Procedure to Upgrade from SYSCON+ to SYSCON2 (SYSCON Cage

SYSCON+ to SYSCON2 1 IP-0004

Procedure to Upgrade from SYSCON+ to SYSCON2 (SYSCON Cage Replacement) and Implement Release 5.0 in a Working Maxum II Analyzer Difficulty Level: High Estimated time to execute: 2 Hours Revision History Issue Date Reason 001 12/15/09 First Draft – Based on Beta Procedure 002 1/13/10 Removed fallback procedure 003 1/18/10 Lab tested 004 3/1/10 Added images of adapter bracket


1.0 Description This document describes the procedure to replace an original version SYSCON+ with a SYSCON2 and to install and activate release 5.0 software. This procedure involves replacement of the entire SYSCON mounting cage. Some older versions of SYSCON cage are designed with different mounting hardware than the new cage. In these cases, a special mounting adapter bracket will be required. This bracket is included in the retrofit kit. A retrofit kit (part number A5E02599495001) is required for this procedure. Depending on the existing configuration some parts in this kit may not be required. This kit contains the following items.

Description Quantity New Version SYSCON Cage 1 SYSCON2 (consisting of an SIB with CAC3 installed on it) – Pre-installed in cage 1 Ethernet Cable for SNECON (conversion from 10Base2 to 10BaseT) – Pre-installed in cage 1 Ethernet Switch Board with 1 ft Ethernet cable – Preinstalled in cage 1 New HMI Interface Cable – Preinstalled in cage 1 SNE Debug Cable and Null Modem Cable 1 SNE Debug terminator plug 1 Filter for MMI Ribbon Cable and Double-sided tape for installing Filter 1 Adapter plate and mounting hardware (for old rail version original cages) 1 RS-485 Adapter Cable 1

Note: The above list is included for reference only and is not intended to be all

inclusive. For a complete list with part numbers, refer to the packing list sent with the kit. Also required is a tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers. A laptop computer with a COM port will be necessary for the upgrade as well.

Note: If multiple SNECON boards are equipped, additional hardware is required

for installation. Refer to the prerequisites and Appendix 1 of this procedure.

Warning: Full safety precautions must be followed throughout all sections of

this procedure to prevent possible injury, equipment damage, or death. Verify that the area is clear of flammable gases and vapors and that appropriate authorization is obtained to do the work (hot work permits).


2.0 Prerequisites

This procedure must be performed by a user who has detailed knowledge of the Maxum. This includes detailed knowledge of the hardware, operation, and database setup of the device. In addition, the user should have sufficient computer skills to be able to install and operate the new software. If a customer does not have the knowledge required for this procedure, then it is recommended that Siemens Field Service personnel be contracted to assist.

Additional hardware will be required if the Maxum analyzer is equipped with

more than one SNE Controller. This hardware includes a second Ethernet switch in addition to the one installed in the new cage. DO NOT perform this procedure unless this hardware is available. Refer to Appendix 1 of this procedure for more information.

The analyzer will be equipped with either a first generation or second

generation Maxum II SYSCON cage. These versions are not interchangeable. A special adapter bracket is included in the retrofit kit, and its use will depend on the type of cage installed in the existing analyzer.

If the existing cage is the newer version (see photo below) then the adapter plate will not be needed.

If the existing cage is the old version (see photo below) then the plate will be required in order to install the new cage.

Old Version Cage Newer Cage

A tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers is required to perform this procedure

A laptop computer or other computer located near the analyzer will be

necessary to complete the upgrade. The computer MUST be equipped with a COM port in order to be able to perform necessary changes to the SNECON.


3.0 Upgrade System Manager This section covers upgrading of the Maxum System Manager software to various workstations. This is required for proper communication with the new Maxum II software Release 5.0. This section is not required if the software was installed previously.

Step Procedure

System Manager Upgrade

1. To upgrade the System Manager software, insert the Maxum System Manager installation disk. The installation program will launch automatically (if it does not run automatically, execute the setup.exe file on the disk).

2. Follow the directions given by the installation tool to upgrade to the new

software. You may accept the defaults by clicking "Next" as needed in the installation windows.

3. Repeat the installation for all computers that you wish to upgrade.


4.0 Install SNECON Communication Software This section covers the procedure to add software that will be used later to modify the SNECON communication link for use with the new SYSCON2.

Step Procedure

Note: Original SYSCON+ boards communicate with the SNECON using a

10Base2 connection. However, the SYSCON2 board communicates using 10BaseT. In order for the new SYSCON2 to communicate correctly, it is necessary to modify the communications link setting for any SNECON boards that are installed. Modification of the link requires connecting a laptop computer to the debug port of the SNECON and running a special program that is designed to modify the link. This program is called SNECommset.exe. It is a simple executable program that is easy to install and run. This program can be found in the following directory in the updated Rel 5.0 version of System Manager: \Maxum System Manager\

1. Confirm that the file SNECommset.exe is available by looking in the main

Maxum System Manager directory.

2. If a different computer (without System Manager software) will be used to interface locally to the SNECON, then the SNECommset.exe program must be copied to that computer. If required, copy the file SNECommset.exe to a known location on the new computer. No further installation is required.


5.0 Upgrade by Replacing SYSCON Cage This section covers upgrading to SYSCON2 by replacement of the SYSCON cage. This section is applicable only if the newer version SYSCON cage is in use (refer to Section 2.0 of this document for a description of the cage versions).

Step Procedure

Note: All figures are located at the end of this document.

1. Verify that hard copies of current chromatograms are available. This

information will be used to verify the configuration and operation of the analyzer following the upgrade. Also verify that the IP addresses (IP address, IP mask, and router address) of the analyzer are available as they will be needed in order to configure the new SYSCON2.

2. Place the analyzer in hold status and allow it to finish the current cycle.

3. Using System Manager, save the analyzer’s existing database to the hard drive of the Workstation. From the System Manager software choose:

“System” > “Unit Backup / Restore” Choose the desired Maxum analyzer Enter the desired file name for the backup file Select the “Backup the Analyzer” button in the window

Result: The .amd database file is saved to the hard drive of the PC.


Step Procedure

4. Using the Maxum Utilities software upgrade feature, upgrade the SNECON

software. From the System Manager software choose:

“Tools” > “Maxum Utilities” From Maxum Utilities choose:

“Tools” > “Upgrade Unit” Choose the correct unit. Then choose OK and login with the

appropriate password. If the resulting window has a button titled “Show Details” then click it.

This will bring up an advanced window with checkboxes that allow the user to upgrade individual components.

In the “Upgrade Directory” field choose the “Upgrade4.30” selection. Note: The Upgrade4.30 directory is required because the software in the upgrade tool will detect that upgrade to 5.0 is not possible (because the old SYSCON+ is still installed). Because of this the tool will disable 5.0 upgrades. For the purposes of the SNECON software, the 4.30 upgrade directory is correct.

Uncheck all boxes except the “SNE Components”, OS(bootload.qs) and Application (app.qs).

Click OK and wait for the upgrade to complete. This may take several minutes.

Result: the SNECON software is upgraded to support the new software.

5. Verify the new SNECON software versions are correct using the HMI (or

HMI emulator in the System Manager). Choose the “Select Menu” hotkey and then “3” to select the Configure

menu Select menu item “7” for System I/O From the System I/O menu select item “5” for SNE Controllers In the table, the APP Ver field should be 4.e16 and OSVER should be

4.t15.


Step Procedure

6. Updating the Database to Rel 5.0

A new function in Maxum Utilities, DBConverter, is used to update the Maxum database from older software versions to software Release 5.0. Note: Details and instructions for running DBConverter can be accessed by opening the DBConverter help file from the Maxum Reference Help File. DBConverter Help may also be assessed from the DBConverter window. This step will use DBConverter to create a new database file for use in loading the analyzer later in this procedure. Perform the following to convert the analyzer database to Release 5.0. Start Maxum System Manager and access the analyzer. Open Maxum Utilities using the Tools menu in System Manager. Start DBConverter by selecting the Loader menu in Maxum Utilities. Under the Source File section In the DBConverter window choose

“Database File”. This will cause a “Select File” button to appear. Hit the “Select File” button.

Select the .amd database file that was saved at the beginning of this procedure. The Target File part of the window will now be populated.

When the target file selection appears, choose “Database File” From the drop down menu select software version 5.0 for the target. Select “Start” in the DBConverter window. Either choose the default name offered or enter a desired new name of

the output .amd file (do not overwrite an existing file). Press “Save”. The conversion will begin and the progress will be shown in the DBConverter window. Note that a comparison log file is available that shows if there were any errors with the conversion. Contact Siemens support if there are errors (not warnings) with the database conversion.

After conversion is complete, close the DBConverter window.


Step Procedure

7. Shut down power to the analyzer.

8. Original SYSCON+: Remove the SYSCON cage.

Unscrew and pull out the SYSCON assembly tray. Unplug the thin brown 10Base2 cable at the WDB end (it is easier to

unplug from this end than from the SYSCON+) One at a time, remove all other external cable connectors (both power

and signal) that connect to the SYSCON board and cage. Label the cables with their connection points and functions as they are unplugged. Refer to figure 1. Note: When unplugging cables, unplug the orange I/O connector blocks with the wires still attached. The blocks will plug into the new SYSCON tray. It is very important that all I/O connectors get labeled to prevent them being reversed when plugged into the SYSCON2.

Unplug the HMI cable at the HMI end. A newer, longer cable will be used for the SYSCON2.

After all cables are disconnected, remove the tray from the SYSCON cage.

(If old version of cage is equipped) - After the tray is removed, use a hex wrench to remove the mounting rails from the analyzer enclosure. All that should remain are the screw standoffs that are part of the analyzer enclosure. Refer to figure 2 and Appendix 2.

(If newer version of cage is equipped) - After the tray is removed, use a nut driver to loosen the nuts that secure the SYSCON cage to the analyzer enclosure. After all four nuts are loose, slide the cage forward and then pull down and out to remove the cage. Refer to figure 3. Note that the newer version of the cage and the cage shipped with the SYSCON2 look similar; however, these cages are not identical and the old cage must be removed.

Make a note of which boards are located in which slots in the assembly tray. This information will be needed in the unlikely event that a fallback is required.


Step Procedure

9. (If old SYSCON cage was equipped) – The adapter plate will be required if

the old version SYSCON cage was equipped. Attach it to the enclosure at this time using the hardware provided and the existing standoffs. Refer to figure 4 and Appendix 2.

10. New SYSCON2: Install new SYSCON cage

Remove the new SYSCON assembly tray from the new SYSCON

cage. Install the new cage (without the tray) into the analyzer enclosure. Use

a nut driver to tighten the four nuts to secure the new SYSCON cage to the analyzer enclosure. Refer to figure 5.

CAUTION: To support backwards compatibility of peripheral boards,

the board slots in the SYSCON2 are not keyed. In the following step DO NOT install any boards that are not approved for use by Siemens into the SYSCON2 cage. Doing so may damage the board, the SYSCON2, or both. All boards received from Siemens for use with the SYSCON+ cage are approved for use with the SYSCON2. Boards not supplied by Siemens are not approved.

11. Old SYSCON+ and New SYSCON2: Move any extra boards that are

installed in the old SYSCON+ assembly tray (e.g. I/O boards, CAN boards, Fiber Optic Converter boards, etc.) to the new SYSCON2 assembly tray. Note: Any board equipped in the FAR RIGHT slot (slot 5) is NOT to be moved. Boards that plug into this slot in the SYSCON+ are not required in the SYSCON2. There will be an Ethernet switch board already installed in the far right slot of the new SYSCON2 assembly tray. Do not remove this board.


Step Procedure

12. New SYSCON2: Install new SYSCON tray

Insert the new SYSCON tray in the analyzer (leave the tray in the

pulled-out dropped-down position). Connect all cables to the new SYSCON. Refer to the labels that were

applied in step 10. Refer also to Figures 6 and 7. Notes on Serial Ports:

1. The pinout for the serial ports, when configured for RS-485 operation, is different between the SYSCON+ and SYSCON2. Also, the RS-485 connection is now a male connector. There is an adapter cable supplied with the upgrade kit that is used to adapt an existing RS-485 cable to the SYSCON2. If an RS-485 cable is equipped, install the adapter cable at this time.

2. In Release 5.0 software all serial ports may be configured as either RS-232 or RS-485. However, Serial 1 on the SYSCON2 is hardcoded to always operate as Modbus (Serial 2 may be used to operate as a printer connection). If there is an RS-485 Modbus connection on the SYSCON+, the cable must be moved to Serial 1. Also, any non-Modbus cable in the RS-232 connector must be moved to Serial 2. Note that if this configuration exists, the software will be automatically changed by the DBConverter program to match.

Notes on Other Connections:

1. The connection from SYSCON2 to SNECON is now 10BaseT (compared to 10Base2 for SYSCON+). The new cable is provided in the upgrade kit. The plug-in location of the new cable is indicated in Figure 6 and figure 10. The cable is routed through the back of the new SYSCON cage as shown in figure 8. If more than one SNECON is equipped, refer to Appendix 1 for connecting to multiple SNECONs using an Ethernet switch.

2. The external RJ-45 Ethernet connection is now located on the Ethernet Switch board which is located in the far right slot of the cage. The existing Ethernet cable can be plugged into any location in the Ethernet Switch. If necessary, this cable can be plugged in after the tray is slid into the cage (step on the next page).

3. The new HMI cable connects directly from the SYSCON2 board to the HMI. It does not connect to the front of the SYSCON tray as with the SYSCON+. Refer to figure 8 for the proper installation. Note that in some locations the pre-existing HMI cable may have a black sheath over it. This is not required for the new HMI cable.


Step Procedure

13. Slide the new SYSCON tray into the cage and tighten the nuts.

14. A filter must be added to the HMI ribbon cable to prevent interference. If it is

not already installed, install the filter at this time as shown in Figure 9.

15. Plug the SNECON debug cable (with null modem cable) into the debug port (J4) of the SNECON board and also into communications port 1 (COM1) of your laptop computer. Refer to Figure 10 for location of the debug connector on the SNECON. It may be necessary to loosen and remove the SNE assembly (keeping all connections intact) in order to plug in the cable. If there is a terminator plug in the debug port of the SNE, the plug should be removed and set aside.

16. Power up the analyzer. Note that the system will boot with errors because

communication with the SNECON is not yet possible.

17. Modify the SNECON to SYSCON2 communication link. On your laptop computer, start the program, SNECommSet.exe, which

is used to reconfigure the SNECON to SYSCON communications link. Refer to figure 11.

Using the Reset switch (figure 10), manually reset the SNECON After waiting 30 seconds for the SNECON to boot, select the menu

item that starts communication via the computer’s COM1 port. After communication is established (“Connected Successfully”), hit the

button that configures the link for 10BaseT operation from 10Base2. After configuration is complete the SNECON should reboot

successfully. This could take up to 30 seconds. At this point the SYSCON2 should have communication with the SNECON.

Close the SNECommSet program and unplug the debug cable Plug the debug terminator plug back into the SNECON debug port (or

install the new plug from the upgrade kit, if a plug was not already installed). Refer to figure 10 and the photograph below.

If multiple SNECON boards are equipped, repeat for each.


Step Procedure

18. From the physical HMI on the analyzer, set the IP addresses for the new

SYSCON2. This will allow the System Manager software to communicate with the device so that the updated database may be loaded. The HMI software in Release 5.0 is slightly different from the software in prior releases. However, the path for setting IP addresses is the same. From the Configure Menu choose “System Setup”. Then choose the “IP SET INFO” softkey and modify the IP address, the IP mask, and the Router IP address to match the desired settings that were noted earlier in this procedure.

CAUTION: In the following step, verify that the CORRECT analyzer is downloaded. Loading the wrong analyzer will lead to loss of data.

19. Load New SYSCON2 with Converted Database:

Open System Manager and choose the “System” menu and then “Unit Backup / Restore”.

In the Backup/Restore window, select the analyzer to be upgraded. Choose the file name for the AMD file that was created by

DBConverter earlier in this procedure. Enter the “super” login ID and the password for that ID. Select “Restore the analyzer”. A warning message will appear indicating that all of the current data on

the analyzer will be destroyed and the analyzer will be rebooted. Verify that the CORRECT analyzer is chosen and hit “Yes” to continue.

The database will load and reset automatically. Perform a startup of all hardware in accordance with all standard safety

procedures.

20. After verifying that all hardware is up and running, start the analyzer and allow chromatographic measurements to stabilize. After stabilization, run test chromatograms on the analyzer. Verify that results are as expected by comparing with chromatograms obtained before the upgrade.

21. Calibrate the analyzer, if necessary.

22. Verify the operation of any I/O that is configured in the analyzer, including

any remote I/O for the analyzer that is configured in other analyzers. Note that some modification of the I/O datatype may be necessary in order for the I/O to function the same as in the prior release.


Step Procedure

23. Check the operation of the following (if equipped):

1. System Manager connection to the analyzer via Ethernet 2. Maintenance Panel on the analyzer 3. MaxBasic Programs (run each manually, if feasible) 4. Any other communication links that may exist (e.g. Modbus, printer).

24. If the purge alarm wire is installed, verify that the purge alarm is working.

Verify that a purge alarm is not present when properly purged and verify that a purge alarm is created when the door is opened. If purge bypass is used, verify that no purge alarm exists when the door is opened.

25. Perform any other system checks that may be needed.

26. The following steps must be taken to allow for the unlikely event of a

fallback to the old hardware. 1. A copy of the original AMD file must be saved. This file should

be stored in a safe location to prevent it from being accidentally deleted.

2. The original SYSCON+ board and cage should remain on site in a protected location to prevent damage. Any additional hardware or cables that were removed as part of the upgrade should remain with the original SYSCON+ board and cage. The original SYSCON+ and the other hardware must NOT be used as spares or replacements in any other analyzer.

3. On a piece of paper, make notes indicating which boards were installed in which slots in the original SYSCON+ configuration. Store this information with the original SYSCON+ cage.

4. All other kit hardware (including the SNECON debug cable and null modem cable) and removed hardware should remain with the old SYSCON board and cage.

5. Save original chromatograms.

This hardware and information should be saved for at least one month to ensure that no problems arise with the new device. If a problem arises, do not attempt to fall back without the advice and assistance of Siemens support. If a fallback becomes necessary, Siemens support will provide a fallback procedure.


6.0 Figures

Figure 1 – SYSCON1 Connections

Internal Bus

CAN Direct 1

CAN Direct 2

CAN Direct 3

CAN Direct 4

CAN Direct 5

AT Bus

PCI Slot 1

PCI Slot 2

PCI Slot 3

PCI Slot 4

10BaseTI/O Terminal Blocks

Maintenance Panel Display SIMM 80 #2 Flash/SRAM

SIMM 80 #1 Flash/DRAM

RS 232/485

Not Used

Not Used

SYSCON Debug

Power

Reset

CAN Bus

Purge

10Base2

SIMM 72


Figure 2 – Removal of Existing SYSCON Cage Hardware (Old version)

Figure 3 – Removal of Existing SYSCON Cage Hardware (Newer version)


Figure 4 – Mounting of Adapter Plate

Figure 5 – Installation of New SYSCON Cage


Figure 6 – SYSCON2 Board Connections


Figure 7 – SYSCON2 Cage Connections

Figure 8 – Installation of HMI and 10BaseT Cables for SYSCON2


Figure 9 – Application of Filter for MMI Ribbon Cable


Figure 10– SNECON Debug Connection Location

J4 SNE Debug Connector

SNE Reset Switch

10BaseT Connector


Figure 11– Program to Modify SYSCON to SNECON Communications


Appendix 1: Configuration of Multiple SNE’s with SYSCON2 An additional kit is required to configure the SYSCON2 for multiple SNE configuration. This kit is part number A5E02599495001. Do not attempt to convert a multiple SNE configuration without this hardware.

The legacy SYSCON was designed to support hardware configurations with more than one SNE by utilizing a “daisy-chain” configuration from SNE to SNE. Because the SYSCON2 communicates to installed SNE hardware using 10BaseT Ethernet, of which each SNE has only one connector, this daisy-chain configuration is not possible.

In cases where a SYSCON2 is required to communicate with multiple SNE boards, an Ethernet Switch Board with Fiber (ESBF) is used as shown in figure 10 below. The ESBF plugs into a free PCI slot and is used to switch the 10BaseT Ethernet to as many as three SNE boards. Note that the ESBF is used because the standard Ethernet Switch Board (ESB) is designed for use only in slot 5 (keyed differently) for external Ethernet connection.

Configuration for Multiple SNEs Using ESBF

Notes on installation:

DO NOT begin this procedure unless the ESBF is available. Also necessary are sufficient Category 5 Ethernet cables to connect from the ESBF to each SNECON.

The ESBF may be plugged into any free slot (1 through 4) in the new SYSCON cage. If no free slot is available then some reconfiguration may be necessary.

The ESBF board is “plug and play” and no software configuration is required.

Refer to the following page for information regarding the hardware installation of the ESBF.

Note that the fiber connection on the ESBF is not used when communicating with SNECON boards.


Hardware Information Regarding the ESBF:

The ESBF, shown below, is a board that is designed to plug into any free SYSCON cage slot. Because slot 5 in the SYSCON is keyed differently than slots 1-4, the ESBF is designed with two sets of slot connector strips, one on the top of the board and one on the bottom.

Ethernet Switch Board with Fiber (ESBF)

To support the dual connector strip configuration, the ESBF is equipped with a special reversible bracket. This bracket is detached and turned upside down when the board is installed in a PCI slot (slots 1-4). For the purposes of communicating with multiple SNECON boards, the ESBF will be installed only in a PCI slot. This means the protruding tab on the bracket should be installed away from the fiber connection as shown in the figure below. To reverse the bracket, if required, unscrew it and turn it upside down. Then, connect the bracket using the opposite set of holes (so that the bracket will line up appropriately).

Reversal of ESBF Bracket


Appendix 2: Installation of SYSCON2 Cage Using Adapter Bracket As mentioned in the prerequisites for this procedure, there are two distinct types of cage for the SYSCON+. In the Maxum I and earliest versions of Maxum II the SYSCON cage was installed using a rail system. This was later replaced with a cage and tray configuration. These two systems are attached to the enclosure in different ways.

Although the SYSCON2 boards (SIB and CAC) are designed to fit in the older cages, the upgrade includes a new cage to allow for full SYSCON2 functionality and easy installation. Because the rail system is not compatible with the screw holes on the new cage, an adapter plate is necessary. This plate will be installed on the original standoffs of the enclosure and the new cage will mount to the plate. Refer to the figures below.

The adapter plate kit includes the plate, eight screws with washers, and four nuts for attaching the new cage to the plate.

Removal of Rails

Standoffs in the Maxum Enclosure


The plate is not symmetrical. It is designed so that the holes only line up when it is installed correctly. If the holes do not line up, turn the plate around.

The original screws that attached the rails to the standoffs will be too long for the adapter plate. Shorter screws are provided with the adapter plate.

Installation of Adapter Plate

When installing the nuts for attaching new cage to adapter plate, leave them loose enough to slide the cage on.

Installation of Nuts


When installing the cage on the adapter plate, line the holes up with the nuts and slide the cage all the way to the back.

Installation of New SYSCON Cage on Adapter Plate

After installing, tighten the nuts. Then, continue with the procedure.

Documents

Procedure to Upgrade from SYSCON+ to SYSCON2 (SYSCON Cage