Emerson FloBoss S600+ Installation and operation manual

Remote Automation Solutions
Form Number A6299
Part Number D301668X412
February 2011
FloBoss™S600+ Field Upgrade Guide

FloBoss S600+ Field Upgrade Guide
ii Revised Feb-11
Revision Tracking Sheet
February 2011
This manual may be revised periodically to incorporate new or updated information. The
revision date of each page appears at the bottom of the page opposite the page number. A
change in revision date to any page also changes the date of the manual that appears on
the front cover. Listed below is the revision date of each page (if applicable):
Page Revision
Entire manual Feb-11
Initial Issue Dec-10
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S600+ Field Upgrade Guide
Overview
This guide describes the processes required to upgrade your FloBoss
S600 to a FloBoss S600+. Two general processes are involved:
replacing the CPU module and replacing the front panel faceplate. The
new CPU module provides increased processing speed, increased
memory, additional communication ports, and an enhanced operating
system, and represents a significant improvement from the current
CPU module. The new front panel faceplate provides the correct logos
and identifies the S600+.
Warning This upgrade process is intended ONLY for systems which DO NOT
have MID approvals. To upgrade a system with MID approval, contact
your sales representative.
Security Plate If you have a security plate currently installed on your S600, that plate
does not fit the new CPU module. A new security plate (part number
S600+EMCPLATE) is included in the upgrade kit.
Note: Refer to the S600+ technical specification (S600, available
from www.EmersonProcess.com/Remote) for further technical
details.
General Procedure The procedure requires that you perform a number of steps in a
specific sequence:
1. Save the current configuration in the CPU module to your PC.
2. Power down the S600 and remove appropriate wiring.
3. Remove the front panel faceplate.
4. Install the printed circuit board (PCB) in the new faceplate.
5. Replace the front panel connector cable.
6. Reattach the front display panel to the S600 chassis.
7. Remove and safely store the old CPU module.
8. Unpack the new S600+ CPU module from its shipping container
and anti-static bag.
9. Set communication jumpers.
10. Set security jumper.
11. Set cold start jumper.
12. Install the new CPU module in the chassis.
13. Wire the new CPU module.
14. Apply power.
15. Set TCP/IP communications parameters.
16. Download configuration.
17. Perform a cold start.
The following pages discuss each of these steps in detail.
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S600+ Field Upgrade Guide
S600+ Upgrade Kit Before you begin, open the upgrade kit and verify that you have all
the components you need to complete this process:
CPU module (P152 R5, part number 7381520) in an anti-static bag.
New S600+ front panel faceplate.
Front panel connector cable (with ferrite clamp filter)
Modified security plate.
1. Save Configuration
The Config600 software installed on your PC maintains copies of all
configurations you have defined, storing them in the folder
C:\Program Files\Config600 X.X\Configs (where X.X represents the
current installed version of the Config600 software).
Note: This is the system default folder for configurations; your site
may have changed this location.
If you have not recently modified any of your configurations, you may
not need to re-save them. As a precaution, you might review and save
the most recently used configurations or use the Config Transfer utility
to upload the active configuration (refer to the Config600
Configuration Software User Manual (A6169).
Proceed to the next step.
2. Power Down S600
Before powering down the S600, ensure that any processes it may
control are themselves shut down or otherwise controlled. Once you
are sure of this, disconnect power from the S600 by removing the
power wire terminal block.
Proceed to the next step.
3. Remove the Front Panel Faceplate
1. Using a 2.5 mm Allen key, remove the hex cap screw from the
bottom centre of the front panel.
Figure 1. Removing the Hex Cap Screw
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S600+ Field Upgrade Guide
Note: A security cap may cover this hex screw.
2. Carefully slide the front panel up 4 mm to allow it to clear the
retaining groove at the top of the case, and then allow the panel to
come forward to clear the case completely.
Figure 2. Lifted Front Panel
3. Disconnect the ribbon cable from the back of the front panel at the
blue connector.
Disconnect
Here
Figure 3. Ribbon Cable
Proceed to the next step.
4. Install the Printed Circuit Board (PCB)
1. Place the front panel faceplate button-side down on a flat surface.
2. Remove the eight screws that secure the printed circuit board
(PCB) to the faceplate (see Figure 4).
Revised Feb-11 3

S600+ Field Upgrade Guide
Screw
Screw
Screws
Screws
Figure 4. Securing Screws
3. Lift the PCB from the old faceplate and place the PCB in the new
faceplate.
4. Replace and secure the two top-most screws and the two bottom-
most screws (see Figure 4).
5. Replace and gently tighten the four central screws.
Caution Do not over-tighten the four central screws. This can cause the rubber
keypad to bind and affect the functioning of the S600+.
Proceed to the next step.
5. Replace the Front Panel Connector Cable
1. Unscrew the two hex screws on the metal panel protecting the
connector cable (see Figure 5) and remove the metal plate.
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S600+ Field Upgrade Guide
Hex nuts
Figure 5. Protective Plate
2. Carefully pull the connector cable free from its connection in the
chassis. Note the orientation of the cable connector.
3. Select the longer connector cable from the upgrade kit and plug it
into the connection in the S600 chassis.
4. Replace the metal protective plate and the two hex screws.
5. Select the ferrite EMC clamp from the upgrade kit and peel the
protective coating from its adhesive backing.
6. Place the top of the ferrite clamp 6 cm below the bottom of the
protective plate. Position the clamp so that it opens to the left and
press the clamp so that it adheres to the chassis.
Note: This positioning ensures that the clamp does not interfere
with components on the PCB.
7. Thread the connector cable through the ferrite clamp and close the
clamp. See Figure 6.
Revised Feb-11 5

S600+ Field Upgrade Guide
Figure 6. Installed Ferrite Clamp
Proceed to the next step.
6. Reattach the Front Panel
1. Connect the ribbon cable to the front panel.
Caution Note how the connector fits into the keyway. You must insert the
ribbon cable correctly. Do not force the connector into the keyway.
2. Place the top of the front panel over the retaining groove on the top
boss and slide the front panel downwards.
3. Secure the front panel by placing the hex cap screw into its recess
in the bottom centre of the front panel.
4. Using a 2.5 mm Allen key, tighten the screw finger-tight. Turn an
additional 180 degrees to complete the installation.
Caution Do not over-tighten the screw. Over-tightening will damage the panel
face.
Note: If a cap protected the hex screw, replace the cap.
Proceed to the next step.
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S600+ Field Upgrade Guide
7. Remove Current CPU Module
Before you can remove the current CPU module, you may have to
open the case for the S600. Depending on how the S600 is installed at
your site, you may first have to remove a security plate that prevents
easy access to the modules.
1. Disconnect all wiring to the CPU and any other installed modules.
Note: The power wiring to the new CPU module is identical to
the old CPU module. However, other wiring is very similar.
TB2 on the old CPU module has 13 pins. Pin 13 is not
supported. Pins 5-13 are a single 5-pin connector block. If
you use these, swap this 5-pin connector for a 4-pin
connector. Detail the current wiring structure so you can
replicate it with the new CPU module.
2. Remove the aluminium security plate at the back of the S600
chassis.
Note: Removing this plate may require you to detach wire seals
placed in accordance with measurement requirements (such
as NMi). Ensure that you follow the appropriate procedures
to replace these seals.
3. Unscrew the retaining screws and remove the cover plate at the
back of the CPU module.
4. Using the attached lifters, detach and slide the CPU module out of
the chassis. Store it in an anti-static bag for safekeeping.
Proceed to the next step.
8. Unpack New CPU Module
The new S600+ CPU module (P152 Rev 5 or above) is factory-packed
in an anti-static bag. Carefully remove it from the bag, observing all
cautions—including personal grounding—to prevent accidental static
discharge (which might damage the CPU module). Place the module
flat on a static-safe surface so that the communication connectors face
up, as shown in Figure 7:
Revised Feb-11 7

S600+ Field Upgrade Guide
Securit
y
j
um
p
er
(
P3
)
Cold start jumper P2)
Communication
j
um
p
ers
(
P7 throu
g
h- P15, P17, and P18
)
Figure 7. S600+ CPU Module Jumpers
Proceed to the next step.
9. Set Communcations Jumpers
Use the communication jumpers to configure comm port settings. An
explanatory diagram printed on the CPU module helps you determine
what settings to choose (see Figure 8).
Figure 8. CPU Module Communication Jumpers
8 Revised Feb-11