Is there a way to update software revisions in redundant 800F controllers without shutting system down?
We have an installation with redundant controllers and need to update both the operating system on the PCs and the software revision on the redundant controllers. We can't shut the process down to do so. There doesn't seem to be a "built in" way to do this update.
Our guys have tested placing the I/O in hold and removing from the bus, which seems to work, but I hoped there were some other thoughts out there.
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Thanks for all of your help!
We successfully updated this Control System last Wednesday. We were able to hold the values of the AOs while the plant was in a fairly stable state. We used the following process:
- PC A is running WINDOWS XP and freelance 9.2 combo station
- PC B is running WINDOWS XP and Freelance 9.2 Operator Station
- PC C is running Windows 7 and Freelance 9.2 SP1 Combo Station
(1.) Go through the hardware (On PC A), AO module -> Configure, Set OSP control to ‘Keep current value’.
(2.) 900 AO modules -> Offline Parameterize, Set failsafe value to ‘last valid value’.
(3.) Download changed objects
(4.) While CTRL is selected, go to LOAD -> Parameters and correct all.
(5.) Save Project.
(6.) Export Project.
(7.) Disconnect Ethernet from PC A
(8.) Change IP address and Resource ID in PC C to match PC A(9.) Import Project into PC C
(10.) Download whole station to controller.
(11.) Download whole station to operator stations.
(12.) Reconnect Ethernet and restore IP adresses
(13.) Install Windows 7 and Freelance 9.2 SP1 on PC B
(14.) Install Windows 7 and Freelance 9.2 SP1 on PC A
(15.) Repair Freelance 9.2 SP 1 on PC C to restore as operator station.
This does not address holding DOs, which we did not have to do in this instance. A wholestation load took less than a minute, so this solution should be applicable to most processes (depending on project size).
The Operating system of PC(Incase it is Engineering station) you can update. take required backup and update OS. Even you can update your freelance software version.
But in case of updating controllers software version i.e firmware version can not be changed/updated online.
But can you pls more specific from which version to which version you want to upgrade ? the existing freelance and OS type and version ? the Os you want to change on PC is engineering station or operator staion ? I hope it will help community to respond...
First, we could be sure that AC 800F controllers does not support on-line upgrading.
AC800F controller 'firmware could be changed by using "Boot EPROM Download" from CBF Configure window Via Enthernet . This "Boot EPROM Download" action will delete firmware (operating system) from controller 's flash memory and also delete project applicationfron from RAM memeory, and reload new firmware to flash memeory.
When you put controller into on-line mode, you will see message like" no Operating System".
No operating system means that the operating system is loaded but is not yet being executed.In the case of redundancy however the operating system version must match for both AC 800,otherwise sync status is not possible. You should do downloading whole station this will cause controller stop and process will be attected.
I had a similar case, where it was said that process cannot be stopped...
(and we did NOT stop it!)
in my case it was a single controller.
What we did was as follows:
0. configure your field devices to use last value if communication is lost - basic functionality of the I/O (with drives you have option continue with last know set point or stop in case of communication lost).
1. in old CBF check if the project is running and all is OK
2. make export to CSV format
> the old system is running
3. purchase new set of PCs
4. install the newest Freelance version
5. import the project
6. check the project - should be no errors
> the old system is running and connected to the network.
>> the new PCs should have the same IP addresses as the old PCs and the same Resource IDs... they cannot be connected to the same network yet...
>>> use a new/temporary ethernet switch and connect all PCs together.
7. take a spare AC 800F controller or buy new one (exactly the same as the old running one)
8. download the newest firmware
> connect it to the temporary ethernet network
9. change into commisioning mode and download the project to the spare/new AC 800F and to the new operator stations
---------> up to now the old system is fully operational & the new system is running on the side and is not connected to the field.
*** get as many people as possible, put as many processes in local/manual operation
*** try to have your process running "slowly" or not in critical way
10. go to old CPU and power up the new one (in case of 24DC power there are 2 power plugs - 1 is enough, if you have 230V power supply to your AC 800F, just make additional power connection) take away all field connections from old AC 800F, take away the old CPU, put the new one and connect all field connections. Your system should be running
11. disconnect the old PCs from the main network and connect the new PCs from temporary network to the main network - Now you should be able to see if the whole system is running as it should.
|-> the above steps 10 & 11 should be done in parallel and it should not take more than 1 minute... Most processes can sustain such a small interuption - please remember about point 0 - if there is no communication the I/O and drives should continue with last know values |
12. check if all is ok, put all loops into automatic etc
*** if there is any problem (there should not be) than you can go back to the old system you still have the old controller and the old PCs
>>>> back to original question with redundancy - do all the same as above the only difference is to take offline the standby CPU and treat it as spare/new
finally if all works as it should the the old one need to get new firmware and after connection it should sync with the running one. (this should be done once you are 100% sure that all is running smoothly after upgrade)
I hope it helps