Huong Dan Plcda Nhimptp21a40032-Ec

Controcad V3 - User's Manual - Volume 5
Automation Cell Start-up

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DATE NOM
SIGNATURE
15/01/03 NAME
DEPARTEMENT CS – SERVICE CS T3
ETABLI J. BARTHEROTTE
ESTABLISHED A. COATLEVEN
VERIFIE
J.F. CABADI
CHECKED
Power
APPROUVE Electrical and Control Systems
D. CANTERO
APPROVED
REV STAT. F°/F° FIN Nb F°

SH/SH END N of SH
P T P 2 1 A 4 0 0 3 2 - E C P T P 2 1 A 4 0 0 3 2
C GFE 1/64 64
PA 400 D
TABLE DES MODIFICATIONS / MODIFICATIONS TABLE
ETABLI VERIFIE APPROUVE

REV DATE MODIFICATIONS STAT.
ESTABLISHED CHECKED APPROVED
A J. Bartherotte J.F. Cabadi D.Cantero 13/08/01 Première version document GFE
B J. Bartherotte J.F. Cabadi D. Cantero 21/03/02 Section 3 added GFE

J. Bartherotte
C J.F. Cabadi D. Cantero 15/01/03 Section 4 added GFE
A. Coatleven
Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.2/64

PA 401 C

TABLE OF CONTENTS
1 INTRODUCTION.......................................................................................... 6
1.1 AIM OF THE DOCUMENT............................................................................. 6
1.2 REFERENCE MANUALS ................................................................................ 6
1.3 ARCHITECTURE............................................................................................ 7
1.4 CONNECTION POINTS ................................................................................ 8
1.4.1 Cell Controller ............................................................................................ 8
1.4.2 Field Controller........................................................................................... 9
2 LOADING CELL FIRMWARE ....................................................................... 10
2.1 WHEN TO LOAD BOARD FIRMWARE ......................................................... 10
2.2 LOADING THE EEM FIRMWARE (C80-35) .................................................. 10
2.2.1 Operating Procedure ............................................................................... 10
2.2.2 Checking the Firmware Version ............................................................... 12
2.3 LOADING THE FBC30 FIRMWARE (C80-35) ............................................... 15
2.3.2 Checking the Firmware Version ............................................................... 16
2.4 LOADING THE EX7 (C80-75 CELL)............................................................. 17
2.5 LOADING THE FBC70 (C80-75 CELL) ......................................................... 18
2.6 CONFIGURATION ..................................................................................... 20
3 LOADING A C80-35 CELL.......................................................................... 21
3.1 LOADING THE HARDWARE CONFIGURATION ON THE CELL

CONTROLLERS .......................................................................................... 21
3.2 LOADING THE F8000 FIELDBUS CONFIGURATION................................... 25
3.3 LOADING SUB-CONTROLLERS.................................................................. 29
3.3.1 Loading the Hardware Configuration in the Sub-controllers ................... 29

3.3.2 Loading the F8000 Fieldbus Configuration .............................................. 33
4 LOADING A C80-75 CELL.......................................................................... 37
4.1 INITIAL LOADING OF A C80-75 CELL........................................................ 37
4.1.1 Loading the Hardware Configuration by Serial Link. .............................. 37
4.2 LOADING A C80-75 CELL CHRONOLOGICALLY VIA ETHERNET................. 43
4.2.1 Loading the Hardware Configuration of a C80-35 Field Controller ......... 43
4.2.2 Loading the Hardware Configuration of a Redundant C80-75 Cell

Controller ................................................................................................. 45
4.2.3 Loading the Software Configuration of a Redundant C80-75 Cell

Controller ................................................................................................. 46
4.2.4 Loading the Network Configuration of a C80-35 Field Controller............ 48
4.2.5 Loading the Software Configuration of a C80-35 Field Controller ........... 51
4.2.6 Loading a Non-TRX CE2000. .................................................................... 53
4.2.7 Loading a TRX CE2000 ............................................................................. 55
4.2.8 Action when the Hardware Loading Chronology Executes Incorrectly ..... 59
5 MODIFYING A C80-75 CELL ON LINE BY P80 ........................................... 60
5.1 ON-LINE MODIFICATION WITH TRANSFER............................................... 60
5.2 ON-LINE MODIFICATION WITHOUT TRANSFER ........................................ 61
6 FULL RELOAD OF THE F8000 CONFIGURATION........................................ 62
6.1 WHEN IS FULL RELOAD NECESSARY?........................................................ 62
6.2 PROCEDURE .............................................................................................. 63

PREAMBLE
The present document applies to Controcad Version 3.2.4 and later.
The versions of the different components must be at least:

C80-35 Controller
CPU364 : 10.0
EEM Firmware : 2.0
FBC30 Firmware : 4.01
C80-75 Controller
CPX935 : 8.10 9A5
EX7 Firmware : 2.12 1113
FBC70 Firmware : 2.7 1327
Please refer to the commercial P320 system version file for information regarding the
host hardware managed by Controcad.
In particular, check the version file for details of the firmware versions applicable
relative to the Controcad version implemented.

1 INTRODUCTION
1.1 AIM OF THE DOCUMENT
This document describes the operations necessary for putting an automation cell into
service, with respect to loading software programs.
It applies to standard architectures managed by the Controcad engineering tool.
It is intended for those persons responsible for platform installation of the controllers,
but it can also be considered as a guide for maintenance of controllers that are
already in service.
Prerequisites: the users of this document should be familiar with Controcad, the P320
system software engineering tool, and with P80, the automation cell programming
tool.
1.2 REFERENCE MANUALS
Controcad V3 Glossary
P-TP21-A40000
Controcad V3 Installation Manual

P-TP21-A40003
Controcad V3 User's Manual, Volume 1 - Centralog P-TP21-A40005
Controcad V3 User's Manual, Volume 2 - Centralog P-TP21-A40006

Supervisory Functions
Using Alspa P80 V2.3

ALS52212

1.3 ARCHITECTURE
The illustration below shows a typical example of architecture comprising a

Controcad server station and a Controcad client station.
Site network
CONTROCAD CONTROCAD
SERVER / CLIENT CLIENT
S8000 network
AUT 1 Cell controller AUT 16 Cell controller
F8000 F8000
Field Field
controllers . . . controllers
Various types of architecture are possible (redundant or non-redundant cell

controllers, Controcad client and server stations supported by the same device etc.).
The term Controcad station in the remainder of this document, may indicate a client
station or a server station.
All the C8035 controllers, whether they are cell controllers or sub-controllers, require
minimum loading (firmware, hardware configuration): the controllers are loaded by
connecting a Controcad station COM port with the various controller interfaces.

1.4 CONNECTION POINTS
The different connection points are as follows:
1.4.1 Cell Controller
POWER CPU364 FIP Fieldbus

SUPPLY communication
15-pin RS422 connector port
RJ45 RS232 connector port
15-pin SNP link connector
Cords to be used:
• PC<->Power Supply : HE693SNP232A

• PC<->FBC30 : HE693SNP232A
• PC<->CPU364 : CNX-T-RJ11-C4+ ADAPT-RJ12DB9F

1.4.2 Field Controller
CPU3xx
POWER FIP Fieldbus
SUPPLY communication
15-pin RS422 connector port
15-pin SNP link connector
Cords to be used:
• PC<->Power Supply : HE693SNP232A

• PC<->FBC30 : HE693SNP232A
At the conclusion of the operations described in this document, all maintenance

operations (with the exception of loading new firmware) can be performed remotely
from any Controcad station via the S8000 network (for cell controllers) and the
F8000 fieldbus (for sub-controllers).

2 LOADING CELL FIRMWARE
2.1 WHEN TO LOAD BOARD FIRMWARE
Specific firmware is necessary on the following boards:

• The CPU364 in the C80-35 cell controllers and in the C80-35 field controllers
in C80-75 cells: this firmware manages Ethernet communications on the board
and is also called EEM Firmware.
• The FBC30 on the F8000 interface in the cell controllers or field controllers.
• The CMM 742 in the C80-75 cell controllers: this firmware manages
communications on the E900 network and is also called EX7firmware.
• The FBC70 on the F8000 interface in the C80-75 cell controller.

The board firmware must be loaded when a new interface is installed.
Loading need only be done once, since it is saved even when the rack containing the
board is de-energized or if the board is removed from the rack.
This operation can also be carried out on a recycled coupler whose origin is
unknown: firmware may be loaded as many times as may be necessary.
2.2 LOADING THE EEM FIRMWARE (C80-35)
2.2.1 Operating Procedure
This operation need only be performed once, since the software is permanently
stored in the CPU364 board.
Depress the Ethernet restart button located on the front face of the CPU364 board for
more than 5 seconds until the Stat LED of the board lights up: when the 3 LEDs are
flashing simultaneously, the CPU 364 board is in wait mode for the EEM firmware.
Connect the serial port of the CPU364 board (port RJ45 indicated Port-1 RS232
located on the front face of the board) to the COM1 or COM2 port of the Controcad
PC
Using the Windows NT browser, go into directory:

<drive>\firmware\eemr<version_EEM>\winloader<version_winloader>
Note: the EEM firmware version must be at least 2.0.

Double click on Winloader.exe
Select the COM Port of your PC linked to the serial port of the CPU364 board.
Checkmark the Advanced field if this is not already the case.
Then click on the DAT icon.
Go back up one level in the directory to display the Firmware.dat file.

Select Firmware.dat by a single click and then double click on Open.
In the Winloader window, begin loading by clicking on Update.
The firmware loading operation begins; do not interrupt the process (the operation lasts
for approximately 2 minutes).
Quit the window when the firmware loading process is terminated.
Power cycle (on/off) the cell controller: the board Ethernet software is now operational.
2.2.2 Checking the Firmware Version
On the Controcad station, select the relevant controller in the hardware branch

Connect the SNP port of the controller power supply to the COM1 or COM2 port of
the Controcad station
Select the "DEFAULT" device and click on Connect to start the communication.

Right click in the small window indicating the status of connection with the target.
The following window opens indicating the EEM firmware version:

2.3 LOADING THE FBC30 FIRMWARE (C80-35)
stored in the FIP FBC30 interface board.
Position the board in a slot other than its definitive location.
Connect the serial port of the FBC30 board (15-pin port marked RJ-422 located on
the front face of the board) to the COM1 or COM2 port of the Controcad PC.
Using the windows NT browser, go into directory:

<drive>\firmware\bem340-v<release_BEM>\winloader<release_winloader>
Note: the FBC30 firmware version must be at least 4.1.

Select the COM Port of your PC linked to the serial port of the FBC30 board.
Checkmark the Advanced field if this is not already the case.
Go back up one level in the directory to display the Firmware.dat file

Click to select the Firmware.dat file and then click on Open.
In the Winloader window, click on Update
The firmware loading operation begins, do not interrupt the process (the operation
lasts for approximately 4 minutes). The OK and RUN LEDs on the FBC30 flash during
loading.
At the end of loading, only the OK LED is permanently lit.
Power off the controller and reposition the board in its correct slot.
2.3.2 Checking the Firmware Version
The FBC30 firmware version can be verified by means of the HHP mini terminal
connected to the power supply serial port: press the mode key, use the vertical arrows
to position the cursor on config, and select by enter.
Use the vertical arrows to scroll through the different boards present in the rack to
the FBC board (Rxx:yy is the rack board in row xx at position yy): read the version
displayed Rxx:yy FBC V.R

2.4 LOADING THE EX7 (C80-75 CELL)
stored in the IC697CMM 742 interface board.
Connect PC and the IC697CMM742 module by an IC690ACC900B cable.
Boot the IC697CMM742 module as follows:
Depress the reset button on the front face for 5 seconds until trhe lower LED lights
up.
When the IC697CMM742 module is in boot mode all the LEDs on the front face
flasht.

<drive>\firmware\ex7-v<release_EX7>\winloader<release_winloader>
Note: the EX7 firmware version must be at least 2.12.

Select the PC COM port linked to the serial série on the CMM 742 board.
Checkmark the Advanced field if this is not already done.

lasts for approximately 4 minutes). The LEDs continue to flash during loading.
2.5 LOADING THE FBC70 (C80-75 CELL)
stored in the FIP FBC70 interface board.
Connect the serial port of the FBC30 board (15-pin port marked RJ1 located on the
front face of the board) to the COM1 or COM2 port of the Controcad PC.

<drive>\firmware\bem742-v<release_BEM>\winloader<release_winloader>
Note: the FBC70 firmware version must be at least 2.7.


Select the PC COM Port linked to the serial port on the FBC30 board.
Checkmark the Advanced field if this is not already done.
lasts for approximately 4 minutes). The OK and RUN LEDs of FBC30 flash during
loading.

2.6 CONFIGURATION
Before going on to the next phases, the cell must be fully configured (hardware and
software).
Use the Controcad software to produce the files to be loaded into the cell.
The principal operations are:
• Creation in the hardware branch of a controller from a standard configuration,

• Customization of the hardware configuration (addition of I/O boards in the cell
controllers and sub-controllers),
• Development of cell controller and sub-controller programs,
• Generation of the cell code.
Please refer to the Controcad user's manuals for detailed information regarding these
operations.

3 LOADING A C80-35 CELL
3.1 LOADING THE HARDWARE CONFIGURATION ON THE CELL CONTROLLERS
Select the controller to be loaded in the hardware branchon the Controcad station:
Connect the SNP port of the controller power supply to the COM1 or COM2 port of
the Controcad station

Select the "DEFAULT" device, then click on Connect to start the communication.

After connection, click on the Store button.
In the new window, click on Select All and begin the transfer of the programs and the
hardware configuration to the controller by clicking on store.
Store button
Accept the application build proposed by the P80 software.
At the end of the loading process, acknowledge any Warning (7136) that may have
been detected.

Acknowledge the PLC faults, then I/O the faults, by pressing the F9 key.
The cell now has an IP address of the class 195.9.207.x
• 1<= x <=32 for primary controllers (x is the controller number),

• 33<= x <=64 for secondary controllers (x is the controller number
increased by 32).
This can be checked on connecting the CPU364 board to the S8000-E network by
typing the following order in a command prompt on the Controcad PC:
ping 195.9.207.x: The controller must respond to this order
All loading operations can now be executed on the cell controller via the S8000-E
network.

3.2 LOADING THE F8000 FIELDBUS CONFIGURATION
An F8000 fieldbus configuration file must be loaded in the FBC30 board.
If the previous operation has been successfully completed this task can now be
performed via the S8000 network and the CPU364 board,.
Select the relevant controller in the hardware branch on the Controcad station.

Then double click on Hardware configuration to open the description of the rack I/O
boards.
Single click to select the FBC30 board.
Select Edit Module operations Store cell

The following screen is displayed:
Click on Connect, then select the required device in the next screen.
ATTENTION: the software highlights the first device recognized rather than the device
selected during the "access target" operation. Make sure the correct device is selected.

Click on Connect
Click on Select All and then Store;
Confirm that you want to perform loading via the F8000.
If the following window is displayed, the version that you are about to load is identical
to that already contained in the FBC30 board.
Confirm the loading operation.
The following window should display indicating that no error has occurred.

3.3 LOADING SUB-CONTROLLERS
3.3.1 Loading the Hardware Configuration in the Sub-controllers
Select the required sub-controller in the hardware branch on the Controcad station:
Connect the SNP port of the sub-controller power supply to the COM1 or COM2 port
on the Controcad station and start the communication between P80 and the cell via
the COM port by selecting the "DEFAULT" device

After connection, click on the Store button.
In the new window, click on Select All and start the transfer of the programs and the
hardware configuration to the controller by clicking on Store.
Store button
Accept the application build proposed by the P80 software.
At the end of the loading process, acknowledge any Warning (7136) that may have
been detected.

Acknowledge the PLC faults, then the I/O faults, by pressing the F9 key.
The sub-controller now has an IP address of the class 195.9. x.y

• x = 207 + cell number (1 to 16)
• y = FIP subscriber number on F8000
This can be checked on connecting the FBC board to the F8000 fieldbus by typing the
following order in a command prompt on the Controcad PC:
ping 195.9.x.y: The controller must respond to this command
All the loading operations can now be executed on the sub-controller: the
configuration is loaded via the S8000 network, routed by the cell controller and then
transported via the F8000 fieldbus.

3.3.2 Loading the F8000 Fieldbus Configuration
An F8000 fieldbus configuration file must be loaded in the FBC30 board.

Select the relevant controller in the hardware branch on a Controcad station.
Then double click on the hardware configuration to open the description of the sub-
controller I/O boards.

Single click to select the FBC30 board.
Select Edit Module Operations Store Cell
The following screen is displayed:
Click on Connect, then select the required device in the next screen.

ATTENTION: the software highlights the first device recognized rather than the device
that was selected during the "access target" operation. Make sure the correct device
is selected.
Then click on Connect
Click on Select All and Store

Confirm that you want to perform loading via the F8000.
If the following window is displayed, the version that you are about to load is identical
to that already contained in the FBC30 board.
Confirm the loading operation.

The following window should be displayed indicating that no error has occurred.

4 LOADING A C80-75 CELL
4.1 INITIAL LOADING OF A C80-75 CELL
The cell must be loaded initially via the serial link of the CPX935.
4.1.1 Loading the Hardware Configuration by Serial Link.
4.1.1.1 Loading the C80-75 Cell Controller.
• Connect the serial link between the COM1 or COM2 port on the Controcad
station and the upper 15-pin connector on the CPX 935 in the Normal C80-75
(on the left of the cell controller C80-75 rack).
• In Controcad, select the 'Primary' C80-75 controller

• Open the Connect window.
Comm Connect
Select COM1 by DEFAULT and click on Connect.
• Stop the C80-75.

• Access the 'Store' window.
• Load the E900 configuration and the Hardware configuration simultaneously.
• Start loading by clicking on 'Store'.

• Confirm loading by clicking on OK.
• The loading process executes and the following window opens.
• At the end of the loading process a Results window is displayed.
• A loading report is displayed (the Warning means that the fault tables must be
reset to zero after acknowledgement); click on OK.

• Move the serial link on the Right hand controller.
• Redo the same operations, connected to the 'Secondary' controller
The Hardware configuration is now loaded and it is possible to connect via Ethernet
to both the 'Normal C80-75 and to the 'Backup' C80-75.
NOTE:
The loading of a C80-75 "Hardware" configuration, implies the loading of the

"F8000" configuration of the same C80-75. This process is transparant for the
user.
The E900 configuration "User Protocol Files" must be loaded at the

same time

4.1.1.2 Loading C80-35 Field Controllers
• Connect the serial link between the COM1 or COM2 port of the Controcad
station, and the 15-pin connector on the front face of the CPU360.
• Connect to the C80-35 controller via Controcad.
• Open the connection window

Comm Connect
Select COM1 by DEFAULT and click on Connect

• Load the Hardware configuration of the C80-35.
• The report below is displayed.
• Click on OK.
The hardware configuration is now loaded and it is possible to connect

through the C80-75 cell controller, via Ethernet, to the C80-35 field
controller.

4.2 LOADING A C80-75 CELL CHRONOLOGICALLY VIA ETHERNET
• The cell has been loaded at least once via the serial link, and the Ethernet
adresses are therefore already loaded in the different controllers.
• The loading chronology of the "Hardware" Configurations must be respected.
• 1) load the "Hardware" configuration of the C80-35 field controller.
• 2) load the "Hardware" configuration of the C80-75 cell controller.
4.2.1 Loading the Hardware Configuration of a C80-35 Field Controller
• Connect to the C80-35 field controller via the Ethernet link.
Comm -> Connect
• If the C80-35 is Dual/Redundant:

• Connect to the primary C80-35 via the Primary Folder, without
association.
• Connect to the secondary C80-35 via the Secondary Folder, without
association.

• Load the Hardware configuration.

• Select the Hardware configuration file.
• Load the Hardware configuration of the C80-35 by clicking on 'Store'.

4.2.2 Loading the Hardware Configuration of a Redundant C80-75 Cell
Controller
• Connect to the C80-75 Cell controller by Ethernet link
Comm Connect
• Connect to the Primary C80-75 via the Primary folder, without association.
• Connect to the Backup C80-75 via the Backup folder, without association.
• Load the Hardware configuration

• Stop the C80-75
• Select the Hardware configuration file and the E900 conf file
• Load the Hardware configuration of the C80-75 by clicking on 'Store'

4.2.3 Loading the Software Configuration of a Redundant C80-75 Cell
Controller
• Connect to the C80-75 Cell Controller by Ethernet link
Comm Connect
• Connect in associated mode to the Primary C80-75 via the Primary Folder.
• Load the software configuration.

• Stop the C80-75 (Primary and Secondary).
• Select the software configuration and/or parameters.

• Select the associated mode.
• Click on 'Store'.

• P80 displays the following message:
• Close the window by clicking on 'OK'.
When the loading process is terminated, P80 displays the following window:
If both indicators are green, the Conf Software of both the Primary and Secondary
controllers has been loaded correctly.
• Restart the Primary and Secondary C80-75 controllers.

4.2.4 Loading the Network Configuration of a C80-35 Field Controller
• Open the C80-35 rack (double click on Hardware Configuration).

• Place the cursor on the BEM 340.
• In the main menu, execute the command sequence Module Operation->Store
Cell.
• Execute 'Connect'.
• The following window opens.
• The FBC70 must be in 'IDLE' state
• Click on 'Store'

• P80 requests confirmation of the command.
• When loading is terminated, the following window displays the loading report.
• Click on 'OK' to close the window.

• Check that the FBC30 has switched to 'RUN' state.
• Close the window by clicking on 'Close'.
• Check that the FBC30 (BEM 340) is operational: 'RUN' LED lit (2nd from the top on
the front face).

4.2.5 Loading the Software Configuration of a C80-35 Field Controller
• Connect to the C80-35 field controller by Ethernet link.
Comm Connect
• Load the Software configuration.

• Stop the C80-35 (both Primary and Secondary if redundant).
• Select the software configuration.

• Click on 'Store'.

• P80 displays the following message:
• When the loading process is terminated, P80 displays the following window:
• Restart the C80-35.

4.2.6 Loading a Non-TRX CE2000.
• Connect to the C80-75 Cell Controller by Ethernet link.
Comm Connect
• Connect to the Primary C80-75 via the Primary folder, without association .
• Load the CE2000 (Tools -> Transfer Utilities -> Store)

• The C80-75 cell is in 'Run' mode.
• Select the CE2000(s) to be loaded.

• Execute loading by clicking on 'Store'.

• P80 displays the following warning message (even when the CE2000 is non-TRX).
• Click on 'OK' to start loading.
• The following window displays when loading is terminated:
This message indicates that the transfer of the program to be loaded from the
CPU to the FBC70 has executed correctly and that the CE2000 has responded
to the load command.
Wait several minutes to check that the CE2000 starts and that the LEDs on the
front face of the CE2000 rack boards are lit. The "RUN" LEDs on the 'Normal
and 'Backup' UT129 units must also be lit.

4.2.7 Loading a TRX CE2000
• Before loading a TRX CE2000, the TRX must be stopped:
either by means of P80 Base.

or by uplugging then replugging the UT129C.
4.2.7.1 Stopping Reflex Processing by P80 Base.
• Open P80 Base then the CE2000 rack.

• Establish connection with the F8000 fieldbus (F8000 Connect To Cell).

• Select the F8000 bus of the cell being loaded.
• FBUS240 for cell 1.

• The following message is displayed:
• Click on OK. The following message appears:
This means that the CE2000 contains a network configuration that is different
from that generated by P80 F8000.
Click on OK, then stop the TRX.

• Right click:
Stop TRX processing

The Password is necessary (see in ccadfile.txt).
The Controcad "password" is 'P320'.
4.2.7.2 Loading the TRX CE2000 Rack(s)
• Connect to the C80-75 Cell controller by Ethernet link.
Comm Connect
• Connect to the Primary C80-75 via the Primary folder, without association.

• Open the load window and select the CE2000 racks to be loaded.
To load the CE2000, the connection must not be associated.
• Execute loading by clicking on ‘Store’.
• The following message appears:
• followed by the message(s) below (1 per CE2000 selected):
This means that reflex processing must be stopped before the TRX CE2000
rack(s) can be loaded.

• After a few seconds, the following message appears:
This means that the CE2000 has responded to the load cell controller
command.
If the cell controller is stopped, the message is: "STOP MODE Store operation
is complete".
After several seconds (determined by the quantity of code transferred) the

CE2000 will become operational (WDR lit on the UT129C or UT150) and
TRX processing is automatically restarted by the C80-75.
4.2.8 Action when the Hardware Loading Chronology Executes Incorrectly
1) Disconnect the FIP media of the C80-35 field controller(s) and the SI80.
2) Reload the Hardware configuration of the C80-75 cell controllers (Primary and
Secondary) via the serial link.
3) Reload the Hardware configuration of the C80-35 field controllers via the
serial link.
4) Reconnect the FIP media to the C80-35 field controller(s).
5) Execute an "Import Configuration" on the SI80, then reconnect its media FIP.
• When the cell has resumed normal operation, the other loading operations
can be continued by ETHERNET link following the procedures outlined above.

5 MODIFYING A C80-75 CELL ON LINE BY P80
5.1 ON-LINE MODIFICATION WITH TRANSFER
1) At Controcad level, generate the new program to be loaded (in the context of
the on-line modification) as shown below:
Edit Workspace at the level of the workspace
• in Manual mode
• and Generation for on-line modification with redundancy data transfert
2) Stop the standby controller

3) From the Primary Folder connect to the standby controller and load the
application program that has just been compiled into the standby controller
4) Restart the standby controller:
5) In the "Ccad_controller_name.txt" file, note the address of the variable:
_AD_USR_ACTION :(ex %AI,7801)
6) Set the address _AD_USR_ACTION(0) (%AI7801) to the value 1

7) Switch the standby controller to RUN mode,
8) The Standby must remain in RUN mode despite the differences of program
9) Execute a Master/Standby switchover:

_AD_USR_ACTION(3) = 1 (%AI7804) on the current Master
10) If the modifications in the program are satisfactory, reload the new Standby with
the program that has been loaded in the old Standby
11) Restart the new Standby; the on-line modification is terminated
12) If the modifications are not satisfactory, execute another switchover on the new
Standby:
_AD_USR_ACTION(3) = 1 (%AI7804) on the new Master

5.2 ON-LINE MODIFICATION WITHOUT TRANSFER
1) At Controcad level, Generate the new program to be loaded (in the context of
the on-line modification) as outlined below:
Edit Workspace at the level of the workspace
• in Manual mode
• and Generation for on-line modification without redundancy data transfert
2) Stop the standby controller.

3) From the Primary Folder, connect to the standby controller and load the
application program that has just been compiled into the standby controller.
4) Restart the standby controller :
5) In the file "Ccad_ controller_name.txt", note the address of the variable:
_AD_USR_ACTION :(ex %AI,7801)
6) Set the value of the password defined in "Ccad_controller_name.txt" at the

address _AD_USR_ACTION(1) (%AI7802).
7) Switch the standby controller to RUN mode,
The Standby must remain in RUN mode despite the differences of program
8) Execute a Master/Standby switchover:
_AD_USR_ACTION(3) = 1 (%AI7804) on the current Master
9) If the modifications in the program are satisfactory, reload the new Standby
with the program that has been loaded in the old Standby, connect to the
primary controller
10) Restart the new Standby; the on-line modification is terminated
11) If the modifications are not satisfactory, execute another switchover on the new
Standby:
_AD_USR_ACTION(3) = 1 (%AI7804) on the new Master

6 FULL RELOAD OF THE F8000 CONFIGURATION
6.1 WHEN IS FULL RELOAD NECESSARY?
The configuration of data exchanges on F8000 fieldbus is handled by Controcad:

buffer size, synchronizing etc.
When the exchange buffer size has significantly changed, the software indicates that
the configuration must be reloaded on all the LCUs connected to the F8000 fieldbus
of a cell.
The operator is advised by messages that appear at the end of code generation. One
message is generated for each LCU and each message must be acknowledged:
For a C80-35 Cell
For a C80-75 Cell
followed by the message below, if the C80-75 cell contains remote C80-35
controllers
Controllers loaded with dissimilar F8000 configurations cannot co-exist on the same
F8000 fieldbus.
This section describes how to proceed in order to maintain the availability of the
whole cell and the routing.

6.2 PROCEDURE
• Load the hardware configurations on all the field controllers

• For each of the sub-controllers of the cell (C80-35/75), connect using Enet
(Ethernet) mode, selecting only the Hardware configuration (see Section 3.3.1).
• The result of this action is to stop the FBC30 board on detection of an F8000
configuration anomaly.
• Load the hardware configurations on all the cell controllers
• For each cell controller, connect using Enet (Ethernet) mode, selecting only the
Hardware configuration (see Section 3.1)
• The result of this action is to stop the FBC30/FBC70 board on detection of an
F8000 configuration anomaly.

• Load the configuration FBC30/FBC70 cell controller.
• For each of the cell controllers, load the F8000 fieldbus configuration (for C80-
35 only, see Section 3.2, for the C80-75 cells the network configuration is loaded
at the same time as the Hardware configuration).
• Load the FBC30 configuration on the field controllers
• For each field controller, load the F8000 configuration (see Section 3.3.2)
• Load the program on the cell controllers
• For each cell controller, connect using Enet (Ethernet) mode, selecting only the
Software configuration (see Section 3.1)
• At the end of the loading process, acknowledge any faults and start the controller
• Load the program on each field controller

• For each cell controller belonging to the cell, connect using Enet (Ethernet) mode,
selecting only the Software configuration (see Section 3.3.1)
• At the end of the loading process, acknowledge any faults and start the controller


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Controcad V3 - User's Manual - Volume 5

Automation Cell Start-up

DIFFUSION : CONFIDENTIELLE RESTREINTE CONTROLEE LIBRE

REV STAT. F°/F° FIN Nb F°

ETABLI VERIFIE APPROUVE

A J. Bartherotte J.F. Cabadi D.Cantero 13/08/01 Première version document GFE

B J. Bartherotte J.F. Cabadi D. Cantero 21/03/02 Section 3 added GFE

Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.2/64

Automation Cell Start-up

1.1 AIM OF THE DOCUMENT............................................................................. 6

1.2 REFERENCE MANUALS ................................................................................ 6

1.4 CONNECTION POINTS ................................................................................ 8

1.4.1 Cell Controller ............................................................................................ 8

1.4.2 Field Controller........................................................................................... 9

2 LOADING CELL FIRMWARE ....................................................................... 10

2.1 WHEN TO LOAD BOARD FIRMWARE ......................................................... 10

2.2 LOADING THE EEM FIRMWARE (C80-35) .................................................. 10

2.2.1 Operating Procedure ............................................................................... 10

2.2.2 Checking the Firmware Version ............................................................... 12

2.3 LOADING THE FBC30 FIRMWARE (C80-35) ............................................... 15

2.3.1 Operating Procedure ............................................................................... 15

2.3.2 Checking the Firmware Version ............................................................... 16

2.4 LOADING THE EX7 (C80-75 CELL)............................................................. 17

2.4.1 Operating Procedure ............................................................................... 17

2.5 LOADING THE FBC70 (C80-75 CELL) ......................................................... 18

2.5.1 Operating Procedure ............................................................................... 18

2.6 CONFIGURATION ..................................................................................... 20

3 LOADING A C80-35 CELL.......................................................................... 21

3.1 LOADING THE HARDWARE CONFIGURATION ON THE CELL

3.2 LOADING THE F8000 FIELDBUS CONFIGURATION................................... 25

3.3 LOADING SUB-CONTROLLERS.................................................................. 29

3.3.1 Loading the Hardware Configuration in the Sub-controllers ................... 29

Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.3/64

4 LOADING A C80-75 CELL.......................................................................... 37

4.1 INITIAL LOADING OF A C80-75 CELL........................................................ 37

4.1.1 Loading the Hardware Configuration by Serial Link. .............................. 37

4.2 LOADING A C80-75 CELL CHRONOLOGICALLY VIA ETHERNET................. 43

4.2.1 Loading the Hardware Configuration of a C80-35 Field Controller ......... 43

4.2.2 Loading the Hardware Configuration of a Redundant C80-75 Cell

4.2.3 Loading the Software Configuration of a Redundant C80-75 Cell

4.2.4 Loading the Network Configuration of a C80-35 Field Controller............ 48

4.2.5 Loading the Software Configuration of a C80-35 Field Controller ........... 51

4.2.6 Loading a Non-TRX CE2000. .................................................................... 53

4.2.7 Loading a TRX CE2000 ............................................................................. 55

5 MODIFYING A C80-75 CELL ON LINE BY P80 ........................................... 60

5.1 ON-LINE MODIFICATION WITH TRANSFER............................................... 60

5.2 ON-LINE MODIFICATION WITHOUT TRANSFER ........................................ 61

6 FULL RELOAD OF THE F8000 CONFIGURATION........................................ 62

6.1 WHEN IS FULL RELOAD NECESSARY?........................................................ 62

6.2 PROCEDURE .............................................................................................. 63

Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.4/64

The present document applies to Controcad Version 3.2.4 and later.

The versions of the different components must be at least:

Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.5/64

1.1 AIM OF THE DOCUMENT

1.2 REFERENCE MANUALS

Controcad V3 Installation Manual

Controcad V3 User's Manual, Volume 1 - Centralog P-TP21-A40005

Controcad V3 User's Manual, Volume 2 - Centralog P-TP21-A40006

Using Alspa P80 V2.3

Controcad V3 - User's Manual - Volume 5 P-TP21-A40032.6/64

The illustration below shows a typical example of architecture comprising a

AUT 1 Cell controller AUT 16 Cell controller

Various types of architecture are possible (redundant or non-redundant cell