Migration from 800xa 5.0 SP2 to 800xa 6.0 Changes to 5.0 Aspects.
We have a customer that is in the planning stages of a 5.0 SP2 to 6.0 Upgrade. The upgrade will begin soon with new Servers to be staged within ABB and final site upgrade will occur later in the year.
The issue is once we get their 5.0 SP2 Backup and work on the Upgrade, at site they will continue to make changes on the 5.0 system. Things like Graphic Changes, PLC Connect Changes and AC800M Changes.
Reviewing the 800xa 5.0 SP2 to 6.0 Upgrade Manual it specifically says:
Do not make any configuration changes such as modifying displays, modifying or deleting objects as these changes made to the system will be lost from this point forward.
So this would simply mean Customer cannot make changes which for months would be difficult for the Customer. They will continue with changes even after we take the 800xa Backup.
It also states in the same manual:
The 800xA System import/export utility can be used to save 800xA System information one portion at a time. However, the 800xA System backup utility is the functional equivalent of exporting all 800xA System information at one time. The critical difference between these utilities is that individually exported portions of 800xA System information can be imported back into the original system or into a completely different system while backed up 800xA System information can only be used to restore a specific system on specific nodes.
This kind of suggests the Export Tool could be used to get these changes and bring them into the 6.0 System ?
Otherwise a Complete 800xa Backup and Restore would need to be performed again once System 6.0 was ready to be delivered. This requires Stopping and deleting the ready 6.0 system. Not the greatest thing to do.
1) Can we Export any changes in the 5.0 system and Import into new 800xa 6.0 system ?
2) Must we do a Backup/restore instead ?
They are also using the Infi90 and PowerNam Library as well. Will this be an issue with Export ?
What is the supported method ?
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That is usual scenerio. Mostly all customers upgrading has to go through this issue. Delay taking the backup as much as you can. Order hardware, install software, connect nodes and do all other steps you can do before restoring.
Many of Customer I have worked with maintain a change register in which all the changes onwards are noted and then same changes are repeated again in upgraded system.
Audit trail also plays a role here.
Import/Export can also be used in case for example a new faceplate of graphic is added. System is backward compatible.
With BU specific libraries this could be tricky. If the work you are exporting is dependent on BU library then you need to test it seperately. New library could have added new pin, removed a pin on function block or rename the block. In those cases you need to manually fix the stuff. Of course just the import process will be successful.
> "The issue is once we get their 5.0 SP2 Backup and work on the Upgrade, at site they will continue to make changes on the 5.0 system. Things like Graphic Changes, PLC Connect Changes and AC800M Changes."
Having been through a 5.0 to 6.0 upgrade recently, here is some of my feedback .....
- Upgrading the AC800M controller code is fairly easy. Upgrading the code is a one day task. It can be repeated by deleting the code and reimporting it again from the 5.0 system.
- PG2 graphics conversion from VB works reasonably well for AC800M graphics.
- Upgrading PLC connect was HORRIFIC. Pretty much every PLC Connect graphic element on the customers site had to be rebuilt. This was around 3 to 4 weeks labour. The PG2 graphics convertor was simply incapable of properly converting Images and the Symbol Factory icons. Everything has to be verified and patched by hand. Depending on how your graphic elements are built this may or may not be a problem for you.
You do not need to stop the customer from making changes, but you do have to stop them from making some types of changes ....
- They CANNOT change, create, delete etc Object Types after you have begin the conversion process. Modifying object types can cause real problems with other things you have already converted.
- They CAN modify operator graphics. You will have to re-import and re-convert them on your test system. As long as the obect types are unchanged, the PG2 graphics convertor will do this fairly easily.
- They CAN continue to modify AC800M controller code. You can import the applications late in the project and convert them at that point.
- They CAN continue to add tags and objects to the PLC Connect control Structure. You will need to re-import these changes.
Obviously at some point, you have to tell the customer to stop making changes, but this can actually be quite late in your project. You just need enough time to convert the changes that they make.
Its quite possible to allow the customer to continue to maintain their DCS while you work on the upgrade. You do however need good communicatons, and a clear process for exporting changes from the existing system and into the new system. Also, any changes that the customer makes need to be relatively minor - ie. a couple of graphics changes here or there, some tweaks in controller code. It is not realistic for them to have other major project occuring at the same time.