2. Upgrading a Premium PLC from PL7 to Unity

Premium Operating System
Upgrade and Update procedure
03/2011 eng
Edition V0.3
wwww.schneider-electric.com
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Why this Documentation?
Subject of this
Chapter
This user’s guide explains how to upgrade Premium PLC’s Operating System
but also the firmware of Ethernet modules
Premium PLC’s
3 Upgrade a PLC from PL7 to Unity
3 Update a PLC from Unity to Unity
3 Update Premium ETY modules and embedded Ethernet modules
3 Restore PL7 on a Unity processor
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Summary
1. Prepare a Premium update .......................................................................................................4
2. Upgrading a Premium PLC from PL7 to Unity ......................................................................7
3. Updating a Premium PLC from Unity to Unity ....................................................................17
4. Updating Premium PLC with an Ethernet Port ...................................................................24
5. Updating Premium PLC with an Ethernet or Hot Standby Co-Processor.........................26
6. Updating Hot Standby Premium PLC ..................................................................................28
7. Restoring a Premium PLC from Unity to PL7......................................................................30
Appendix 1 : ETY Module Upgrade Procedure.......................................................................41
Appendix 2: Premium Ethernet or Hot Standby CoProcessor Upgrade Procedure ..........53
Appendix 3 : FactoryCast ETY 510 Module Upgrade Procedure..........................................60
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1. Prepare a Premium update
Object of this
Chapter
This chapter describes how to prepare a Premium PLC in order to update or
upgrade PLC’s Operating System and / or Ethernet modules.
Prerequisites
This update requires a PC with Unity installed and the binary file containing
the OS firmware to download.
Software
The following software are required :
3 Unity Pro V2.0 mini must be installed on the PC (note that is not
necessary to launch Unity for an OS upgrade).
3 Unity Pro V4.0 mini for upgrading Hot Standby processors .
3 The CD “Unity OS firmware” provided with Unity Pro <=V4.0 and
that contains all the OS for Quantum and Premium PLC’s or only the
specific OS file for your PLC you previously have downloaded from
the Schneider web site http://www.schneider-electric.com.
3 For Unity >V4.0 , CD with OS is no more supplied in Unity Pro
package so you must get the eCD “Unity OS firmware” on
http://www.schneider-electric.com. it contains all the OS for
Quantum, Premium and M340 PLC’s. Last versions of eCDOS are
provided separately, please consult “eCDOS Premium”
3 The OS Loader (installed with Unity Pro). This tool allows the user to
download PLC’s Operating System and Ethernet modules firmware.
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Connecting the
PC to the PLC
to update an
Ethernet
module
Although Ethernet allows a remote access via the network and then the
upload / download procedure, we strongly recommend installing the
processor with the embedded Ethernet module in a system consisting of only
the CPU, Power Supply and Rack. Once done,
3 Configure the PLC system with an empty program containing only the
ETY IP address configuration. Note that the ETY module must be on
the same logical Ethernet network than the PC with the OS loader (for
that both IP address, Subnet mask and default gateway must be
compatible)
3 If the PLC system has no configuration you can also connect the PC
to the Ethernet module like this :
- Use 85.16. XXX.YYY as Ethernet IP address for the module .XXX
and YYY are the two last terms of MAC address converted in
decimal. Mask is 255.255.255.0
- Use 85.16.XXX.zzz for PC local IP address with the same mask.
3 Ensure the only devices connected to the Ethernet network are the PC
running the OS loader and the ETY module
3 The CPU must be in Stop mode and the ETY module must have no
TCP traffic.
The physical connection between the PC running the OS loader and the ETY
module can be performed :
3 by connecting directly a “crossed” Ethernet cable between the PC and
the ETY module
3 by connecting the PC and the ETY module with two “non crossed”
Ethernet cables via a Hub
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Connecting the
PC to the PLC
for an OS
update
Two possibilities can be proposed to connect the PC to the PLC :
1) Using the RS232 COM port of the PC by connecting the cable
TSXPCX1031 to the TER port of the Premium PLC. The rotary switch of the
cable must be set on TER DIRECT and the Unitelway driver already installed
on the PC.
2) Using one USB port of the PC as described below. In this case :
3 plug the USB – RS485 converter (TSXCUSB485) into the PC’s USB
port
3 plug the RJ45 connector of the TSXCRJMD25 cable into the RJ45
port of the TSXCUSB485 converter
3 plug the Mini Din connector of the TSXCRJMD25 cable to the TER
port of the Premium PLC.
The rotary switch of the converter must be set on TER DIRECT and the
Unitelway driver (V1.9 minimum) already installed on the PC
Note that the cable TSXPCX3030 (no more commercialized) can be used to
connect the USB port of the PC to the TER port of the PLC.
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2. Upgrading a Premium PLC from PL7 to Unity
Object of this
Chapter
This chapter describes how to upgrade a Premium PLC from PL7 to Unity.
The screens shots given below show how to upgrade a TSX P57 253 (PL7) to
TSX P57 254 (Unity). This procedure is similar for all other type of PLC’s
Warning
Upgrading a PLC from PL7 to Unity requires to perform three main phases :
3 Phase 1 - Upgrade the PLC to Unity with an intermediate OS
3 Phase 2 - Power OFF then ON the PLC
3 Phase 3 - Update the Operating system with the appropriate file
Those phases are mandatory and cannot be by-passed.
Each phase is described in the following procedure
Connecting the
PC to the PLC
This phase is fully described in the chapter 1 of this document.
Launching the
OS loader
The OS Loader (installed with Unity Pro) allows the user to download the
Operating System to the PLC. To open it, click on
Start/Program/Schneider-Electric/Unity-Pro/OS loader
Once done, the following screen appears :
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Select the com
munication
protocol
From the main screen of the OS loader, click on the
following screen appears :
button. The
To download the operating System into the PLC select the Unitelway
communication protocol (UNITLW01) and click on the
button.
Select the
Target Device
On the Device Type field, select Processor
Get the PL7
version
(optional)
Knowing which PL7 version is installed on the processor could be useful if
for any reason a restore function from Unity to PL7 is needed. For that
proceed as follow :
1
Select the PLC
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2
Click on the
button to connect the PC to PLC. Once
connected, the yellow TER led of the PLC is flashing.
3
Click on the
button to get info from the PLC
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The following screen gives to the user some information regarding
the PLC status
3 Started, stopped,
3 Processor type (in this example : TSX 57253)
3 The Hardware identification (for Schneider internal use only)
3 The OS version (in this example the OS version is 5.9)
4
5
6
Select the
Download
Function
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Note this version number to avoid compatibility issues between the
application program and the OS if for any reason the previous CPU
Os (PL7) has to be restored.
Press the
button to return back to the OS update process
From the screen described above in the section “Select the Target Device”
press the
OS to device”
button. A new screen is proposed : select “Download
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Select the file to
download
Click on the
button in order to select the file to download into the
PLC. In this example we will update the OS from TSX P57 253 to TSX P57
254. For that select the folder Premium\Processors_modules\PL7_to_Unity\
and select TSXP57253_to_254 (in your case, select the folder according to
your processor)
For an upgrade from PL7 to Unity two binary files can be selected :
3 PL7_to_Unity_254.bin (allows to “format” the processor for Unity)
3 TSXP57254M_V240.bin is the OS that will finally be download in the
processor
In our example we have to “format” the processor (remember, we still are in
the Phase 1) then select and Valid “PL7_to_Unity_254.bin”.
Once done click on the
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button.
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Download the
intermediate
OS
Once the previous screen validated, a warning is displayed
Click the
button. Two screens that give information
regarding the file, the processor and the download are now displayed :
Warning : If the system detects a discrepancy between the hardware or the
OS versions, the download will not be possible. This is indicated by a red
cross and the
button becomes not available.
Solve this issue and continue. When the hardware - OS are compatible, click
on the
EIO0000000511.01
button launches the download of the intermediate OS file
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Download the
intermediate
OS file (cnt’d)
During the download (roughly 15 to 20 mn) the remaining time is displayed
Warning : During the download, do not power OFF the PLC, neither
disconnect the cable nor shut down the OS loader. If unfortunately it
happens, the PLC may have lost some important files and therefore be unable
to run correctly and must be returned back for repair.
Once the download successfully completed, the screen below is displayed.
Click twice on the
then ON or reset the PLC).
button and go to the Phase 2 (Power OFF
Reset the PLC
Once the download of the intermediate binary file completed, the PLC has to
be initialized. This task can be performed by one of the two following actions:
3 Reset the PLC by pushing on the Reset button located on the PLC’s
power supply (for more information, refer to the PLC technical
documentation
3 Power OFF then ON the PLC.
Once the PLC restarted, go to phase 3 : download the final Unity OS file.
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Presentation
The final binary file “TSXP57254M_V240.bin” (in our example) has to be
downloaded.
For that, follow the same procedure as the one described in the Phase 1.
Download
procedure
As all the actions necessary to download the final Unity OS have been
already fully described in the Phase 1, they are shortly reminded here after :
1
Open the OS loader (the PC should be still connected to the PLC).
2
Select the Protocol (UNTLW01) – Refer to Phase 1
Select the target device and click on the
screen appears after few seconds.
button. The next
3
Click on the
button and select (for our example) the file
“TSXP57254M_V240.bin” located on the CD OS. Then valid this
screen
4
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5
Select the operation to perform (Download OS to device) and press
on the
Download
procedure
(cnt’d)
button
At this stage, and as no functional Operating System is present in the
PLC the screen displays the string ??? in the field “OS Version” and
an error message. Click
to validate this message
6
Then click on the
button.
and validate the warning message displayed on
Click on
the screen to launch the download of the final OS file.
7
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Download
procedure
(cnt’d)
During the download (roughly 35 to 45 mn) the remaining time is
displayed
8
9
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Warning : During the download, do not power OFF the PLC,
neither disconnect the cable nor shut down the OS loader. If
unfortunately it happens, the PLC may have lost some important files
and therefore be unable to run correctly and must be returned back for
repair.
Once the download successfully completed, the screen below is
displayed.
button to exit the OS loader tool.
Click twice on the
Reset or power OFF then ON the PLC.
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Checking
version (not
mandatory)
If needed, you can check the new CPU version. For that
3 Open the OS loader tool,
3 Select the protocol (UNITLW01),
3 Click on
3 Click on
.
In our example, the CPU has been upgraded to TSX P57 254M and the OS
version is 2.31 40.
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3. Updating a Premium PLC from Unity to Unity
Object of this
Chapter
This chapter describes how to update a Premium PLC from Unity version >=
V2.0 to a more recent one. Note that the update from Unity V1.0 to V2 and
above is not provided.
Warning: In case of upgrading a high End processor you have to update
first the Ethernet co-processor described in Appendix 2
The screens shots given below show how to update a TSX P57 454 processor.
Connecting the
PC to the PLC
This phase is fully described in the chapter 1 of this document
Launching the
OS loader
The OS Loader (installed with Unity allows the user to download the
Operating System to the PLC. To open it click on Start/Progam/SchneiderElectric/Unity-Pro/OS loader
Once done, the following screen appears :
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Select the com
munication
protocol
From the main screen of the OS loader, click on the
following screen appears :
button. The
To download the operating System into the PLC select the Unitelway
communication protocol (UNITLW01) and click on the
button.
Select the
Target Device
On the Device Type field, select Processor
Get the Unity
version
(optional)
Before the update, knowing which Unity version is already installed on the
processor could be useful if for any reason a restore function is needed. For
that proceed as follow :
1
Select the PLC
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2
button to connect the PC to PLC. Once
Click on the
connected, the yellow TER led of the PLC is flashing.
3
Click on the
button to get info from the PLC
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The following screen gives to the user some information regarding
the PLC status
3 Started, stopped, Not Configured, ……..
3 Processor type (in this example : TSX P57 454M)
3 The Hardware identification (for Schneider internal use only)
3 The OS version (in this example the OS version is 2.1)
4
5
6
Select the
Download
Function
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Note this version number to avoid compatibility issues between the
application program and the OS if the previous version has to be
restored.
Press the
button to return back to the OS update process
From the screen described above in the section “Select the Target Device”
press the
OS to device”
button. A new screen is proposed : select “Download
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Select the file to
download
button in order to select the file to download into the
Click on the
PLC. In this example we will update the TSX P57 454 OS from version 2.31
to V2.40. For that select the folder :
Premium\Processors_modules\Unity_Upgrade\ and select TSXP57254 (in
your case, select the folder according to your processor)
Then, select the binary file “TSXP57454M_V240.bin”
Once done click on the
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button.
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Download the
OS
Once the previous screen validated, two screens display the current OS
version, the processor and the OS file to download :
Warning : If the system detects a discrepancy between the hardware or the
OS versions, the download will not be possible. This is indicated by a red
cross and the
button becomes not available.
Solve this issue and continue. When the hardware - OS are compatible, click
on the
button and validate the warning message displayed on the
screen to launch the download of the OS file.
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Download the
OS file (cnt’d)
During the download (roughly 45 to 55 mn) the remaining time is displayed
Warning : During the download, do not power OFF the PLC, neither
disconnect the cable nor shut down the OS loader. If unfortunately it
happens, the PLC may have lost some important files and therefore be unable
to run correctly and must be returned back for repair.
Once the download successfully completed, the screen below is displayed.
Click twice on the
Reset the PLC
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Once the download of the OS file completed, the PLC has to be initialized.
This task can be performed by one of the two following actions:
3 Reset the PLC by pushing on the Reset button located on the PLC’s
power supply (for more information, refer to the PLC technical
documentation
3 Power OFF then ON the PLC.
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Checking
version
(optional)
If needed, you can check the new CPU version. For that
3 Open the OS loader tool,
3 Select the protocol (UNITLW01),
3 Click on
3 Click on
,
.
In our example the processor TSX P57 454M has been updated to the version
2.40-46.
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4. Updating Premium PLC with an embedded Ethernet Port
Object of this
Chapter
This chapter describes how to update a Premium PLC with an embedded
Ethernet port. This procedure is applicable to the following modules :
3 TSX P57 2623M
3 TSX P57 3623M
3 TSX P57 1634M
3 TSX P57 2634M
3 TSX P57 3634M
The screens shots given below show how to update a TSX P57 1634M.
Warning
For updating Premium PLC’s with an Ethernet port embedded it is imperative
that the update be carried out in the following order :
3 Update the Ethernet module (Phase 1)
3 Update the PLC Operating System (Phase 2)
Update the
Ethernet
module
This phase is fully described in the Appendix 1 of this document.
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Once done update the PLC Operating System.
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Updating the
Processor
As the ETY port is now updated it is time to update the processor according
to the latest version available. This download does not need an Ethernet
connection but the PC has to be connected to the TER port of the processor.
The update procedure is fully described in the chapter 3 of this document and
will not be repeated here. Please refer to this chapter.
Update the processor according to its type. Note that in our example (ETY
Port TSX P57 1634M) the file will be downloaded from the following
directory : Premium\Processors_modules\Unity_Upgrade\ :
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5. Updating Premium PLC with an Ethernet Co-Processor
Object of this
Chapter
This chapter describes how to update a Premium PLC with an Ethernet or Hot
Standby Co-Processor. This procedure is applicable to the following modules
:
3 TSX P57 4634M
3 TSX P57 5634M
3 TSX P57 6634M
The screens shots given below show how to update a TSX P57 5634M.
Warning
For updating Premium PLC’s with a Co-Processor embedded it is imperative
that the update be carried out in the following order :
3 Update the Co-Processor (Phase 1)
3 Update the PLC Operating System (Phase 2)
Update the
Ethernet
module
This phase is fully described in Appendix 2 of this document.
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Once done update the PLC operating system.
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Updating the
Processor
As the Co-Processor of the Premium PLC is now updated it is time to update
the Processor operating system according to the latest version available. This
download does not need an Ethernet connection but the PC has to be
connected to the TER port of the processor
The update procedure is fully described in the chapter 3 of this document and
will not be repeated here.
Update the processor according to its type. Note that in our example (TSX
P57 5634M) the file will be downloaded from the following directory :
Premium\Processors_modules\Unity_Upgrade\ :
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6. Updating Hot Standby Premium PLC
Object of this
Chapter
This chapter describes how to update a Premium PLC with an Hot Standby
Co-Processor module. This procedure is applicable to the following modules :
3 TSXH5724M
3 TSXH5744M
The screens shots given below show how to update a TSX P57 5634M.
however, the upgrade procedure is the same for Hot Standby processors .
CAUTION
The module upgrade MUST be done with the two PLC in STOP
Performing a firmware upgrade in Run is forbidden on a Premium Hot
Standby configuration and must not be attempted for any reason.
In a Premium Hot Standby configuration, the CPU to be upgraded must be
stopped before updating the firmware.
It is not possible to use System Words (%SW60.4) to restart the Hot
Standby system in a redundant state, therefore the second CPU must be
stopped before being able to restart the first one. Then, the first CPU (now
upgraded) will control the process, and it is now possible to upgrade the
firmwares of the second CPU and to restart it afterwards. Under those
conditions only, the CPU firmwares in a redundant system can be
upgraded.
Failure to follow these instructions can result in equipment
damage.
Warning
For updating Premium Co-Processor of PLC with an Co-Processor it is
imperative that the update be carried out in the following order :
3 Make sure to have stored the program application on your computer. In
case you are not sure it is present on your computer, it is possible to
upload it from the PLC.
3 Update the coprocessor module (Phase 1)
3 Update the PLC Operating System (Phase 2)
3 Download program application because in most cases it can be lost.
Those phases are mandatory and cannot be by-passed.
3 Each phase is described in the following procedure
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Update the
Ethernet Coprocessor
This phase is fully described in Appendix 2 of this document.
Updating the
Processor
As the Ethernet Co-Processor module of the Premium PLCis now updated it
is time to update the Operating System according to the latest version
available. This download does not need an Ethernet connection but the PC
has to be connected to the TER port of the processor
Once done update the PLC operating system.
The update procedure is fully described in the chapter 3 of this document and
will not be repeated here.
Update the processor according to its type. Note that in our example (TSX
P57 5634M) the file will be downloaded from the following directory :
Premium\Processors_modules\Unity_Upgrade\ :
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7. Restoring a Premium PLC from Unity to PL7
Object of this
Chapter
This chapter describes how to restore a Premium PLC from Unity to PL7. The
screens shots given below show how to restore a TSX P57 254 (Unity) to
TSX P57 253 (PL7).
Warning
Restoring a PLC from Unity to PL7 requires to perform three main phases :
3 Phase 1 – Restore the PLC to PL7 with an intermediate OS
3 Phase 2 - Power OFF then ON the PLC
3 Phase 3 – Restore the PL7 Operating System with the appropriate file
Those phases are mandatory and cannot be by-passed.
Each phase is described in the following procedure
Connecting the
PC to the PLC
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This phase is fully described in the chapter 1 of this document.
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Launching the
OS loader
The OS Loader (installed with Unity allows the user to download the
Operating System to the PLC. To open it click on Start/Progam/SchneiderElectric/Unity-PRO/OS loader
Once done, the following screen appears :
The next steps are fully described later in this document.
Select the com
munication
protocol
From the main screen of the OS loader, click on the
following screen appears :
button. The
To download the operating System into the PLC select the Unitelway
communication protocol (UNITLW01) and click on the
EIO0000000511.01
button.
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Select the
Target Device
On the Device Type field, select Processor
Select the
Download
Function
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From the screen described above press the
is proposed : select “Download OS to device”
button. A new screen
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Select the file to
be downloaded
Click on the
button in order to select the file to download into the
PLC. In this example we will restore the OS from TSX P57 254 to TSX P57
253 version V5.9. For that select the folder :
Premium\Processor_modules\Unity_to_PL7\ :
Then select TSXP57254_to_253 (in your case, select the folder according to
your processor)
Select the OS version to download (V5.9 in our example)
Valid the choice SV5.9
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Select the file to
be downloaded
(cnt’d)
To restore the OS from Unity to PL7, two binary files can be sectioned :
3 Unity_to_PL7_253.bin (allows to “format” the processor to PL7)
3 TSXP57253_V59.bin is the OS that will finally be download in the
processor
In our example we have to “format” the processor (remember, we still are in
the Phase 1) then select and Valid “Unity_to_PL7_253.bin”.
Once done click on the
EIO0000000511.01
button.
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Download the
intermediate
OS
Once the previous screen validated a warning is displayed
Click the
button. Two screens that give information
regarding the file, the processor and the download are now displayed :
Warning : If the system detects a discrepancy on the hardware or on the OS
version, the download will not be possible. This is indicated by a red cross
and the
button becomes not available.
Solve this issue and continue. When the hardware - OS are compatible, click
on the
EIO0000000511.01
to launch the download of the intermediate OS file
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Download the
intermediate
OS file (cnt’d)
During the download (roughly 30 to 40 mn) the remaining time is displayed
Warning : During the download, do not power OFF the PLC, neither
disconnect the Ethernet cable nor shut down the OS loader. If
unfortunately it happens, the PLC may have lost some important files and
therefore be unable to run correctly and must be returned back for repair.
Once the download successfully completed, the screen below is displayed.
Click twice on the
then ON or reset the PLC).
button and go to the Phase 2 (Power OFF
Reset the PLC
Once the download of the intermediate binary file completed, the PLC has to
be initialized. This task can be performed by one of the two following actions:
3 Reset the PLC by pushing on the Reset button located on the PLC’s
power supply (for more information, refer to the PLC technical
documentation
3 Power OFF then ON the PLC.
Once the PLC restarted, go to Phase 3 : download the final PL7 OS
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Presentation
The final binary file “TSXP57XXX_VZZ.bin” where XXX represents the
processor type (253, 353, 453, ….) and ZZ the OS version, has to be
downloaded.
For that, follow the same procedure as the one described in the Phase 1.
Download
procedure
As all the actions necessary to download the final PL7 OS have been already
fully described in the Phase 1, they are shortly reminded here after :
1
Open the OS loader (the PC should be still connected to the PLC)
2
Select the Protocol (UNTLW01) – Refer to Phase 1
Select the target device and click on the
screen appears after few seconds.
button. The next
3
Click on the
button and select (for our example) the file
TSXP57253_V59.bin located on the CD OS. Then valid this screen
4
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5
Select the operation to perform (Download OS to device) and press
on the
Download
procedure
(cnt’d)
button
At this stage, and as no functional Operating System is present in the
PLC the screen displays the string “ ???” in the field “OS Version”
and an error message. Click
to validate this message
6
Then click on the
button.
Click on
and validate the warning message displayed on
the screen to download the final OS file.
7
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During the download (roughly 10 to 15 mn) the remaining time is
displayed
8
Warning : During the download, do not power OFF the PLC,
neither disconnect the Ethernet cable nor shut down the OS
loader. If unfortunately it happens, the PLC may have lost some
important files and therefore be unable to run correctly and must be
returned back for repair.
Once the download successfully completed, the screen below is
displayed.
9
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Click twice on the
button to exit the OS loader tool.
Reset or power OFF then ON the PLC.
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Checking
version
(optional)
If needed, you can check the new CPU version. For that
3 Open the OS loader tool,
3 Select the protocol (UNITLW01),
3 Click on
3 Click on
,
.
In our example, the CPU has been restored to TSX P57 253 and the OS
version is V5.9
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Appendix 1 : ETY Module Upgrade Procedure
Purpose
The upgrade of the ETY and Ethernet Port modules are completed by installing a single file
using the Unity Pro V2.2 or higher OS Loader. Please note that prior version of the OS Loader
are not compatible with this revision of the firmware. You MUST be at the proper OS Loader
revision of 2.2 or higher.
Applicable Modules
TSXETY4102 V2.0 or V2.1
TSXETY4103 V3.0 or higher
TSXP572623M Ethernet Port
TSXP573623M Ethernet Port
TSXP571634M Ethernet Port
TSXP572634M Ethernet Port
TSXP573634M Ethernet Port
Resulting Module after upgrade
TSXETY4103 BootRom V3.1, Exec V4.1
TSXP571634M Ethernet Port BootRom V3.1, Exec V4.1
TSXP572634M Ethernet Port BootRom V3.1, Exec V4.1
TSXP573634M Ethernet Port BootRom V3.1, Exec V4.1
Overview
The upgrade of an ETY module is a multi-step process. Two components must be considered to
be upgraded, the BootRom and the Exec version. Steps 6, 7 and 8 describe the various files used
to upgrade the modules. Not all steps may be required depending on the version of the ETY
module before this upgrade procedure is started.
Note - For Premium configurations TSX P57 2623M / TSX P57 3623M / TSX P57 1634M /TSX
P57 2634M / TSX P573634M, it is imperative that the update be carried out in the following
order:
- Update of Ethernet Port.
- Update of processor Operating System.
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CAUTION
In case of monitored ETY upgrade the module upgrade MUST be done
with the two PLC in STOP
Performing a firmware upgrade in Run is forbidden on a Premium Hot
Standby configuration and must not be attempted for any reason.
In a Premium Hot Standby configuration, the CPU to be upgraded must be
stopped before updating the firmware.
It is not possible to use System Words (%SW60.4) to restart the Hot
Standby system in a redundant state, therefore the second CPU must be
stopped before being able to restart the first one. Then, the first CPU (now
upgraded) will control the process, and it is now possible to upgrade the
firmwares of the second CPU and to restart it afterwards. Under those
conditions only, the CPU firmwares in a redundant system can be
upgraded.
Failure to follow these instructions can result in equipment damage.
Step1
Ensure the ETY module to be upgraded is listed in the Applicable Modules section of this
document. Refer to the ETY module web pages for version numbers.
Step2
Install the ETY module in a system consisting of only the PLC CPU, Power Supply, Rack and
ETY module. Configure the PLC system with an ‘empty’ program containing only the ETY IP
address configuration.
Ensure the ETY module must be installed in a PLC rack with a configured IP address.
The CPU module must be in STOP mode and the ETY must have NO TCP traffic.
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Step3
The PC must be running OS Loader V2.2 or higher. To identify this, the first screen of the OS
Loader should look like the screen below.
Select ‘Next’
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Step4
Select the FTP Driver.
Select ‘Next’
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Step5
Select ‘Direct Device’ and enter the device IP address and select Connect. If requested enter the
module’s MAC address, the MAC address can be found on the front of the module.
Select ‘Next’
Note If your module is located remotely, you can get the MAC address by pinging the module's
IP address, then using the arp -a command to display the module's physical MAC address.
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Step6
Select Operation ‘Download OS to Device’
Select the filename to download based on the Current Module Version in the following table.
If module not listed proceed to Step7.
If module is listed select the correct file and click ‘Next’.
Current Module
Version
TSXETY4102
Exec V2.0 or V2.1
TSXP572623M
Ethernet Port
TSXP573623M
Ethernet Port
File to Select
Resulting Module
Premium\Ethernet_modules\Pl7_to_U
nity\TSXETY4102_to_4103\TSXETY
4103_V300.bin
Premium\Processor_modules\Pl7_to_
Unity\TSXP572623_to_2634\Eth_OS\
TSXP572634_EtyPort_V300.bin
Premium\Processor_modules\Pl7_to_
Unity\TSXP573623_to_3634\Eth_OS\
TSXP573634_EtyPort_V300.bin
TSXETY4103 Boot V2.1 Exec
V3.0
TSXP572634M Ethernet Port
Boot 2.1 Exec V3.0
TSXP573634M Ethernet Port
Boot 2.1 Exec V3.0
The following Screen will appear
Both Hardware ID and OS Version must be followed by a green tick.
Select ‘Next’ and then ‘Download’
After the download is completed the following screen will appear.
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If this screen does not appear recheck each step and contact your local Schneider office for
assistance if required.
Select ‘Close’ and ‘Back’ in the OS Loader.
Exit the OS loader.
Allow the module 60 seconds to complete any actions and power cycle the module to allow the
new exec to be loaded.
Restart this procedure from Step 1 and continue to Step7.
Step7
Select the filename to download based on the Current Module Version in the following table.
Current Module
File to Select
Resulting Module
Version
TSXETY4103 Boot Premium\Ethernet_modules\Pl7_to_ TSXETY4103 Boot V3.1
V2.1 and Exec V3.0 Unity\TSXETY4102_to_4103\TSX Exec V3.0
ETY4103_V310_BOOT.bin
TSXP571634M
Premium\Processor_modules\Unity TSXP571634M Ethernet
Ethernet Port Boot
_Upgrade\TSXP571634\Eth_OS\TS Port Boot 3.1 Exec V3.0
V2.1 and Exec V3.0 XP571634_EtyPort_V310_BOOT.b
in
TSXP572634M
Premium\Processor_modules\Pl7_to TSXP572634M Ethernet
Ethernet Port Boot
_Unity\TSXP572623_to_2634\Eth_ Port Boot 3.1 Exec V3.0
V2.1 and Exec V3.0 OS\TSXP572634_EtyPort_V310_B
OOT.bin
TSXP573634M
Premium\Processor_modules\Pl7_to TSXP573634M Ethernet
Ethernet Port Boot
_Unity\TSXP573623_to_3634\Eth_ Port Boot 3.1 Exec V3.0
V2.1 and Exec V3.0 OS\TSXP573634_EtyPort_V310_B
OOT.bin
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If module not listed proceed to Step8.
If module is listed select the correct file and click ‘Next’.
The following screen will appear.
The Hardware ID and OS Versions must be both followed by green ticks. If an error message
regarding hardware ID is received ensure you have completed all previous steps correctly and
contact your local Schneider office for assistance if required.
Click ‘Next’ and ‘Download’
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Following the download the screen above will appear.
Select close and exit the OS Loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Boot Files. This
process will be complete once the module again shows the ‘RUN’ and ‘STS’ LED’s on solid for
at least 30 seconds continuously.
If the RUN and STS LED’s do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module. After completion restart this procedure and proceed to Step8.
Step8
Select the filename to download based on the Current Module Version in the following table.
Current Module Version
TSXETY4103 Boot V3.1,
Exec V3.0 or higher
File to Select
Premium\Ethernet_modules\U
nity\TSXETY4103\TSXETY4
103_V500.bin
Resulting Module
TSXETY4103 Boot V3.1
Exec V5.0
Comment: TSXETY 4103
Boot V3.1, Exec V3.0 can
be directly upgraded to
Exec V5.0. If users want
to use an early version, it
also can be upgraded
directly.
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TSXP571634M Ethernet
Port Boot V3.1 and Exec
V3.0 or higher
Comment:
TSXP571634M Ethernet
Port Boot V3.1 Exec V3.0
can be directly upgraded
to Exec V5.0. If users
want to use an early
version, it also can be
upgraded directly.
TSXP572634M Ethernet
Port Boot V3.1 and Exec
V3.0 or higher
Comment:
TSXP572634M Ethernet
Port Boot V3.1 Exec V3.0
can be directly upgraded
to Exec V5.0. If users
want to use an early
version, it also can be
upgraded directly.
TSXP573634M Ethernet
Port Boot V3.1 and Exec
V3.0 or higher
Premium\Processor_modules\
Unity_Upgrade\TSXP571634\
Eth_OS\TSXP571634_EtyPort
_V500.bin
TSXP571634M Ethernet
Port Boot V3.1 Exec V5.0
Premium\Processor_modules\
Unity_Upgrade\TSXP572634\
Eth_OS\TSXP572634_EtyPort
_V500.bin
TSXP572634M Ethernet
Port Boot V3.1 Exec V5.0
Premium\Processor_modules\
Unity_Upgrade\TSXP573634\
Eth_OS\TSXP573634_EtyPort
_V500.bin
TSXP573634M Ethernet
Port Boot V3.1 Exec V5.0
Comment:
TSXP573634M Ethernet
Port Boot V3.1 Exec V3.0
can be directly upgraded
to Exec V5.0. If users
want to use an early
version, it also can be
upgraded directly.
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If module is listed select the correct file and click ‘Next’.
The following screen will appear.
The Hardware ID and OS Versions must be followed by green ticks.
The Device Boot Loader Version must be V3.1. If an error message regarding hardware ID is
received ensure you have completed all previous steps correctly and contact your local Schneider
office for assistance if required.
Click ‘Next’ and ‘Download’
Following the transfer the following screen will appear.
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Select ‘Close’ and exit the OS loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Exec Files. This
process will be complete once the module again shows the ‘RUN’ and ‘STS’ LED’s on solid for
at least 30 seconds continuously.
If the RUN and STS LED’s do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with the OS
Loader.
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Appendix 2: Premium Ethernet or Hot Standby CoProcessor
Upgrade Procedure
Applicable Modules
TSXP574634M
TSXP575634M
TSXP576634M
TSXH5724M
TSXH5744M
Overview
The upgrade of the CoProcessor is complete by installing a single file using the Unity Pro v2.2
or higher OS Loader. Please note that prior version of the OS Loader are not compatible with
this revision of the firmware. You MUST be at the proper OS Loader revision of 2.2 or
higher.
Note If the Copro firmware version is less than v2.2, you must upgrade to v2.2 using Unity OS
Loader v2.2 only.
Note: the CPU exec MUST be at OS2.31 or higher before the Ethernet port is upgraded. If the
CPU is not at this revision level the Ethernet port of the CoPro will not be configured and it will
default to its “default IP address” (as defined by the MAC address).
Special Case: channel not configured
If the Ethernet channel is not configured in the Unity Pro application, it takes the IP address built
from its MAC address:
085.016.xxx.yyy where xxx and yyy are the last two numbers of the MAC address converted in
decimal.
Example:
The MAC address is (in hexadecimal): 00 80 F4 01 12 20
In this case the default IP address is (in decimal): 085.016.018.032
Step1
The coprocessor to be upgraded must be listed in the Applicable Modules section of this
document. Refer to the Ethernet port web pages for version numbers.
Step2
Install a system consisting of only the PLC CPU, Power Supply, and Rack. Configure the PLC
system with an ‘empty’ program containing only the module’s Ethernet link IP address
configuration.
Ensure the coprocessor has a configured IP address.
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Step3
The PC must be running OS Loader V2.2 or higher. To identify this, the first screen of the OS
Loader should look like the screen bellow.
Select ‘Next’
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Step4
Select the FTP Driver.
Select ‘Next’
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Step5
Select ‘Direct Device’ and enter the device IP address and select Connect. If requested enter the
module’s MAC address, the MAC address can be found on the front of the module.
Select ‘Next’
Note If your module is located remotely, you can get the MAC address by pinging the module's
IP address, then using the arp -a command to display the module's physical MAC address
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Step6
Select Operation ‘Download OS to Device’
Select the filename to download based on the Current Module Version in the following table.
Module Version
TSXP574634M
V2.2 or higher
File to Select
Premium\Processor_modules\Unity_Up
grade\TSXP57x634\Eth_OS\TSXP5746
34_EthCopro_V260.bin
Resulting Module
Eth Embedded link
V2.6
Current Module
Version
TSXP575634M
V2.2 or higher
File to Select
Resulting Module
Premium\Processor_modules\Unity_Up
grade\TSXP57x634\Eth_OS\TSXP5756
34_EthCopro_V260.bin
Eth Embedded link
V2.6
Current Module
Version
TSXP576634M
V2.4 or higher
File to Select
Resulting Module
Premium\Processor_modules\Unity_Up
grade\TSXP57x634\Eth_OS\TSXP5766
34_EthCopro_V260.bin
Eth Embedded link
V2.6
Current Module
Version
TSXH5724M
V2.5 or higher
File to Select
Resulting Module
Premium\Processor_modules\Unity_Up
grade\TSXH5724\Eth_OS\TSXH5724_
EthCopro_V28.bin
Eth Embedded link
V2.8
Current Module
Version
TSXH5744M
V2.5 or higher
File to Select
Resulting Module
Premium\Processor_modules\Unity_Up
grade\TSXH5744\Eth_OS\TSXH5744_
EthCopro_V28.bin
Eth Embedded link
V2.8
If module is listed select the correct file and click ‘Next’.
The following Screen will appear
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Ensure that both the Hardware ID and OS Version are followed by a green tick.
Select ‘Next’ and then ‘Download’
After the download is completed the following screen will appear.
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Select ‘Close’ and exit the OS loader.
Allow the Ethernet coprocessor at least 60 seconds to reboot and implement the new Exec Files.
This process will be complete once the module again shows the ‘RUN’ and ‘STS’ LED’s on
solid for at least 30 seconds continuously.
If the RUN and STS LED’s do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with the OS
Loader.
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Appendix 3 : FactoryCast ETY 510 Module Upgrade Procedure
Purpose
The upgrade of the ETY 510 module is completed by installing a single file using the Unity Pro
v2.2 or higher OS Loader. Please note that prior version of the OS Loader are not compatible
with this revision of the firmware. You MUST be at the proper OS Loader revision of 2.2 or
higher.
Applicable Modules
TSXETY5102 V2.0 or V2.1
TSXETY5103 V3.0 or higher
Resulting Module after upgrade
TSXETY5103 BootRom V3.1, Exec V4.5
Overview
The upgrade of an ETY module is a multi-step process. Two components must be considered to
be upgraded, the BootRom and the Exec version. Steps 6, 7 and 8 describe the various files used
to upgrade the modules. Not all steps may be required depending on the version of the ETY
module before this upgrade procedure is started.
Note
OS Version numbers displayed in screenshots of following steps are only examples.
Step1
Ensure the ETY module to be upgraded is listed in the Applicable Modules section of this
document. Refer to the ETY module web pages for version numbers.
Step2
Install the ETY module in a system consisting of only the PLC CPU, Power Supply, Rack and
ETY module. Configure the PLC system with an ‘empty’ program containing only the ETY IP
address configuration.
Ensure the ETY module is installed in a PLC rack with a configured IP address.
Ensure the only devices connected to the Ethernet network are the PC running the OS Loader
and the ETY module.
The CPU module must be in STOP mode and the ETY must have NO TCP traffic.
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Step3
Ensure the PC is running OS Loader V2.2 or higher. To identify this, the first screen of the OS
Loader should look like the screen bellow.
Select ‘Next’
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Step4
Select the FTP Driver.
Select ‘Next’
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Step5
Select ‘Direct Device’ and enter the device IP address and select Connect. If requested enter the
module’s MAC address, the MAC address can be found on the front of the module.
Select ‘Next’
Note If your module is located remotely, you can get the MAC address by pinging the module's
IP address, then using the arp -a command to display the module's physical MAC address.
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Step6
Select Operation ‘Download OS to Device’
Select the filename to download based on the Current Module Version in the following table.
Current Module
Version
File to Select
Resulting Module
TSXETY5102 Exec Premium\Ethernet_modules\Pl7_t TSXETY5103 Boot V2.1 Exec
o_Unity\TSXETY5102_to_5103\T V3.0
V2.0 or V2.1
SXETY5103_V300.bin
If device name is TSXETY5103 proceed to Step8.
If module is listed select the correct file and click ‘Next’.
The following Screen will appear
Ensure that both the Hardware ID and OS Version are followed by a green tick.
Select ‘Next’ and then ‘Download’
After the download is completed the following screen will appear.
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If this screen does not appear recheck each step and contact your local Schneider office for
assistance if required.
Select ‘Close’ and ‘Back’ in the OS Loader.
Exit the OS loader.
Allow the module 60 seconds to complete any actions and power cycle the module to allow the
new exec to be loaded.
Restart this procedure from Step 1 and continue to Step7.
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Step7
Select the filename to download based on the Current Module Version in the following table.
Current Module
File to Select
Resulting Module
Version
TSXETY5103 Boot Premium\Ethernet_modules\Pl7 TSXETY5103 Boot V3.1 Exec
V2.1 and Exec V3.0 _to_Unity\TSXETY5102_to_5 V3.0
103\TSXETY5103_V310_BO
OT.bin
If module not listed proceed to Step8.
If module is listed select the correct file and click ‘Next’.
The following screen will appear.
Ensure that the Hardware ID and OS Versions are both followed by green ticks. If an error
message regarding hardware ID is received ensure you have completed all previous steps
correctly and contact your local Schneider office for assistance if required.
Click ‘Next’ and ‘Download’
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Following the download the screen above will appear.
Select close and exit the OS Loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Boot Files. This
process will be complete once the module again shows the ‘RUN’ and ‘STS’ LED’s on solid for
at least 30 seconds continuously.
If the RUN and STS LED’s do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module. After completion restart this procedure and proceed to Step8.
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Step8
Select the filename to download based on the Current Module Version in the following table.
Current Module
Version
File to Select
Resulting Module
TSXETY5103 Boot
V3.1, Exec V3.0 or
higher
Premium\Ethernet_modules\Pl7_t
o_Unity\TSXETY5102_to_5103\
TSXETY5103_V400.bin
TSXETY5103 Boot V3.1 Exec
V4.0
Comment: TSXETY
5103 Boot V3.1, Exec
V3.0 can be directly
upgraded to Exec V4.0.
If users want to use an
early version, it also
can be upgraded
directly.
OR
Premium\Ethernet_modules\Unit
y\TSXETY5103\TSXETY5103_
V400.bin
If module is listed select the correct file and click ‘Next’.
The following screen will appear.
Ensure that the Hardware ID and OS Versions are both followed by green ticks. Ensure
that the Device Boot Loader Version is V3.1. If an error message regarding hardware ID is
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received ensure you have completed all previous steps correctly and contact your local
Schneider office for assistance if required.
Click ‘Next’ and ‘Download’
Following the transfer the following screen will appear.
Select ‘Close’ and exit the OS loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Exec Files. This
process will be complete once the module again shows the ‘RUN’ and ‘STS’ LED’s on solid for
at least 30 seconds continuously.
If the RUN and STS LED’s do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with the OS
Loader.
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