Engineering Tools. Backup & Restore. Data saving and restoring _ Software Manual EN. Ä.R7Tä

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1 Engineering Tools Backup & Restore Data saving and restoring _ Software Manual EN Ä.R7Tä L

2 Contents 1 About this documentation _ Document history Conventions used Terminology used Definition of the notes used 9 2 Controller-based Automation: Central motion control 10 3 Basic concept _ What are the functions offered by»backup & Restore«? _ Storage media used _ Differences between backup, restore, and update Backup _ Restore and auto-restore _ Update and auto-update _ Standard procedure _ Signalling of the processing state _ 20 4 Creating a backup and carrying out a restore process _ Creating a backup Creating a backup on the Engineering PC (recommended variant) _ Creating a backup on the Controller _ Creating a backup using the»webconfig« Creating a backup with the Windows Explorer (on the directory/file level) _ Carrying out a restore/auto-restore Carrying out a restore on the Engineering PC (recommended variant) _ Carrying out a restore on the Controller _ Carrying out a restore with the»webconfig« Carrying out a restore with the Windows Explorer (on the directory/file level) _ Carrying out an auto-restore _ Carrying out an update/auto-update (only available for control technology) 35 5 Diagnostics Status LEDs of the Controllers _ Status LEDs of the Controller 3200 C _ Status LEDs of the Controllers c300/p Status LEDs of the Controllers p Specific signals during a»backup & Restore«process Text outputs (optional panel/screen required) Error messages for the execution of a backup or restore Error messages for the execution of an update _ Fault: Controller c300/p300 does not start 46 Index _ 47 Your opinion is important to us _ 48 2 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

3 1 About this documentation 1 About this documentation This documentation... contains some information relating to the use of the»backup & Restore«Lenze software tool in the context of the Lenze "Controller-based Automation" system; is part of the "Controller-based Automation" manual collection. It consists of the following sets of documentation: Documentation type System manuals Communication manuals Online helps Reference manuals Online helps Software manuals Online helps Subject Visualisation (system overview/sample topologies) Bus systems Controller-based Automation EtherCAT Controller-based Automation CANopen Controller-based Automation PROFIBUS Controller-based Automation PROFINET Lenze Controllers: Controller 3200 C Controller c300 Controller p300 Controller p500 Lenze Engineering Tools:»PLC Designer«(programming)»Engineer«(parameter setting, configuration, diagnostics)»visiwinnet Smart«(visualisation)»Backup & Restore«(data backup, recovery, update) Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 3

4 1 About this documentation More technical documentation for Lenze components Further information on Lenze products which can be used in conjunction with Controller-based Automation can be found in the following sets of documentation: Mounting & wiring Mounting instructions Controllers Communication cards (MC-xxx) I/O system 1000 (EPM-Sxxx) Inverters, Servo Drives Communication modules Hardware manuals Inverters, Servo Drives Operating instructions Controllers Servo system ECS (ECSxE, ECSxM) Sample applications/using application templates Online help/reference manuals Application Sample i700 Application Samples Application Template FAST technology modules Parameterisation, configuration, commissioning Online help/reference manuals Controllers Inverters, Servo Drives I/O system 1000 (EPM-Sxxx) Online help/communication manuals Bus systems Communication modules Operating instructions Servo system ECS (ECSxE, ECSxM) Symbols: Printed documentation PDF file / online help in the Lenze engineering tool Tip! Current documentation and software updates with regard to Lenze products can be found in the download area at: 4 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

5 1 About this documentation Target group This documentation addresses to persons who back up/restore data and carry out software updates using the Lenze»Backup & Restore«tool on a Controller. Information regarding the validity The information in this documentation applies to... the Lenze "Controller-based Automation" system from release 3 onwards; Lenze Cabinet and Panel Controllers. Screenshots/application examples All screenshots in this documentation are application examples. Depending on the firmware version of the field devices and the software version of the Engineering tools installed (e.g.»plc Designer«,»Backup & Restore«), the screenshots in this documentation may deviate from the screen representation. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 5

6 1 About this documentation 1.1 Document history 1.1 Document history Version Description /2015 TD17 Update for the "Controller-based Automation" 3.10 Lenze automation system /2015 TD17 Update for the Lenze automation system "Controller-based Automation" /2014 TD17 Revision on the Lenze automation system "Controller-based Automation" /2012 TD11 Update for the Lenze automation system "Controller-based Automation" /2011 TD11 Update for the "Controller-based Automation" 3.1 Lenze automation system /2010 TD11 First edition for the Lenze automation system "Controller-based Automation" 3.x 6 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

7 1 About this documentation 1.2 Conventions used 1.2 Conventions used This documentation uses the following conventions for highlighting different types of information: Type of information Highlighting Examples/notes Spelling of numbers Decimal Normal spelling Example: 1234 Decimal separator Point The decimal point is always used. For example: Hexadecimal 0x[0... 9, A... F] Example: 0x60F4 Binary Nibble Text 0b[0, 1] Example: '0b0110' Example: '0b ' Version information Blue text colour All information that only applies to a certain controller software version or higher is identified accordingly in this documentation. Example: This function extension is available from software version V3.0! Program name» PLC Designer«... Window italics The message window... / The Options dialog box... Variable names Setting benable to TRUE... Control element bold The OK button... / The Copy command... / The Properties tab... / The Name input field... Sequence of menu commands If several commands must be used in sequence to carry out a function, the individual commands are separated by an arrow. Select File Open to... Shortcut <bold> Use <F1> to open the online help. If a key combination is required for a command, a "+" is placed between the key identifiers: With <Shift>+<ESC>... Hyperlink underlined Reference to further information: Hyperlink to further information. Icons Page reference ( 7) Reference to further information: Page number in PDF file. Step-by-step instructions Step-by-step instructions are indicated by a pictograph. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 7

8 1 About this documentation 1.3 Terminology used 1.3 Terminology used Term Controllers Engineering PC FAST Control file USB device Meaning The Controller is the central component of the Lenze automation system which controls the motion sequences by means of the operating system. The Controller communicates with the field devices via the fieldbus (inverter). The Engineering PC and the Engineering tools installed serve to configure and parameterise the system. The Engineering PC communicates with the controller via Ethernet. Ethernet specifies the software (protocols) and hardware (cables, plugs, etc.) for wired data networks. In the form of "Industrial Ethernet", the Ethernet standard is used in industrial production systems. On the basis of IEEE 802.3, standard Ethernet is specified by the Institute of Electrical and Electronics Engineers (IEEE), USA. EtherCAT (Ethernet for Controller and Automation Technology) is an Ethernetbased fieldbus system which fulfils the application profile for industrial realtime systems. EtherCAT is a registered trademark and patented technology licensed by Beckhoff Automation GmbH, Germany. Feasibly Applicable Software Toolbox (Lenze Application Software) The control file is a configuration file for the»backup & Restore«runtime. The configuration of this file is used to carry out the action on the Controller. The USB device... is the central storage medium for creating a backup/executing a restore; serves to transfer data between the Controller and the Engineering PC. 8 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

9 1 About this documentation 1.4 Definition of the notes used 1.4 Definition of the notes used The following signal words and symbols are used in this documentation to indicate dangers and important information: Safety instructions Layout of the safety instructions: Pictograph and signal word! (characterise the type and severity of danger) Note (describes the danger and gives information about how to prevent dangerous situations) Pictograph Signal word Meaning Danger! Danger of personal injury through dangerous electrical voltage Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken. Danger! Danger of personal injury through a general source of danger Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken. Stop! Danger of property damage Reference to a possible danger that may result in property damage if the corresponding measures are not taken. Application notes Pictograph Signal word Meaning Note! Important note to ensure trouble-free operation Tip! Useful tip for easy handling Reference to another document Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 9

10 2 Controller-based Automation: Central motion control 2 Controller-based Automation: Central motion control The Lenze "Controller-based Automation" system serves to create complex automation solutions with central motion control. Here, the Controller is the control centre of the system. System structure of the Controller-based Automation [2-1] Example: EtherCAT bus system with Controller 3231 C, I/O system 1000 and Servo-Inverter i Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

11 2 Controller-based Automation: Central motion control Lenze provides especially coordinated system components: Engineering software The Lenze Engineering tools on your Engineering PC (Windows operating system) serve to parameterise, configure, and diagnose the system. The Engineering PC communicates with the Controller via Ethernet. Controllers The Lenze Controller is available as Panel Controller with integrated touch display and as Cabinet Controller in control cabinet design. Cabinet Controllers provide a direct coupling of the I/O system 1000 via the integrated backplane bus. Bus systems EtherCAT is the standard "on-board" bus system of the Controller-based Automation. EtherCAT enables the control of all nodes on one common fieldbus. Optionally, CANopen, PROFIBUS and PROFINET can be used as extended topologies. The controllers c300/p300 are also provided with an "on board" CANopen interface (in addition to EtherCAT). Inverter (e.g. Servo-Inverter i700) "Application software" of the Lenze Controllers The "application software" of the Lenze Controllers enables the control and/or visualisation of motion sequences. These versions are available: "FAST Runtime": The sequence control takes place (by logically combined control signals) in the Controller. The motion control takes place in the inverter. "FAST Motion": The sequence control and the motion control take place in the controller. The inverter merely serves as actuating drive. Motion applications make special demands on the cycle time and real-time capability of the bus system between the Controller and the subordinate fieldbus nodes. This, for instance, is the case if the field devices are to move in a synchronised way or if position setpoints are to be transmitted. FAST technology modules provide for an easy development of a modular machine control in the»plc Designer«. "Visualisation": The optional visualisation of the automation system can be used separately or additionally to "FAST Runtime" or "FAST Motion". For this purpose, an external monitor panel/display can be connected to the Cabinet Controller 3231 C/3241 C. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 11

12 2 Controller-based Automation: Central motion control Fieldbus communication The Lenze controllers have different interfaces for fieldbus communication: Range Cabinet Controller Panel Controller c C 3231 C 3241 C p300 p500 Interfaces (on board) Ethernet EtherCAT 1 1) 1 1 1) 1 CANopen 1 1) - 1 1) 2) - Optional interfaces (communication cards) CANopen MC-CAN ) PROFIBUS master MC-PBM PROFIBUS slave MC-PBS PROFINET device MC-PND Ethernet MC-ETH Serial interfaces MC-ISI ) Only the master functionality is supported. 2) Up to release 3.9: "EL 100 CAN" driver / from release 3.10: "Lenze CAN driver" The Ethernet interface serves to connect the Engineering PC or to create line topologies (no integrated switch for Controller c300/p300). More information on the bus systems and configuration can be found in the operating instructions for the MC cards and the communication manuals: Controller-based Automation EtherCAT Controller-based Automation CANopen Controller-based Automation PROFIBUS Controller-based Automation PROFINET 12 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

13 3 Basic concept 3.1 What are the functions offered by»backup & Restore«? 3 Basic concept This chapter contains information on the functional principle of»backup & Restore«. 3.1 What are the functions offered by»backup & Restore«?»Backup & Restore«allows you to... create backups (saving the data of a Lenze Controller) perform restore processes (restoring the data of a Lenze Controller) install updates (updating the software version of the Lenze Controller, only available for control technology) 3.2 Storage media used The Lenze Controller manages the data bases within an internal flash memory and on the SD memory card. [3-1] Storage media used»backup & Restore«allows for saving and restoring the data of the internal flash memory and the SD card on a USB flash drive. Internal flash memory The Lenze Controllers are provided with an internal flash memory. This memory contains the operating system and the Lenze software. The Controller boots from this memory. Since this memory is fixedly installed in the device, the data stored must be saved by means of»backup & Restore«. SD card The SD card serves to save project data in the Lenze Controller.»Backup & Restore«saves the data of the SD card. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 13

14 3 Basic concept 3.2 Storage media used USB device The USB device is the central storage medium for performing backup, restore, and update processes. Note! Only use USB devices approved by Lenze. Only USB devices approved by Lenze ensure perfect functionality. Currently approved models and memory sizes can be gathered from the current Lenze sales documents. Tip! Current documentation and software updates with regard to Lenze products can be found in the download area at: 14 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

15 3 Basic concept 3.3 Differences between backup, restore, and update 3.3 Differences between backup, restore, and update The»Backup & Restore«tool enables the actions... "Backup" (saving data), "Restore" (restoring data), "Update" (software update) "Auto-restore"/"Auto-update" (optimises the performance of series commissioning) Backup What is a backup? A backup saves the whole data base of a Lenze Controller The backup saves the following permanently stored data bases of the Controller: Operating system of Software Project data A backup provides the basis for being able to carry out a restore process in the event of an error. We recommend the regular creation of backups to avoid data losses. Functional principle of a backup [3-2] Functional principle of a backup When a backup is created on the Controller, components (from the internal flash memory and the SD card) are copied to the USB flash drive. The USB device is the storage medium for the backup processes. A backup always comprises the contents of the internal flash memory and the SD card. A backup is created manually. Creating a backup ( 21) Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 15

16 3 Basic concept 3.3 Differences between backup, restore, and update Restore and auto-restore What is a restore/auto-restore? Restoring a (previously created) backup is referred to as a restore. Restore and auto-restore are identical in terms of their data contents. They merely differ with regard to their use (one-time restoration or multiple restorations of the data). Functional principle of restore and auto-restore [3-3] Functional principle of restore and auto-restore A restore writes the (previously saved) backup data from the USB device back to the internal flash memory and the SD card. In the case of a restore, first a safety backup is created, in order to be able to restore the original state in the event of an error. In the case of an auto-restore, no safety backup is performed. In the case of an auto-restore, a restore without a safety backup is performed. Differences between a restore/auto-restore Restore One-time restoration of a backup that has been configured beforehand. Select this process to restore the data bases of a backup on an individual Controller. When a restore is carried out, a safety backup is created beforehand. Auto-restore Multiple restorations of a backup on an optional number of Controllers without further configuration. When the USB device is connected to a further Controller, the auto-restore is executed automatically (series commissioning). When an auto-restore is carried out, a restore is executed directly. The system does not create a safety backup beforehand. 16 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

17 3 Basic concept 3.3 Differences between backup, restore, and update Update and auto-update What is an update / auto-update? During an update, the Lenze operating system is updated (only available for control technology). Update and auto-update are identical in terms of their data contents. Use an auto-update to carry out an update on several Controllers successively: series commissioning. Where can I receive an update and auto-update? Lenze provides software updates. Tip! Current documentation and software updates with regard to Lenze products can be found in the download area at: Functional principle of update and auto-update [3-4] Functional principle of update and auto-update»backup & Restore«updates the software of the Controller. An update transfers the data from the USB flash drive to the internal flash memory (Flash). In the case of an update first a safety backup is created, in order to be able to restore the original state in the event of an error. When an auto-update is performed, no safety backup is created. An optional number of Controllers can be provided successively with this update. Differences between an update and an auto-update Update One-time update of the Controller software Select this process in order to update the software on an individual Controller. When an update is performed, a backup is created beforehand for the purpose of safety. Auto update Multiple updates of the Controller software, on an optional number of Controllers in succession. After connecting the USB device to a further Controller, the auto-update is started automatically: series commissioning. When an auto-update is carried out, an update is executed directly. The system does not create a backup beforehand. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 17

18 3 Basic concept 3.4 Standard procedure 3.4 Standard procedure To carry out»backup & Restore«, corresponding software applications are pre-installed on the Controller. Since the Controller is available with different operating systems, different software applications are provided for the configuration. [3-5] Example: Ethernet connection between the Engineering PC and the Lenze Controller (3200 C) The following possibilities are provided to you to carry out a»backup & Restore«: Software application»backup & Restore«on the Engineering PC Operating system of Engineering PC Windows XP/7 Operating system of Controllers Windows CE/ Embedded Compact 7 Windows Embedded Standard - - [3-6] Example:»Backup & Restore«Windows 7»Backup & Restore«on the Controller - [3-7] Example:»Backup & Restore«Windows CE 18 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

19 3 Basic concept 3.4 Standard procedure Software application»webconfig«(as an alternative - for remote access via Engineering PC to a Cabinet Controller without monitor panel) Operating system of Engineering PC Windows XP/7 (via remote access to Windows CE) Operating system of Controllers Windows CE/ Embedded Compact 7 Windows Embedded Standard - - Windows Explorer (as an alternative, if no (executable) Controller is available) [3-8] Example: Windows Explorer Windows XP The»Backup & Restore«software application writes a control file to the USB device. The control file is evaluated by the system at the next restart. Then the action selected is executed. Cabinet Controllers with a DVI interface provide for the connection of an external monitor panel. The panel that can be connected optionally makes it possible to monitor the progress of the actions. The current processing state is shown via the status LEDs. Status LEDs of the Controllers ( 36) Depending on the action selected, the Controller is restarted automatically (after the process has been carried out successfully), or a signal is output and it is waited until the USB device is removed and the Controller is restarted manually. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 19

20 3 Basic concept 3.5 Signalling of the processing state 3.5 Signalling of the processing state When an error occurs, it is indicated via the Status LEDs of the Controllers ( 36) and by a text message on the screen. Signal transmitter Status LEDs on the Controller»Backup & Restore«Software application»webconfig«description The Controllers are equipped with status LEDs representing the current operating status. When a backup, restore, or update is carried out, the LEDs Error and Status 1 indicate the processing progress or a possible error status. On an optionally connected panel (screen) texts showing status and error messages can be read. The»Backup & Restore«application provides status information in the form of dialog windows. On an optionally connected panel (screen) texts showing status and error messages can be read. When an update is carried out (only available for control technology), status messages are written. The status messages can be viewed via the»webconfig«logbook function. The»WebConfig«indicates the respective status by displaying a text in the corresponding code: 20 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

21 4 Creating a backup and carrying out a restore process 4.1 Creating a backup 4 Creating a backup and carrying out a restore process The»Backup & Restore«functionality of the Controller can be executed by means of different software applications which are described in the following subchapters. A backup and restore (update) process can be carried out in the following ways: A. On the Engineering PC via...»backup & Restore«application,»WebConfig«, Windows Explorer. B. Directly on the Controller via»backup & Restore«application. 4.1 Creating a backup Note! A backup saves all data of the Controller (data of the internal flash memory and the SD card). In order to successfully create a backup, the USB device must have sufficient memory capacity. Guide values for the size of a backup file: Windows CE 6.0: 100 MB (3200 C/p500) Windows Embedded Compact 7: 200 MB (c300/p300) Windows Embedded Standard: 2 GB The free memory capacity of the USB device at least has to be half of the SD card capacity + 2 GB (guide value for Windows Embedded Standard). After having carried out the backup, remove the USB device from the Controller. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 21

22 4 Creating a backup and carrying out a restore process 4.1 Creating a backup Parts of the backup name The name of the»backup & Restore«directory is composed as follows: <prefix>_<controller>_<serial number>_<operating system>_<backup name>_<date>_<time> Element Prefix Product name Serial number Operating system of Backup name Date/time Information IPC backup for a backup IPC update for a (software) update Product name (available depending on the device) Examples: "c300", "p300" Serial number of the controller Operating system with which the backup has been created. Example: CE for Windows CE. Backup name (length: 2-16 characters) Specify a name for the backup that relates to the machine functionality, so that you can identify the backup better later on. Example: "Winder" Creation time of the backup Example: IPCBackup_ _CE_Winder_ _ Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

23 4 Creating a backup and carrying out a restore process 4.1 Creating a backup Creating a backup on the Engineering PC (recommended variant) How to carry out a backup on the Engineering PC: 1. Connect a USB device to the Engineering PC. 2. Start»Backup & Restore«on the Engineering PC. 3. Change to the Backup tab. [4-1] Example: Backup with»backup & Restore«under Windows 7 4. Select the USB flash drive. 5. Assign a backup name in the input field (length: 2-16 characters). Parts of the backup name ( 22) 6. Click the Start button. A control file is written to the USB device into the "/Backup" directory. 7. Remove the USB device from the Engineering PC. 8. Connect the USB device to the Controller of which you want to create a backup. 9. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. 10. After starting the Controller, remove the USB device from the Controller. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 23

24 4 Creating a backup and carrying out a restore process 4.1 Creating a backup Creating a backup on the Controller Note! Cabinet Controllers with a DVI interface require an external monitor panel. How to carry out a backup on the Controller: 1. Connect a USB device to the USB interface of the Controller. 2. Start»Backup & Restore«on the Controller. 3. Change to the Backup tab. [4-2] Example: Backup with»backup & Restore«under Windows CE 4. Assign a backup name in the input field (length: 2-16 characters). Parts of the backup name ( 22) 5. Click the Start button. A control file is written to the USB device into the "/Backup" directory. 6. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. 7. After starting the Controller, remove the USB device from the Controller. 24 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

25 4 Creating a backup and carrying out a restore process 4.1 Creating a backup Creating a backup using the»webconfig«tip! Use the»webconfig«for Cabinet Controllers without an external panel. Note! When the Refresh button is clicked, the values from the Controller are re-imported. When the Submit button is clicked, only the values that have changed are overwritten. How to carry out a backup using the»webconfig«: 1. Connect a USB device to the USB interface of the Controller. 2. Start the»webconfig«. 3. Navigate to the Backup Restore menu button. 4. Select the Backup menu item. [4-3] Example: Backup using the»webconfig«lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 25

26 4 Creating a backup and carrying out a restore process 4.1 Creating a backup 5. Select the main action Backup in the display area. 6. Assign a backup name in the input field (length: 2-16 characters). Parts of the backup name ( 22) 7. Select the Start Backup action and confirm this selection via the Submit button. A control file is written to the USB device. The Controller is restarted. The backup is written to the USB device. 8. After starting the Controller, remove the USB device from the Controller. 26 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

27 4 Creating a backup and carrying out a restore process 4.1 Creating a backup Creating a backup with the Windows Explorer (on the directory/file level) Note! For carrying out a backup with the Windows Explorer, only USB devices which have previously been used for a»backup & Restore«process can be used. Tip! If there is no (executable) Controller or the Controller does not start correctly, the»backup & Restore«functions can for instance be executed via the Windows Explorer. Only create a backup if the Controller is executable. How to carry out a backup using the Windows Explorer: 1. Connect a USB device to the Engineering PC. 2. Start the Windows Explorer. 3. Change to the directory [USB flash drive]:\backup\copy_backup_file. 4. Copy the Backup.xml file to the higher-level directory [USB flash drive]:\backup. Note: If there is a Restore.xml file in this directory, it has to be deleted. 5. Applies to the Controller 3200 C/p500: Copy the menu.lst file from the directory [USB flash drive]:\backup\copy_backup_file to the root directory [USB flash drive]:\. 6. Remove the USB device from the Engineering PC. 7. Connect the USB device to the Controller of which you want to create a backup. 8. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. 9. After starting the Controller, remove the USB device from the Controller. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 27

28 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore 4.2 Carrying out a restore/auto-restore Note! A restore/auto-restore can only be executed if the USB device used contains a valid backup. Creating a backup ( 21) When a restore process is carried out, a safety backup is created beforehand. When an auto-restore process is carried out, a restore is executed directly. The system does not create a safety backup beforehand. After carrying out the restore process, remove the USB device from the Controller. Only applies to Windows Embedded Standard: After a restore has been carried out, an automatic check of the file system is performed (chkdsk.exe). If you have a separate backup/update file, e.g. by reception via or download, first create the main "/Backup" directory on a USB device ([USB flash drive]:\backup). Then copy the backup/update file to the backup directory. 28 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

29 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore Carrying out a restore on the Engineering PC (recommended variant) How to carry out a restore on the Engineering PC: 1. Connect a USB device with available backups/updates to the Engineering PC. 2. Start»Backup & Restore«on the Engineering PC. 3. Change to the Restore/Update tab. [4-4] Example: Restore with»backup & Restore«under Windows 7 4. Select the USB flash drive. 5. Select the Restore action. Available backups/updates are shown. 6. Select a backup/update. 7. Click the Start button. A control file is written to the USB device. 8. Remove the USB device from the Engineering PC. 9. Connect the USB device to the Controller on which you want to carry out a restore. 10. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. The backup selected is loaded to the Controller. 11. After starting the Controller, remove the USB device from the Controller. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 29

30 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore Carrying out a restore on the Controller Note! Cabinet Controllers with a DVI interface require an external monitor panel. How to carry out a restore on the Controller: 1. Connect a USB device with available backups/updates to the Controller. 2. Start»Backup & Restore«on the Controller. 3. Change to the Restore/Update tab. [4-5] Example: Restore with»backup & Restore«under Windows CE 4. Select the Restore action. Available backups/updates are shown. 5. Select a backup/update. 6. Press Start. A control file is written to the USB device. 7. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. The backup selected is loaded to the Controller. 8. After starting the Controller, remove the USB device from the Controller. 30 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

31 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore Carrying out a restore with the»webconfig«tip! Use the»webconfig«if the Controller is not provided with a DVI interface or no monitor panel is connected. How to carry out a restore with the»webconfig«: 1. Connect a USB device with available backups/updates to the Controller. 2. Start the»webconfig«. 3. Navigate to the Backup Restore menu button. 4. Select the Restore Update menu item. 5. Select the main action Restore in the display area. [4-6] Example: Restore with the»webconfig«6. Select the desired display area of the backup/update files from the selection list. Up to ten backups are shown in the display area. Here you can select the available backups , , or Note: If more than 30 backups are available on a USB flash drive, only the first 30 backups can be selected via the»webconfig«. 7. Select a backup/update. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 31

32 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore 8. Select the Start Restore Update action and confirm this selection via the Submit button. A control file is written to the USB device. The backup selected is loaded to the Controller. (For purposes of safety, a backup is created beforehand.) After the restore, the Controller is restarted. 9. After starting the Controller, remove the USB device from the Controller. 32 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

33 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore Carrying out a restore with the Windows Explorer (on the directory/file level) If the Controller does not start anymore, it is possible to manually prepare a USB device on the Engineering PC. With the USB device prepared you can then carry out a restore on the Controller. How to carry out a restore with the Windows Explorer: 1. Connect a USB device to the Engineering PC. 2. Start the Windows Explorer. 3. Change to the directory [USB flash drive]:\backup. It includes all backups and updates available on the USB device. 4. Open the folder of the backup which is to be loaded to the Controller. The folder name corresponds to the backup file name. 5. Copy the Restore.xml file to the higher-level directory [USB flash drive]:\backup. 6. Only for the Controller 3200 C/p500: Copy the menu.lst file from the directory [USB flash drive]:\backup\copy_backup_file to the root directory [USB flash drive]:\. 7. Remove the USB device from the Engineering PC. 8. Connect the USB device to the Controller on which you want to carry out a restore. 9. Restart the Controller (with connected USB device) by mains switching. If Windows CE systems are used, the Controller is restarted automatically. The restore is carried out automatically when the Controller is restarted. 10. After starting the Controller, remove the USB device from the Controller. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 33

34 4 Creating a backup and carrying out a restore process 4.2 Carrying out a restore/auto-restore Carrying out an auto-restore Note! When an auto-restore is carried out, a restore is executed directly. The system does not create a safety backup beforehand. An auto-restore is an optimised process for carrying out series commissioning with»backup & Restore«or»WebConfig«. With an auto-restore you can automatically load identical backup data to several Controllers. Carrying out an auto-restore requires a one-time backup of the Controller the data bases of which are to be copied. Creating a backup ( 21) A USB device configured for auto-restore can afterwards be used for an optional number of autorestore processes on different Controllers. How to carry out an auto-restore: The individual steps of an auto-restore process are identical to those of a restore process. In contrast to the restore process, you have to select the Auto-restore action. Carrying out a restore on the Engineering PC (recommended variant) ( 29) Carrying out a restore on the Controller ( 30) Carrying out a restore with the»webconfig«( 31) 34 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

35 4 Creating a backup and carrying out a restore process 4.3 Carrying out an update/auto-update (only available for control technology) 4.3 Carrying out an update/auto-update (only available for control technology) Note! When an update is carried out, a safety backup is created beforehand. When an auto-update is carried out, an update is executed directly. The system does not create a safety backup beforehand. An update/auto-update can be carried out by means of»backup & Restore«,»WebConfig«, or with the Windows Explorer (on the directory/file level). A (software) update provided by Lenze has to be copied to the USB flash drive into the directory [USB flash drive]:\backup. How to carry out an update/auto-update: The individual steps of an update/auto-update are identical to those of a restore/autorestore process. In contrast to the restore/auto-restore process, you have to select the Update or Autoupdate action. Carrying out a restore on the Engineering PC (recommended variant) ( 29) Carrying out a restore on the Controller ( 30) Carrying out a restore with the»webconfig«( 31) Carrying out a restore with the Windows Explorer (on the directory/file level) ( 33) Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 35

36 5 Diagnostics 5.1 Status LEDs of the Controllers 5 Diagnostics 5.1 Status LEDs of the Controllers The Controllers are provided with LEDs which indicate the current operating status. Depending on the Controller used, the colouring of the LEDs may vary. Power: green/blue*, yellow Error: green, red Status 1: green, yellow Status 2: no function * Device-dependent LED colour: either green or blue [5-1] Example: Cabinet Controller 3200 C 36 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

37 5 Diagnostics 5.1 Status LEDs of the Controllers Status LEDs of the Controller 3200 C LED Colour 1 / colour 2 Power Green Interval is lit constant Yellow is lit constant Blinking (2.0 Hz) Green Yellow Blinking (0.5 Hz) Only for Controller 3241 C: Green Blinking (5.0 Hz) Only for Controller 3241 C: Green Yellow Blinking (5.0 Hz) Error Red Blinking (5.0 Hz) Green Red Blinking (5.0 Hz) Status 1 Green is lit constant Blinking (0.5 Hz) Green Yellow Blinking (0.5 Hz) Status 2 Meaning - - No function Starting sequence completed successfully. No error pending. Controller is switched on. Supply voltage OK. The supply voltage has not reached the minimum value (voltage failure/"powerfail") State after switch-on/restart or reset System clock is not synchronised" (missing time information). Note: If the Controller is switched off for more than two weeks, the time information set will be lost. The next starting process generates a logbook entry (power LED blinking green/blue). Set the current time manually via the»webconfig«(parameter 91). Capacitor pack (CAPS-PACK) not fully charged. The length of the dark bar indicates the charge condition: CAPS-PACK almost empty: long dark phase CAPS-PACK almost full: short dark phase Error status of the capacitor pack (CAPS-PACK) UPS function not available, possible cause: Connection to the CAPS-PACK interrupted. CAPS-PACK not connected, cable break/short circuit. Errors: Fatal error (Abort) SD card not available/not inserted correctly. No operating system licence available. Mains switching required. Controller in test mode: A problem has occurred, but the device is running. Operating status: Controller is running. PLC project is running. Starting sequence of the Controller active. PLC project (e.g. the boot project) is loaded. After being loaded successfully, the LED is lit constantly green. Or user action required: Load PLC project: PLC started, project is not running Remove USB device. Controller in test mode: SD licence card with higher "Application Credit" required. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 37

38 5 Diagnostics 5.1 Status LEDs of the Controllers Status LEDs of the Controllers c300/p300 LED Meaning Power Error Status 1 Status 2 is lit Off Off Off Supply voltage available and system clock synchronised. blue is lit blue is lit blue is lit Yellow Blinking Yellow Blinking blue/ yellow Off Blinking Red Blinking Yellow Blinking Yellow Off Off Operating system is running and the control technology (PLC project) is started. SD card not available/not inserted correctly. Off Off Off Input voltage has fallen below a minimum value (power fail). UPS function is triggered. Off Off Off State after switch-on/restart or reset Off Off Off System clock not synchronised. Off Off Off Off Reset has been triggered. Off Blinking Off Off Controller in test mode: red/green A problem has occurred, but the Controller keeps running. Off Off Blinking green/ yellow Off PLC project (e.g. the boot project) is loaded. After being loaded successfully, the LED is lit constantly green. Or user action required: Load PLC project: PLC started, project is not running Remove USB device. Controller in test mode: SD licence card with higher "Application Credit" required. 38 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

39 5 Diagnostics 5.1 Status LEDs of the Controllers Status LEDs of the Controllers p500 LED Meaning Power Error Status 1 Status 2 is lit Off Off Off Supply voltage available and system clock synchronised. blue is lit Off Off Off Input voltage has fallen below a minimum value (power fail). Yellow Blinking Off Off Off State after switch-on/restart or reset Yellow Blinking Off Off Off System clock not synchronised. blue/ yellow Off Off Off Off Reset has been triggered. Off Blinking red/green Off Off Controller in test mode: A problem has occurred, but the Controller keeps running. Off Off Blinking green/ yellow Off PLC project (e.g. the boot project) is loaded. After being loaded successfully, the LED is lit constantly green. Or user action required: Load PLC project: PLC started, project is not running Remove USB device. Controller in test mode: SD licence card with higher "Application Credit" required. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 39

40 5 Diagnostics 5.1 Status LEDs of the Controllers Specific signals during a»backup & Restore«process When a backup, restore, or update process is carried out, the Controllers display the corresponding status of the»backup & Restore«process by means of the Error and Status 1 LEDs. The status LED signalling indicates the respective status: LED Interval Meaning Colour 1 / colour 2 Error - during a»backup & Restore«Green Is lit constantly»backup & Restore«process completed, status: "Ready". Red Blinking (5.0 Hz) Green Red Blinking (5.0 Hz)»Backup & Restore«process, status: "Error". Possible causes: Fatal error (Abort) SD card not available/not inserted in the slot correctly Mains switching required Status 1 ("busy") -during a»backup & Restore«Green Blinking (0.5 Hz)»Backup & Restore«process active. Green Yellow Blinking (0.5 Hz) PLC project (e.g. the boot project) is loaded. After being loaded successfully, the LED is lit constantly green. Or user action required: Remove USB device. 40 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

41 5 Diagnostics 5.2 Text outputs (optional panel/screen required) 5.2 Text outputs (optional panel/screen required) While the actions are processed, the software outputs some information in the form of text messages and progress bars (requires optional panel/screen). The backup and restore processes involve several successive steps. A sequence step can only be executed if the previous step has been successful. In order to be able to trace the processing order of the individual steps, messages are output during the entire processing procedure. The respective message indicates the processing step which has been passed through Error messages for the execution of a backup or restore While the backup/restore is processed, the following error messages may occur: Backup Restore Processing order Error messages Processing order Error messages Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 41

42 5 Diagnostics 5.2 Text outputs (optional panel/screen required) Error message E0 Failed to initialize hardware modules E1 E2 E3 E4 E5 E6 E7 ERROR: No Backup and Restore device found! ERROR: CONTROL FILE MISSING OR CORRUPT! No changes applied! ERROR: The target drive is the Backup device! No hard disk found. ERROR: No internal storage device detected! The system is unchanged! ERROR: No operating system found for backup! The backup was aborted! No data was saved! Error: Not enough disk space on Backup device! The backup was aborted! No data was saved! Error: No storage device for user data for backup found! The backup is aborted! No data was saved! Information / remedy An attempt is made to carry out a backup or restore on an unknown device. Use the approved Lenze hardware for carrying out the»backup & Restore«processes. The USB device inserted does not contain a valid data structure. Prepare the USB device with the»backup & Restore«software application. Creating a backup ( 21) The USB device inserted does not contain a valid control file. Prepare the USB device with the»backup & Restore«software application. Creating a backup ( 21) Access to the internal storage medium is not possible. The hardware is damaged! Contact the Lenze support. Access to the internal storage medium is not possible. The hardware is damaged! Contact the Lenze support. No valid operating system was found on the device, or the system is damaged. Execute a restore. Carrying out a restore/auto-restore ( 28) If it fails, contact the Lenze support. The USB device does not provide enough space to save the system. Use a USB device with a greater storage capacity, or remove the data that are not needed from the USB device. The SD card has been removed. No backup has been carried out. Remove the USB device Insert another SD card Restart the device Create a backup Creating a backup ( 21) E8 User data device is empty! The SD card does not contain data. E9 ERROR: Windows did not shutdown properly. Please reboot Windows and correct any consistency of the filesystem The file system is damaged. Windows has to be started and an error check of the file system has to be carried out while the write filter is switched off. E10 E11 E12 E13 ERROR: Backup of the Windows filesystem failed! backup aborted! No Data was saved! ERROR: No storage device for user data found! No changes applied! ERROR: CPU module incompatible with software version! No changes applied! Error: Not enough disk space on target device! Errors have occurred during the backup of Windows Embedded Standard. No backup was carried out. Try again to create a backup. If this attempt fails, contact the Lenze support. The SD card was removed. Insert another SD card. The backup selected is not compatible with the hardware used. Use a backup compatible with the hardware. The processor type must comply with the one installed in the system. The data stored do not fit on the SD card. Use an SD card with sufficient storage capacity. 42 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

43 5 Diagnostics 5.2 Text outputs (optional panel/screen required) Error message E14 ERROR: Storage capacity of the selected backup is too small. Invalid backup! E15 ERROR: The size of the target device is too small. Backup exceeds storage capacity of target device! Information / remedy The control file does not match the backup, or the backup was manipulated. Only use backups that are consistent in themselves. The backup originates from a greater storage medium. Contact the Lenze support. Log file Then the text messages are stored on the USB device in a log file: [USB flash drive]:\backup\log.txt Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 43

44 5 Diagnostics 5.2 Text outputs (optional panel/screen required) Error messages for the execution of an update When an update is executed, there is the following processing order: 44 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

45 5 Diagnostics 5.2 Text outputs (optional panel/screen required) During an update the following error messages may occur: Error message E1 System version is identical to the selected update package. No action necessary. Remedy The software version of the Controller is already up to date (version identical to that of the update). Remove the USB device from the Controller. No further action required. E2 No Backup package found Errors have occurred during the creation of the backup. The update process cannot be continued. Check messages in the file [USB flash drive]\backup\log.txt. Eliminate error. Restart update process. E3 E4 E5 Migration finished successfully. Update finished with <<1>> errors. Please restore your previous Backup. Migration failed. The system is corrupt! Please restore your previous Backup. Migration failed. The system is unchanged! The migration of the databases has been carried out successfully, but the installation of the update has failed. Try the following: Configure USB device for a restore. Execute restore. (Like this your system is reset to the original state.) Carrying out a restore/auto-restore ( 28) Repeat update process. Carrying out an update/auto-update (only available for control technology) ( 35) Update of the data has failed. Configure USB device for a restore. Execute restore. (Like this your system is reset to the original state.) Carrying out a restore/auto-restore ( 28) Repeat update process. Carrying out an update/auto-update (only available for control technology) ( 35) The attempt to carry out modifications has been made in the temporary directory, so that no changes have been made to the system. Try to import the update again. The error messages can be viewed via the»webconfig«in the Logbook section. Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 45

46 5 Diagnostics 5.3 Fault: Controller c300/p300 does not start 5.3 Fault: Controller c300/p300 does not start If Controller c300 or p300 does not start, you can activate the Lenze standard settings with the Reset button. How to activate the Lenze standard settings: 1. Switch off voltage supply. 2. Press Reset button. 3. Switch on the voltage supply while the Reset button is pressed and keep the Reset button pressed for at least 10 s. If the Error-LED (green/red) blinks after this action has been executed, manual mains switching is required. The Controller must be disconnected from the mains until all LEDs have gone off. 46 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17

47 Index A Activating the Lenze standard settings (Reset button) 46 Activating the standard settings (Reset button) 46 Application notes 9 Application software of the Lenze Controllers 11 Auto update 17 Auto-restore 16 B Backup 15 Backup/restore error messages 41 Basic concept of»backup & Restore«13 C Carrying out a restore on the Controller 30 Carrying out a restore on the Engineering PC 29 Carrying out a restore with the»webconfig«31 Carrying out a restore with the Windows Explorer 33 Carrying out a restore/auto-restore 28 Carrying out an auto-restore 28, 34 Carrying out an auto-update 35 Carrying out an update/auto-update 35 Carrying out the restore 21 Controller c300/p300 does not start (fault) 46 Creating a backup 21 Creating a backup on the Controller 24 Creating a backup on the Engineering PC (recommended variant) 23 Creating a backup using the»webconfig«25 Creating a backup with the Windows Explorer 27 D Diagnostics 36 Differences between a restore/auto-restore 16 Differences between an update and an auto-update 17 Differences between backup, restore, and update 15 E to Lenze 48 Error messages for the execution of a backup or restore 41 Error messages for the execution of an update 44 I Interfaces for fieldbus communication 12 L Layout of the safety instructions 9 LEDs of the Controller 3200 C 37 LEDs of the Controllers 36 LEDs of the Controllers c300/p LEDs of the Controllers p Log file 43 P Processing state 20 R Reset button 46 Restore and auto-restore 16 S Safety instructions 9 Screenshots 5 Signalling of the processing state 20 Standard procedure 18 Status LEDs of the Controller 3200 C 37 Status LEDs of the Controllers 36 Status LEDs of the Controllers c300/p Storage media 13 Internal flash memory 13 SD card 13 USB device 14 System structure of Controller-based Automation 10 T Target group 5 Terminology used 8 Troubleshooting 36 U Update and auto-update 17 Update error messages 44 F Fault: Controller c300/p300 does not start 46 Feedback to Lenze 48 Fieldbus communication (interfaces) 12 Functional range of»backup & Restore«13 Lenze Backup & Restore Software Manual DMS 1.5 EN 05/2015 TD17 47

48 Your opinion is important to us These instructions were created to the best of our knowledge and belief to give you the best possible support for handling our product. Perhaps we have not succeeded in achieving this objective in every respect. If you have suggestions for improvement, please us to: Thank you very much for your support. Your Lenze documentation team 48

49 Backup & Restore Software Manual SHPSTV3BCKNRST DMS 1.5 EN 05/2015 TD17 Lenze Automation GmbH Postfach , D Hameln Hans-Lenze-Straße 1, D Aerzen Germany Service Lenze Service GmbH Breslauer Straße 3, D Extertal Germany (24 h helpline) [email protected] L