Abstract: This paper first introduces the purpose and significance of upgrading an existing MasterPiece 200/1 to an Advant Controller 450 system. Then, it analyzes the hardware and software aspects separately, demonstrating the differences and similarities between the two and the specific upgrade steps through charts, concrete examples, etc., laying a good foundation for future system upgrades. Keywords: MasterPiece 200/1; Advant Controller 450; upgrade [b][align=center]The software and hardware configuration from MP200 to AC450 ZhouLiPing WangFeng[/align][/b] The 200/1 series PLC system has been in use for nearly ten years. Related spare parts are no longer produced, are difficult to purchase, and are expensive. In addition, the program has been modified and functions added over the years, resulting in a larger data volume than before. Furthermore, the workshop's speed increase of the rolling mill has greatly increased the load on the entire system, pushing it close to its limit and affecting the stable operation of the system. Taking all factors into consideration, it was decided to upgrade some of the original PLCs. This will allow some old templates to be replaced and used as spare parts. On the other hand, it will allow for advance preparation, testing the effectiveness of the upgrade, and accumulating relevant knowledge and practical experience for future large-scale upgrades and renovations. In general, the upgrade from MP200 to AC450 can be a smooth transition. However, they are not the same system and each has its own characteristics. For the network structure, no major changes are needed; simply replace the original PLC nodes with new ones. Of course, the network and node numbers must match the original network. The network diagram is shown in Figure 1 (with terminating resistors at both ends). The original system used a bus Ethernet connection with coaxial cable, while the upgraded system uses a star topology with twisted-pair and fiber optic connections to the switches. The latter offers more flexible control, faster network fault diagnosis and troubleshooting, and easier maintenance. [align=center] Figure 1 Network Diagram[/align] AC450 is the successor to the MP200 system, with increased storage capacity, faster CPU processing speed, enhanced system functionality, and mostly backward compatible. We will analyze the differences between the two from both hardware and software perspectives below. 1. From a hardware perspective, the main differences are as follows: 1) The AC450 rack has a different height, 435mm. 2) The MP200 can be placed in the same rack as the S100 module, but the AC450 CPU cannot. 3) The AC450 system software is on the program template, not the PROM template. 4) The S100 I/O and S400 I/O can still be used, and the fan unit can also be retained. 5) The communication template DSCS140 is replaced by the template CS513, and the connection unit DSTC190 is no longer needed. 6) The communication template DSCS131 is replaced by the template CI570, and the connection unit DSTC408 is replaced by the modem TC560. 7) DSBC172 and DSBC173 are replaced by DSBC173A. 8) The AI, AO, DI, and DO templates can still be used. 9) The DSSA160 and DSSA165 power supply units and their connection boards can still be used, but they must meet the load requirements of the new system. 10) The DSSR122 power conversion unit is replaced by the SR511. 11) The DSSB120 backup battery unit is replaced by the SB510 for AC or the SB511 for DC. The SB520 battery unit must be used. For the power supply unit, based on the principle of making full use of existing resources, we generally do the following: Since the S100 module cannot be placed on the same rack as the AC450 CPU, we use a new power supply on the CPU-dedicated rack, while the signal modules of the old system are still powered by the original power supply unit. In this way, the original power supply unit is put back into use, and the load is reduced compared to the original. The combination of the new and old systems makes full use of resources and achieves good results. The specific power supply method is shown in Figure 2 below: [align=center] Figure 2 Power System[/align] For a single AC450 CPU module, the extension distance of the S100 I/O bus extension cable does not exceed 12M. It can carry up to 5 I/O sub-modules, and the original sub-modules of MP200/1 can continue to be used; however, the AC450 CPU module cannot carry I/O sub-modules. They are connected through communication modules. The communication module on the AC450 CPU is CI540, and the modem is TC560 and TC561, while the communication module on the sub-module is DSBC173A, and the connection unit is TK575. As shown in Figure 3 below: [align=center] Figure 3[/align] 2. Software Processing From a software perspective, the original application software of the MP200/1 system can be converted to source code for use by the AC450. The biggest difference between MP200/1 and AC450 in application software is that in the AC450, all submodules must be configured in the database. That is, all submodules (except for CS513 and MB510, which can be automatically configured by the system) must have a corresponding database element created and configured by the user. Each hardware module database element contains address terminals BUS, STATION, and POSITION (or POS_I) to precisely specify a unique hardware module. We will briefly describe the application software to source code conversion process below: 1) Upload the database source code in MP200/1 using the DUBDS command. 2) Upload the PC program source code in MP200/1 using the DUPCS command. 3) Upload all DB and PC application programs and the contents of the backup area of ​​the USER directory in MP200/1 using the DUAP command. 4) Start the AC450 and set the CPU boot mode to "CLEAR". 5) Recalibrate the AC450's database area using the DIMDB command. 6) Download the database source code using the TRDBS command. 7) Create the necessary DB elements for the submodules (AC450, CI531, CI540, CI570...) using the CRDB command and configure them correctly. 8) Recalibrate the AC450's PC area using the DIMPC command. 9) Download the PC program source code using the TRPCS command. 10) Start the system using the DICONFIG command. 11) Check if all templates are in the correct working state; this can often be visually determined by the indicator lights on the front panel. 12) Exit the configuration mode and unlock the PC program. 13) Verify that the system functions correctly. 14) Back up the new system using the DUAP command. Editing the uploaded source code: Generally, it's unnecessary to edit the uploaded source code. However, if necessary, you can modify it using the AMIS editor in the AS100 series. Upload PC program source code using the DUPCS command: We can use HELP DUPCS to view the specific usage of the DUPCS command, and the number of PC programs in the original system can be listed using the LSS command. 3. Merging two MP200/1 systems into one AC450 system: If the relevant conditions are met, merging two MP200/1 systems into one AC450 system is possible. Of course, the total capacity of the two MP200/1 systems should not exceed the load of the AC450 system. First, we should ask the following questions: 1) Does the total number of I/O sub-modules exceed 5? 2) Is the S100 I/O bus expansion cable within 12 meters? 3) Do the total number of signals, board channels, DATs, MOTCONs, etc., exceed the capacity of the AC450 system? 4) Does the AC450 system's memory meet the program requirements? 5) Does the AC450 system's CPU meet the program requirements? Of course, the more complex aspect is the merging of PCs and DBs. If two MP200/1 systems are merged, the PCs and DBs in one of the systems must be modified because they contain a large number of duplicate names and codes. Taking the PC source code as an example: If System 1 has PC1 to PC5, and System 2 has PC1 to PC3, a simple method is to change System 2's PC1 to PC3 to PC6 to PC8. The changes to the database (DB) are also significant, as illustrated in Figure 4 below: [align=center] Figure 4: Example of merging database signals[/align] In summary, upgrading from MP200 to AC450 is a complex system engineering project. We need to address both hardware and software aspects, taking a comprehensive approach and making overall arrangements, paying attention to even the smallest technical details. There is still a lot of meticulous and complex follow-up work to be done, ensuring a solid and reliable foundation for the upgrade. At the same time, we need to practice extensively in actual operation, constantly identifying and solving problems to ensure a smooth transition of the system to the AC450 system. Through the joint efforts of all parties and collaborative work, we have completed this project, laying a solid foundation for future system upgrades.