1. To Join the Telephone Conference . . .
In the United States, dial
Outside the United States, dial
Please specify conference ID
Upgrade Boundaries
RS5K
V2 to present– CFlash local chassis modules only
V13 and prior f/w releases – Hyperterminal was required to SERCOS drives, UltraWARE for U3K
V13 – Implemented “Browsing” over SERCOS to the servo drive using RSLinx
Important because you can now see the drive through RSLinx, although you cannot flash to it.
V13 - AutoFlash was implemented for motion modules in the chassis (not drives).
V15 - ControlFlash & AutoFlash over SERCOS implemented (1756-RN619C-EN-E & 2094-RN006E).
V16 - Firmware Supervisor Implemented
V17 – Kinetix 6200 introduced – CFlash capable
V18 –Kinetix 6500 introduced – CFlash capable
V19 – Kinetix 300 – Uses MotionView for upgrades
V20 – Kinetix 350 introduced – CFlash capable (hardware available now)
We will send a link to a recording of
this broadcast following the WebEx session.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

2. Managing ControlLogix Motion Firmware Upgrades
September 2011 TechConnect Genius Webinar
Ken Minichiello
Screens on the ready
RS5000
Kinetix 6000 release note opened at the restrictions / known anomalies page
Support Webpage
ControlFlash

3. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Agenda
We’ll cover the following topics:
1. Flash Upgrade Boundaries
2. Compatibility Conflicts
3. Upgrade Tools & Diagnostics
4. EDS Files & Motor DB Files
Products Covered
Kinetix 300, 350, 2000, 6000, 6200, 6500, 7000
Ultra 3000 SERCOS
1394 SERCOS
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

4. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
RSLogix 5000 Boundaries
V2 to present – ControlFlash, local chassis
V13 and prior – Hyperterminal
V13 – Browsing Only
V13 – AutoFlash local chassis
V15 – ControlFlash & AutoFlash over SERCOS
V16 – Firmware Supervisor
V17 – Kinetix 6200
V18 – Kinetix 6500
V19 – Kinetix 300 – MotionView
V20 – Kinetix 350
Upgrade Boundaries
RS5K
V2 to present– CFlash local chassis modules only
V13 and prior f/w releases – Hyperterminal was required to SERCOS drives, UltraWARE for U3K
V13 – Implemented “Browsing” over SERCOS to the servo drive using RSLinx
Important because you can now see the drive through RSLinx, although you cannot flash to it.
V13 - AutoFlash was implemented for motion modules in the chassis (not drives).
V15 - ControlFlash & AutoFlash over SERCOS implemented (1756-RN619C-EN-E & 2094-RN006E).
V16 - Firmware Supervisor Implemented
V17 – Kinetix 6200 introduced – CFlash capable
V18 –Kinetix 6500 introduced – CFlash capable
V19 – Kinetix 300 – Uses MotionView for upgrades
V20 – Kinetix 350 introduced – CFlash capable (hardware available now)
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

5. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Firmware Boundaries for ControlFlash, AutoFlash and Firmware Supervisor
SERCOS Module ---> v15.32
Kinetix > V1.xx
Kinetix > v1.95
Kinetix 6000 Series A ---> v1.85
Kinetix 6000 Series B ---> v1.111 *
Kinetix 6000 (safe-off) ---> v1.88 **
Kinetix 6000 Series B HV ---> v1.118 ***
Kinetix > v1.003
Kinetix > v1.011
Kinetix > v1.90
ULTRA > v1.50
> v1.085
> v 3.85
RSLinx > v 2.50
Firmware Boundaries for ControlFlash, Auto-Flash & F.S.
SERCOS Module ---> v15.32
Kinetix > v1.xx
Kinetix > v1.95
Kinetix 6000 Series A ---> v1.85
Kinetix 6000 Series B --->v1.111*
Kinetix 6000-S (safe-off) ---> v1.88 **
Kinetix 6000 Series B HV ---> v1.118 ***
Kinetix > v1.003
Kinetix > v1.011
Kinetix > v1.90
Ultra > v1.50
> v1.085
> v 3.85
RSLinx ---> v 2.50
* Cannot be back flashed prior to v However it is drop in compatible to V13 of the controller & motion mod.
** SafeOff drive cannot be flashed prior to V ControlFlash will timeout & HyperTerminal will err before xmitting.
*** The 2094-BM03 & BM05 series B with the new power structure cannot be backflashed prior to V1.118
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

6. Resources That Can Help You to Avoid Compatibility Conflicts
Get Support Now Site
Firmware Updates
Software Updates
EDS Files
Motion Database
Release Notes
Drive Amplifier
Motion Module
Controller
RSLogix 5000
Rockwell Automation Support Center/Knowledgebase
Call Technical Support
Product Compatibility & Download Center
Avoiding Compatibility Conflicts
This slide will focus on firmware compatibility, other upgrades, such as motor, amp, etc.. beyond scope of presentation
Firmware Downloads -
Firmware Download Matrix shows straight-line compatibility. Essentially what was tested in-house as a system. Product Notices & PSA are removed although.
Also on the firmware page includes the pdf downloadable release note.
Software Downloads -
Current and Past Software releases
EDS File Downloads -
Motion Database – RAWiki (Rockwell Folks or Knowledgebase document for distributors)
Release Notes contain Corrected anomalies, Current anomalies, Restrictions, and New enhancements. Therefore each of the following:
Drive Amplifier; Motion Module; Controller (L63, L73,etc); RS5K
Knowledgebase
All PSAs, PNs available
Call Technical Support
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

7. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Examples
FEATURE ENHANCEMENTS -Phase Loss detection added in V1.95 & V16; Home to Torque added V1.95 & V16
Slight Risk Example 1: Have a running system at V16 using phase loss detection. One of the drives running at V1.95 or greater fails. You noticed you have a v1.90 sitting on a shelf. The problem is that installing V1.90 doesn’t understand phase loss detection. Therefore upon power up the ring would most likely get stuck at phase 3 with an attribute error.
Slight Risk Example 2: Instead of running phase loss detection, your system is set up to use the feature “Home to Torque”. The outcome is the same. The old fw does not recognize the new feature, and will stall at phase up.
Slight Risk Example 3: Considerations for instruction execution times, Drive Status update rates etc..
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

8. Upgrade Tools: ControlFlash
Objective
Availability of firmware
Breaking down the install process
Download as .ZIP
Unzip
ControlFlash.msi (V16 and later)
Setup.exe (V15 & prior)
Installation
.bin
.nvs
ControlFlash utility
Run ControlFlash
Log file (traps errors)
ReadMe file (Rev history & Limitations)
Control Flash the first of three available tools
ControlFlash – Objective : Control Flash is the utility used to update firmware on ControlLogix Modules, including SERCOS and CIP servo drives.
Control Flash – Availability : Most firmware revisions for most products can be found on our support website:
ControlFlash – Breaking down the install process
Control Flash firmware kits are downloaded as .zip files.
Unzipping the downloaded file will reveal either an ControlFlash.msi install file (V16 & later release), or multiple files including a Setup.exe file (V15 and prior release).
Executing the ControlFlash.msi or the setup.exe will install Control Flash, its required drivers, & product specific nvs & binary files (.bin) .
The .bin is the actual firmware loaded on to the module
The .nvs is the roadmap for that binary (bin) file to know which product and revision it is allowed to download to.
Lastly run CFlash.
Log File will trap errors when CFlash fails to complete.
A readme file exists - rev history of changes to ControlFlash and other known limitations
NOTE: Previous slide: f/w Kit 2 (KB 45509)
A kit change denotes a change in the CFlash NVS files associated with the specified module. The first use of this signature was with V16.1 Kit 2 f/w for the M02AE
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

9. Upgrade Tools: AutoFlash
Objective
Breaking down the execution process
Auto-Flash Objective - is a process, triggered during a download, that maintains correlation between the modules properties in RS5K, and the actual firmware on the module.
Auto-Flash Breaking Down the process: Auto-Flash relies on keying (compatible or exact match) to trigger pop-up dialog to warn the user of mismatching firmware. In this example, exact match was selected for keying, with a minor rev level discrepancy on the hardware .
If Firmware Revision comes up as “Not Found” the revision being requested to “Update To”, does not exist in the ControlFlash folder hierarchy. In other words, selecting exact match v1.112 when only V1.113 exists in the ControlFlash subfolder.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

10. Upgrade Tools: Firmware Supervisor
Objective
Breaking down the configuration process
Advantages
Faster than ControlFlash
Five instances can execute simultaneously (excluding drives)
Maintain consistent revision matching during replacement process
Error Messages
Controller Properties page
RSLogix 5000 message window
References
Knowledgebase 38137
Processor Specifics
The L6x controllers should never brick
Backing up an ACD project
Firmware Supervisor – Objective
Firmware Supervisor is a method used to automatically maintain firmware revision levels on a module or drive to a specific major and minor revision level (excluding the controller) without user intervention. In the event a module or drive is changed out, Firmware Supervisor will use the flash files stored on the Compact flash card, to automatically flash the module or drive hardware, to the selection specified on its associated modules properties page. So how do we configure F.S. to allow this to happen?
Firmware Supervisor – Breaking Down the Configuration Process
On each module / drives properties page, specify exact match & the desired f/w rev.
Processor Properties  Non-volatile tab, the Inhibit automatic update box should not be checked .
Compact Flash card must be resident in the processor (Load/Store option with be grayed otherwise)
Processor in either Program or Remote Program mode (Load/Store option will be grayed otherwise)
“Automatic Firmware update” should be checked on the Proc Properties --> Non-volatile  Load / Store page.
NOTE: The Load / Store page, Load Image selection “On Corrupt Memory” or On Power Up” is for restoring or upgrading the processors memory and ACD project
Use the Store option to a copy the firmware flash files to the Compact flash card using the store option.
Firmware Supervisor - Advantages
Firmware Supervisor is much faster than ControlFlash when flashing multiple modules, because up to 5 instances of flashing can take place simultaneously with Clogix modules, although only one amplifier can be flashed at a time.
Firmware Supervisor – Error Messages
If FS fails to locate the binary file on the Compact Flash card, error message “Firmware Update files not found on workstation or controller” will get annunciated.
Firmware Supervisor - References
More info on Firmware Supervisor can be found in KB 38137
Processor Specifics
The L6x processors should never brick (in theory), because they are loaded with a boot image. The boot image should allow the processor to recover whenever memory from an upgrade fails.
When an ACD project is upgraded to a newer revision, the old project will be saved with the extension of the old project rev. For an example, a project named TEST.ACD created as a V16 project, when converted to V17 will create a file named TEST.ACD_V16.
Controller must match the ACD project revision.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

11. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Diagnostics
Upgrade - Diagnostics
Kinetix SERCOS Amplifier
Kinetix CIP Amplifier
ULTRA 3000
ControlLogix SERCOS Modules
ControlLogix Analog Modules *
RSLogix 5000 (Firmware Supervisor)
* Analog Module exceptions - M02AE, M02AS, HYD02
Eliminate backplane connections
ShutDown non-essential services
ShutDown software programs
V17 enhancement
WARNING: Do not interrupt the module (remove power, remove comm cable, pull module, etc..) during the flash process. Wait for ControlFlash to time out; otherwise the module can be damaged (solid red OK LED).
Upgrade – Diagnostics
Kinetix SERCOS Amplifiers
K2K, K6K, K7K amplifiers will display an “F”, and associated Kinetix amplifiers will display a “5”. When complete should re-phase to level 4, or minimally phase 2
Kinetix CIP Amplifier
K6500 amplifier will display “Firmware Update” (RS5K =16#0010). When completed should reset, reconfigure, and minimally reach a precharge state.
Ultra 3000
U3K amplifier will also display an “F”. When complete SERCOS should re-phase to level 4 (or min phase 2).
CLogix SERCOS Modules
CP (com phase) led, and the OK led will flash green
CLogix Analog Modules
OK led will typically flash red, and will change to blinking green when flash completes
RS5K (Firmware Supervisor)
Message displayed in RS5K’s modules info tab implying “firmware upgrade in Progress”.
Processor properties page  Non-volatile memory tab will also imply firmware upgrade in progress.
User can program a GSV to read the “Firmware Supervisor Status” bit. However the status bit is only reliable with V18 and above firmware.
Analog Module Exceptions - Occasionally the analog modules (M02AE, M02AS, HYD02) can be temperamental when initiating the Control Flash process. Therefore check or execute the following when the CFlash process times out.
Make sure the ok led is flashing or solid green prior to flashing.
Remove as many modules from the local chassis as possible (partially slide out of the slot).
Worse case scenarios, remove all modules in the chassis, then move the card to another slot .
Absolute worse case, Move the card to a different chassis altogether.
Run CFlash on a non-dual / quad core PC.
Shutdown all Rockwell Software & Services, then allow CFlash to launch RSLinx (KB27253).
Once the firmware on the above modules are at V17, it will contain a more robust flash algorithm.
WARNING: Do not interrupt the module (remove power, remove com cable, pull module, etc.) during the flash process, until it has completed the flash process. The module will eventually time-out will an error (check the log file) if the flash cannot complete. Otherwise the module can be damaged (solid red OK led).
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

12. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
EDS Files
Objectives
Attaining EDS files
RSLinx
Knowledgebase
Determining resident EDS files
EDS hardware installation tool
Windows folder
RSLinx & EDS Files
RSLinx 2.54 or greater must be used for V17.
RSLinx 2.55 or greater must be used for V18
RSLinx 2.56 does not contain any new EDS files for any motion
RSLinx 2.57 or greater must be used for V19 (2.58 latest release).
EDS Objectives
EDS (Electric Data Sheets) files are needed by RSLinx to identify specific modules and unique f/w revs for that module. Without the EDS file present, the module will not be distinguishable in RSLinx, typically showing up with a question mark. Thus data exchange is not necessarily guaranteed.
Each product and product revision has a unique EDS File, approx 1000 EDS files exist.
Typically, missing EDS files will prohibit the user from browsing beyond that device
Attaining EDS Files
EDS files are automatically installed with RSLinx. However you’ll only get the latest EDS files at the time of that release of RSLinx.
Another option, download EDS file from our website -
Brand new firmware release, check our knowledgebase.
Determining Resident EDS Files
From Rockwell Software  RSLinx  Tools run the EDS hardware installation Tool. Once the dialog window appears, select the “Remove” option. This option will populate the window (takes a few minutes) with all the installed EDS files. HOWEVER, do not proceed beyond this point (select exit), or EDS files will be removed.
If you are familiar with the file coding scheme, you can also check the windows folder ProgramFiles / RockwellSoftware / RSCommon as all the EDS files are stored here.
RSLinx & EDS Files
RSLinx 2.54 or greater must be used for V17.
RSLinx 2.55 or greater must be used for V18
RSLinx 2.56 does not contain any new EDS files for any motion
RSLinx 2.57 or greater must be used for V19 (2.58 latest release)
A few identified limitations with missing EDS file
If the correct EDS file is not registered for the associated f/w revision of the Kinetix 6500 drive, the option “IP Port Configuration” located in RSLinx under “Module Configuration” will not be present.
If the correct EDS file is not registered for the associated f/w rev on the enet module, browsing to the Kinetix 6500 drive not possible to update its firmware.
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

13. Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
Motor DB Files
Motor Electrical Characteristics
Standard
Custom
RSLogix 5000, axis properties drop-down selection
Previously created motors
New Motor request
V17 and prior
V18 / V19 changes
Start -> Programs -> RockwellAutomation -> MotorDatabaseTool
Import Utility Restrictions
Must be RSLogix 5000 v12 and later
It is Not Windows 7 compatible
Identifying Motor db revision levels :
RS5K Tools -> Options - Motion
Motor db 5.xx  V17
Motor db 4.xx  V16
Motor db 3.xx  V12 thru V15
Motor DB Objectives – Brief Look
Motor Electrical Characteristics - Each motor interfaced to one of our servo systems, needs to be defined by its electrical characteristics. Those electrical characteristics are stored in a Standard or Custom motor db file, that RS5K uses, for the default axis configuration data.
Standard – Pre-existing grouping of Rockwell motors.
As new motors are created they are added to the database at the next release.
Custom - Any motor created for a specific app that’s not part of the standard database. Example: 3rd party motors (Koll-Morgan, Anorad Linear), or some combinations thereof.
RS5K - Once the motor or motors (cmf file) has been imported to the motor db file, it should show up in the drop-down list on the Drive / Motor tab.
Previously Created motors – RA folks (RAWiki) or the Distributor (KB335952) can check if a motor cmf has already been created. If so, Commercial Engineering the appropriate cmf file and import utility.
New Motor Request – We’ve been instructed to contact your local SA or TC
V17 and prior – A motor db would have been created for a specific application.
V18 / V19 – Motor db file was eliminated. Use import utility to bring in an existing .cmf that was created for your app.
Start -> Programs -> RockwellAutomation -> MotorDatabaseTool
Import Utility Restrictions
Must be RS5K v12 or later
Not Windows 7 compatible
Motor db revision levels
RS5K Tools -> Options - Motion
Motor db 5.xx  V17
Motor db 4.xx  V16
Motor db 3.xx  V12 thru V15
always an option for a new RA motor not found
Copyright © 2011 Rockwell Automation, Inc. All rights reserved.