Quantum Upgrade Procedure
Quantum Upgrade Procedure
Quantum Upgrade Procedure
www.schneider-electric.com
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Purpose
Subject of this
Chapter
This users guide explains how to upgrade Quantum PLCs Operating System
but also the firmware of Ethernet modules
3 Upgrade a PLC from Concept to Unity.
3 Update a PLC from Unity to Unity.
3 Restore Concept IEC / LL984 on a Unity processor
3 Update Quantum NOE modules and embedded Ethernet modules.
3 Upgrade Remote I/O Head and Drop for Change Config On The Fly
Implementation.
Note: Examples and screen shots are provided in this documentation using
OSLoader version 3.0. However, other versions, ranging from 2.0 to latest
versions, may be used. The procedures described hereafter match all versions
from 2.0, and the operating modes are the same for all versions. Please refer
to chapter "Preparing a Quantum update" for more information.
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Summary
1. Preparing a Quantum update ................................................................................................... 4
2. Upgrading a Quantum PLC from Concept to Unity .............................................................. 7
3. Updating a Quantum PLC from Unity to Unity ................................................................... 22
4. Restoring a Quantum PLC from Unity to Concept.............................................................. 32
5. Upgrading a Quantum Hot Standby PLC ............................................................................. 46
Appendix 1: NOE Module Upgrade Procedure ........................................................................ 49
Appendix 2: Quantum CoPro Ethernet Port Upgrade Procedure.......................................... 57
Appendix 3: FactoryCast NOE 77111 Module Upgrade Procedure ....................................... 65
Appendix 4: 140CPU67160 HotStandby CPU Copro upgrade procedure............................. 73
Appendix 5: Upgrading a RIO Head Execs (140 CRP 93X00)................................................ 82
Appendix 6: Upgrading a RIO Drop Execs (140 CRA 93X00)................................................ 89
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Object of this
Chapter
Prerequisites
This update requires a PC with Unity installed and the binary file containing
the OS firmware to download.
Software
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Connecting the
PC to the PLC
for an OS
update or
upgrade
Using the RS232 COM port 1 of the PC by connecting the cable 990
NAA 263 20 (3.7 m) or 990 NAA 263 50 (15 m) to the MODBUS 9 pin
sub-D of the Quantum PLC. The protocol used in this case is MODBUS.
For Quantum CPU 140 CPU 6x1y0 (65150, 65160, 65160S, 65260,
67160,67261, 67160S):
In any case the right communication driver must be first installed on the PC.
Note: All the examples given in this document are using the Modbus
protocol.
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Connecting the
PC to the
Ethernet
module or PLC
coprocessor to
update the
Ethernet
firmware
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 IP
address configuration. Note that the Ethernet 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 Ensure the only devices connected to the Ethernet network are the PC
running the OS loader and the CPU or NOE module.
3 The CPU must be in Stop mode and the NOE module must have no TCP
traffic.
The physical connection between the PC running the OS loader and the CPU
or NOE module can be performed:
3 by connecting directly a crossed Ethernet cable between the PC and the
NOE module
3 by connecting the PC and the CPU or NOE module with two non
crossed Ethernet cables via a Hub.
In these 2 cases, FTP protocol is used and only the Ethernet Coprocessor
firmware of the CPU can be updated by this way.
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Object of this
Chapter
Important
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Connecting the
PC to the PLC
Launching the
OS loader
The OS Loader (provided with Unity) allows the user to download the
Operating System to the PLC. To open it click on Start/Program/SchneiderElectric/Unity-PRO/OS loader.
Once done, the following screen appears:
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Select the
communication protocol
To download the Operating System into the PLC select the right
communication protocol (MODBUS01 or MBPLUS01, in accordance with
established physical link) and click on the
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button.
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Select the
Target Device
Get the
Concept
version
(Optional)
1
Select the PLC
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Click on the
Click on the
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5
6
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Select the
Download
Function
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From the screen described above in the section Select the Target Device
press the
OS to device.
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Click on the
button in order to select the file to download into the
PLC. In this example we will update the OS from 140CPU43412A to
140CPU43412U. For that select the folder:
Quantum\Processor_modules\Concept to_Unity (in your case, select the
folder according to your processor).
For an upgrade from Concept to Unity two binary files can be selected:
3 Concept_to_Unity_43412U.bin (allows to format the processor for
Unity)
3 140CPU43412U_V240.bin is the OS that will finally be download in the
processor.
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button.
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Download the
intermediate
OS
Click the
button. Two screens that give information regarding
the file, the processor and the download are now displayed:
Solve this issue and continue. When the hardware and OS are compatible,
clicking on the
OS file.
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Download the
intermediate
OS file (cntd)
Note: During intermediate download of OS, CPU LEDs do not change state,
Ready LED remains steady and RUN LED keeps blinking.
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CAUTION
EQUIPMENT DAMAGE
During the download:
Do not power OFF the PLC
Do not power OFF the PC
Do not disconnect the cable
Do not shut down Unity Loader
Any loss of communication during the update procedure can cause severe
damage to the CPU or NOE module.
Failure to follow these instructions can result in injury or equipment
damage.
Once the download of the intermediate binary file has 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 Restart button located on the CPU (for
more information, refer to the PLC technical documentation.
3 Power OFF then ON the PLC.
Once the PLC has restarted, If steady Run light and no connection with OS
loader, Reset the PLC. If State of PLC is steady Ready and blinking Run
light, Proceed for phase 3: download the final Unity OS file.
Presentation
The final binary file 140CPU43412U.bin (For the selected CPU in our
example) has to be downloaded.
For that, follow the same procedure as the one described in the Phase 1.
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Download
procedure
As all the necessary actions to download the final Unity OS have been
already fully described in the Phase 1, they are shortly reminded here after:
1
Click on the
button and select (in our example) the file
140CPU43412U_Vxyz.bin located on the CD OS. Then validate this
screen.
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button.
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Download
procedure
(cntd)
button.
Click on
and validate the warning message displayed on
the screen to launch the download of the final OS file.
7
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CAUTION
EQUIPMENT DAMAGE
During the download:
Do not power OFF the PLC
Do not power OFF the PC
Do not disconnect the cable
Do not shut down Unity Loader
Any loss of communication during the update procedure can cause severe
damage to the CPU or NOE module.
Failure to follow these instructions can result in injury or equipment
damage.
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
3 Click on
3 Click on
In our example, the CPU has been upgraded to 140CPU43412U and the OS
version is 2.60.
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This chapter describes how to update a Quantum PLC from Unity version
higher than V2.0 to a more recent one. Note that the update from Unity V1.0
to V2 and above is not covered by this document.
The screens shots given below show how to update a 140CPU65150
processor.
Note: This procedure can be adopted for all Quantum platforms (High End
and Legacy platforms).
Connecting the
PC to the PLC
Launching the
OS loader
The OS Loader (provided with Unity) allows the user to download the
Operating System to the PLC. To open it click on Start/Program/SchneiderElectric/Unity-PRO/OS loader.
Once done, the following screen appears:
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Select the
Communication protocol
button. The
To download the Operating System into the PLC select the right
communication protocol (MODBUS01 or MBPLUS01) for Quantum CPU, in
accordance with established physical link) and click on the
button.
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Select the
Target Device
Before the update, knowing which Unity version is already installed on the
processor may be useful if for any reason a restore function is needed. For
that proceed as follows:
1
Select the PLC
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Click on the
Click on the
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The following screen gives the user some information regarding the
PLC status
3 Started, stopped, Not Configured
3 Processor type (in this example: 140CPU65150
3 The Hardware identification (for Schneider internal use only)
3 The OS version (in this example the OS version is 2.6)
5
6
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Select the
Download
Function
From the screen described above in the section Select the Target Device
press the
OS to device.
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button.
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Download the
OS file
Once the previous screen is validated, two screens display the current OS
version, the processor and the OS file to download:
Solve this issue and continue. When the hardware and OS are compatible,
button and validate the warning message displayed
click on the
on the screen to launch the download of the OS file.
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Download the
OS file (cntd)
During the download (the duration depends on the protocol used, roughly 60
minutes with Modbus) the remaining time is displayed:
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button.
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CAUTION
EQUIPMENT DAMAGE
During the download:
Do not power OFF the PLC
Do not power OFF the PC
Do not disconnect the cable
Do not shut down Unity Loader
Any loss of communication during the update procedure can cause severe
damage to the CPU or NOE module.
Failure to follow these instructions can result in injury or equipment
damage.
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Once the download of the OS file has 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 CPU (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
3 Click on
3 Click on
In our example the CPU has been updated to the version 2.60.
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Object of this
Chapter
This chapter describes how to restore a Quantum PLC from Unity to Concept.
The screen shots given below show how to restore a 140CPU43412U (Unity)
to 140CPU43412A (Concept).
Important
Connecting the
PC to the PLC
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Launching the
OS loader
The OS Loader (provided with Unity) allows the user to download the
Operating System to the PLC. To open it click on Start/Program/SchneiderElectric/Unity-PRO/OS loader.
Once done, the following screen appears:
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Select the
Communication protocol
button. The
To download the Operating System into the PLC select the right
communication protocol (in accordance with established physical link) and
click on the
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button.
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Select the
Target Device
On the Device Type field, select Processor and the other needed parameters
(Modbus address.). Then connect to the selected PLC (Node).
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Select the
Download
Function
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Click on the
button in order to select the file to download into the
PLC. In this example we will restore the OS from 140CPU43412U to
140CPU43412A. For that select the following folders:
Quantum\Processor_modules\Unity_to_Concept.
To restore the OS from Unity to Concept, two binary files can be selected:
3 Unity_to_Concept_43412A.bin (allows to format the processor to
Concept)
3 q5rv135E.bin is the OS that will finally be downloaded in the processor
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button.
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Download the
intermediate
OS
Click the
button. Two screens that give information regarding
the file, the processor and the download are now displayed:
Solve this issue and continue. When the hardware - OS are compatible, click
on the
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Download the
intermediate
OS file (cntd)
Note: During intermediate download of OS, CPU LEDs do not change state,
Ready LED remains steady and RUN LED keeps blinking.
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CAUTION
EQUIPMENT DAMAGE
During the download:
Do not power OFF the PLC
Do not power OFF the PC
Do not disconnect the cable
Do not shut down Unity Loader
Any loss of communication during the update procedure can cause severe
damage to the CPU or NOE module.
Failure to follow these instructions can result in injury or equipment
damage.
Once the download of the intermediate binary file has 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 Restart button located on the CPU (for
more information, refer to the PLC technical documentation).
3 Power OFF then ON the PLC.
Once the PLC has restarted, go to Phase 3: download the final Concept OS.
Presentation
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Download
procedure
As all the necessary actions to download the final Concept OS have been
already fully described in the Phase 1, they are shortly reminded here after:
1
Click on the
button and select (in our example) the file
q5rv135E.bin located on the CD OS. Then validate this screen.
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button.
Download
procedure
(cntd)
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button.
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Click on
and validate the warning message displayed on
the screen to download the final OS file.
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CAUTION
EQUIPMENT DAMAGE
During the download:
Do not power OFF the PLC
Do not power OFF the PC
Do not disconnect the cable
Do not shut down Unity Loader
Any loss of communication during the update procedure can cause severe
damage to the CPU or NOE module.
Failure to follow these instructions can result in injury or equipment
damage.
Checking
version
(optional)
If needed, you can check the new CPU version. For that
3 Open the OS loader tool
3 Select the communication protocol
3 Click on
3 Click on
In our example, the CPU has been restored to 140CPU43412A, version 1.60.
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Object of this
Chapter
This chapter describes how to upgrade a Quantum Hot Stand By PLCs (CPU
67160 , CPU 67261). This Upgrade can be managed by one of the two
communications methods available in the OS loader:
3 Modbus
3 Modbus Plus
Important: the procedure below only gives, step by step, the procedure to
follow. The upgrade procedure itself is described in the chapter 3 of this
document.
Compatibility
issues
Upgrading PLC
while the
process is
running
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Upgrading the
OS without
stopping
Upgrade
procedure
5.
6.
7.
8.
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Applicable Modules
140NOE77101 / 140NOE77111 Kernel 1.0 or higher with any version of Exec.
Overview
The upgrade of a NOE module requires multiple steps. Two components must be
considered to be upgraded, the Kernel and the Exec version. Not all steps listed
below may be required depending on the version of the NOE module before this
upgrade procedure is started.
Pre-conditions
The CPU module must be in STOP mode and the NOE must have NO TCP
traffic.
A loss of power during the upgrade may cause the NOE module to be
inoperable. Make sure the power supply on the NOE module rack will not be
interrupted during the upgrade.
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Step 1
Verify the Kernel and Exec using Concept Exec Loader or Unity OS Loader or
NOE web page.
For modules that have Kernel V1.0 and Exec. Lower than V3.3, you must
upgrade to Kernel V2.0 and Exec V3.30 using the Concept Exec Loader.
For modules that have Kernel V2.0 or higher and Exec. V3.3 or higher, you must
upgrade to Exec. V4.4 using the Unity OS Loader V2.2 or higher.
Step 2
Select the filename to download based on the Current Module Version in the
following table.
Current Module
Version
140NOE77101
Kernel V1.0,
Exec Any
140NOE77101
Kernel V2.0,
Exec < V3.3
File to Select
Resulting Module
Quantum\Ethernet_modul
es\Concept_to_Unity\140
NOE77101\140NOE77101
_V200_KER.bin
Quantum\Ethernet_modul
es\Concept_to_Unity\140
NOE77101\140NOE77101
_V330.bin
140NOE77101 Kernel
V2.0
140NOE77101 Kernel
V2.0,
Exec V3.3
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Step 3
Upgrade the Exec and Web pages to the current V4.4 using the Unity V2.2 OS
Loader or higher.
Ethernet OS Files to Update: 140NOE771x1 Kernel V2.0 or higher, Exec at least
V3.3.
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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 modules MAC address, the MAC address can be found on
the front of the module.
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.
Select Next.
In this example, the IP address used is 192.168.1.11. Adapt this address for the
one of your PLC.
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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
140NOE77101
Kernel V2.0 or
higher, Exec at
least V3.3
File to Select
Resulting Module
Note: For NOE77101 with kernel V4.5 or higher, the compatible firmware exec.
is a V4.0 or higher.
Note: Please read file "Quantum Compatibility Rules" for more version
compatibility information.
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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.
Note: NOE modules should be upgraded to at least Kernel V2.0, Exec V3.30
while installed in a PLC rack containing a CPU running a Concept Level
Executive. Modules running Kernels and Execs without this upgrade may not
complete their boot sequence in a PLC rack containing a Unity CPU.
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Overview
The upgrade of the CoPro Ethernet Port 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 be at its default IP address (as defined by the MAC address).
For Quantum configurations, it is imperative that the update is being carried out
in the following order:
Update of Ethernet coprocessors for 140CPU65150/ 140CPU65160/
140CPU65260.
Update of PLC processors.
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.
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.
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Step1
Ensure the CoPro Ethernet port to be upgraded is listed in the Applicable
Modules section of this document. Refer to the CoPro Ethernet port web pages
for version numbers.
Step2
Install the CoPro module in a system consisting of only the PLC CPU, Power
Supply, and Rack. Configure the PLC system with an empty program containing
only the modules Ethernet link IP address configuration.
Ensure the CoPro Ethernet port has a configured IP address.
Ensure the only devices connected to the Ethernet network are the PC running
the OS Loader and the CoPro Ethernet port module.
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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 modules MAC address, the MAC address can be found on
the front of the module.
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.
Select Next.
In this example, the IP address used is 192.168.1.50. Adapt this address for the
one of your PLC.
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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
140CPU65150
140CPU65160
V2.2 or higher
140CPU65260
V2.4 or higher
File to Select
Resulting Module
Quantum \
Processor_modules \
Unity_Upgrade\
140CPU651x0
\Eth_OS\140CPU651x0_Eth
Copro_V280.bin
Quantum \
Processor_modules \
Unity_Upgrade\
140CPU65260
\Eth_OS\140CPU65260_Eth
Copro_V280.bin
Note: Please read file "Quantum Compatibility Rules" for more version
compatibility information.
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Applicable Modules
140NOE77111 Kernel 1.0 or higher with any version of Exec.
Overview
The upgrade of a NOE module requires multiple steps. Two components must be
considered to be upgraded, the Kernel and the Exec version. Not all steps listed
below may be required depending on the version of the NOE module before this
upgrade procedure is started.
Pre-conditions
The CPU module must be in STOP mode and the NOE must have NO TCP traffic.
A loss of power during the upgrade may cause the NOE module to be inoperable.
Make sure the power supply on the NOE module rack will not be interrupted during
the upgrade.
Note: OS Version numbers displayed in screenshots of following steps are only
examples.
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Step 1
Verify the Kernel and Exec using Concept Exec Loader or Unity OS Loader or NOE
web page.
For modules that have Kernel V1.0 and Exec lower than V3.0, you must upgrade to
Kernel V2.0 and Exec V3.30 using the Concept Exec Loader.
For modules that have Kernel V2.0 or higher and Exec. V3.0 or higher, you must
upgrade to Exec V4.2 using the Unity OS Loader v2.2 or higher.
Step 2
Select the filename to download based on the Current Module Version in the
following table:
Current Module
Version
File to Select
Resulting Module
140NOE77111 Kernel
V1.0, Exec Any
Quantum\Ethernet_modules\Concept_to_
Unity\140NOE77111\140NOE77111_V20
0_KER.bin
140NOE77111 Kernel
V2.0, Exec < V3.10
Quantum\Ethernet_modules\Concept_to_
Unity\140NOE77111
\140NOE77111_V330.bin
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Step 3
Upgrade the Exec and Web pages to the current V4.2 using the Unity V2.2 OS
Loader or higher.
Ethernet OS Files to Update: 140NOE771x1 Kernel V2.0, Exec at least V3.0.
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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 modules MAC address, the MAC address can be found on the
front of the module.
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.
Select Next
In this example, the IP address used is 192.168.1.11. Adapt this address for the one
of your PLC.
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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
140NOE77111 Kernel
V2.0, Exec at least V3.0
Quantum\Ethernet_modules\C
oncept_to_Unity\140NOE7711
1\ 140NOE77111_V460.bin*
Comment:
140NOE77111Kernel
V2.0, Exec V3.0 or
higher can be directly
upgraded to Exec V4.6.
If users want to use the
early version 3.x, it also
can be directly
upgraded.
Resulting Module
140NOE77111 Kernel V2.0,
Exec V4.60
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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.
Note: NOE modules should be upgraded to Kernel V2.0, Exec V3.30 while installed
in a PLC rack containing a CPU running a Concept Level Executive. Modules running
Kernels and Execs without this upgrade may not complete their boot sequence in a
PLC rack containing a Unity CPU.
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Procedure
The procedure needs 2 preliminary steps before the upgrade operation:
(Each step is detailed in the following pages)
24 Vdc
490NOC00005 fiber
optic cable
RJ45/RJ45
direct cable
PC + ETH card
Switch
TCSESM083F2CU0
140CPU67160
24 Vdc
RJ45/RJ45
direct cable
PC + ETH card
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VDIF0626463505 fiber
optic cable
Switch
TCSESM083F2CS0
140CPU67261
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Note: Copro Firmware is common for CPU 67160 and CPU 67261.
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Download the file into the PC (in this example HSBY Copro Firmware 2.11IE80).
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Click twice on the network corresponding to the ETH card , then on Internet Protocol
(TCP/IP) from associated window (hereunder).
From Internet Protocol window (above on the right part) change IP address field
according to PLC one (ex: 85.16.33.12) (dont forget to notice the existing parameters
in order to restore them if necessary).
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Fill the FTP Address field with the PLC IP address (available by the LCD Screen) then:
Click on Connect.
Fill the MAC Address field with the PLC MAC Address then click on OK.
Click on Next.
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Choose Download OS to Device and Retrieve the firmware file using the Browse facility
(in this example hsby copro fw_ie80.bin).
Valid by clicking on Next.
The Device identification screen is displayed. Check that the right Copro Firmware will be
downloaded in the device.
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Follow the steps below to download a new CRP Exec using Osloader.
Note : Here is the configuration used for the procedure.
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Step
1
2
3
Action
Activate the OSloader program.
Click Next to start the OSloader process.
Click the MBPLUS01 button, and click Next.
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Step
4
Action
Click the Local Head (for CRP) and precise Slot number (for this
configuration is 6), and click Next.
Scanning a Network
To scan a network, select the Scan button. As the network is scanned, a
graphic representation of the network is displayed in the Devices scroll box.
All currently active devices are represented by icons on the display.
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Step
5
Action
Click the Download OS to device button.
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Step
7
Action
The OSloader File and Device info dialog box opens. Click Next.
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Step
8
Action
The OSloader Summary dialog box opens:
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Step
10
11
Action
The OSLoader Progress dialog box opens:
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Action
Activate the OSloader program.
Click Next to start the OSloader process.
Click the MBPLUS01 button, and click Next.
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Step
4
Action
Click the Remote I/O Drop (for CRA) and precise Slot number (for this
configuration is 6) and drop number (for this configuration is 2), and click
Next.
Scanning a Network
To scan a network, select the Scan button. As the network is scanned, a
graphic representation of the network is displayed in the Devices scroll box.
All currently active devices are represented by icons on the display.
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Step
5
Action
Click the Download OS to device button.
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Step
7
Action
The OSloader File and Device info dialog box opens. Click Next.
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Step
Action
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Step
10
11
Action
The OSLoader Progress dialog box opens:
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