INSTRUCTIONS FOR UPGRADING

IC693CPU363 WITH VERSION 10.60 FIRMWARE

PER UPGRADE KIT 44A747766-G0[Author ID1: at Tue Mar 23 11:50:00 1999 ]4148-G03[Author ID1: at Tue Mar 23 11:50:00 1999 ]

This CPU model has operating firmware stored in FLASH memory. The firmware upgrade is provided on floppy disks[Author ID1: at Fri Mar 19 14:40:00 1999 ]diskettes[Author ID1: at Fri Mar 19 14:40:00 1999 ]. To perform the upgrade using a personal computer (PC) running Microsoft Windows®, refer to the section “Updating Firmware Under Windows” below for instructions to use the WinLoader program. To perform the upgrade using a PC running Microsoft® MS-DOS®, refer to the section “Updating Firmware Under DOS” later in this document for instructions to use the PC Loader program. The program that you run on the PC is referred to as the ”Firmware Update Utility” in the instructions that follow.

NOTE: The instructions provided outline a specific sequence of procedure that MUST be followed. If the procedure for some reason is not followed, please contact the GE FANUC hotline for help in setting up the PLC. USER FLASH MEMORY WILL NOT BE PRESERVED OVER AN UPDATE. ANY PROGRAM STORED IN USER FLASH WILL BE LOST.

This upgrade is only valid if PLC firmware is at Version 9.01 or later. If the firmware is not already at Version 9.01 or later, the PLC MUST be upgraded to Version 9.01 before upgrading to Version 10.60

TO PERFORM THE FIRMWARE UPGRADE, YOU WILL NEED THE FOLLOWING CABLE:

1. a standard programmer cable (see the table at the end of this document for options)

TO INSTALL NEW FIRMWARE RECEIVED ELECTRONICALLY, PERFORM THE FOLLOWING STEPS:

1. Extract the zip file named a R1060 36x PS.ZIP from the main zip file named cpu363-r1060.zip.

2. Extract all files from the zip file named R1060 36x PS.ZIP to a single high density diskette.

3. Label that diskette “ SNP Port on Power Supply”

4. Extract all files from the zip file named R1000 ESCM P2.ZIP to a second high density diskette.

5. Label that diskette “Port 2 on CPU”.

6. Follow the instructions below.

TO INSTALL THE NEW FIRMWARE, PERFORM THE FOLLOWING STEPS:

1. Save or backup any programs or data resident in the module before performing the update function.

2. Place the PLC in STOP/NOIO Mode.

3. Clear any faults in the PLC.

4. Set the memory protect switch (labeled as “Keyswitch” in accompanying figure) to the OFF position.

5. Clear the configuration in your PLC. This will set the power-supply port baud rate to 19200 and the ESCM port 2 baud rate to 19200. (If they are already set to default values, then this step may not be necessary.)

***Updating Firmware Under Windows (For Windows 95 Windows NT, Windows 98, NOT WINDOWS 3.1): ***

You will need an IBM compatible PC running Windows 95, Windows 98, or Windows NT 4.0, equipped with a 3.5 inch high-density floppy disk[Author ID1: at Fri Mar 19 14:41:00 1999 ]diskette[Author ID1: at Fri Mar 19 14:41:00 1999 ] drive, and an RS-232 serial port. The firmware update process requires 500 KB of hard drive space. If you are using Windows 3.xx or Windows NT 3.51, follow the instructions in the “Updating Firmware under DOS” section.

6. When updating a 363 CPU model, one MUST install the `ESCM' Firmware first. To install `ESCM' Firmware, connect the serial port of your computer (master) to port 2 on the 363 CPU module (refer to Figure 1 to locate port) to be updated (slave). Use a standard LM90 cable and RS232/RS422 converter (GEF part numbers for cables and converters are at the end of this document).

7. Insert the supplied floppy disk[Author ID1: at Fri Mar 19 14:41:00 1999 ]diskette[Author ID1: at Fri Mar 19 14:41:00 1999 ] labeled “Port 2 on CPU” into the floppy disk[Author ID1: at Fri Mar 19 14:41:00 1999 ]diskette[Author ID1: at Fri Mar 19 14:41:00 1999 ] drive of your PC.

8. Invoke the WinLoader either by double clicking on its icon displayed by Windows Explorer or use the “Run…” selection of the Start menu and specify the location of the WinLoader Utility, e.g. “A:\winloader”.

9. The WinLoader Utility uses the COM1 port of your PC by default. If you connected your cable to COM1, skip the rest of this step. If you connected your cable to a different COM port, use WinLoader's “COM Port” drop-down box to select the proper COM port.

10. Select the proper “firmware.dat” file. Left-click on the “DAT” icon in the “Firmware File Selection” section. From the root directory of the disk select the “firmware.dat” file by double-clicking its icon or single clicking on the icon and then clicking on the “Open” button.

11. Click the “Update” button to begin loading the new ESCM firmware. A progress bar appears at the bottom right portion of the window.

12. Upon completion of the update, a window will appear indicating the completion status of the update. If the load completes successfully, the Firmware Update Utility will ask if you want to perform another update. Click “no” and remove the ESCM update floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] from the drive. Go to step 14-WIN below to update the CPU firmware.

13. If the firmware load fails, a window appears indicating the specific error condition that occurred. Take appropriate steps to correct the error and retry the update. Refer to Restarting An Interrupted Firmware Upgrade later in this document.

14. Next, connect one of the serial ports of your PC to the serial port on the power supply (refer to Figure 1) next to the PLC to be updated using one of the cable/converter combinations listed at the end of this document.

15. Insert the disk labeled “SNP Port on Power Supply” into the floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] drive of your PC.

16. Invoke the WinLoader. You may use Windows Explorer and select the root directory, then double click on the displayed WinLoader executable icon. Alternately you can use the “Run…” selection of the Start menu and specify the location of the WinLoader Utility, e.g. “A:\ winloader”.

17. Select the CPU firmware by single clicking on the “DAT” icon in the “Firmware File Selection” section of the WinLoader screen. From the root directory, select the “Firmware.dat” file by double clicking on its icon or single clicking on its icon and single-clicking on the “Open” button. (The name of the CPU firmware file is 360[Author ID1: at Fri Mar 19 14:32:00 1999 ]_[Author ID1: at Fri Mar 19 14:32:00 1999 ]1.emf)[Author ID1: at Fri Mar 19 14:32:00 1999 ]

18. Click the “Update” button to begin loading the new CPU firmware. A progress bar appears at the bottom right portion of the window.

19. Upon completion of the update, a window will appear indicating the status of the update. If the update was successful, power cycle the PLC. All new firmware has been installed. Click “no” to indicate that no additional updates will be performed. If the update was not successful, see the Common Causes of Failure section to determine how to correct the mistake.

***Updating Firmware Under DOS and Windows 3.xx): ***

You will need an IBM compatible PC running DOS (Revision 3.3 or higher), Windows 3.11, or Windows NT 3.51, equipped with a 3.5 inch high-density floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] drive, at least 640K RAM, and an RS-232 serial port. This PC Loader functions optimally with a hard drive with at least 1M available space.

6-DOS [Author ID0: at Fri Mar 19 14:39:00 1999 ] [Author ID1: at Fri Mar 19 14:39:00 1999 ] [Author ID1: at Fri Mar 19 14:37:00 1999 ] [Author ID1: at Fri Mar 19 14:36:00 1999 ]When updating a 363 CPU model one MUST install the `ESCM' Firmware first. To install `ESCM' Firmware, [Author ID0: at Fri Mar 19 14:38:00 1999 ][Author ID0: at Thu Nov 30 00:00:00 1899 ]

[Author ID1: at Fri Mar 19 14:38:00 1999 ]connect the serial port of your computer (master) to port 2 on the 363 CPU module[Author ID0: at Thu Nov 30 00:00:00 1899 ]

[Author ID1: at Fri Mar 19 14:38:00 1999 ] [Author ID1: at Fri Mar 19 14:37:00 1999 ](refer to Figure 1 to locate port) [Author ID0: at Fri Mar 19 14:38:00 1999 ] [Author ID1: at Fri Mar 19 14:38:00 1999 ]to be updated (slave). Use a standard LM90 cable and RS232/RS422 [Author ID0: at Thu Nov 30 00:00:00 1899 ]

[Author ID1: at Fri Mar 19 14:38:00 1999 ]converter (GEF part numbers for cables and converters are at the end of this document).

7. Move the write-protect switch on the floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] to the unprotected position and insert the supplied floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] labeled “Port 2 on CPU” into the A or B floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] drive of your PC.

8. At the C:\> prompt, type A:install (or B:install if your floppy drive is B:) followed by the Enter key. The install program will copy several files to the hard drive then run the PC Loader program. These files will be removed upon completion of the update.

Install can also be run from the floppy drive directly if there is no hard drive or not enough space on the hard drive. To run from the floppy, type install at the A:\> or B:\> prompt.

9. The PC Loader uses the COM1 port of your PC by default. If you connected your cable to COM1, skip the rest of this step. If you connected your cable to COM2, press the F3 key from the PC Loader main menu. Then use Tab to select COM2, and Enter to accept the new setting.

10. Press the F2 key to select the baud rate menu, then use TAB to select 9600 baud, then ENTER. Loader connection to port 2 MUST be initiated at 9600 baud

11. From the PC Loader main menu, press the F1 function key to attach. The message

<< Sending ATTACH - try # 1 >>

will appear. If all is well, this message will blink off briefly and then reappear. If the attach fails, check the serial connection and the Port 1 configuration, then carefully repeat steps 8-DOS through 11-DOS.

12. When the

<< BOOT MODE ACTIVE >>

message appears, you can press the F2 function key to change the baud rate on both ends of the connection. Press the Tab key once to change from 9600 to 38,400 baud. Select a lower baud rate by holding the Shift key down while pressing Tab. Press the Enter key to accept the new setting.

13. Another

<< BOOT MODE ACTIVE >>

message will appear. Press the F1 function key to update the firmware. This message will appear:

THIS WILL ERASE ALL FIRMWARE!

ONCE STARTED YOU CANNOT ABORT

ARE YOU SURE ?!? (Y/N)

WARNING: Pressing the `y' or `Y' key at this point will commit you to completing the firmware load.

Press the `y' key to proceed. The firmware load will take approximately 3-4 minutes at 38,400 baud, 5-6 minutes at 19,200 baud, or 9-10 minutes at 9,600 baud. Upon successful completion, the files that were added to your hard drive are removed. If the firmware load fails, please refer to Restarting an Interrupted Firmware Update.

14. Next, connect either the COM1 or COM2 port on your PC to the serial port on the power supply (refer to Figure 1) next to the PLC to be updated using one of the cable/converter combinations listed at the end of this document. The PC Loader is unable to use COM3 or COM4.

15. Move the write-protect switch on the floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] to the unprotected position and insert the supplied floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] labeled “SNP Port on Power Supply” into your A: or B: drive.

16. At the C:\> prompt, type A:install (or B:install if your floppy drive is B:) followed by the Enter key. The install program will copy several files to the hard drive then run the PC Loader program. These files will be removed upon completion of the update.

Install can also be run from the floppy drive directly if there is no hard drive or not enough space on the hard drive. To run from the floppy, type install at the A:\> or B:\> prompt.

17. The PC Loader uses the COM1 port of your PC by default. If you connected your cable to COM1, skip the rest of this step. If you connected your cable to COM2, press the F3 key from the PC Loader main menu. Then use Tab to select COM2, and Enter to accept the new setting.

18. From the PC Loader main menu, press the F1 function key to attach. The message

<< Sending ATTACH - try # 1 >>

will appear. If all is well, this message will blink off briefly and then reappear. If the attach fails, check the serial connection and the Port 1 configuration, then carefully repeat steps 16-DOS through 18-DOS.

19. When the

<< BOOT MODE ACTIVE >>

message appears, you can press the F2 function key to change the baud rate on both ends of the connection. Press the Tab key once to change from 19,200 to 38,400 baud. Select a lower baud rate by holding the Shift key down while pressing Tab. Press the Enter key to accept the new setting.

20. Another

<< BOOT MODE ACTIVE >>

message will appear. Press the F1 function key to update the firmware. This message will appear:

THIS WILL ERASE ALL FIRMWARE!

ONCE STARTED YOU CANNOT ABORT

ARE YOU SURE ?!? (Y/N)

WARNING: Pressing the `y' or `Y' key at this point will commit you to completing the firmware load.

Press the `y' key to proceed. The firmware load will take approximately 3-4 minutes at 38,400 baud, 5-6 minutes at 19,200 baud, or 9-10 minutes at 9,600 baud. Upon successful completion, the files that were added to your hard drive are removed. If the firmware load fails, please refer to Restarting an Interrupted Firmware Update.

21. To complete the update process, turn PLC power OFF and remove the CPU module. Place the update label adjacent to existing product label. Replace the module and reapply power.

Common Causes of Failure

1. CPU fault table not empty. Using PC Loader: an error message will appear saying “CPU MUST BE IN STOP/NOIO MODE!!” Using LM90, CC90, or an HHP, clear fault tables and make sure PLC is in STOP/NOIO mode. Then go to step 16-DOS and proceed. Using WinLoader: a dialog box will appear saying “CPU State Mismatch.” WinLoader will ask if it's OK for WinLoader to clear fault tables and place PLC in STOP/NOIO mode. Select yes and proceed.

2. Connected to wrong serial port. Using PC Loader: an error message will appear saying “FIRMWARE INCOMPATIBLE WITH CPU MODEL.” Examine cable connections and move cable to Power Supply port (refer to Figure 1). Power cycle PLC and go to step 16-DOS. Using WinLoader: a dialog box will appear saying “FIRMWARE UPDATE FAILED” and listing several possible reasons why the firmware update failed. Examine cable connections and move cable to Power Supply port (refer to Figure 1). Power cycle PLC and go to step 16-WIN.

3. Trying to attach at incorrect baud rate. **Applies to PC Loader only** An error message will appear saying “CPU ATTACH FAILED” Always select 19200 baud. Start at step 11-DOS if the ESCM firmware update failed or step 18-DOS if the CPU firmware update failed and adjust baud rate until attach works then proceed.

4. Memory protect keyswitch at wrong position. Using either PC Loader or WinLoader: an error message will appear that indicates that a FLASH erase operation failed. Place key switch in Off/Stop position (refer to Figure 1 to locate keyswitch). Power cycle PLC and start at step 16-DOS or 16-WIN.

5. Updating in incorrect order. The correct order is ESCM and then CPU firmware. Be sure to follow the instructions sequentially. If an update has already been attempted in the incorrect order, please contact the GE Fanuc Hotline for help and instructions.

6. Disk write-protected. **Applies to PC Loader only** Move the write-protect switch on the floppy disk[Author ID1: at Fri Mar 19 18:05:00 1999 ]diskette[Author ID1: at Fri Mar 19 18:05:00 1999 ] to the protect unlocked position and start over at step 7-DOS if the ESCM firmware update failed or step 16-DOS if the CPU firmware update failed.

7. Cannot connect to the target device. **Applies to WinLoader only** After verifying all of the items listed in the Firmware Update Status dialog box, press OK. Then press the “Settings” button to bring up the WinLoader Settings dialog. Change the “Connect Baud” combo box from “Auto” to “19200”. Press OK and start over at step 18-WIN.

Restarting an Interrupted Firmware Upgrade

A. Carefully check the cables, the RS-232/RS-485 converter, and all connections.

B. If you are restarting the CPU firmware upgrade, power cycle the module and verify that the memory protect switch is set to the OFF position. If a partial or erroneous download was performed, the module will power up with the OK and RUN LEDs on the power supply flashing in unison.

C. You must exit the Firmware Update Utility (on the PC) and start it again, then repeat the upgrade process. If your previous attempt progressed beyond the FLASH memory erase step, began loading data blocks, and then displayed an error message or stalled, try a lower baud rate.

GE Fanuc Cables and RS-232/RS-485 Converters

IC690ACC901	GE Fanuc/Horner Mini Converter with Cable, or
IC690ACC900	GE Fanuc Converter (requires cable IC690CBL303 and either IC690CBL702 or IC690CBL705 below)
IC690CBL303	15-pin RS-442 Serial Cable
IC690CBL702	9-pin RS-232 Serial Cable
IC690CBL705	25-pin RS-232 Serial Cable

Approximate Download Times for CPU363 Upgrades

19200 baud	less than 5 minutes
9600 baud	less than 8 minutes
300 baud	less than 3 hours

Simple Port Diagram

® Microsoft, MS-DOS, and Windows are registered trademarks of Microsoft Corporation.

If you are performing a bulk update of a large number of CPU363s, you may update all the modules' ESCM firmware first and then all the modules' CPU firmware. Note that all of the CPU363s will be tied up with the update process while the bulk update is in progress.

REV DESCRIPTION DATE APPROVED

REVISIONS

DRAWN

CHECKED

ENGRG

ISSUED

DIMENSIONS ARE IN INCHES/MM

TOLERANCES ON:

2 PL DECIMALS

3 PL DECIMALS

ANGLES=

FRACTIONS=

UNLESS OTHERWISE NOTED SIGNATURES DATES

SIZE

A

SCALE

GEGS NO

DWG NO

44A749511148[Author ID1: at Tue Mar 23 11:51:00 1999 ]

SHEET OF

TITLE

INSTALLATION INSTRUCTIONS

THIRD ANGLE PROJECTION

621

VERSION LEVEL

DIST

1 9

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