Remote Firmware Upgrade Tool User Manual

Remote Firmware Upgrade Tool User Manual
Remote Firmware Upgrade Tool
User Manual
User Manual V1.0 - March 3, 2016
© 2015 General Electric Corporation
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Remote Firmware Upgrade Tool
User Manual
GE
Table of Contents
1 Introduction ............................................................................................................................................................................................................... 3 1.1 Overview of the Upgrade Process ...................................................................................................................................................... 3 2 What you need to do the Remote Upgrade ............................................................................................................................................... 4 3 Examples of the Upgrade Process.................................................................................................................................................................. 5 3.1 3.1.1 5 Port selection .......................................................................................................................................................................................... 6 3.2 Installation of the RS485 interface driver ........................................................................................................................................ 6 3.3 Installation of the USB-to-I2C Adapter driver................................................................................................................................. 7 3.3.1 4 Interfacing via I2C ....................................................................................................................................................................................... 6 USB-to-I2C Adapter Setup ................................................................................................................................................................. 9 Running the Remote Firmware Upgrade Tool .......................................................................................................................................... 9 4.1 Discovery of upgradable modules....................................................................................................................................................10 4.2 Loading the upgrade program...........................................................................................................................................................10 4.3 Upgrading the Power Supplies ...........................................................................................................................................................11 Error Messages from the Remote Firmware Upgrade Tool ..............................................................................................................13 5.1 The adapter was not found .................................................................................................................................................................13 5.2 No modules found ....................................................................................................................................................................................13 5.3 Module upgrade error ............................................................................................................................................................................13 5.4 Loss of connection error .......................................................................................................................................................................13 5.5 RS-485 installation error .......................................................................................................................................................................13 5.6 Compatibility code mismatch .............................................................................................................................................................13 User Manual V1.0 - March 3, 2016
© 2015 General Electric Corporation
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Remote Firmware Upgrade Tool
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1
Introduction
The GE Remote Firmware Upgrade Tool allows users to perform firmware updates of certain upgradeable GE
Critical Power power supplies. On-site upgrading is rapid and economical. It avoids having to send power supplies
back to the factory for firmware updates. The upgrade of the power supply can be accomplished either stand-alone
externally from the system, or, with the power supply in the system.
The tool can be downloaded from the GE Critical Power web site. It runs on Windows based computers. Please note
that Windows versions higher than 7 may reject the upgrade program because of enhanced security requirements
built into the latter operating systems.
The upgrade can be performed through either I2C or RS-485 interfaces, whichever is supported by the power supply.
Check the web site to see which power supply products can be upgraded via this tool.
1.1
Overview of the Upgrade Process
The Remote Firmware Upgrade process replaces the existing application firmware in the power supply with newer
versions. As an example, in the CP3500 rectifier there are three separate processors controlling different portions of
the power supply. Each of these processors is partitioned into a boot loader and an application section as shown in
the figure below;
Functional representation of processors in the CP3500 Rectifier
During the upgrade process, the Remote Firmware Upgrade Tool serves as a System Controller communicating to
and instructing the rectifier via the communications interface (I2C or RS-485). In a system there may be multiple
power supplies connected to the same communications bus. The first step in the Upgrade Process is to identify all
power supplies connected to the communication interface. The user then loads into the tool the new firmware from
a distribution file. This is followed by selecting which of the identified power supplies the user would like to upgrade.
Once a set of power supplies are selected for upgrade, the upgrade commences automatically. The tool sequentially
sends the new firmware to the various processors, bypassing those that do not need to be upgraded. In the process
the tool first turns OFF output power of the power supply, directs the processor into the boot block section, erases
the application in the processor, and then writes into the application section the updated firmware. When the
upgrade is completed, the tool turns ON the output power of the power supply. This upgrade process is repeated for
all power supplies that have been chosen to be upgraded.
In the CP3500 example above, if the RS-485 communications interface is used, there is no need to upgrade the I2C
processor, and hence the Remote Upgrade Tool bypasses it and updates only the DC-DC and PFC firmware.
An alternate approach to using the Remote Firmware Upgrade Tool to upgrade power supplies is to use commands
listed in the product data sheet to support an upgrade in a running system with power supplies. In this scenario, this
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tool is not needed and customers can implement the firmware upgrade using the set of upgrade-related
commands. The new versions of firmware can be downloaded from the GE Critical Power Website. Please contact
your GE Critical Power Technical Representative for additional details on how to accomplish this method of
upgrading power supply firmware.
2
What you need to do the Remote Upgrade
The following list details what is needed to perform a successful Remote Firmware Upgrade.
 The Remote Firmware Upgrade Tool
 Downloaded from the GE Critical Power Website
 .Zip files containing the new firmware programs
 Downloadable from the GE Critical Power Website
 Physical interface from the computer running the Remote Upgrade Tool to the power supply
 If I2C is being used, the GE USB-to-I2C interface adapter shown below is required along with the connecting
cables. Please contact your GE Critical Power Technical Representative for details on how to obtain the
adapter and cables.
I2C_USB_ISO_Translator_kit Part #: 150036482
(Isolated Adapter with cables)
 If RS-485 is being used, an appropriate USB to RS-485 cable along with a USB isolator is recommended.
Although the isolator is not required for establishing communications, but it could protect against hardware
damage if a grounding fault exists. The adapter cable set below terminates the blunt end of the Future
Technology Devices International LTD USB to RS485 Serial Converter module with an RJ45 connector. The
adapter with the blunt-end could also be procured directly from the manufacturer, if a different termination
than RJ45 is desired by the user. Power for the adapter is obtained from the USB port on the computer. The
communications protocol is compatible with USB 2.0. The adapter cable may be procured through your GE
sales contact (see the part number below).
The adapter plugs into either
– RJ45 connectors of the GE RS485 based shelves
– Into the RJ45 connector of a dedicated interface board designed for communicating to stand-alone
power supplies.
– Customer provided RJ45 interface
USB to RJ45 interface adapter
Part #: 850047401
USB to blunt-end obtained from Future Technology
Part #: USB-RS485-WE-1800-BT
USB isolator - available from a number of sources
(example: UH201 - B&B Electronics)
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 If a power supply is to be upgraded standalone (i.e. outside a system shelf), an interface board is likely
required to provide input, output and communications interfaces to the power supply. See below for an
example of such a board (used with the CP3500 rectifier). Please contact your GE Technical Representative
for interface boards to be used with other GE Critical Power products.
1U_CP3500_Interface board
Part #: 150039572
Input connector – IEC 320 C19
Output termination – not required
Address selection – add strap between P1 pin D1 and
the path connecting R25 to R26
AM5 already includes this strap
Selector switch - Protocol ON, all other switches OFF
CAUTION: Use care when handling the 1u_CP3500_ interface board as mains voltage AC is being brought into
the board. Do not apply input before the power supply is inserted into the mating connector on the interface
board. Do not attempt to plug in or remove the power supply from the interface card with input power present
on the card. Make sure that the interface card is flush with the mating connector of the power supply prior to
applying input power to the interface board. ALWAYS, disconnect input AC power first prior to removing the
power supply from the interface board.
For further reference on how to use the 1u_CP3500_interface board download the application note Interfacing and
Integrating CPL modules from the GE Critical Power website.
 If the power supplies are to be upgraded while in a GE shelf, and the I2C communications interface is to be
used, an additional piece of hardware is needed. This is the 1u_CP3500_shelf_interface board shown below.
This board mates directly into the signal connector of the GE shelf.
1u_CP3500_shelf_interface board part #:
150045498
150040608
GE I2C shelf, model J2014003L001 part #
Interface cable to AC shelf
part #: CC848848960
Output termination – not required
Selector switch – Enable ON, all other switches OFF
Interface adapter can be plugged into either I2C port
3
Examples of the Upgrade Process
As outlined previously, there are at least three possible example upgrade configurations: stand-alone, within a shelf,
or in the using system.
In stand-alone mode the dedicated interface board connects the power supply to the AC mains, sets the addressing
and configuration requirements, and connects to the USB to I2C interface adapter.
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Upgrading power supplies in a GE shelf in I2C mode requires a dedicated shelf interface board. The dedicated
interface board converts the signals from the J1 signal connector of the shelf to the connector mate of the USB to
I2C interface adapter.
In RS-485 mode the interfacing cable connects directly into the RJ45 connector of the GE RS485 based shelf. Shelves
include all the required interfacing functions and a mechanical interlock for securing the rectifier.
In system upgrade may be accomplished while the system is operational. The remote upgrade tool could be used if
the system tolerates such intrusion. Note that since the specific power supply being upgraded must be turned off,
the system must have sufficient numbers of rectifiers to allow redundant operation while the rectifier being
upgraded is turned off.
3.1
Interfacing via I2C
Updating in I2C mode requires the GE USB Interface Adapter if the GE Remote Upgrade is used. The adapter’s
functionality is to translate between the USB protocol in the computer and the I2C protocol in the power supply.
Functions such as start, stop, clock signals, PEC computation and other required I2C functions are generated by the
processor to the adapter. Note that the adaptor is specifically designed for communicating with GE modules.
Power for this USB 2.0 compatible adapter is provided by the USB port of the computer. Adapters may be procured
through your GE sales contact.
3.1.1
Port selection
The CP3500 rectifier has dual I2C ports, of which only one is in control at any one time. The interface adapter can be
connected into either Port-0 or Port-1 of the power supply. The upgrade automatically issues a ‘take-over-control’
command instruction prior to finding the modules on the bus.
3.2
Installation of the RS485 interface driver
There are two ways of obtaining the required drivers for the USB-RS-485 interface. The first is by letting the
computer find the drivers automatically. The second way is by configuring the drivers manually. The manual
configuration starts by obtaining the drivers free from: http://www.ftdichip.com. The driver makes the cable appear
as a virtual COM port.
We recommend the automatic installation process for the USB-RS-485 interface drivers. Switch to the manual
install only if the automatic installation fails. Simply plug the cable into any USB port of the computer and allow the
computer to find the driver automatically. The computer will display a message that the driver has not been
successfully installed and that it is searching for the driver. Let the search continue. After some time the search
completes and the computer will install the USB serial converter driver first, followed by the USB serial port driver.
Shown below are example messages displayed by a computer during a USB-RS-485 driver install.
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It will take some time for both drivers to install, when completed the completion announcement should appear
On the host computer, verify through Control Panel – Device Manager that the serial port is identified under Ports.
When identified, the driver is correctly installed in the computer.
3.3
Installation of the USB-to-I2C Adapter driver
If the GE Critical Power DPI software suite has previously been installed on the computer used to perform the
Remote Firmware Upgrade, then the USB driver for the USB-to-I2C interface adapter is likely already installed on the
computer. If the driver is not installed, the computer will indicate that it cannot find the appropriate driver when the
USB-to-I2C adapter is connected to one of the USB ports of the computer.
Two versions of the USB-to_I2C drivers are available, one for 32-bit computers and the other for 64-bit computers. To
verify the computer’s capability click on the START button, followed by clicking on Computer, and that followed by
clicking in the upper left corner on System properties. The resulting window will show the capability of the operating
system.
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In the example shown below a number of system properties are listed. Next to system type, the 64-bit operating
system is identified. So, on this computer the 64 bit driver needs to be installed.
Download the required driver, either 32-bit or 64-bit, from the GE website into either the WINDOWS\System32 or
WINDOWS\System64 directory, or another specific directory of your choice (You may create a special directory
within program files to handily identify the down loaded drivers).
The driver files are:
GE_Power_Electronics_USB_Interface_Adapter.inf
GE_Power_Electronics_USB_Interface_Adapter_64bit.inf
for 32 bit machines
for 64 bit machines
Once the appropriate driver file is downloaded, the Interface Adapter may need to be reinserted again into the USB
port of the computer in order to get the unidentified driver message on the screen again.
When prompted for the driver location, select the Install from a list of specific location (advanced) then click on the
NEXT > button. On the next screen, enter the location of the downloaded that was selected above. In the example
below the driver was placed into the WINDOWS\System32 directory.
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Click on the Next> button and the computer should now install the driver for the USB Interface Adapter. Wait until
the driver installation completes before proceeding to the next step.
Once the adapter is properly recognized by the computer further feature selection may be required depending on
needs of the system connection.
3.3.1
USB-to-I2C Adapter Setup
3.3.1.1 Pull‐upresistors
The USB Interface Adapter has internal pull-up resistors connected to 3V for clock (SCL), Data (SDA) and SMBAlert.
The default setting for SCL and SDA is 3.3mA. [ Other possible values are 0.9mA, 0.44mA, or no pull-up]. SMBAlert# is
pulled up to 3V via a 7.5kΩ resistor. This value cannot be changed. The pull-up resistors can be changed using the
Command Line Interface (CLI). The gui application note describes the correct procedure.
3.3.1.2 LEDstatusindicator
A tri-color (Green/Orange/Red) LED located next to the mini USB interface connector provides visual adapter status
messaging as follows:
• Green ON – Normal operation
• Green – Fast Blinking – The translator is communicating on the bus.
• Orange – Blinking or ON – The SMBAlert# line is active. An SMBusASlert# LO state requests service from the
system controller because an event change occurred in one of the modules connected to the system. The
Alert# signal will remain LO until it gets cleared.
• Red – Internal fault
3.3.1.3 I2CClockSpeedSettings
The default value of the I2C clock speed within the Interface Adapter is set at 100kHz. The upgrade program
changes the adapter’s clock speed to 400kHz, in order to upgrade the application as rapidly as possible.
4
Running the Remote Firmware Upgrade Tool
Click on the Remote Upgrade icon on the desktop to open the program. The Comm Port area in the Remote Upgrade
display will identify connected interfaces. Select the desired method of communications, either I2C (USB-to-I2C
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Translator) or GP (USB Serial Port). Both communication interfaces can be connected to the computer
simultaneously, but only one can be selected for the upgrade.
The screen below shows that both the RS485 and I2C interfaces are available on the Comm ports. In this case the GP
interface is selected. Once the appropriate interface is selected in the Comm Port window (the selected interface will
highlight in blue), click on the Connect button
4.1
Discovery of upgradable modules
The upgrade tool starts by identifying all power supplies connected to the communications bus. The display
example below shows a single CSAC0250BZ power supply connected to the I2C bus. The tool displays the address,
product code, serial number, and the revision numbers of the processors in this power supply.
Connection through the I2C interface
If more than one power supply is identified, it would be listed sequentially below the first unit.
4.2
Loading the upgrade program
The next step is to load the upgrade firmware into the tool. The Remote Firmware Upgrade tool remembers the last
upgrade firmware file that has been uploaded into the tool. If the listed upgrade firmware revision is correct then go
to the next step. If it is not displayed, or if it not correct, then load the desired upgrade firmware file into the upgrade
tool at this time.
The upgrade firmware package can be downloaded from the GE Critical Power Website. If it is not found, please
contact your local sales or FAE for further assistance. If the upgrade firmware package is found it first needs to be
downloaded into a specific directory in the computer. After completion of the download, click on the Select Upgrade
File button of the tool. The click brings up the standard Windows Explorer screen. Navigate to the directory where
the upgrade firmware has been placed. This file is a .zip file containing the upgrade programs. Do not open the .zip
file, simply identify it and click on the Open button.
In the example below the CSAC0250BZ power supply upgrade file has been selected. The file name includes the
product code followed by the processors names and revision numbers. Subsequent executions of the program will
automatically bring in the selected upgrade file.
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4.3
Upgrading the Power Supplies
Now that the power supplies have been identified, and an upgrade package has been brought into the tool, it is time
to initiate an upgrade. Click inside the box in the Upgrade column to select individual power supplies or click in the
select-all box to upgrade all listed power supplies simultaneously.
Once the power supply selection has been made, start the upgrade process by clicking on the <Upgrade> button.
Click in the box to select an individual or a set of power supplies
Click in the Select All box to upgrade all modules simultaneously
The upgrade is accomplished one power supply at a time. The Event Monitor bar will scroll as the upgrade is
progressing. When the upgrade is completed, the word completed will be displayed in the Status bar and the Status
LED will turn Green.
The upgrade commences one module
at a time. The Event Monitor and the
Status LED display the state of the
upgrade. The Status LED will change to
RED if an upgrade error occurred.
The tool will perform the upgrade only if the firmware revision numbers in the power supply and in the upgrade file
are different. If the firmware versions are the same, the tool will skip the upgrade and lit the green LED in the Status
column.
The upgrade tool can be used to either modify the programs in the power supply with an updated version, or, the
tool can also be used to down grade the programs in the power supply to an earlier version.
Once all of the selected power supplies have been upgraded the tool announces that the upgrade has been
completed.
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Note: The program will attempt to upgrade a specific processor several times before finally abandoning the upgrade
process if the upgrade is still unsuccessful.
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5
Error Messages from the Remote Firmware Upgrade Tool
5.1
The adapter was not found
Note: If neither the USB Interface Adapter nor the RS-485 cable is found by the program, the Comm Port message
would indicate that no suitable devices have been located. Try closing the program, connecting the adapter to one
of the USB ports and restarting the program. Sometimes repeating this process two or three times can result in the
adapter being found by the program.
Another known error message indicates that the dongle is an early revision less than rev1.5. In fact the problem is
that the dongle does not respond. Disconnect and reconnect the USB cable to the dongle to reset the USB port of
the computer. Try again.
5.2
No modules found
If an upgrade is terminated prior to completion of the upgrade, the USB port or Interface Adapter may have hung up.
For example, this may occur if a battery powered laptop turns off in the middle of an upgrade. To recover,
disconnect the Interface Adapter, wait for about a minute and reconnect the adapter. Restart the Remote Firmware
Upgrade Tool and continue.
5.3
Module upgrade error
If a specific module cannot get upgraded, the Status LED in the GUI screen for that power supply will turn RED.
5.4
Loss of connection error
If the interface should get disconnected during the upgrade process, the Tool will display a message indicating a
disconnect and upon correction of the problem the upgrade can restart.
5.5
RS-485 installation error
Connecting the RS-485 cable may not always be successful the first time. Disconnect and reconnect the RS485
cable.
5.6
Compatibility code mismatch
Compatibility codes are used to validate that the firmware in the power supply is suitable to be upgraded by the
uploaded program. If a compatibility code mismatch occurs between the firmware inside the power supply and the
upgrade package, the Tool will not execute the upgrade.. In the event of this error, please contact your GE Technical
Representative for further help.
If multiple power supplies are being upgraded the tool upgrades them one at a time. If an error occurs while
upgrading one of the power supplies, a message is displayed, and the program halts until the OK button is clicked.
The Tool will then proceed to the next power supply and attempt to upgrade it.
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Below is an example of a compatibility error message, in this case the secondary processor compatibility code inside
the power supply does not match that of the upgrade package secondary processor. The upgrade will not
commence.
5.7
Program error
The error below indicates that a non-recoverable programming problem occurred. Contact your local
representatives for further assistance.
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