495HF & HR Commissioning Manual - V3.1 - 7 - Section 3 - Loading Software

495HF & 495HR CLASS EXCAVATORS
ELECTRICAL COMMISSIONING
MANUAL
Page 1
SECTION 3: Loading software
1) Once the MRC HMI has booted-up, remove the Rocky Computer Keyboard either from the Folding
Tray or from the NODE 7 Compartment, and using a " Windows Key" break into the Windows Operating
System, then use key stroke " Windows Key " and " E Key " to break into the Windows Explorer.
In the Rocky Computer's " C " - Drive, create " Backup " folder for the storage of PLC, SIBAS and HMI
programs as illustarted in the following images :
PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

Commissioning Manual Created by:
Jacek ( Jack ) Janiszewski
Bucyrus Canada Limited
Loading Software Version 3.1
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COMMISSIONING ENGINEER'S NOTES :

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1) Creating " Backup " folder in the Rocky Computer's " C " Drive - continued

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1) Creating " Backup " folder in the Rocky Computer's " C " Drive - continued.
Once the " Backup " folder has been created, transfer all pertinent files from your Laptop into the
newly created folder with the use of a USB Mass Storage Device ( Memory Stick )
For your reference, the subject programs will have the following names & extensions:
* Step 7 PLC Software

- normally delivered in the following format : ( machine S/N )_(version letter).zip i.e. 141178_c.zip
- upon unzipping : L( lot number )SY_v( version number ) i.e. L63SY_v2
* SIBAS Software
- ZR System Flash : OSZR0200.LOC
- ZR User Flash : Shovel.PGM
- SIP System Flash : OSSI0127.LOD
- AFE SIP User Flash : AF_0BQ17.PGM
- Crowd SIP User Flash : PWCROW14.PGM
- Hoist SIP User Flash : PWHST02.PGM
- Swing SIP User Flash : PWSWING9.PGM
* HMI - WINCC Software

- Shovel.zip ( WinCC Project Files )
- HTMLfiles.zip ( Files for Online Troubleshooting Manual )
- Textfiles.zip ( Project Associated Files )
- FaultHistory.zip ( Files for the Fault History Backup )
* Operator's Cab HMI Software

- normally delivered in the following format : DCab( machine S/N )_e.zip i.e. DCab141178_e.zip
Comments :
Date : Initials:

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2) In the Rocky Computer's Programs List, locate program called SIMATIC Manager, and activate it.
Once the program is running, use the instructions on the following pages, and download the PLC
Software from the Rocky Computer's previously created " Backup Folder " into the STEP7 PLC
Processor :

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COMMISSIONING
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2a) Use the "Retrieve" function to locate the PLC Program in its stored location
2b) Open the previously created Backup File in the Rocky Computer

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2c) Highlight the subject file and click "Open"
2d) Select location where you wish the SIMATIC Manager to store the subject program ( default = S7Proj ),
and click "OK"

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2e) At this point the SIMATIC Manager will unzip and extract the target program
2f) Upon successful extraction, the SIMATIC Manager will post the project final location notice - click "OK"

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2g) If you wish to view the program and work with it - click "Yes"
2h) At this point, the SIMATIC Manager Main Menu will appear. Double click on the "Simatic 400(1)"

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2i) At this point, the Simatic 400 Menu will appear. Double click on "CPU 416-2 DP" if you wish to view
or work with the software. Double click on "Hardware" if you wish to work with the hardware configuration.
2j) If software option is chosen, the CPU 416-2 DP Menu will appear. Double click on "S7 Program(1)"

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2k) At this point the S7 Software Menu will appear.

To view the software structure double click on "Blocks"
At this point, minimize the SIMATIC Manager.

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3) Utilizing the Siemens issued " General Information and Procedures for SIBAS 32 Control System "
Manual, locate Chapter 2 ( excerpts attached on the following pages ), and activate the SIBAS 32 Monitor

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The SIBAS Monitor should have beeen already initalized from Siemens facility.
Review the steps just to ensure correct settings.
Note :
This procedure must be performed if a new ZR has been installed

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NOTE : At this point, close the SIBAS Monitor Program to complete the initialization routine.
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MANUAL Page 34

PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION Jacek ( Jack ) Janiszewski
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4) Utilizing the Siemens issued " General Information and Procedures for SIBAS 32 Control System "
Manual, locate Chapter 7 ( excerpts attached on the following pages ), and load the SIBAS System
Flash ( OEM firmware program ), and the SIBAS User Flash ( user specific program ).
The subject files will typically have the following description, and should be loaded in the order
listed below :
- Central Processor Unit ( L011 ) - ZR System Flash i.e. OSZR0200.LOC ver. loaded
- Central Processor Unit ( L011 ) - ZR User Flash i.e. SHOVEL.PGM ver. loaded
- Crowd SIP ( L019 ) - Crowd System Flash i.e. OSSI0127.LOD ver. loaded
- Crowd SIP ( L019 ) - Crowd User Flash i.e. PWCROW14.PGM ver. loaded
- Swing SIP ( L027 ) - Swing System Flash i.e. OSSI0127.LOD ver. loaded
- Swing SIP ( L027 ) - Swing User Flash i.e. PWSWING9.PGM ver. loaded
- Hoist SIP ( L035 ) - Hoist System Flash i.e. OSSI0127.LOD ver. loaded
- Hoist SIP ( L035 ) - Hoist User Flash i.e. PWHST_02.PGM ver. loaded
- AFE 1/2 SIP ( L043 ) - AFE System Flash i.e. OSSI0127.LOD ver. loaded
- AFE 1/2 SIP ( L043 ) - AFE User Flash i.e. AF_0BQ17.PGM ver. loaded
- AFE 3/4 SIP ( L051 ) - AFE User Flash * Note: both AFEs use the same User Flash
IMPORTANT NOTE :
If an error is made during the programming process ( i.e. System Flash inadvertently loaded instead of
the User Flash etc. ), and the subject card appears to be locked-up, utilize the above noted SIBAS 32
Control System Manual, Chapter 10 " Operating Instructions Customer Monitor ", Section 4.4.2.3
" Hardw. BOOT ZR " and " BOOT DSP ". Follow the instructions precisely step-by-step !
See excerpt of " SIBAS 32 Control Units - Operating Instructions Customer Monitor " starting on Page 71
for details.

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This concludes the SIBAS Software loading procedure.
Note :
The recovery instructions contained on the following pages are to be used only if the ZR or SIP's are
locked-up, or corrupted due to mis-programming !

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495HF & 495HR CLASS EXCAVATORS

PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

* Step 7 PLC Software

* HMI - WINCC Software

* Operator's Cab HMI Software

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PROPRIETARY DOCUMENT - NOT FOR PUBLIC DISTRIBUTION

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2c) Highlight the subject file and click "Open"

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2k) At this point the S7 Software Menu will appear.

At this point, minimize the SIMATIC Manager.

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COMMISSIONING ENGINEER'S NOTES :

Commissioning Manual Created by:

SECTION 3: Loading software

Commissioning Manual Created by:

COMMISSIONING ENGINEER'S NOTES :

Commissioning Manual Created by:

SECTION 3: Loading software

Commissioning Manual Created by:

COMMISSIONING ENGINEER'S NOTES :

Commissioning Manual Created by:

SECTION 3: Loading software

Commissioning Manual Created by:

COMMISSIONING ENGINEER'S NOTES :

Commissioning Manual Created by:

SECTION 3: Loading software

Commissioning Manual Created by:

COMMISSIONING ENGINEER'S NOTES :

Commissioning Manual Created by:

SECTION 3: Loading software

Commissioning Manual Created by: