Rocky Restoration - 20110522

Rocky Restore DVD
Procedure
For New or Existing Rocky Computers on Shovels and
Draglines
22 May 2011
This procedure covers the steps to use Maintenance Station Restore

DVD to update the software installation on a Rocky MT7 or MT8
computer.
WARNING:
These steps will overwrite existing data on the Rocky hard
drive.
SAFETY NOTICE:
WHILE WORKING ON THIS EQUIPMENT / PROJECT, ALL SAFETY
REGULATIONS INCLUDING LOCK OUT / TAG OUT REQUIREMENTS
MUST BE FOLLOWED.
© Siemens Energy & Automation 2011. All Rights Reserved. For Internal Use Only.
Procedure | Rocky Restore DVD | 22 May 2011 2
Contents
1. Requirements ......................................................................... 3
1.1. Hardware .................................................................................3
1.2. Software ..................................................................................3
2. Preparation ............................................................................. 4
2.1. DVD Verification ......................................................................4
2.2. USB Check................................................................................5
2.3. Data Backup.............................................................................5
2.4. Windows License Key...............................................................6
2.5. Step7 and WinCC License Keys.................................................7
3. Installation ............................................................................10
3.1. BIOS Setup .............................................................................10
3.2. Restore DVD ...........................................................................13
3.3. Windows Setup ......................................................................15
3.4. Windows First Boot ................................................................19
3.5. Windows Activation ...............................................................22
3.6. Backup Drive Setup................................................................24
3.7. Secondary Language Option..................................................27
3.8. Restore Step7 and WinCC Licenses ........................................29
3.9. Touchscreen Driver Selection ................................................30
Abbreviations..................................................................................... 34
1. Requirements
The following items are needed to successfully complete this procedure. Please check to ensure
they are available before proceeding further. With exception of the Restore DVD, these items were
previously shipped with the shovel / dragline and should be in possession of the end customer at the
mine site.
It is critical that the hard drive is installed in the Rocky computer in which it will be used for
hardware detection to be successfully performed.
1.1. Hardware
DVD Drive installed in Rocky Computer
NOTE: Upgrade required for older Rocky computers which only have a CD drive
Rocky MT7 Computer with 8GB or 16GB Hard Drive
Rocky MT8 Computer with 32GB Hard Drive
USB Flash Drive
1.2. Software
Siemens Maintenance Station Restore DVD
Symantec pcAnywhere CD (if applicable)
Windows XP Label on Rocky Computer
Step7 v5.4 (or greater) Flash Drive, Floppy Disk, or Product Box with License #
NOTE: Upgrade required for existing Step 7 v5.3 licenses
WinCC v6.0 (or greater) Flash Drive, Floppy Disk, or Product Box with License #
NOTE: GTO Shovel Type A Retrofit requires WinCC v7.0 license
2. Preparation
Please perform the following steps to ensure a successful installation.
2.1. DVD Verification

Each DVD is typically stamped with a Serial Number that corresponds to the specific Shovel
or Dragline for which it has been created.
In some cases, e.g. due to upgrading hardware, the original DVD may no longer match the
system configuration.
To verify the configuration for a 495 Shovel, please refer to the following diagram:
To verify the configuration for a Dragline or Level 2 Retrofit Shovel, please refer to the
following diagrams:
2.2. USB Check

Before copying any files to USB flash drive, check to ensure the USB port voltage is
approximately 5V.
A USB cable (red and black wires) and voltmeter can be used for this test as shown in the
picture below. With the multimeter in DC voltage mode, measure the voltage of the USB
port you will be using.
5.03V – Good Reading 7.78V – Bad Reading
If the voltage reading is greater than 5.25V (see example above) on one of the ports labeled
USB or Mouse, this most likely indicates a problem with the USB 4-port hub. Please contact
your local service personnel to obtain an RMA replacement through Siemens. You can still
complete the file transfer by using the port labeled Keyboard (which is directly connected
to the Rocky) after verifying that the voltage on this port is between 4.75V and 5.25V.
2.3. Data Backup

All files on the C drive will be erased once imaging has begun with the Restore DVD. (If the
Restore DVD was previously used to create two partitions, the contents of the D drive will
not be overwritten.)
It is the responsibility of the user to copy any important files from the hard drive before
using the Restore DVD.
Suggested folders to copy to flash drive include the following:
C:\Logs
C:\Siemens\FaultHistory
C:\Trace
C:\Documents and Settings\All Users\Documents\Rockwell Automation\Activations
Suggested files to copy to flash drive include the following:
C:\DisConfig.txt
C:\MidasIni.txt
C:\Program Files\RockySimaticServer\simatic_com_init.txt
2.4. Windows License Key

The Windows Product Key is a 25-digit combination of letters and numbers found on a label
located on the bottom of the Rocky computer.
The Windows Product Key is unique for each Rocky computer. To gain access to view this
label, please follow “FSA: SE&A_005 Drive Control PLC Cards Removal Procedure”.
Windows Product Key
2.5. Step7 and WinCC License Keys

Each Shovel ships with a unique Step 7 License Key and a unique WinCC License Key. These
two License Key numbers are present in three locations:
(1) The Product Box
(2) The License Media
(3) The License File
The Product Box contains the License Key number on the front cover as shown.
Product Box Cover
The License Media format may be either a USB Flash Drive or a Floppy Disk.
License Media: USB Flash Drive License Media: Floppy Disk
The License Media format is based on the software version.

Step7 WinCC
v5.3 v5.4+ v6.0 v6.2+
Format
USB USB
Media
Floppy Floppy
Flash Flash
Disk Disk
Drive Drive
License Media Format
The License Media are labeled with the License Key numbers as shown. There may be two
floppy disks. Please locate the disk labeled Single License, not Emergency License.
License Key: USB Flash Drive License Key: Floppy Disk
The Siemens Step 7 and WinCC license files may be stored on the hard drive of the Shovel /
Dragline or on the original License Media.
If the license files cannot be located, they may be recoverable from the original license keys
by contacting the Siemens Automation Support Hotline.
To check if licenses are present on the hard drive of the Shovel / Dragline, open the
Automation License Manager shortcut on the Windows Desktop.
Select Local Disk (C:), highlight all the license keys, then right click and select Transfer.
(Note that several keys may exist, but the keys labeled WinCC RT and STEP 7 are the only
ones required to use the Siemens HMI and PLC programs, respectively.)
Select LICENSE_KEY (F:), or whichever drive corresponds to the removable Siemens USB
memory stick and click OK
Right click Safely Remove Hardware and choose Safely remove USB Mass Storage Device
When the Safe to Remove Hardware message appears, unplug the Memory Stick
3. Installation
Verify Preparation steps have been completed before proceeding. The following Installation steps
will overwrite data on the Rocky hard drive.
3.1. BIOS Setup

All of the Rocky MT8 computers should be setup by default to boot from CD/DVD.
Some of the Rocky MT7 computers may not be setup by default to boot from CD/DVD.
The remainder of this section applies to the Rocky MT7 computers (but may be used to
verify the Rocky MT8 computers).
Restart the computer and press F2 to enter Setup
When the BIOS Setup Utility sceen appears press the right arrow key to select the Boot page
Press the down arrow key until CD-ROM Drive is highlighted, then press the plus key to
move it to the top of the list
Press the right arrow key to select the Exit page then verify Exit Saving Changes is
selected and press Enter
Verify Yes is selected and press Enter
3.2. Restore DVD

Insert the appropriate Restore DVD into the Rocky computer CD/DVD drive
Restart the computer to boot from the Restore DVD
When the “twin penguins” Clonezilla screen appears, press Enter to accept the default
selection of clonezilla live with img
After hardware checks are complete, a Select mode install screen will appear.
Click Ok or press Enter to continue
Verify that the RESTORE DVD – SOFTWARE CHECKLIST items have been completed.
If so, then yes and press Enter to continue.
A progress bar will be shown while the Restore DVD is loading the image to the hard drive.
Once completed, the computer will automatically reboot and the disc will be ejected.
At this point, it is critical that the hard drive is installed on the actual Rocky computer before
it reboots into Windows Setup.
3.3. Windows Setup

After this, an initial Windows setup screen will appear. This may remain for several minutes.
This is followed by another Windows XP Setup screen which will appear for a shorter time.
Finally, the first Setup screen will appear. Click Next.
To proceed, you must select I accept this agreement and click Next.
Enter the 25-digit Product Key from the label on the Rocky and click Next. If not readily
available, click Next and click No. There is a 30-day grace period to enter this later.
Enter the correct Date & Time and select the appropriate Time Zone, then click Next.
A Networking Settings progress window will display momentarily.
The last Setup window will display progress Performing Final Tasks.
After these tasks are completed, the computer will reboot.
3.4. Windows First Boot

A startup script will run on the first boot into Windows. Please allow several minutes for this
to complete.
Rocky MT8 Computers

At the Terminal bus selection window, select Realtek RTL8168/8111 and click OK.
Rocky MT8 Computers

Click Yes, when prompted to re-initialize communication.
Rocky MT7 Computers

At the Install/Remove Interfaces window, select TCP/IP -> Realtek RTL8139 Family… and
click Close.
Rocky MT8 Computers

At the Install/Remove Interfaces window, select TCP/IP -> Realtek RTL8168/8111 and click
Close.
Rocky MT7 Computers

At the Set PG/PC Interface window, leave selected TCP/IP -> Realtek RTL8168/8111 and click
OK.
Rocky MT8 Computers

At the Set PG/PC Interface window, leave selected TCP/IP -> Realtek RTL8168/8111 and click
OK.
3.5. Windows Activation

Click Start -> Activate Windows
If prompted, enter the 25-digit Product Key from the label on the Rocky and click Update
Select Yes, I want to telephone a customer service representative and click Next
Call 888-571-2048 with the Installation ID

Enter the Confirmation ID provided and click Next
Click Finish
3.6. Backup Drive Setup

Open My Computer and double click on Local Disk (D:)
If this is the first time a Restore DVD has been used with this hard drive, the following
prompt will appear. Click Yes to format now.
(If applicable) Select Quick Format and click Start.
(If applicable) Click OK to confirm format.
(If applicable) Click OK to acknowledge format is complete.
(If applicable) Click Close to exit the format dialog box.
Double click on Local Disk (D:) then right click and choose New -> Folder
Name the folder Backup and create sub folders D:\Backup\HMI, D:\Backup\PLC,
D:\Backup\SIBAS, D:\Backup\HTML
For Retrofit Shovels with Allen Bradley PLCs also create D:\Backup\Rockwell
Place the latest machine-specific program files in these folders
3.7. Secondary Language Option

If a Secondary Language Option has been purchased, open Windows Explorer and copy the
self-extracting .zip file to D:\Backup\HTML
Double click the secondary language self-extracting .zip file and click Unzip
Once complete, click OK then click Close
If the secondary language is Chinese or Russian, click Start -> Settings -> Control Panel
Double click Regional and Language Settings
Select the Languages tab and verify that both boxes are checked for East Asian languages
and complex script and right-to-left languages
Select Chinese (PRC) or Russian as appropriate -- all other languages leave the default value
of English (United States) selected
3.8. Restore Step7 and WinCC Licenses

Select LICENSE_KEY (F:), or whichever drive corresponds to the removable Siemens USB
memory stick, highlight all the license keys, then right click and select Transfer.
(Note that several keys may exist, but the keys labeled WinCC RT and STEP 7 are the only
ones required to use the Siemens HMI and PLC programs, respectively.)
Select the Backup partition Local Disk (D:), and click OK

(This is critical to ensure the licenses are not overwritten by future use of the Restore DVD.)
Right click Safely Remove Hardware and choose Safely remove USB Mass Storage Device
When the Safe to Remove Hardware message appears, unplug the Memory Stick
3.9. Touchscreen Driver Selection

If the touch screen is not responsive, this most likely indicates the driver currently selected
does not match your touch screen or somehow the wrong COM port has been selected.
Click Start -> Programs -> UPDD -> Settings to open the touch screen driver utility
Draglines and 495 Shovels use COM2
Retrofit Shovels with the 4-port PCMCIA serial card use COM3
The newest Vartech monitors use the Hampshire Touch, TSHARC-12/10 driver
Previous generation GE Fanuc monitors use the Elo, E281A-4002 Intellitouch driver
The existing driver is shown at the top left hand corner of the screen. To change the driver,
click Remove this device
Click Yes to confirm removal
Click Add a new device
Select the appropriate Device setup and serial port, then click OK
(Example: Dragline / 495 Shovel with Vartech Monitor)
Click Calibrate
Follow the onscreen calibration instructions
Finally, click Close
Abbreviations
BIOS Basic Input Output System
DMI Desktop Management Interface
CD Compact Disc
DVD Digital Versatile Disc
HDD Hard Disk Drive
HMI Human Machine Interface
L2R Level 2 Retrofit
MT7 Amrel Rocky Mobile Computer, MT786EX version
MT8 Amrel Rocky Mobile Computer, MT886EX version
NIC Network Interface Card
PLC Programmable Logic Controller
Rocky Rugged Industrial Laptop Computer used in Shovel
Step7 Siemens PLC Software
USB Universal Serial Bus
WinCC Siemens HMI Software
www.siemens.com Siemens Industry, Inc.
All rights reserved. All trademarks used Industry Solutions Division

are owned by Siemens or their respective owners. 100 Technology Drive
Alpharetta, GA 30005
© Siemens Industry, Inc. 2011

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Rocky Restore DVD

This procedure covers the steps to use Maintenance Station Restore

1.1. Hardware .................................................................................3

1.2. Software ..................................................................................3

2.1. DVD Verification ......................................................................4

2.2. USB Check................................................................................5

2.3. Data Backup.............................................................................5

2.4. Windows License Key...............................................................6

2.5. Step7 and WinCC License Keys.................................................7

3.1. BIOS Setup .............................................................................10

3.2. Restore DVD ...........................................................................13

3.3. Windows Setup ......................................................................15

3.4. Windows First Boot ................................................................19

3.5. Windows Activation ...............................................................22

3.6. Backup Drive Setup................................................................24

3.7. Secondary Language Option..................................................27

3.8. Restore Step7 and WinCC Licenses ........................................29

3.9. Touchscreen Driver Selection ................................................30

Please perform the following steps to ensure a successful installation.

2.1. DVD Verification

2.2. USB Check

5.03V – Good Reading 7.78V – Bad Reading

2.3. Data Backup

2.4. Windows License Key

Windows Product Key

2.5. Step7 and WinCC License Keys

Product Box Cover

License Media: USB Flash Drive License Media: Floppy Disk

 The License Media format is based on the software version.

License Key: USB Flash Drive License Key: Floppy Disk

3.1. BIOS Setup

 Verify Yes is selected and press Enter

3.2. Restore DVD

 If so, then yes and press Enter to continue.

3.3. Windows Setup

 Finally, the first Setup screen will appear. Click Next.

 A Networking Settings progress window will display momentarily.

3.4. Windows First Boot

 Rocky MT8 Computers

 Rocky MT8 Computers

 Rocky MT7 Computers

 Rocky MT8 Computers

 Rocky MT7 Computers

 Rocky MT8 Computers

3.5. Windows Activation

 Call 888-571-2048 with the Installation ID

3.6. Backup Drive Setup

 (If applicable) Select Quick Format and click Start.

 (If applicable) Click OK to confirm format.

 (If applicable) Click OK to acknowledge format is complete.

 (If applicable) Click Close to exit the format dialog box.

3.7. Secondary Language Option

 Once complete, click OK then click Close

3.8. Restore Step7 and WinCC Licenses

 Select the Backup partition Local Disk (D:), and click OK

3.9. Touchscreen Driver Selection

 Click Yes to confirm removal

 Click Add a new device

 Follow the onscreen calibration instructions

 Finally, click Close

BIOS Basic Input Output System

DMI Desktop Management Interface

DVD Digital Versatile Disc

HDD Hard Disk Drive

The License Media format is based on the software version.

Verify Yes is selected and press Enter

If so, then yes and press Enter to continue.

Finally, the first Setup screen will appear. Click Next.

A Networking Settings progress window will display momentarily.

Rocky MT8 Computers

Rocky MT8 Computers

Rocky MT7 Computers

Rocky MT8 Computers

Rocky MT7 Computers

Rocky MT8 Computers

Call 888-571-2048 with the Installation ID

(If applicable) Select Quick Format and click Start.

(If applicable) Click OK to confirm format.

(If applicable) Click OK to acknowledge format is complete.

(If applicable) Click Close to exit the format dialog box.

Once complete, click OK then click Close

Select the Backup partition Local Disk (D:), and click OK

Click Yes to confirm removal

Click Add a new device

Follow the onscreen calibration instructions

Finally, click Close