Executing the Operating System Upgrade Procedure
Original instructions
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General
Perform an operating system upgrade using the OSLoader tool. Use one of 2 communication methods available in the OSLoader:
Using Modbus
List of the useful material:
All the references about the keyboard are detailed in the Quantum Hardware Reference Manual:
To upgrade without stopping, refer to the Upgrading the Operating System without Stopping topic.
OS Upgrade Procedure
When using Modbus or Modbus Plus, only address 1 is allowed for downloading. Ensure that no other device on the network uses address 1:
Step
Action
1
Connect Control Expert to the primary CPU (through Modbus, Modbus Plus or USB).
2
Set the Command Register system bit %SW60.4 to 1.
3
Disconnect Control Expert from the primary CPU.
4
Note the Modbus or Modbus Plus address of the standby CPU using the keyboard functions.
  • for Modbus: PLC Communications → Communications Serial Port
  • for Modbus Plus: PLC Communications → Communications Modbus Plus
5
Stop the standby CPU with the keyboard functions.
NOTE: The standby CPU goes to STOP Offline mode; the primary CPU operates as a standalone CPU.
6
Disconnect all the communication links (Hot Standby fiber optic cable, Ethernet cables, Modbus Plus cables …) from the standby rack.
7
Switch off the power of the standby rack.
8
When using an application in the PCMCIA card:
  • Remove the PCMCIA card from the standby CPU.
  • Remove the PCMCIA batteries to empty the card contents.
9
Power on the standby CPU.
10
If not set to 1, change the Modbus or Modbus Plus address of the standby CPU to 1 with the keyboard functions
  • for Modbus: PLC Communications → Communications Serial Port
  • for Modbus Plus: PLC Communications → Communications Modbus Plus
11
coprocessor upgrade:
  1. Connect the PC to the standby CPU using Ethernet (with appropriate switch and optical cable).
  2. Open the OSLoader tool.
  3. Select the FTP communication option.
  4. Connect the PC to the standby CPU using the PLC IP address (read on the keypad).
  5. Download the operating system to the standby coprocessor.
  6. Power cycle the CPU.
12
CPU operating system upgrade:
  1. Connect the PC to the standby CPU using Modbus or Modbus Plus.
  2. Open the OSLoader tool.
  3. Select the Modbus or Modbus Plus communication option.
  4. Connect to the standby CPU using address 1.
  5. Download the operating system to the standby CPU.
13
140CRP31200 firmware upgrade:
Use the instructions in the following Firmware Upgrade Procedure topic to upgrade the firmware for the 140CRP31200 remote I/O head module in the standby rack.
NOTE: During the firmware upgrade, the I/O communications with the remote I/O adapter module and the 140CRP31200 module in the primary and standby racks are interrupted.
When the firmware on the 140CRP31200 in the standby rack is upgraded, perform a manual switch-over that gives the newly upgraded standby rack the role of primary rack.
Upgrade the firmware for the adapter in the (new) standby rack to facilitate future Hot Standby switch-overs.
14
Disconnect the PC from the standby CPU.
15
Switch off the power of the standby CPU.
16
When using an application in the PCMCIA:
  1. Insert the PCMCIA batteries.
  2. Insert the PCMCIA card in the standby CPU.
17
Power on the standby CPU.
NOTE: The CPU must be in the No Conf state.
18
Check the copro and operating system versions in the CPU LCD screen.
19
Reconnect all the communication cables (140CRP31200 module, Ethernet cables, …). Connect the Hot Standby sync-link fiber optic cable last.
20
Check that the application program is automatically transferred to the standby CPU. If not, perform the transfer with the keyboard.
NOTE: Verify that the Modbus or Modbus Plus address is the same as the address indicated in step 4.
21
Put the primary and standby CPUs in the RUN Primary and RUN Standby modes.
22
Perform a switchover by stopping the primary CPU with the keyboard.
NOTE: Verify that the standby CPU becomes the primary CPU (check the LCD screen).
23
Repeat steps 4 through 22 on the new standby CPU.
24
Connect Control Expert to the new primary CPU (through Modbus, Modbus Plus or USB).
25
Set the Command Register system bit %SW60.4 to 0.
26
Disconnect the PC and verify that the primary and standby CPUs are in Run Primary and Run Standby modes.
Executive Firmware Upgrade Procedure
Follow these steps to upgrade either the firmware kernel or the firmware executive.
NOTE:
  • We recommend that you update the kernel before you upgrade the exec. Both firmware upgrade files are installed in the same manner. The only difference is the name of the file you select.
  • Make sure that there is no interruption to power or communications during the firmware upgrade process. Otherwise, the 140CRP31200 module can be damaged.
Step
Action
Comment
1
Connect the PC that is running the Control Expert OS Loader directly to one of the module ports.
Available ports:
  • SERVICE port:
    • 140CRP31200 remote I/O head module
    • 140CRA31200 remote I/O adapter module (Quantum remote drop)
    • BMXCRA31210 remote I/O adapter module (M340 remote drop)
  • INTERLINK port (140CRP31200)
  • DRS port that is configured for a distributed I/O cloud
2
Launch OS Loader.
Start → Programs → EcoStruxure Control Expert → OS Loader.
3
Click Next to continue.
Go directly to the first installation step.
4
Select the FTP communication driver and press Next to continue.
The next screen displays a list of devices discovered by OS Loader. It also displays the FTP address for each discovered device.
5
In the Target Address area, type in the FTP Address of the 140CRP31200 module that is the target of the upgrade.
—
6
Click Next to continue. Perform these tasks at the next installation screen: a Select Download OS to device. b Click the Browse button to navigate to and select the desired firmware upgrade file.
—
7
Click Next. Perform these tasks at the next installation screen: a Compare the selected firmware File against the firmware already loaded in the Device. b Confirm that the Hardware ID for both the file and the device are the same
—
8
Click Next. On the summary page, click Download.
The OS Loader displays the progress of the FTP session. The download is complete when it displays the word SUCCESS.
9
Click Close.
The firmware download is finished.
The upgrade process takes approximately 2 minutes:
NOTE: During the firmware upgrade, the I/O communications with the adapter module on the remote drop are interrupted. After the hold up time expires, the I/O modules return to their fallback state.
Compatibility Issues
To upgrade a Quantum Hot Standby Operating System without shutting down the process, the current application program must be executable by the new Operating System.
Observe this requirement when installing minor revisions targeted for bug fixes or minor enhancements.
When a major function enhancement needs to be made, maintaining this compatibility may not be possible.
In this case, to perform an Operating System upgrade requires a system shut down.