ABB ABB Schweiz AG 1KHZ 101 968

Responsible department: Take over department: Revision: Doc.-type: File No.:

PTUPA2 C
Prepared: Checked: Approved: Language: Page:
R. Käch M. Layes H.-K. Scherrer eng 1/10
Valid for: Derived from: Replaces: Classify No.: Data set:
1KHZ101968
Rev C

Upgrade AC160 Controller from PM645 to PM665

and firmware from version 1.x to version 2.x

Introduction ..................................................................................................................................................... 2
Relevant changes in the Base Software 2.x and the controller PM665 ....................................................... 2
Prerequisite .................................................................................................................................................... 3
HW/SW requirements ................................................................................................................................. 3
1. Backup your application.............................................................................................................................. 4
2. Installation of SP6a for Windows NT 4.0, if applicable ................................................................................ 4
3. Installation of the SW Control Builder A ...................................................................................................... 4
4. Update the AC160 applications................................................................................................................... 4
4.1 S800 Upgrade...................................................................................................................................... 4
4.2 Edit the BAX file ................................................................................................................................... 4
4.2 Edit the AAX file ................................................................................................................................... 5
4.3 Change node settings in the APB ........................................................................................................ 5
4.4 Backtranslate source code................................................................................................................... 6
5. Replace the PM645 controllers with PM665 and load the applications ....................................................... 6
5.1 Replace the controllers ........................................................................................................................ 6
5.2 Load Base Software 2.x to remaining PM645 controllers ..................................................................... 6
5.3 Load the applications to the PM665 controllers.................................................................................... 6
6. PID1 update ............................................................................................................................................ 7
Firmware..................................................................................................................................................... 7
FCB add-on ................................................................................................................................................ 7
Application program .................................................................................................................................... 7
7. Important Hardware Differences (COM Ports) ........................................................................................ 8
Appendix......................................................................................................................................................... 9
References ................................................................................................................................................. 9
Abbreviations .............................................................................................................................................. 9
8. Revision Page....................................................................................................................................... 10

WARNING
To upgrade from PM645 to PM665 processor modules the plant has to be in
STAND-STILL (shut-off) mode!

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Introduction
This documentation will guide you through the upgrade process from AC160 controllers PM645 to PM665.
The steps are:
1. Backup your application: Generate source code in your currently installed FCB.
2. Installation of Service Pack 6a for Windows NT 4.0, if applicable
3. Installation of the AdvaBuild Engineering SW (Revisions see Table1): Control Builder A (CBA) on the
engineering station (ES). Function Chart Builder (FCB) 6.0 or higher is needed to communicate with the
PM665 controllers, this program is included in CBA.
4. The node types and the tool versions of the nodes in your project must be changed in the Application
Builder (APB). New source codes of the applications must be generated(see step 1) and backtranslated
in the new installed FCB.
5. Replace the PM645 controllers with PM665. Power off the AC160 station for approx. 5 minutes; Power
on. If applicable: Load new firmware on remaining PM645 controllers. Load the applications to the
controllers.

⇒ NOTE
The instruction above is only a summary. The following chapters contain the detailed information and
references to other documents.
For experienced user:
Relevant changes in the Base Software 2.x and the controller PM665
Base Software changes when updating from 1.x to 2.x

ATTENTION: Live-Extraction of a PM6xx with Base SW 2.x:

To extract a processor module under voltage, follow the following steps
♦ Set Mode selector to 3 (PASSIVE) and
♦ Reset the CPU. The processor module indicates “P0” after power-up.
♦ Extract the CPU in status P0.
ATTENTION: Live-Insertion of a PM6xx with Base SW 2.x:
To insert a processor module under voltage, follow the following steps
Prior to insertion,
♦ Set Mode selector to 3 (PASSIVE)
♦ Insert module in AC160 station; CPU starts up with P0
♦ Watch the status of the CPU. The slot number (AC160 station position) of the CPU should be blinking on
the 7-segment display
If blinking position = physical position
If the blinking position shown on the CPU's 7-segment display equals the CPU's physical position, the
CPU's Bus interface is OK,
♦ Set Mode selector to 0 and
♦ Reset the CPU (CPU shows P3 after power-up)
If blinking position # physical position
The CPU's Bus interface is DAMAGED, replace CPU
!! Do not reset the CPU in Mode 0 or 1 !!
Voter Test with Base SW 1.x: Status display P3 for Successful; 0F for Failure.
Voter Test with Base SW 2.x: Status display 0F for Successful; 0E for Failure.
CPU switch position for Base SW 1.x: CPU Number, relevant only for redundant CPU (Pos=1,2,3); for non
redundant CPU Mode switch is irrelevant.
CPU switch Position for Base SW 2.x: CPU Number, relevant for redundant CPU (Pos=1,2,3) and non
redundant CPU (Pos = 0).
PushButton Ack for Base SW 2.x:
- PushButton Ack on Slave CPU triggers "Update Slave" if Master is on P1and Master RAM = PROM and
Slave CPU is on P3 and Mode switch changed from Pos 0 to Pos 1 during status P3 of Slave CPU.
- PushButton Ack Deletes Diagnostic Messages if CPU is on Status P1 or b1.
Call Names for S800 DB elements modified. Can be updated with a Tool.
Base SW 2.x supported with FCB 6.0 and higher .

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Controller differences when updating from PM645 to PM665

The sensor supply via the COUNT connector is not supported.

We do not use it, therefore the only impact is, that cablebreak can not be detected at standstill (speed = 0)
This has no impact on the real machine, but the simulator will not run. In order to have same logic for
simulator and real machine, a logic change is proposed.
The connector of COM B of PM665 is male. For PM645 the connector COM B is female. Use a gender
changer, to upgrade with given cables from PM645 to PM665
Load CS software via COM A CS Load cable instead via COM B
PM665 supported with FCB 6.0 and higher

Prerequisite
Initial situation Target situation
AC160 Controller PM645 PM665
Base Software (Firmware) 1.0 or 1.1 2.1 or higher
Engineering Tool (AdvaBuild) < CBA 1.0 CBA 1.0 or higher
PC Operating System NT 4.0 NT 4.0 SP6a

HW/SW requirements
The controllers PM665 require Base Software 2.1 or higher.

The requirements to install the SW CBA (including free disk space required) on the PC are documented in
the release document of the Control Builder A.

Example:
For a complete SW installation (NT SP6a & CBA 1.0) 300 MB free disk space is required on the engineering
station.

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1. Backup your application

• Generate new source code in currently installed FCB of all nodes in your project. These source codes
will be needed later on in chapter 4 & 5.
• Close all Function Chart Builder and On-line Builder.
• Backup your project. In the Application Builder go to menu: File > Copy…; Select Scope: Projects.

2. Installation of SP6a for Windows NT 4.0, if applicable

To run the SW CBA 1.0, NT 4.0 with SP5 (service pack 5) or higher is required. You will now install the
release: SP6a.

System Requirements:
• 60 MB disk space (if you wish to have an uninstall directory, the disk space increases to 120 MB)
• No Service Pack requirements needed.

To install the SW run the file: <cdrom>\SP6patch.exe

3. Installation of the SW Control Builder A

NOTE: Each locally installed Control Builder CBA requires one license.

Different versions of the AdvaBuild Engineering SW can run on the same PC. The new CBA will be
additionaly installed.

The installation procedure of the CBA is described in a separate document dependent on the version of the
CBA. The document is available on request.

4. Update the AC160 applications

4.1 S800 Upgrade
Only applicable if S800 I/Os are available. Instruction will follow.

4.2 Edit the BAX file

In the BAX file the DB elements PM645 must be changed to PM665.
• Open the BAX file with a text-editor, as the AS100-Edit (highvcpp).
• Go to the menu: Edit > Replace, search for “PM645“ and replace it with “PM665“. Select Replace all (3
replacement will be done).

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Old: New:
DEFAULT PM645 DEFAULT PM665
:BUS 0 :BUS 0
:STATION 0 :STATION 0
:POSITION 3 :POSITION 3
:IMPL 1 :IMPL 1
:TYPE PM645 :TYPE PM665
:REDUNDAN NO :REDUNDAN NO
:RED_MODE CPU :RED_MODE CPU
etc. etc.

PM1 PM645 PM1 PM665

:NAME CLC1 :NAME CLC1
:REDUNDAN YES :REDUNDAN YES
:TR_MODE UNPLAN :TR_MODE UNPLAN
:RBUS1 1 :RBUS1 1
:RSTA1 10 :RSTA1 10
:RBUS2 1 :RBUS2 1
:RSTA2 10 :RSTA2 10
:RPOS2 4 :RPOS2 4
:RPOS3 5 :RPOS3 5

4.2 Edit the AAX file

Preferably the changes described in chapter 6 PID1 update, Application program, can be done in this step.

4.3 Change node settings in the APB

• Open the APB and open your project.

Update the node type and the tool version for each node (see picture 2):
• Select the node, click the button: Modify…
• Change Node Type to: AC160 with PM66x 2.x, > Yes
If applicable: For remaining PM645 controllers change Node Type to: AC160 with PM64x 2.x, > Yes
• Select all Available Options and copy them to the Selected Options list, > Yes
• Click the button: More…, Tool version is selected, > OK
• Select the Function Chart Builder of your choice, > OK
• And again > OK to finish the settings (see picture 1).

Picture 1: Example, Node settings Picture 2: Example, Node List after changes

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4.4 Backtranslate source code

(If applicable load to PM645)

• Select the node in the APB and open it in the FCB

• Function Chart Builder #15432 dialog box will appear: Node was created with another node type, > OK
• Function Chart Builder #13834 dialog box will appear: Initialize node … are you sure? > Yes
• Run Menu: File > Backtranslate Source…, choose the current PC & DB file name, > OK
• Run Menu: File > Generate Target Code…

The application is now ready to be loaded to the controller(s).

5. Replace the PM645 controllers with PM665 and load the applications
5.1 Replace the controllers
The following instruction explains how to replace the controllers.

1. The controller PM645 has been stopped, the Mode selector is in position 0 (STOP).
2. Power off the cabinet for at least 5 minutes.
3. Exchange the PM645 controllers with PM665.
4. Set Mode selector on the processor module PM665 to STOP (position 0).
5. CPU Number for redundant controllers (Pos=1,2,3) and non redundant controllers (Pos = 0).
6. Power up.the cabinet
7. Processor modules indicate “P3”. (P3 = stop after initialization).

NOTE
To extract or insert processor modules under voltage, set the Mode selector to position 3 (PASSIVE). The
processor module indicates “P0”. See also Live-insertion/ extraction in the Introduction.

5.2 Load Base Software 2.x to remaining PM645 controllers

If applicable load the new firmware to the remaining PM645 controllers according to the load instruction
provided with the distributed media of the controller firmware.

5.3 Load the applications to the PM665 controllers

Load the new firmware to the PM665 controllers according to the load instruction provided with the
distributed media of the controller firmware.

After the application has been loaded and deblocked (status P1 or b1), please delete all diagnostic
messages from the error buffer of the PM645/PM665. This is done by pressing the Ack push button of each
controller.

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6. PID1 update
The PID1 PC-Element is identical to the PID PC-Element from KWL Option Version 1.2, which was used
together with AC160 1.0. PID1 is implemented in a loadable option for PM645B and PM665.

The PC-Element PID in 2.1/x and 2.2/x should not be used in applications until further notice. Instead PID1
should be used.

Firmware
The PID1 Add-On is either loaded together with other base software options to the controller or it has to be
added. The procedures are described on the distribution media of the firmware version.

FCB add-on
For FCB 6.0/0 and FCB 6.2/0 which were already distributed prior to the release of AC160 2.1/3-1, the
PID1 option has to be added to the AC160 Library AC160 2.1 manually.
- The PID1 Add-On is added to above mentioned FCB Versions when installing the firmware from the
CD 1KHZ 103 283 with “install.cmd”.
- Alternatively the PID1 Add-Ons can be installed separately by starting the command
“SetupAdd-Ons_PID1” located in the directory 1KHZ103283R0_MasterCD\AdvaBuild_add-ons\PID1.

For FCB 6.2/1 distributed by CHPAU the PID1 option is already compiled into the FCB

Application program
(could also be done together with the other application program updates in ch. 4)

offline modification:
- go offline
- generate source
- replace PID (1) by PID1 (1)
- replace PID (0) by PID1 (0)
- verify changes
- backtranslate modified source (this step is equivalent with the step described in chapter 4.4
Backtranslate source code)
- load application

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7. Important Hardware Differences (COM Ports)

PM645 PM665
Interfaces COM A and COM B 2 RS 232C opto-isolated serial interfaces, V24 COM A RS-232-C, opto-isolated serial interface, V24
Interface 9-pin Sub-D, female (per interface) (116 kBaud), 9-pin Sub-D, female.
connector COM A Pin-out: Pin-out:
and COM B Pin 2 – TxD Pin 2 – TxD
Pin 3 – RxD Pin 3 – RxD
Pin 5 – GND Pin 5 – GND
COM B RS-232C, opto-isolated serial interface, V24
(116 kBaud), 9-pin Sub-D, male.
Full modem signals:
Pin 1 – DCD
Pin 2 – RxD
Pin 3 – TxD
Pin 4 – DTR
Pin 5 – GND
Pin 6 – DSR
Pin 7 – RTS
Pin 8 – CTS
Pin 9 – RI

Important:

In case of Modbus connection on COM port B (example: touch panel) the cable connector must be pinned as
follows:

COM B RS-232C, opto-isolated serial interface, V24

(116 kBaud), 9-pin Sub-D, male.
Full modem signals:
Pin 1 – DCD To touch panel
Pin 2 – RxD
Pin 3 – TxD
Pin 4 – DTR
Pin 5 – GND
Pin 6 – DSR
Pin 7 – RTS
Pin 8 – CTS
Pin 9 – RI

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parties without express authority is strictly forbidden. © ABB Power Generation Ltd (CH) 2005
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Appendix
References
n.a

Abbreviations
APB Application Builder
CBA Control Builder A (AdvaBuild Engineering Software)
ES Engineering Station
FCB Function Chart Builder
HW Hardware
SP Service Pack (for Windows NT)
SW Software

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third
parties without express authority is strictly forbidden. © ABB Power Generation Ltd (CH) 2005
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8. Revision Page
Department Name Date Signature
Prepared by UTAPE5 René Käch
Checked by UTAPA2 Michael Layes
Approved by UTAPA H.-K. Scherrer

REVISION LIST
Rev. Page (p.) Description Date
Chapt. (c.) Dept. - Name
0 --- original version René Käch
A Introduction Live Insertion Extraction added Michael Layes
A Chapt. 6 Revision Page added
A_01 c. 5.2 2.1/1 replaced with 2.1/x 2004-11-05 N.
Leuenberger
Reference [WORK] updated
A_02 Chapter 6 COM port differences PM645/PM665 2004-11-19
Giovanni Bolognese
B Ch. 6 Inserted new chapter about PID1-Update 2005-03-06 N.
Leuenberger
C Merged with document 2005-04-12
1KHZ101968 Rev B Upgrade PM64x to PM665 Michael Layes
2px.doc issued for Firmware 2.2/0
C Document adapted for AC160 2.2/1 ; focus contents to 2005-04-12
the purpose of the document ; Michael Layes
(version designations generalized and detailed version
specific information eliminated) ;
eliminate unused references

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third
parties without express authority is strictly forbidden. © ABB Power Generation Ltd (CH) 2005