(or the whole server if necessary) a batch file is scheduled to run each day on the
Experion PKS Servers which copies the following data into the "D:\ExperionBackup"
directory: (Note the "..." in the paths below indicates the "C:\Program
Files\Honeywell\Experion PKS\" directory on each Server)
Server A (assumed to be primary*, or synchronised if it is the backup)
Directory backed up Directory’s contents

...\server\data real-time database containing all point definitions,
areas, trend/group/history configuration
...\server\evtarch\backup\ Last two backed up event archives.
...\server\user configuration files for server (eg. redundancy
configuration), installed patches, and individual backup
of some data files.
...\client\abstract All graphics files including popups, process graphics,
custom group templates and group overview displays.
...\qckbld\databases PLC point database configuration including all files
required for mapping to the RNet/ControlNet gateway
c:\StationConfig All configuration files used for configuring the
individual stations on the system, including connection,
menu, toolbar & keyboard definitions.
c:\ChargingReports Configuration for Charging System Reports.
N/A A 'bckbld' (ie. text export) of the point database
configuration is also taken for engineering reference.
Server B (assumed to be backup*, synchronisation status is not relevant)
\Program Files\Honeywell\Experion PKS\Engineering Tools\system\ER\*.snapshot

Stores the latest controller snapshot (analogous to controller memory dump).
This can be updated (saved) manually from ControlBuilder, or individual components
shall be updated when downloaded from the Project Tab in ControlBuilder. These

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snapshots can be used to quickly restore a controller in the situation that the controller
pair loses its database (for example power and battery failure on primary controller).
ERDB Database
The engineering repository database (Control Builder database) is scheduled
to be automatically backed up daily to the “D:\ExperionBackup” directory using a
maintenance plan configured using the Microsoft SQL Server 2000 Enterprise
Manager.
* Note if the B Server is primary and not synchronised to the A server and database
changes are made on the Server (for example area, trend, group, history or point
configuration) these changes shall not be backed up by this backup regime. It is
recommended that the system be run with the A server as primary and synchronised
whenever possible.
3.1.1. Backup Batch Files on Servers

To simplify the daily backup strategy batch files are run on each server daily to
consolidate the data required into a single directory which is then backed up across
the network. The batch files are saved in the
“\Program_Files\Honeywell\Experion_PKS\Server\User” directory and are scheduled
using the Windows Task Scheduler Control Panel on each Server. The batch files are
given below for reference:
SERVER A BACKUP BATCH FILE (ServerABackup\DailyBackupA.bat)

-----------------------------------------------------------------------------------------------------
echo on
D:
set RCOPYOPTS=/MIR /R:3 /W:5 /NP /LOG+:d:\ExperionBackup\backuplog.log
cd \ExperionBackup
del d:\ExperionBackup\backuplog.log /Q
bckbld -out sdabkup.pnt >> d:\ExperionBackup\backuplog.log
sleep 2
bckbld -out cdabkup.pnt -tag cda >> d:\ExperionBackup\backuplog.log
sleep 2
bckbld -out rdabkup.pnt -tag rda >> d:\ExperionBackup\backuplog.log
sleep 2
REM Copying client files...
robocopy "C:\Program Files\Honeywell\Experion PKS\client\qckbld\Databases"
D:\ExperionBackup\Databases %RCOPYOPTS%
robocopy "C:\Program Files\Honeywell\Experion PKS\client\abstract"
D:\ExperionBackup\abstract %RCOPYOPTS%
REM Collecting Experion Server Files...
"C:\Program Files\Honeywell\Experion PKS\server\run\fildmp" -DUMP -FILE
"C:\Program Files\Honeywell\Experion PKS\server\user\stdhist.dmp" -FILENUM
25 -RECORDS 1,1000 -FORMAT HEX

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"C:\Program Files\Honeywell\Experion PKS\server\user\fasthist.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\exthist.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\messages.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\UserAcronym.dmp" -
FILENUM 27 -RECORDS 2881,3880 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\groups.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\trends.dmp" -FILENUM 11
-RECORDS 1,1000 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\areas.dmp" -FILENUM 7 -
RECORDS 1,255 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\reports.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\keyboard.dmp" -FILENUM
sleep 2
shheap 1 backup
sleep 2
REM Copying Experion Server\user Files...
robocopy "C:\Program Files\Honeywell\Experion PKS\server\user"
D:\ExperionBackup\user %RCOPYOPTS%
REM Copying Experion StationConfig Files...
robocopy "C:\StationConfig" D:\ExperionBackup\StationConfig %RCOPYOPTS%
REM Copying Server Data Files...
xcopy "C:\Program Files\Honeywell\Experion PKS\server\data\*.*"
D:\ExperionBackup\data\*.* /E /Y /Q /I /H
sleep 5
REM Copying Event Archive Files...
robocopy "C:\Program Files\Honeywell\Experion PKS\server\evtarch\backup"
D:\ExperionBackup\evtarch %RCOPYOPTS%
REM Copying Engineering Database Files...
robocopy "\\EXP_SVRB\ExpBackup" D:\ExperionBackup\erdb %RCOPYOPTS%
REM Copying Charging Report Files...
robocopy "C:\ChargingReports" D:\ExperionBackup\ChargingReports %RCOPYOPTS%
echo on
REM ... Completeecho on
d:
set RCOPYOPTS=/MIR /R:3 /W:5 /NP /LOG+:\ExperionBackup\backuplog.log
cd \ExperionBackup

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del \ExperionBackup\backuplog.log /Q
bckbld -out sdabkup.pnt > \ExperionBackup\backuplog.log
sleep 2
bckbld -out cdabkup.pnt -tag cda >> \ExperionBackup\backuplog.log
sleep 2
bckbld -out rdabkup.pnt -tag rda >> \ExperionBackup\backuplog.log
sleep 2
REM Copying client files...
robocopy "c:\Program Files\Honeywell\Experion PKS\client\qckbld\Databases"
\ExperionBackup\Databases %RCOPYOPTS%
robocopy "c:\Program Files\Honeywell\Experion PKS\client\abstract"
\ExperionBackup\abstract %RCOPYOPTS%
REM Collecting Experion Server Files...
"C:\Program Files\Honeywell\Experion PKS\server\user\stdhist.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\fasthist.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\exthist.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\messages.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\UserAcronym.dmp" -
FILENUM 27 -RECORDS 2881,3880 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\groups.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\trends.dmp" -FILENUM 11
-RECORDS 1,1000 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\areas.dmp" -FILENUM 7 -
RECORDS 1,255 -FORMAT HEX
"C:\Program Files\Honeywell\Experion PKS\server\user\reports.dmp" -FILENUM
"C:\Program Files\Honeywell\Experion PKS\server\user\keyboard.dmp" -FILENUM
sleep 2
shheap 1 backup
sleep 2
REM Copying Experion Server\user Files...
robocopy "C:\Program Files\Honeywell\Experion PKS\server\user"
\ExperionBackup\user %RCOPYOPTS%
REM Copying Experion StationConfig Files...
robocopy "C:\StationConfig" \ExperionBackup\StationConfig %RCOPYOPTS%

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REM Copying Server Data Files...
xcopy "C:\Program Files\Honeywell\Experion PKS\server\data\*.*"
\ExperionBackup\data\*.* /E /Y /Q /I /H
sleep 5
REM Copying Event Archive Files...
robocopy "C:\Program Files\Honeywell\Experion PKS\server\evtarch\backup"
\ExperionBackup\evtarch %RCOPYOPTS%
REM Copying Engineering Database Files...
robocopy "\\EXP_SVRB\ExpBackup" \ExperionBackup\erdb %RCOPYOPTS%
echo on
REM ... Complete
-----------------------------------------------------------------------------------------------------
SERVER B BACKUP BATCH FILE (ServerBBackup\DailyBackupB.bat)

-----------------------------------------------------------------------------------------------------
D:
cd \ExperionBackup
REM Copying files ...
echo off
xcopy "C:\Program Files\Honeywell\Experion PKS\Engineering
Tools\system\ER\*.snapshot" D:\ExperionBackup /Y /Q /I /H
echo on
REM ... Completed:
cd \ExperionBackup
REM Copying files ...
echo off
xcopy "C:\Program Files\Honeywell\Experion PKS\Engineering
Tools\system\ER\*.snapshot" \ExperionBackup /Y /Q /I /H
echo on
REM ... Complete
-----------------------------------------------------------------------------------------------------
3.2. Weekly Backup Strategy

The weekly backup to tape on each Experion PKS Server copies the same
D:\ExperionBackup directory as the Daily Backup (see section above) as well as the
history and text dump of the event archives (D:\archive) to ensure that a backup of the
history archives is maintained.
The History archives are stored on the D: drive under the D:\archive directory on the
each server and are synchronized when the Server is synchronized. This drive has
been compressed to ensure there is sufficient capacity to provide immediate access to
long term history on the operator stations. As both the PlantScape and Experion
Systems maintain separate tag databases, both systems maintain their own set of
history archives.
As the PlantScape history is already being backed up, and is considered the primary
source of process history, the Experion PKS archive directory is of lesser importance.

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Given that the history is also maintained on the backup Experion PKS Server and is a
significantly large amount of data, the archive directory is only to be backed up to
tape weekly. This backup is scheduled to occur weekly using the Windows NT
Backup Utility, with the tapes being changed as per CSC‟s policies.
Note that the D: drive should be checked regularly to ensure there is always
sufficient space for future archives.
3.3. Engineering Configuration Backup

This backup procedure provides an adequate ad-hoc backup to replace corrupted
configuration files, but does NOT include any real-time information such as history,
events or restorable point algo block configurations. This backup is specifically to
capture the following engineering configuration which may be used to restore
corrupted files or as a basis for offline configuration changes if required:
- Engineering Database for C200 configuration (erdb database)
- Point Database for ControlLogix controllers and „database resident‟ points
- All custom graphics, including shapes and popups
- Area, Group, Trend, Acronym & Messages configuration
3.3.1. Backup Procedure

1. Log on to a Maintenance (or Operator) station using the ps_user administrator‟s
account.
2. From Start > Run... enter:
\\exp_svra\vncviewer$\vncviewer.exe
and hit [Enter] key
3. When asked which Server to connect to type:
EXP_SVRA
for connecting the remote desktop to Server A
4. The password for connection to the remote desktop software is:
Honeywell!
5. If presented with a Logon or Unlock dialog box send a Ctrl-Alt-Del command to
the remote desktop by right-clicking on the title bar of the remote desktop and
selecting "Send Ctl-Alt-Del" as per the screenshot below:

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6. Login to the Server using the ps_user password. You will then be presented with
the Server Desktop (Dell 'ripple' picture as Desktop background).
NOTE: Some keyboard shortcuts are not sent to the remote system (for example
Windows-E to call up Windows Explorer).
7. From the desktop double-click the "Shortcut to Eng Backup" shortcut to copy the
server configuration to the D:\ExperionBackup directory on the server. This takes
some minutes to complete. This batch file performs the following:
- Dumps of the following server database files are made to disk in the
server\user directory:
 Areas
 Acronyms
 Messages
 Trend configuration
 Group configuration
 Fast History configuration
 Slow History configuration
- Point database backbuilds are then taken for all points of the following
types:
 CDA – cdabkup.pnt (i.e. C200 resident points)

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 SCADA – sdabkup.pnt (i.e. ControlLogix & Server Database resident
points)
 RDA – rdabkup.pnt (i.e. DSA tag „skeletons‟. Ie. tags that exist on
PlantScape Server that are referenced on Experion PKS Server).
-The contents of the following directories are then copied:
 C:\Program Files\Honeywell\Experion PKS\client\abstract
(i.e. All custom graphics including shapes & popups)

 C:\Program Files\Honeywell\Experion PKS\user
(i.e. All database file dumps)

 C:\Program Files\Honeywell\Experion PKS\client\qckbld\Databases
(i.e. Quickbuilder file & mappings for gateway points)

 C:\StationConfig
(i.e. Master Station configuration files)

1. Repeat steps 2 to 6 above to get a remote desktop session with the B Server (i.e.
EXP_SVRB).
2. From the Start Menu on the B Server (you may need to scroll the window
containing the B server desktop) select Start > Programs > Experion PKS
Engineering Tools > DBAdmin
3. Expand the tree until prompted for ControlBuilder password
4. Log on to DBAdmin using the same „mngr‟ password as Control Builder
5. Expand the tree on the left until “Admin Tasks” is shown
6. From the available “Admin Tasks” select “Backup Database”
7. Save the database to the local ExperionBackup directory as “erdb.bak”.
8. When complete open Windows Explorer from the task bar on the server and
navigate to the newly created backup file.
9. Select “erdb.bak” and right click, select WinZip > Create erdb.zip
10. Once the compression is complete there should be a erdb.zip file in the
ExperionBackup directory.
11. Log off on the B Server.
12. Once the log on window is shown close the remote desktop window using the X
on the top right corner of the window.
13. Switch back to the EXP_SVRA remote desktop window.
14. From Windows Explorer find the mapped drive to “d$ on exp_svrb” and open it.
15. Copy the ExperionBackup\erdb.zip file from the mapped drive to the local
D:\ExperionBackup directory on the A server.
16. Zip the whole ExperionBackup directory using WinZip (by right clicking the
directory in Windows Explorer). This zip file then contains the backup of the
system.
17. Log off the A Server (DO NOT SHUTDOWN THE SERVER)
18. Once logon window appears close the remote desktop.

Honeywell
19. Open windows explorer on the local station (Programs > Accessories)
20. Browse to the c$ share on exp_svra and open the ExperionBackup directory to
locate the zip file. Copy the zip file to the temp directory. Don‟t use windows
copy & paste CD writing technology.
21. Insert blank CD in drive and load up Start > Programs > Roxio Easy CD Creator
5> Project Selector.
22. Select: Make a Data CD > Data CD Project. Browse to the temp directory and
select the zip file then press the ADD button.
23. Press the red Record button, then click the OPTIONS button
24. Check that the Option to Finalise Session and Don‟t finalise CD is selected.
25. Click the Start Recording button. The progress will be shown. When burning is
complete, remove the CD and write on the label.

Honeywell
3.3.2. Restoring files from Engineering Backup

To restore any particular individual components of the Onesteel Whyalla Blast
Furnace control system configuration there are a number of factors which must be
considered. These are outlined in the sub-sections of Section 4.9 for each of the
different components of the configuration, as per the table below:
Component See Section

Custom Displays Section 4.9.1
Group Configuration Section 4.9.9
Trend Configuration Section 4.9.9
History Assignment Section 4.9.9
Area, Messages, Acronyms or Reports Section 4.9.9
SCADA Point Database (Quickbuilder Section 4.9.6
Points for PLC‟s & T/C‟s)
Engineering Repository Database - whole database - Section 4.9.4
(CM‟s, SCM‟s, & IOM‟s) See Knowledge Builder for assistance in
importing/exporting individual Control
Modules.

Honeywell
4. Experion PKS Server Restore Procedure

Due to restrictions with network binding to FTE virtual adapters it has not been
possible to use a full NT backup to tape to restore onto a server with different network
hardware. As a result the procedure for building a spare or replacement server
requires the manual software installation of the Windows Operating System and
Experion PKS Server software as per the following procedure. The following
software and installation guides are required:
Experion PKS R101 Installation CD‟s
Base Software CD
Support Software CD
Knowledge Builder CD
Application Software CD
Common Components Software CD v141.3
Dell provided CD‟s
Dell OpenManage Server Assistant CD
Windows 2000 Server SP3 Installation CD
Intel Pro/1000 XT Drivers CD
Experion PKS R101 Software Installation & Upgrade Guide (SIUG)
(EP-DCSX31 Release 101 Rev 06/26)
FTE R110 Planning, Installation and Service Guide
(fe05-110 R110 12/2002)
This installation procedure
Network Configuration Worksheet (Honeywell Doc: 2330002-DCS-0002)
Passwords for „ps_user‟ and „csc‟ administration accounts
Password for Experion PKS „mngr‟ user account password
Latest issue of license certificate for Experion PKS R101 Software
(At least issue 56)
Latest issue of license certificate for Common Components (i.e. FTE node
licenses)
4.1. Hardware Configuration

The spare Server requires the following hardware to be installed in its PCI slots
(numbered up from bottom slot on Dell PowerEdge 2600 Server PC):
 Slot 1 – PCIC (ControlNet Interface Card)
 Slot 2 – Intel Pro/100S Desktop Network Adapter
 Slot 3 – Empty
 Slot 4 - Intel Pro/100S Desktop Network Adapter

Honeywell
4.2. Install Windows 2000 Server SP3 Operating System
1. Insert the Dell OpenManage Server Assistant CD
2. Restart the Server
3. During Re-boot go into BIOS and disable the Onboard Network Port
4. Once Server Assistant has loaded select “Click Here for Server Setup”
5. Click OK on “A pre-installed OS already exists” warning if presented
6. Set Date, Time and Timezone (Adelaide) and click “Continue”
7. Select Windows 2000 and click “Continue”
8. Select NTFS and check “Use Existing Boot Partition (size = 12291 MB)”. Click
“Continue”
9. Click OK on “The primary partition will be re-formatted” warning
10. Fill out the details of the Configuration as follows depending on whether you are
re-building Server A or Server B:
Configuration Field Server A Server B

Keyboard Language English English
User Name Blast Furnace Blast Furnace
Organization Onesteel Whyalla Onesteel Whyalla
Computer Name EXP_SVRA EXP_SVRB
Product ID [get from sticker on server] [get from sticker on server]
Installation Directory \winnt \winnt
License Type Per-server Per-server
Client Licenses 10 10
Join Workgroup Checked Checked
WorkGroupName EXPERIONPKS EXPERIONPKS
Select Optional None required None required
Components
Enable SNMP UNCHECKED UNCHECKED
st
1 Intel Pro Adapter Select Specify an IP Address Select Specify an IP Address
IP: 10.66.11.14 IP: 10.66.11.16
Subnet: 255.255.255.0 Subnet: 255.255.255.0
Gateway: 10.66.11.254 Gateway: 10.66.11.254
DNS: leave blank DNS: leave blank
WINS: leave blank WINS: leave blank
nd
2 Intel Pro Adapter Select Specify an IP Address Select Specify an IP Address
IP: 10.66.11.15 IP: 10.66.11.17

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Subnet: 255.255.255.0 Subnet: 255.255.255.0
Gateway: 10.66.11.254 Gateway: 10.66.11.254
DNS: leave blank DNS: leave blank
WINS: leave blank WINS: leave blank
Install Dell UNCHECKED UNCHECKED
OpenManage Server
Administrator
11. Click “Continue”

12. Review summary and click “Continue”
13. On Windows Installation Wizard ensure “Install Service Pack” is checked and
Service Pack 3 is selected from the drop down list. Click “Next >”. And wait
until the Dell drivers and Service Pack are copied to disk.
14. Once the copy is finished insert the Windows 2000 Server Installation Disk and
click “Next >”.
15. When prompted (after approx. 3 minutes) click “Finish” to run the Windows 2000
Setup Program.
16. The automated system installation will then take approx. 20 minutes to complete.
17. Click “OK” to Dell OpenManage Software warning
18. In Windows 2000 Server Configure Your Server window Select “I will configure
this server later” and click Next
19. Uncheck “Show this screen at startup” and close the window.
20. In the Desktop Help window uncheck “Show this screen next time you start
Windows” and close window.
21. Complete installation of Windows Components
Open the Add/Remove Programs Control Panel. Select “Add/Remove Windows
Components” and check the following options:
- Indexing service
- Script Debugger
Ensure that “Internet Information Services (IIS)” is NOT checked!
Click “Next >”
Insert the Windows 2000 Server CD when requested.
Click “Exit” on Windows 2000 Server CD menu
Click “Finish” on setup wizard and close control panel.
22. Double click the time in the task bar and select the Time Zone tab. Uncheck the
“Automatically adjust clock for daylight saving changes” selection and click
“OK”.

Honeywell
4.3. Disable the Logical Processors
1. Restart the computer and press F2 to enter the BIOS set-up before the start-
up of Windows begins.
2. Go to CPU Information then Enter. Use the space bar to change the Logical
Processors to disabled.
3. Press Enter to return to the main menu.
4. Press Esc
5. Select Save Changes and Exit.
4.4. Install Experion PKS Server Software

1. Follow the instructions in the Experion PKS R101 Installation Guide to complete
the Experion PKS Server Software Installation taking into account the following
points:
[Follow the checklist on page 58 for Server A, page 60 for Server B]
- The steps in the section above in this procedure have met the installation
requirements of the “Install Windows 2000 Server procedures starting on
Page 122”.
- The PC‟s are on a workgroup (EXPERIONPKS) so ignore the step to add
the computer to a domain.
- The following entries should be put in the hosts file (or copy hosts file from
StationConfig directory in the Experion Backup):
127.0.0.1 localhost
10.66.11.14 EXP_SVRA EXP_SVRA0
10.66.11.16 EXP_SVRB EXP_SVRB0
10.66.11.20 EXP_OPS1
10.66.11.22 EXP_OPS2
10.66.11.24 EXP_OPS3
10.66.11.26 EXP_OPS4
10.66.11.34 EXP_MNT1
10.66.11.36 EXP_MNT2
10.66.11.38 EXP_MNT3
10.66.11.40 EXP_MNT4
10.66.11.42 EXP_MNT5
Formatted
10.66.19.33 cscbf1a cscbf1a0
10.66.19.34 cscbf1b cscbf1b0
203.7.35.175 CSCBF1A CSCBF1A0
203.7.35.174 CSCBF1B CSCBF1B0
- Microsoft Excel does not need to be installed

Honeywell
- Etrust Inoculate should be installed as per CSC procedures to protect against
viruses. This should be done after the Experion PKS Software installation
is complete.
- Network adapter drivers should have been installed by Windows. These
shall be updated after the Experion PKS Software installation is complete.
- NO Terminal Servers or Serial Adapters are required for the system.
- The type of Knowledge Builder installation is “Full”
- Accept the default paths for all installations.
- When prompted for user account passwords use the following:
1. oper account – “oper”
2. engr account – “engr1”
3. mngr account – [MUST BE as per “mngr” user account on
PlantScape Servers. This is the Honeywell installed “mngr”
account, not the CSC administration account.]
- The firmware version of the ControlNet interface PCIC card should be
checked in NTOOL‟s to ensure it is version 3.7.39. Simply open Experion
PKS Engineering Tools > NTOOLS and click the Resume toolbar (red line
button) and check that there is not a red-cross against the TC-PCIC card.
Instructions for updating the firmware are in Knowledge Builder.
Redundancy Configuration:
Complete the configuration of the Server redundancy according to the
following instructions:
1. Ensure a copy of the existing “redun.hdw” file is obtained (and saved into the
same directory) from the …\server\user directory from a current backup of the
live system.
2. run the following command from a command prompt on the server being built:
hdwbld “\Program Files\Honeywell\Experion PKS\server\user\redun.hdw”
RSLinx Activation Code:

The RSLinx OEM Activation will be required from a RSLinx Master Diskette.
Although this activation is not required for communications to the Honeywell
controllers and the system does not use an Ethernet supervisory network, this
activation IS required for communication to the ControlLogix PLC‟s. The
Activation should be moved to the C: drive from the Floppy disk using the Rockwell
Activation utilities. Note that this process leaves the Master Diskette without an
activation. If the C: drive is to be formatted the activation should be returned to the
master diskette, as the master diskette activation can only be reset (ie. recreated) once
per year from the Rockwell Internet site.

Honeywell
After configuring the RSLinx drivers the only tasks remaining that are
required in the Experion PKS Software Installation checklist are:
- Tune the performance of the server (Following tasks listed below only)
1. Set the Application Response to Background Services (page 253)
2. Set File and Printer Sharing to “Maximize data throughput for
network applications” (page 254)
- Install the FTE using the instructions in the FTE installation guide and notes
in the following section.
4.5. Install Fault Tolerant Ethernet Drivers

Prior to the installation of the Fault Tolerant Ethernet Drivers it is important that a
number of pre-SP4 HotFixes are applied to the system. The executables should be run
in turn on the server as per the following list:
 D:\Updates\Win2kSp3\q313664_w2k_sp4_x86_en.exe
 D:\Updates\IE6.0_Feb_2003_rollup\iehotfixes.vbs
The qualified network card drivers for the Intel Pro/100S Desktop Network Adapters
are on the Common Components v141.3 CD. From the Device Manager the drivers
for each of the Intel Pro/100S Network adapter cards should be updated by:
- From the My Computer right click and select “Manage”
- Open the Device Manager
- Select the first network card,
- Right click and select “Properties”
- Select the Driver tab
- Click “Update Driver‟ and follow prompts to “Search for driver” and then
“Specify the location”, browsing to the following location for the driver on
the Common Components CD:
<CDROM>:\Drivers\Intel\pro100_v6.2
- The driver should then install and you can request to Reboot later.
- Repeat for the second network adapter.
- Re-boot the Server.
Force each network adapter card to be 100Mb/Full Duplex

- From the My Computer right click and select “Manage”
- Open the Device Manager
- Select the first network card,

Honeywell
- Right click and select “Properties”
- From the Advanced tab select “Link Speed & Duplex”
- Select “100Mbps/Full Duplex” from the Value list
- Click OK
- Select the second network card and repeat steps 4 to 7
Reboot the Computer
The Fault Tolerant Ethernet should now be installed as per the Fault Tolerant Ethernet
Planning, Installation and Service Guide. The FTE Software Installation instructions
begin in Section 4.3 of the document (page 63). Note „the CD‟ refers to the Common
Components Release 141.3 CD supplied with Experion PKS R101 media.
See the table in Section 2.6 for the required FTE Service Settings and names for the
LAN connections.
The following features of this system are also important:
- NetBIOS does need to be configured
- Each Server should have two single port Intel Pro 100S Desktop network
adapters installed
- Select all of the FTE Driver , FTE Auxiliary Status Display., HCI Runtime
& System Management Runtime components on the Server install.
- The Yellow(A) / Green (B) IP Addresses can be found in the Network
Design Spreadsheet.
4.6. Configure Users

Set the Administrator Account Password to that required (it is blank by default after
installation of Windows).
Create csc user account and add to Administrators group.
Create cscbkup account (with password csc7!BKUP). Add it to the Backup
Operators Group and from the Local Security policies provide this user with “Log on
as Service” rights in the User Rights Assignment.
Create an elec user account with appropriate password as per stations above.
Add the oper & elec accounts to the following groups:
Users
Power Users (only on the Servers, NOT on the stations).
Engineers
Engineering Repository Users
If the mngr account password is not the same as the PlantScape mngr password it
must be changed according to the procedure in Knowledge Builder for changing the
MNGR account password as this password is used for a number of services and
DCOM components.

Honeywell
Prevent local logon of the mngr account from the local security policies.
From Administrative Tools control panel select Security Settings > Local
Policies > User Rights Assignment
Double click “Deny logon locally”
Add local “mngr” account to list.
Ensure oper account password is set to “oper”.
4.7. Configure Server & File System
Archive directory set to D:\archive

1. Create the directory “archive” on the D: drive
2. Shared the folder as “archive” with the following permissions:
1. Everyone – Read Only
2. Administrators – Full Control
3. Honeywell Administrators – Full Control
3. Open the Experion PKS Server Control Panel
4. Set the archive directory to D:\archive and click “Set” & “Close”
5. Open the Start-Stop Experion PKS Server
6. Stop the Server
7. Wait until the Server has stopped
8. Start the Server
Compress D drive
Select properties of D: drive in Windows Explorer
Check the “Compress drive to save disk space” box
Click “Apply”
Select “Apply changes to D:\, subfolders and files
Click “OK”
Share the abstract directory
Share the folder “C:\Program Files\Honeywell\Experion PKS\client\abstract” as
“abstract” with the following permissions:
Create & share Databases directory
Create the folder “C:\Program Files\Honeywell\Experion
PKS\client\qckbld\Databases”
Honeywell
Share the folder as “Databases” with the following permissions:
Disable Automatic Updates
From the Automatic Updates Control Panel UNCHECK the “Keep my
computer up to date…” check box.
Configure the local station

Configure the local station connection as per section 2.9.11 above, using the
local C:\StationConfig restored directory.
4.8. Apply patches and install tools

Unless stated below the patches to be applied to the system are available in the
...\server\user\patches directory.
1. Run the displays_fix batch file from the Experion PKS R101 Reference Tools CD.
2. Install Winzip using the default selections and Classic interface.
Stop the PlantScape Server and SQL Server Services before applying any of the
following patches:
4.8.1. Apply the event database table lock patch:

This patch is installed by running the executable in the file:
ISR45650.PKS.101.fcotv
4.8.2. Update the HMIWeb applications to R3.0 Build 471

Follow the instructions in Section 5.2 “Client Installation for Existing Clients”
of the Software Change Notice for the Release.
THE SERVER INSTALLATION PROCEDURE MAY CORRUPT THE
SERVER INSTALLATION SUCH THAT THE SERVER WILL NOT
START AFTER THE PROCEDURE. ENSURE THE CLIENT INSTALL
PROCEDURE IS USED
Note the required installation file
“HMIWeb_R3_0_454_471_for_R101_Server.exe” can be found in the
StationConfig directory on either server, which is a backed up directory.

Honeywell
4.8.3. Apply server synchronization efficiency patch:
Install ISR 46428 patch by running the executable file in the zip file
(isr46428.PKS.101.fcotv.zip) on both the A and B server.
This patch replaces the ...\server\run\dual_onsrv.exe file with a new version,
after first copying the existing exe to a backup directory. The actions taken
are written to the file c:\Program files\Server\Setup\Software Update Log.txt.
4.8.4. Apply Experion R101.0 Patch 5

Install the Experion Release 101.0 Patch 5 by following the instructions in
Section 4.2.1 “Copy and Unzip the Patch Installer” and then 4.2.2 “Installing
R101.0 Patch 5 in Process Server” of the Software Change Notice for Patch 5.
Note the required Installation file “EPKS R101.0 Post Release Patch 5.zip”
and the Software Change Notice can be found in the C:\Program
Files\Honeywell\Experion PKS\Server\User\Patches directory on either server,
which is a backed up directory.

R101.0 Patch 9 in Process Server” of the Software Change Notice for Patch 9.
Note the required Installation file “R101_Patch9.zip” and the Software
Change Notice can be found in the C:\Program Files\Honeywell\Experion
PKS\Server\User\Patches directory on either server, which is a backed up
directory.

R101.0 Patch 10 in Process Server” of the Software Change Notice for Patch
10.
Note the required Installation file “R101_Patch10.zip” and the Software
directory.
4.8.7. Apply Experion R101 Event Subsystem Update

Install the Experion Release 101.0 Events Subsystem Update by following the
instructions in Section 5.1 “Server Installation” of the Software Change Notice
for the Events Subsystem Update. This will require installation on both the A
and B Servers.
Note the required Installation file “eventupdate.pks.101.exe” and the Software

Honeywell
directory.
4.8.8. Apply Point Attribute Report Efficiency Patch

Install ISR 53362 patch by running the executable file in the zip file
(isr53362.PKS.101.fcotv.zip) on both the A and B server.
The actions taken are written to the file c:\Program
Files\Server\Setup\Software Update Log.txt.

4.8.9. Apply Server Side station components update
Install ISR48315 Server components by running the executable file in the zip
file ISR48315.PKS.101.fcotv.zip on both the A and B Server.

4.8.10. Apply OPC Server update
Install ISR47659 Server components for the OPC Server Update by running
the executable file in the zip file ISR47659.PKS.101.fcotv.zip.
Check the DCOM configuration for the Experion PKS OPC Server by:
a. Open dcomcnfg from the Run command in the Start Menu
b. Locate the “Experion PKS OPC Server” in the Applications list and
open its properties by double-clicking
c. On the Identity tab re-enter the “mngr” account password to ensure it is
aligned with the PlantScape mngr account.

4.8.9.4.8.11. Apply the Microsoft patches:
The Microsoft patches that are qualified for installation on Experion PKS systems are
listed on the following website:
http://www.ssol.acs.honeywell.com/SSOL/Rooms/DisplayPages/LayoutInitial?Container=com.
webridge.entity.Entity%5BOID%5B0E8FB4B95ECD4548A2A0466AA79469AE%5D%5D
All of the executables for the patch installers should be stored in a subdirectory of
“C:\Program Files\Honeywell\Experion PKS\server\user”.
Knowledge
Install Order MS Fix Comments
Base Article
1 MS03-026 KB823980 RPC Vulnerability
2 MS03-041 KB823182
3 MS03-042 KB826232

Honeywell
4 MS03-043 KB828035
5 [Restart*] MS03-049 KB828749
6 MS04-003 KB832483
7 MS04-004 KB832894
8 [Restart*] MS04-007 KB828028
9 MS03-039 KB824146
10 ** Check Add/Remove programs as may have
Pre-SP4 Hotfix Q322913 been installed by prior installations **
11 ** Check Add/Remove programs as may have
SP4 Hotfix Q815021 been installed by prior installations **
* Note that when originally installed on the Server all requests to Restart the Server
were ignored with the exception of those marked [Restart] in the list above.

4.8.10.4.8.12. Install & Configure Anti-virus software
Install E-Trust Innoculate Virus protection as per standard CSC installation
procedures. After installation ensure the following directories are excluded from real-
time virus scanning:
C:\Program Files\Honeywell\Experion PKS\Server\data

C:\Program Files\Honeywell\Experion PKS\Engineering Tools\system\er

Honeywell
4.9. Load Onesteel Whyalla Blast Furnace Configuration

The following sections outline how to restore individual backup components in the
case of file corruption. In the case of loading the configuration onto a spare server
ALL of these sub-procedures shall need to be performed unless indicated otherwise:
4.9.1. Abstract Directory (Custom displays)

Copy the contents of the backed up “abstract” directory to the following directory:
C:\Program Files\Honeywell\Experion PKS\client\abstract
The abstract directory is replicated when the servers are synchronized so this step may
be skipped if loading the spare server, although it is recommended to reduce the
synchronization load on the system.
If restoring a single display in the case of a display corruption note that each display
consists of a “.htm” file and a directory of other files. For example the Overview
display „PO.htm‟ consisted of the following files at time of writing:
...client\abstract\PO.htm
...client\abstract\PO_files\Bindings.xml
DS_datasource1.dsd
Deg C.sha
Ds_ValueUnit.sha
kpa.sha
OS1.sha
Shape1.sha
Value.sha
All of the files need to be restored to the current primary server (usually the A server)
from where they will be automatically replicated to the backup server and all operator
and maintenance stations.
The file sysdtldaca.dsp must be deleted from the …client\system\R101\ directory
since there is a modified display in the NonStandardSystem displays folder.
4.9.2. History Archives

Copy any history archive folders (DO NOT CHANGE THE FOLDER NAMES)
which have been backed up to the “D:\archive” directory. Once the files are copied
the process history contained is immediately available in Station trends when the
Server is running.
4.9.3. Server Database

The real-time Server database (which should not be confused with the Engineering
Repository Database for C200 configuration) contains the definitions for all points,
areas, trends, groups, operators, stations, reports, controllers, channels, server scripts
etc, etc. The database consists of a number of binary files in the
“…\Experion_PKS\server\data” directory. To restore the whole real-time Server
database from a backup the following procedure needs to be performed. If only

Honeywell
certain components of the database (eg. Area definitions) are required to be restored
then see later sections of this document.
1. Make sure the server is stopped using the “Start-Stop Experion PKS Server”
application.
2. Insert the relevant backup tape (or other backup medium) into the appropriate
drive.
3. Open a Command Prompt window.
4. Type the following command to unload the current server database from
memory:
hscserver /unload
5. Use the Windows Backup program or Windows Explorer to restore the data
directory backup to the following folder (create the folder if necessary):
c:\Program Files\Honeywell\Experion PKS\server\backup.
6. Using Windows Explorer rename the following directory:
c:\Program Files\Honeywell\Experion PKS\server\data TO
c:\Program Files\Honeywell\Experion PKS\server\olddata
7. Using Windows Explorer rename the following directory:
c:\Program Files\Honeywell\Experion PKS\server\backup TO
c:\Program Files\Honeywell\Experion PKS\server\data
8. Delete the “points” file in the data directory and rename “points.bak” to
“points”
9. Start the server by typing the following at a command prompt:
hscserver /start

Honeywell
4.9.4. Engineering Repository
The engineering repository database (ERDB) is a Microsoft SQL Server database
which contains the C200 controller configuration information. The management of
this database is separate to the management of the real-time database component of
the Experion PKS Server described in other sections.
The following defines some terms important when managing the Engineering
Repository, with additional notes for activities to be performed when replacing either
an A or B Server.
Control Builder This is the Honeywell programming tool (application) used

for programming the C200 Controllers. It is effectively a
GUI application for manipulating the controller
configuration stored in the ERDB database.
Primary ERDB The Primary ERDB database is ALWAYS on Experion
PKS B Server.
Secondary ERDB The Secondary ERDB database is ALWAYS on Experion
PKS A Server.
Synchronisation of this database with the Primary ERDB is
managed by DBAdmin on the Experion PKS B Server,
NOT the “Synchronise” command on the Station displays.
Project View The view of the offline configuration of the C200
Controllers from within Control Builder.
Monitoring View The view of the online „live‟ configuration currently
running the C200 Controllers from within Control Builder.
Snapshot The snapshot is effectively a memory dump of the current
configuration in a C200 Controller. It is stored in a
separate file for each controller, separate from the ERDB
database itself:
C:\Program Files\Honeywell\Experion
PKS\Engineering
Tools\System\ER\CPM_CTLR_01_snapshot
&
C:\Program Files\Honeywell\Experion
PKS\Engineering
Tools\System\ER\CPM_CTLR_02_snapshot
Note the snapshot files are marked as „hidden‟ and have no
file extension.
It is important that the contents of the snapshot remain
aligned with the Monitoring view in the ERDB database.
DBAdmin This is Honeywell‟s MMC (Microsoft Management
Console) tool for managing the ERDB database.
Restore ERDB This is the process of replacing the current Primary ERDB
on the system with a backed up database. Typically the

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file being restored should have a “.bak” extension and this
would only be done with the Server offline unless the live
database has become corrupted.
Recover ERDB The process of recovering an ERDB is to re-align the
secondary database with the primary, or vice-versa. It can
only be achieved when both servers are on the same
network, and it assumes the database that is the source of
the recovery is still a valid database.
It is important that when restoring an ERDB and snapshot files that the latest backup
files are available to avoid „ghost‟ configurations in the controller. The procedures
for restoring and recovering the ERDB differ between a Server A or B replacement.
Consult the Backup/Restore section of the Administration Guide in Knowledge
Builder for further information about restoring the Engineering Database to a server in
redundant systems.
4.9.4.1. OPENING THE DBADMIN TOOL

Note that all DBAdmin tasks referenced in the procedures below are accessible from
the DBAdmin tool:
o Open the tool on the B Server (Program Files > Experion PKS Engineering
Tools > DBAdmin).
o Expand the tree to get to ERDB Admin Tasks
o When asked, log in with credentials :
User Name mngr
Password mngr1
Server Name EXP_SVRB
Domain Name Classic Server Security
4.9.4.2. WHEN SERVER B BEING RESTORED

The engineering repository and snapshot files from the latest backup should be
restored to the spare „B‟ server to ensure the Server contains a consistent set of
databases. The snapshot files should be placed in the following directory:
C:\Program Files\Honeywell\Experion PKS\Engineering Tools\system\ER
The latest backup of the engineering repository database should be restored using the
DBAdmin tool on EXP_SVRB.
o Disable replication using the target in DBAdmin
o Click the “Restore Database” and select the “*.bak” file from the most recent
backup.
4.9.4.3. SERVER A BEING REPLACED:

There are no actions to be performed for the ERDB while restoring the A server.

Honeywell
4.9.5. Events Database

This restores the Alarm/Event database that has been backed up by the Daily backup.
1. Stop the server and unload the databases by typing hscserver /unload at the
command prompt.
2. Check in
c:\Program Files\Honeywell\Experion PKS\server\evtarch\backup to
determine which Backup file you wish to restore. This is usually the file with
the most recent date and time, but it depends on your circumstances. Note the
name of this file.
3. Start Microsoft SQL Server Enterprise Manager (select Start > Programs >
SQL Server).
4. Expand the left tree down the path:
Microsoft SQL Servers > SQL Server Group > <PC Name> > Databases
> EMS Events
5. Right-click the EMS Events Database and select All Tasks > Restore
Database...
6. In the Restore Database dialog box, ensure that:
o Restore as database is set to EMS Events
o Restore is set to From Device
Press the Select Devices command button and add a new device
c:\Program Files\Honeywell\Experion PKS\server\evtarch\ba
ckup\EMSDailyBackup.dat
Click OK until you return to the Restore Database dialog box.
7. Leave the default values for the other settings:
Backup number = 1
Restore backup = set
Database = Complete
8. In the Restore Database dialog box, select the Options tab.

9. Select the Force restore over existing database check box.
10. Select OK to run the restore.
11. Load the databases and start the Server by typing hscserver /start at the
command prompt.
4.9.6. QuickBuilder Database

Copy the contents of the backed up “Databases” directory to the following directory:
C:\Program Files\Honeywell\Experion PKS\client\qckbld\Databases

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The Databases directory is replicated when the servers are synchronized so this step
can be skipped if loading the second server.
The import/export functions (or copy/paste) can be used to move individual items
between QuickBuilder files. If for instance it was desired to restore a single point
definition from a backup of the QuickBuilder database the following procedure could
be followed:
1. open the backed up database
2. select the point to be copied
3. From the Edit menu copy the point
4. Open the current database in QuickBuilder
5. Paste the point. This will replace the previous point definition
6. Download the point to the Server.
Note that the “.pnt” files which are saved as part of a backup can also be used to
restore individual point definitions to the Server using the “pntbld” utility. See the
Knowledge Builder instructions for details on the use of this utility.
Note that a “.qdb” file which has been restored from a CD backup may have the
“read-only” attribute set by the file system. It is not possible to open any “.qdb” files
with the read-only attribute set.
4.9.7. Station Configurations

Copy the contents of the backed up “StationConfig” directory to the following
directory:
C:\StationConfig
The individual files in this directory should be copied to the locations outlined in
section 2.9.11 for correct configuration of the Station connections (including a local
diagnostic rotary station on each of the Servers).
4.9.8. User Directory

Copy the contents of the backed up “user” directory to the following directory:
C:\Program Files\Honeywell\Experion PKS\server\user
The user directory is replicated when the servers are synchronized so this step may be
skipped if loading the spare server. Loading the user directory is recommended
however to reduce the synchronization load on the system.
NOTE that individual components backed up to the user directory may be restored to
the database in the event of some corruption or error in the configuration of these
components. See section 4.9.9 below for these specific components.
4.9.9. Individual restore of server configuration components

When a backup is taken a number of specific data files are dumped (i.e. stored to disk)
using the utility “fildmp” (more details on this utility can be found in Knowledge
Builder). In the event that any of the following configurations are accidentally

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modified or corrupted the same utility can be used to restore the indicated file in order
to restore the backed up configuration.
Configuration Filename
Area codes and descriptions areas.dmp
User acronym definitions useracronym.dmp
Operator Message definitions messages.dmp
Report definitions reports.dmp
History assignments for points fasthist.dmp (fast history assignment)
and parameters ** stdhist.dmp (standard history assignment)
exthist.dmp (extended history assignment)
Groups configuration (not groups.dmp
including custom group overview
displays) *
Trend configuration * trends.dmp
Reports configuration reports.dmp
(particularly WTP water usage,
and alarming reports)
Keyboard Configurations (server keyboard.dmp
side only, not the pushbutton
actions which are stored in the
Station‟s “.stb” file.
** The history assignments are also contained in the “.pnt” text files which are
generated and saved during the backup process. The “.pnt” files need to be filtered
for all lines starting in “HISTFAST”, “HISTSLOW” and “HISTEXTD” to extract the
fast history, standard history and extended history assignments respectively. Changes
to the assignment can then be made to the filtered file and built onto the Server using
the “pntbld” utility, provided ALL lines in the file ONLY start with one of the three
“HIST*” fields given above.
* The point assignments for the groups and trends are also contained in textual form
in the “.pnt” files which are generated during the backup process. The assignments
can be found by filtering these files for all lines which start with “GROUP” and/or
“TREND”. Although changes to the assignment can then be built using the “pntbld”
utility it is not recommended given the criticality of the group configuration to the
operation of the plant.
4.10. Configure Backup utilities on Server

Setup VNC
VNC is the remote desktop sharing application used for administering the Servers on
the local network as they do not have their own monitor connections.
1. Create a directory on the root of the server called c:\vncviewer

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2. Share the vncviewer directory to the Administrators group as “vncviewer$”
3. Copy the vncviewer.exe application file from the ...\server\user\tools directory
into c:\vncviewer.
4. Run the Setup.exe application in the winvnc directory for VNC
(…\server\user\tools\winvnc\setup.exe).
5. Click Next on Welcome Screen
6. Agree to the license agreement
7. Click Next to accept default install folder
8. Click Next to accept default program folders
9. Click Finish to complete installation.
10. From the Start Menu select Programs > VNC > Administrative Tools > Install
VNC Service
11. From the Services Control Panel start the “VNC Server” service
12. Click OK when presented with a warning regarding the default password
13. Enter the password in the next form as “Honeywell!” and click OK
14. The VNC connection can then be tested using the vncviewer application from a
remote PC connected to the Server.
Create backup directory and configure backup utilities

1. Create a “D:\ExperionBackup” directory
2. Share the directory as “ExpBackup” providing the cscbkup user with read access
permissions to the share, and the Administrators group with Full Control.
3. From the Scheduled Tasks control panel add a scheduled task to run the
appropriate backup batch file from the …\server\user directory at 11:20pm for
Server A and 10:20pm for Server B each day.
4. On the B Server open the SQL Server Enterprise Manager and create a
management plan which saves a backup of the ps_erdb database to the
D:\ExperionBackup directory each day.
Copy robocopy.exe to winnt\system32 directory from …\server\run directory
Set up the Tape Backup as a Scheduled Job

1. Go to the Windows BackUp utility – Start –Programs-System Tools – BackUp
2. Select the “Scheduled Jobs” Tab.
3. Select “Add Job”
4. Select Next
5. Select “BackUp selected Files, drives or network data”, then Next
6. The following directories and drives should be selected to be backed up:
a. D:\Experion BackUp directory

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b. The D:\ drive. (for the history archives)
Once these are selected click Next.
7. Select the BackUp media type to be “4mm DDS” and the BackUp media or
file name to be “New Media”. Then Next.
8. Select the type of BackUp operation to be Copy. Select “BackUp migrated
remote Storage data”. Then Next
9. Leave the “Verify data after BackUp” unchecked and check the “Use
hardware compression” checkbox. Then Next.
10. Check the “replace data on this media with this backup” checkbox. Do not
check “Allow only the owner & the administrator access to the backup data
and to any backups appended to this media”. Then Next.
11. Accept the default labels for the tape. Then Next.
12. Run the backup as EXP_SVR#\ps_user and enter the correct password. (where
# is A or B). Then press OK.
13. Select the job to run later with Job Name = ExpBackUp. Set the schedule so
that the backup runs weekly on Saturdays at 3:15am for Server A and 1:45am
for Server B.
14. On the settings set the task to stop if it runs for more than 12 hours. Leave the
remainder of selections unchecked (default).
15. Click OK. Verify the Schedule and Job properties by going to Start-
Programs-Accessories-System Tools-Scheduled Jobs. There should be a
scheduled job called ExpBackUp with the properties as entered above.
Set up the archiving of events text dump on Server A

1. Create the following directory on the D: drive:
D:\archive\alarmeventlogs
2. Open the Scheduled Tasks Control Panel and add a new task called
“AlarmEventReportArchive”. Configure the task as per the following
screenshots (ensuring you set the password for the ps_user account correctly).

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3. Create another scheduled task with the name “AlarmEventMonthlyArchive”.
The properties are the same as the task above, with the exception of the details
on the following two screenshots:

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5. Putting spare server online
The following sections need to be considered (in order) when putting the spare Server
online after the failure of one of the „on-process‟ Servers. It is assumed that the
replacement Server has been prepared according to the Server Restore instructions
above. Unless indicated otherwise all activities are required for either a Server A or
Server B replacement.
5.1. Actions prior to connection on the plant network
5.1.1. Power down Plant Server and Power-up Replacement

Power down the Server that is being replaced (using Start > Shutdown if possible).
Check that the other server is running and that operator screens are still available and
functioning.
Connect the power, keyboard, mouse and monitor to the replacement server (NOT
THE FTE OR CONTROLNET CONNECTIONS). Power up the replacement
server and log on as “ps_user”or another administrative account (csc or
Administrator).
5.1.2. Stop Experion PKS Server services

Prior to placing the spare Server online on the plant network ensure that the Experion
Server is stopped on the Spare server using the Experion PKS Server > Experion PKS
Start-Stop Server application. If in simple mode simply Stop the Server, if in
Advanced Mode change the Server state to “Database Only”. This shall prevent any
conflict in determining which Server is primary while setting up the network
connections for the new Server.
5.1.3. Set the time on the Server

Ensure that the time on the replacement Server is set as close as possible to the
currently running system time. This includes the time zone and Daylight Savings
settings. Note that if the A Server is being replaced it will become the time master for
the system, so it is important that it is set to the correct time based on the online
system. The B server will always be synchronized with the A server as per the
instructions below.
5.2. Activities during connection of replacement server
5.2.1. Ensure ControlNet Cables are correctly connected

Ensure the ControlNet connections are made such that the A segment is connected to
the A connector on the PCIC cards, and the B segment is connected to the B
connector.
5.2.2. Ensure FTE Cables are correctly connected

When putting the spare Server on the network ensure that you only place the Yellow
cable first. Check that it is connected to the „Yellow‟ LAN connection from the
Network Connections Control Panel on the Server BEFORE connecting the „Green‟
Honeywell
LAN cable. Once the Yellow cable is in the correct port (swap the physical port
connection if required) connect the “Green” cable to the green port.
5.2.3. Check Network configuration and operation

From a command prompt run both “nbtstat –n” and “ipconfig –all”. In both cases the
“Yellow” connection should appear first in the list of bound network cards.
Call up the FTE Auxilliary Status display (Start > Program Files > Honeywell TPS >
Fte Status Display) and ensure that both the local node and all other OPS and MNT
stations on the network are listed, with “OK” connection status.
5.3. Activities after connection of the replacement Server
5.3.1. Synchronising Time between Servers (A or B)

The date and time on the primary and backup servers need to be synchronized to
ensure that all dates and/or times associated with events in the database are consistent
between servers.
In a redundant server system, the primary server is used as the time source and the
backup server is configured to synchronize with the primary server.
To configure the backup server so that it synchronizes with the primary server, you
need to set up a time service on the primary server and then synchronize the backup
server with the primary server.
Note:
Before starting the Time Service, ensure that the primary and backup Experion PKS
Servers, along with the Primary PlantScape Server, are configured to be in the same
time zone and Daylight Savings setting. The time zone setting can be checked by
opening Date/Time in the Windows Control Panel
To set up the time service as a time source on Server A (for Server B and all Stations):
1. Select Start > Run and run settimesource.vbs, which is located in the
server\run folder. This program is silent if successful.
2. Select Start > Settings > Control Panel > Administrative Tools > Services.
3. Select Windows Time service and set the startup type to Automatic.
4. If the Windows Time service is running, stop it.
5. Restart the Windows Time service.
To set up the time service on Server A to synchronise with PlantScape Server A to

ensure DSA times are synchronised:
1. On the A server, open a Command Prompt window and type

net time /setsntp:cscbf1a

Honeywell
To setup the time service on Server B:
1. On the backup server, open a Command Prompt window and type

net time /setsntp:EXP_SVRA.
5.3.2. Configuring Alarm Event Printer on Server (A or B)

Start > Settings > Printers > Add Printer
Click Next to “Welcome to Add Printer Wizard”
Select “Network Printer” and click Next
Select “Connect to a printer on the Internet or on your intranet” and type in the
following URL:
\\EXP_OPS1\AlmEvent1
Click Next
Select “No” so Windows does not use this as the default printer and click Next.
Click Finish.
Repeat for \\EXP_OPS2\AlmEvent1 (for a backup printer).
5.3.3. Engineering Database Considerations

Review the Engineering Database Considerations in Section 4.9.4 and dependent on
the Server being replaced follow the instructions in the subsections below:
5.3.3.1. SERVER B BEING REPLACED

Once the Server is online and communications have been established with the A
server, the primary Engineering repository database should be restored from the
secondary on the A Server. Using the DBAdmin Tool:
1. Disable Database Replication
2. Recover the Primary Database
Note that this process may interrupt communications between the
Experion PKS Server and the C200 controllers for a up to 30 seconds
while the services on the Primary Server are restarted to allow connections
to the new primary database.
If fatal errors are encountered during this process it is possible that the Server
A database has been corrupted, in which case the procedure below for “Server
A corrupted” should be followed.
3. Enable Replication from DBAdmin to ensure the databases remain
synchronized.

Honeywell
4. Then using Windows Explorer copy the snapshot files from the EXP_SVRA
server to the EXP_SVRB server.
Server B is being replaced & Server A ERDB is corrupted:

In the unlikely event that there are fatal errors while recovering the primary database
it may be due to some corruption of the secondary database as the result of the
replications services being disrupted when the B Server failed. In this case the
primary Engineering repository database on EXP_SVRB should be restored from the
latest backup. Using the DBAdmin Tool “Restore the Database”. Copy the backed
up snapshot files to the EXP_SVRB Server as these should represent the snapshots
which are aligned with the ERDB database‟s monitoring view.
Once the Server is online and communications have been established with the A
server run DBAdmin on the B server and:
1. Disable Database Replication
2. Recover the secondary database.
3. Enable Database Replication
4. Then manually copy all the snapshot files from the B server onto the A server.
5.3.3.2. SERVER A BEING REPLACED:

After connecting the A Server onto the network simply run DBAdmin on the B server
and follow the process below:
1. Disable Replication
2. “Recover the secondary database”.
3. Enable Replication
4. Copy all the snapshot files from the B server onto the A server.
As the B Server is the primary ERDB database it is assumed that this should never be
corrupted by a failure of the A Server.
5.3.4. Synchronise Servers

Start the Experion PKS Server (from the Start-Stop Experion PKS application) on the
replacement Server and attempt to synchronise the Servers from the Server
Redundancy status display in Station once it is indicated that the backup is
“Running”. Note that it may be a significant period of time (1hr +) before a manual
failover can be commanded once the servers are synchronized due to the file
replication of the history archives.
5.3.5. Check logs

The following error logs should then be checked on the replaced Server to ensure
there are no reported issues:
 Experion PKS Server Diagnostic Tools > Experion PKS Server Log
 Windows Event Log (Administrative Tools > Event Viewer)
Honeywell
 Experion PKS Alarm Summary for any unexpected alarms, particularly
relating to “LINK”, “BACKUP”, “CPU”, “SYNC‟ or “REDUNDANCY”
5.4. Check functions on replaced Server
5.4.1. Abstract replication

Ensure that any recent changes in the Primary server abstract directory have been
copied to the replacement server.
5.4.2. VNC
Using a Maintenance or Operator Station use the VNC client
(\\exp_svra\vncviewer$\vncviewer.exe) to connect to the replacement server. Ensure
that a remote desktop session is presented after logging on to the Server.
5.4.3. RSLinx
Open Start > Program Files > Rockwell Software > RSLinx
Click on the RSWho toolbar icon.
Expand the AB-PCIC driver to show the online ControlNet nodes.
At least nodes 1 – 4 and one of 23 or 24 MUST be listed. For information the nodes
can be categorized as:
 Nodes 1-4 are the C200 Controllers
 Node 5 is the RNet Gateway PLC
 Nodes 6 – 17 are ControlLogix PLC‟s
 Nodes 18- 22 are Maintenance Stations.
 Nodes 23 and 24 are the Servers (it is expected that only one of these will be
shown in RSLinx).
If no nodes are visible other than a Server node then check the ControlNet
connections and RSLinx Services.
5.4.4. Check Experion PKS Services

From the Services Control Panel (in Administrative Tools) check that the following
Experion PKS services are running:
Experion PKS Server
Experion PKS Daemons
Experion PKS Control Data Access Server
Experion PKS ER Server
Experion PKS System Repository
Note that others may be stopped or running, but these are the critical services.

Honeywell
5.5. Activities when replacement server is running as primary
Once it is possible to failover such that the replacement Server can be run as the
Primary Server the following checks should be made after the failover (issue a manual
failover from the Server Redundancy display in Station).
5.5.1. DSA
When the replaced server is running as primary ensure that PlantScape is polling live
data from the Experion system by requesting the point detail on a PlantScape Station
for the F-BLAST2 point (from a PlantScape station type “F-BLAST2” and press
F12). Ensure that the PV parameter reading in the lower left corner updates (ie.
changes value) at least once every 20 seconds.
Check the DSA status page (pag119) on the PlantScape station by pressing F5 and
typing “119”, followed by [Enter]. Select the EXP_SVRA or EXP_SVRB link to
view the status of the DSA Connection to the Experion PKS Servers. There should at
least be an OK (green) link status to the current Primary Experion PKS Server..
5.5.2. Server Scripts (FTE Alarms)

When the replaced server is running as primary (which may require a manual failover
and re-sync) ensure that FTE alarms are generated if a single network connection is
removed from the back of one of the Stations for a period of 20 seconds. The Station
with the „fault‟ should be indicated in the Message summary on the Station
application (green Message indication in status bar of Station). These messages can
be acknowledged.
5.5.3. Point communications

Check to ensure data that is sourced from both PLC‟s and C200 controllers is being
updated on the displays.
PLC communications:
To check the PLC controllers call up the Controller status page from the Station Menu
on an Experion Station (View > System Status > Channels). Any PLC‟s which are
checked as enabled but indicate a Failed status should be disabled and re-enabled (this
will require ENGR or MNGR assess in Station). If the Controller fails again (which
will be alarmed to the operator) there is a critical problem with the communications to
that PLC. The first point of troubleshooting is to run RSLinx on the Server, open
RSWho and ensure that the PLC which has failed is visible on the ControlNet
network. Also check that the RSLinx Windows Service is running.
To check the PLC Channels call up the Channel status page in Station (View >
System Status > Channels). All enabled channels should indicate a green (OK) status.
The troubleshooting for these is the same as for the Controller communications above.
C200 Controller communications:
To check that data is available from the C200 controllers, along with the general
status of the system, call up the System Summary page (type “ss” and press [Enter] on
Experion Station). Most of the controller elements on this page should be green to
indicate an OK status. If all of the controller rack elements are red there is most likely
a critical communications problem which should be alarmed in the Alarm summary.
The following should be used as first tasks for troubleshooting:
Honeywell
1. Check Station Alarm summary for alarms in System (SY) or I/O (IO) areas.
2. Check that the following services are started on the Server:
o RSLinx
o Experion PKS Control Data Access Server
o Experion PKS ER Server
3. Open RSLinx and open the RSWho window (from the Toolbar) expanding the
AB_PCIC-1 driver to view the ControlNet network (by toolbar icon). Check
to ensure that Nodes 1 & 3 are visible on the network.
If these indicate issues it may be necessary to manually fail-over the server to run the
other server as Primary.
Note that any individual controller rack elements on the System Summary page which
are not green (OK) should be investigated by the plant maintenance and/or electrical
departments.
5.5.4. Check Logs

See Section 5.3.5 above for description of logs to check.
5.6. Post-replacement tasks
5.6.1. Backup batch file

The following day the contents of the c:\ExperionBackup directory should be checked
on the server that was replaced to ensure that the backed up files are current.


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Experion PKS Server & Station

OneSteel Whyalla Steelworks

Blast Furnace Capital and Reline

ISO 9001 Lic. No. QEC0170

OneSteel Whyalla Server & Station Installation & Backup Procedures

Honeywell Signed: Date:

Honeywell Signed: Date:

OneSteel Signed: Date:

OneSteel Whyalla Server & Station Installation & Backup Procedures

Revision Date Prepared By Description

A 21st Aug 2003 S.Allen / Initial Customer Review

OneSteel Whyalla Server & Station Installation & Backup Procedures

OneSteel Whyalla Server & Station Installation & Backup Procedures

OneSteel Whyalla Server & Station Installation & Backup Procedures

OneSteel Whyalla Server & Station Installation & Backup Procedures

OneSteel Whyalla Server & Station Installation & Backup Procedures

1.2. Scope of document

1.3. Reference Documents

Document Source Reference

OneSteel Whyalla Server & Station Installation & Backup Procedures

OneSteel Whyalla Server & Station Installation & Backup Procedures

1.4. Definitions & Abbreviations

DSA Distributed Server Architecture

OneSteel Whyalla Server & Station Installation & Backup Procedures

2. Station Installation and Configuration

2.1. Pre-installation Requirements

o Windows XP SP1 Installation CD

 FTE R110 Planning, Installation and Service Guide

 This installation procedure

 Network Configuration Worksheet

 Passwords for „ps_user‟ and csc administration accounts

 Password for Experion PKS „mngr‟ user account password

 Rockwell RSNetworx for ControlNet Installation and Master Disk

2.2. Install Experion PKS Process Client

OneSteel Whyalla Server & Station Installation & Backup Procedures

 Microsoft Excel is not required on the Operator or Maintenance Stations,

 Video Capture Card

2.3. Install FTE Components not installed during FTE Software

2.4. Install Updated HMIWeb Components

OneSteel Whyalla Server & Station Installation & Backup Procedures

2.5. Install Experion Patch 5

2.6. Install Experion Patch 9

2.7. Install Experion Patch 10

2.8. Install Events Subsystem Update

Note the required Installation file “eventupdate.PKS.101.exe” and the Software

OneSteel Whyalla Server & Station Installation & Backup Procedures

2.8.1. FTE & Network Settings

Selected Adapters Select both “Yellow” and “Green”

OneSteel Whyalla Server & Station Installation & Backup Procedures

2.9. Configure Operating System Software

2.9.1. Network Setup Wizard

ii. Click „Next‟ on the welcome screen

OneSteel Whyalla Server & Station Installation & Backup Procedures

ix. Provide a computer description such as “Experion PKS Operator Station

x. Enter a workgroup name of EXPERIONPKS and Click „Next‟ to

OneSteel Whyalla Server & Station Installation & Backup Procedures

v. Click “OK” and exit Control panel.

OneSteel Whyalla Server & Station Installation & Backup Procedures

2.9.3. Set the logon to Classic Logon Authentication

OneSteel Whyalla Server & Station Installation & Backup Procedures

ix. Click “Sites”