Migrating to a Quantum EIO System

Introduction

The following choices are available when you migrate a to an :

Add Ethernet remote I/O drops to an existing legacy (S908) remote I/O system.

— or —
Replace legacy (S908) remote I/O drops with Ethernet remote I/O drops. Also replace the legacy (S908) remote I/O head module with an Ethernet remote I/O head module.

The steps below provide an overview of upgrading your existing Quantum configuration to a Quantum EIO system. Detailed instructions follow.

Step	Action
1	Upgrade the CPU (only with a 140 CPU 652 •• CPU or 140 CPU 672 •• CPU).
2	Add new modules or replace existing modules.
3	Change the application.

NOTE: After you upgrade your network, rebuild your applications in Control Expert and download the new applications to the Quantum EIO modules on the local and remote racks. Do this for both standalone and configurations.

Upgrading the CPU

You can upgrade the CPU in one of the following ways:

Change the hardware module.

Replace the CPU module with the same module with version 3.0 or later. With a Hot Standby configuration, replace the CPU modules in both PLCs.
Upgrade the firmware.

Download the firmware in the installed CPU with the OS Loader tool. Upgrade both the CPU and coprocessor firmware (Hot Standby or Ethernet).
- For all processors, use the CPU binary file named 140CPU6...._Vxxx.bin, where xxx is equal to or greater than 300.
- For Hot Standby processors (140 CPU 671 60, 140 CPU 672 60, and 140 CPU 672 61), use the coprocessor binary file named 140CPU67.6._HsbyCopro_Vxxx.bin, where xxx is equal to or greater than 300.
- For standalone processors (140 CPU 651 50, 140 CPU 651 60, 140 CPU 652 60), refer to the Quantum with Control Expert Hardware Reference Manual regarding CPU/Ethernet coprocessor firmware compatibility.
NOTE:
- With a Hot Standby configuration, upgrade the firmware in both PLCs.
- You can upgrade a Hot Standby CPU firmware to V3.0 without stopping the process if new features provided by Unity Pro 7.0 are not used (no 140CRP31200 remote I/O head module has been added to the configuration).

NOTE: Unity Pro is the former name of Control Expert for version 13.1 or earlier.

Case 1: Adding Ethernet Remote I/O Modules

Step	Action
1	Add the 140CRP31200 module to an empty slot in the local rack. With a Hot Standby configuration, add the 140CRP31200 module to both local racks.
2	Install the Ethernet remote I/O drops. Refer to the Module Selection topic for a list of compatible modules.
3	Add a 140NOC78000 distributed I/O head module (interlinked with the 140CRP31200 module) if you plan to add distributed I/O devices or diagnose the PLC remotely.

NOTE: For installation and configuration details, refer to the respective Quantum EIO Installation and Configuration Guide.

Case 2: Replacing Legacy (S908) Remote I/O Modules

Step	Action
1	Replace the 140CRP93•00 module with the 140CRP31200 module in the local rack. With a Hot Standby configuration, replace the 140CRP93•00 module with the 140CRP31200 module in both local racks.
2	Replace the 140 CRA 93• 00 adapter module with the 140CRA31200 adapter module in all Ethernet remote I/O drops.
3	Add a 140NOC78000 module (interlinked with the 140CRP31200 module) if you plan to add distributed I/O devices or diagnose the PLC remotely.

Changing the Application

Follow the steps below to change the application.

Step	Action
1	Install Unity Pro V7.0 on the computer.
2	Check that the application program running in the Quantum CPU has been exported in the XEF format and is available on the computer. If not, upload the application program from the PLC and export it in the XEF format.
3	In Control Expert, import the XEF file of the application.
4	In the local drop editor, replace the actual processor version with the new version, V3.10.
5	Configure the new modules in the Control Expert application. Case 1 — Add the 140CRP31200 module in an empty slot of the local rack. Then, add Ethernet remote I/O drops on the EIO Bus just created. Case 2 — Delete the 140CRP93•00 module in the local rack. Then, add the 140CRP31200 module in the same slot. Finally, add Ethernet remote I/O drops on the EIO Bus just created.
6	Depending on the type of upgrade (Case 1 or Case 2), modify the application program in order to manage the new Ethernet remote I/O drops (see below for the impacts of this modification).
7	Rebuild the application program and download it to the CPU. The CPU is in STOP mode. With a Hot Standby configuration, download the application in both PLCs.
8	Put the PLC in RUN mode.

Impacts on the Application Due to Upgrading

When you upgrade your existing configuration to a Quantum EIO system, the application program may be impacted in the following ways:

Case 1

Most of the existing application program does not change.
Add the sequences of the application program to manage the Ethernet remote I/O modules.

Case 2

The section scheduler feature available in a legacy (S908) remote I/O system, which allows remote I/O channels to be updated on section execution without waiting for the entire MAST cycle execution, is not available in a Quantum EIO system. This feature is replaced by IU_EIO (Immediate Update Ethernet I/O) function blocks, which can only be used in MAST task.
The following table shows the system bits and words available to diagnose detected faults in the I/O modules on an Ethernet remote I/O network.

NOTE: Legacy (S908) function blocks like DROP / XDROP, scaling function blocks for analog modules, and the ERT function block for ERT modules are compatible with the Ethernet remote I/O drops.

Legacy (S908) Remote I/O Diagnostic System Bits and words	Ethernet Remote I/O Diagnostic System Bits and Words
%S118: general detected fault	%S117: general detected fault
No equivalent available.	%SW152 to %SW153: drop status bits for remote I/O drops 1 to 31
No equivalent available.	%SW172 to %SW173: connection status bits for remote I/O drops 1 to 31
%SW185 to %SW339: module health bits for drop 1 to 31	%SW641 to %SW702: module health bits for remote I/O drops 1 to 31
%SW535: detected error on start up	No equivalent available.
%SW536 to %SW541: communication status (counters) on cable A and B	Communication status and counters can be read by using 140 CRP 312 00 head module and 140 CRA 312 00 adapter module DDT. For details, refer to the EcoStruxure™ Control Expert Program Languages and Structure Reference Manual.
%SW542 to %SW544: global communication status (counters)

Application Response Time

In both Case 1 and Case 2, consider how the MAST task cycle time may be impacted by the application program change and the number of Ethernet remote I/O drops you replace or add.

For 1 or 2 remote I/O drops configured in a Quantum EIO system, the ART is essentially the same for Ethernet remote I/O and legacy (S908) remote I/O.

For 3 or more remote I/O drops, the application response time is better with Ethernet remote I/O than legacy (S908) remote I/O.

The impact of the number of racks on CPU scan time is smaller for Ethernet remote I/O than for legacy (S908) remote I/O, because scanning is done asynchronously. This provides a better scan time with the same CPU and I/O configuration.