Premium Upgrade Procedure PDF

PLC Operating System
Upgrade and Update Procedure

(Premium Part)
Edition V0.3 - March 2011
Why this Documentation?

Subject of this
Chapter
This users guide explains how to upgrade Premium PLCs Operating System
but also the firmware of Ethernet modules
Premium PLCs
3 Upgrade a PLC from PL7 to Unity
3 Update a PLC from Unity to Unity
3 Update Premium ETY modules and embedded Ethernet modules
3 Restore PL7 on a Unity processor
Summary
1. Prepare a Premium update ....................................................................................................... 4
2. Upgrading a Premium PLC from PL7 to Unity...................................................................... 7
3. Updating a Premium PLC from Unity to Unity.................................................................... 18
4. Updating Premium PLC with an Ethernet Port ................................................................... 25
5. Updating Premium PLC with an Ethernet Co-Processor.................................................... 27
6. Updating HotStandby Premium PLC................................................................................... 29
7. Restoring a Premium PLC from Unity to PL7 ..................................................................... 32
Appendix 1 : ETY Module Upgrade Procedure ...................................................................... 43
Appendix 2: Premium CoPro Ethernet Upgrade Procedure................................................ 54
Appendix 3 : FactoryCast ETY 510 Module Upgrade Procedure ......................................... 61
1. Prepare a Premium update
Object of this
Chapter
This chapter describes how to prepare a Premium PLC in order to update or

upgrade PLCs Operating System and / or Ethernet modules.
Prerequisites
This update requires a PC with Unity installed and the binary file containing
the OS firmware to download.
Software
The following software are required :

3 Unity Pro V2.0 mini must be installed on the PC (note that is not
necessary to launch Unity for an OS upgrade).
3 Unity Pro V4.0 mini for upgrading HotStandby processors .
3 The CD Unity OS firmware provided with Unity Pro <=V4.0 and
that contains all the OS for Quantum and Premium PLCs or only the
specific OS file for your PLC you previously have downloaded from
the Schneider web site http://www.schneider-electric.com.
3 For Unity >V4.0 , CD with OS is no more supplied in Unity Pro
package so you must get the eCD Unity OS firmware on
http://www.schneider-electric.com. it contains all the OS for
Quantum, Premium and M340 PLCs. Last versions of eCDOS are
provided separately, please consult eCDOS Premium
3 The OS Loader (installed with Unity Pro). This tool allows the user to
download PLCs Operating System and Ethernet modules firmware.
Connecting the
PC to the PLC
to update an
Ethernet
module
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
ETY IP address configuration. Note that the ETY 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 If the PLC system has no configuration you can also connect the PC
to the Ethernet module like this :
- Use 85.16. XXX.YYY as Ethernet IP address for the module .XXX
and YYY are the two last terms of MAC address converted in
decimal. Mask is 255.255.255.0
- Use 85.16.XXX.zzz for PC local IP address with the same mask.
3 Ensure the only devices connected to the Ethernet network are the PC
running the OS loader and the ETY module
3 The CPU must be in Stop mode and the ETY module must have no
TCP traffic.
The physical connection between the PC running the OS loader and the ETY
module can be performed :
3 by connecting directly a crossed Ethernet cable between the PC and
the ETY module
3 by connecting the PC and the ETY module with two non crossed
Ethernet cables via a Hub
Connecting the
PC to the PLC
for an OS
update
Two possibilities can be proposed to connect the PC to the PLC :

1) Using the RS232 COM port of the PC by connecting the cable
TSXPCX1031 to the TER port of the Premium PLC. The rotary switch of the
cable must be set on TER DIRECT and the Unitelway driver already installed
on the PC.
2) Using one USB port of the PC as described below. In this case :
3 plug the USB RS485 converter (TSXCUSB485) into the PCs USB
port
3 plug the RJ45 connector of the TSXCRJMD25 cable into the RJ45
port of the TSXCUSB485 converter
3 plug the Mini Din connector of the TSXCRJMD25 cable to the TER
port of the Premium PLC.
The rotary switch of the converter must be set on TER DIRECT and the
Unitelway driver (V1.9 minimum) already installed on the PC
Note that the cable TSXPCX3030 (no more commercialized) can be used to
connect the USB port of the PC to the TER port of the PLC.
2. Upgrading a Premium PLC from PL7 to Unity
Object of this
Chapter
This chapter describes how to upgrade a Premium PLC from PL7 to Unity.
The screens shots given below show how to upgrade a TSX P57 253 (PL7) to
TSX P57 254 (Unity). This procedure is similar for all other type of PLCs
Warning
Upgrading a PLC from PL7 to Unity requires to perform three main phases :
3 Phase 1 - Upgrade the PLC to Unity with an intermediate OS
3 Phase 2 - Power OFF then ON the PLC
3 Phase 3 - Update the Operating system with the appropriate file
Those phases are mandatory and cannot be by-passed.
Each phase is described in the following procedure
Connecting the
PC to the PLC
This phase is fully described in the chapter 1 of this document.
Launching the
OS loader
The OS Loader (installed with Unity Pro) allows the user to download the
Operating System to the PLC. To open it, click on
Start/Program/Schneider-Electric/Unity-Pro/OS loader
Once done, the following screen appears :
Select the com

munication
protocol
From the main screen of the OS loader, click on the

following screen appears :
button. The
To download the operating System into the PLC select the Unitelway
communication protocol (UNITLW01) and click on the
button.
Select the
Target Device
On the Device Type field, select Processor
Get the PL7

version
(optional)
Knowing which PL7 version is installed on the processor could be useful if

for any reason a restore function from Unity to PL7 is needed. For that
proceed as follow :
1
Select the PLC
2
Click on the
button to connect the PC to PLC. Once
connected, the yellow TER led of the PLC is flashing.
Click on the
button to get info from the PLC
The following screen gives to the user some information regarding
the PLC status
3 Started, stopped,
3 Processor type (in this example : TSX 57253)
3 The Hardware identification (for Schneider internal use only)
3 The OS version (in this example the OS version is 5.9)
5
6
Select the
Download
Function
Note this version number to avoid compatibility issues between the

application program and the OS if for any reason the previous CPU
Os (PL7) has to be restored.
Press the
button to return back to the OS update process
From the screen described above in the section Select the Target Device
press the
OS to device
button. A new screen is proposed : select Download
10
Select the file to

download
button in order to select the file to download into the

Click on the
PLC. In this example we will update the OS from TSX P57 253 to TSX P57
254. For that select the folder Premium\Processors_modules\PL7_to_Unity\
and select TSXP57253_to_254 (in your case, select the folder according to
your processor)
For an upgrade from PL7 to Unity two binary files can be selected :
3 PL7_to_Unity_254.bin (allows to format the processor for Unity)
3 TSXP57254M_V240.bin is the OS that will finally be download in the
processor
In our example we have to format the processor (remember, we still are in

the Phase 1) then select and Valid PL7_to_Unity_254.bin.
Once done click on the
button.
11
Download the
intermediate
OS
Once the previous screen validated, a warning is displayed
Click the
button. Two screens that give information
regarding the file, the processor and the download are now displayed :
Warning : If the system detects a discrepancy between the hardware or the

OS versions, the download will not be possible. This is indicated by a red
cross and the
button becomes not available.
Solve this issue and continue. When the hardware - OS are compatible, click
on the
button launches the download of the intermediate OS file

12
Download the
intermediate
OS file (cntd)
During the download (roughly 15 to 20 mn) the remaining time is displayed
Warning : During the download, do not power OFF the PLC, neither
disconnect the cable nor shut down the OS loader. If unfortunately it
happens, the PLC may have lost some important files and therefore be unable
to run correctly and must be returned back for repair.
Once the download successfully completed, the screen below is displayed.
Click twice on the
then ON or reset the PLC).
button and go to the Phase 2 (Power OFF
13
Reset the PLC
Once the download of the intermediate binary file 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 PLCs
power supply (for more information, refer to the PLC technical
documentation
3 Power OFF then ON the PLC.
Once the PLC restarted, go to phase 3 : download the final Unity OS file.
Presentation
The final binary file TSXP57254M_V240.bin (in our example) has to be

downloaded.
For that, follow the same procedure as the one described in the Phase 1.
Download
procedure
As all the actions necessary to download the final Unity OS have been
already fully described in the Phase 1, they are shortly reminded here after :
1
Open the OS loader (the PC should be still connected to the PLC).
Select the Protocol (UNTLW01) Refer to Phase 1

Select the target device and click on the
screen appears after few seconds.
button. The next
14
button and select (for our example) the file

Click on the
TSXP57254M_V240.bin located on the CD OS. Then valid this
screen
4
Select the operation to perform (Download OS to device) and press

on the
Download
procedure
(cntd)
button
At this stage, and as no functional Operating System is present in the

PLC the screen displays the string ??? in the field OS Version and
an error message. Click
to validate this message
Then click on the
button.
15
Click on
and validate the warning message displayed on
the screen to launch the download of the final OS file.
7
Download
procedure
(cntd)
During the download (roughly 35 to 45 mn) the remaining time is

displayed
Warning : During the download, do not power OFF the PLC,

neither disconnect the cable nor shut down the OS loader. If
unfortunately it happens, the PLC may have lost some important files
and therefore be unable to run correctly and must be returned back for
repair.
Once the download successfully completed, the screen below is
displayed.
Click twice on the

button to exit the OS loader tool.
Reset or power OFF then ON the PLC.
16
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 (UNITLW01),
3 Click on
3 Click on
In our example, the CPU has been upgraded to TSX P57 254M and the OS
version is 2.31 40.
17
3. Updating a Premium PLC from Unity to Unity

Object of this
Chapter
This chapter describes how to update a Premium PLC from Unity version >=
V2.0 to a more recent one. Note that the update from Unity V1.0 to V2 and
above is not provided.
Warning: In case of upgrading a high End processor you have to update
first the Ethernet co-processor described in Appendix 2
The screens shots given below show how to update a TSX P57 454 processor.
Connecting the
PC to the PLC
This phase is fully described in the chapter 1 of this document
Launching the
OS loader
The OS Loader (installed with Unity allows the user to download the
Operating System to the PLC. To open it click on Start/Progam/SchneiderElectric/Unity-Pro/OS loader
18
Select the com

munication
protocol

button. The
button.
Select the
Target Device
Get the Unity

version
(optional)
Before the update, knowing which Unity version is already installed on the
processor could be useful if for any reason a restore function is needed. For
that proceed as follow :
1
Select the PLC
2
Click on the
button to connect the PC to PLC. Once
connected, the yellow TER led of the PLC is flashing.
19
Click on the
button to get info from the PLC
The following screen gives to the user some information regarding
the PLC status
3 Started, stopped, Not Configured, ..
3 Processor type (in this example : TSX P57 454M)
3 The Hardware identification (for Schneider internal use only)
3 The OS version (in this example the OS version is 2.1)
5
6
Select the
Download
Function
Note this version number to avoid compatibility issues between the

application program and the OS if the previous version has to be
restored.
Press the
button to return back to the OS update process
From the screen described above in the section Select the Target Device
press the
OS to device
button. A new screen is proposed : select Download
20
Select the file to

download

Click on the
PLC. In this example we will update the TSX P57 454 OS from version 2.31
to V2.40. For that select the folder :
Premium\Processors_modules\Unity_Upgrade\ and select TSXP57254 (in
your case, select the folder according to your processor)
Then, select the binary file TSXP57454M_V240.bin
button.
21
Download the
OS
Once the previous screen validated, two screens display the current OS
version, the processor and the OS file to download :
Warning : If the system detects a discrepancy between the hardware or the

OS versions, the download will not be possible. This is indicated by a red
cross and the
on the
button and validate the warning message displayed on the
screen to launch the download of the OS file.
22
Download the
OS file (cntd)
disconnect the cable nor shut down the OS loader. If unfortunately it
happens, the PLC may have lost some important files and therefore be unable
to run correctly and must be returned back for repair.
Click twice on the
Reset the PLC
Once the download of the OS file completed, the PLC has to be initialized.
This task can be performed by one of the two following actions:
documentation
23
Checking
version
(optional)
3 Click on
3 Click on
,
.
In our example the processor TSX P57 454M has been updated to the version
2.40-46.
24
4. Updating Premium PLC with an Ethernet Port
Object of this
Chapter
This chapter describes how to update a Premium PLC with an Ethernet port
module. This procedure is applicable to the following modules :
3 TSX P57 2623M
3 TSX P57 3623M
3 TSX P57 1634M
3 TSX P57 2634M
3 TSX P57 3634M
The screens shots given below show how to update a TSX P57 1634M.
Warning
For updating Premium PLCs with an Ethernet port embedded it is imperative

that the update be carried out in the following order :
3 Update the Ethernet module (Phase 1)
3 Update the PLC Operating System (Phase 2)
Update the
Ethernet
module
This phase is fully described in the Appendix 1 of this document.

Once done update the PLC Operating System.
25
Updating the
Processor
As the ETY port is now updated it is time to update the processor according
to the latest version available. This download does not need an Ethernet
connection but the PC has to be connected to the TER port of the processor.
The update procedure is fully described in the chapter 3 of this document and
will not be repeated here. Please refer to this chapter.
Update the processor according to its type. Note that in our example (ETY
Port TSX P57 1634M) the file will be downloaded from the following
directory : Premium\Processors_modules\Unity_Upgrade\ :
26
5. Updating Premium PLC with an Ethernet Co-Processor
Object of this
Chapter
This chapter describes how to update a Premium PLC with an Ethernet CoProcessor module. This procedure is applicable to the following modules :
3 TSX P57 4634M
3 TSX P57 5634M
3 TSX P57 6634M
3 TSXH5724M
3 TSXH5744M
Warning
For updating Premium PLCs with an Ethernet Co-Processor embedded it is

imperative that the update be carried out in the following order :
3 Update the Ethernet Co-Processor (Phase 1)
Update the
Ethernet
module
This phase is fully described in Appendix 2 of this document.

Once done update the PLC operating system.
27
Updating the
Processor
As the Ethernet Co-Processor of the Premium PLC is now updated it is time

to update the Processor operating system according to the latest version
available. This download does not need an Ethernet connection but the PC
has to be connected to the TER port of the processor
will not be repeated here.
Update the processor according to its type. Note that in our example (TSX
P57 5634M) the file will be downloaded from the following directory :
Premium\Processors_modules\Unity_Upgrade\ :
28
6. Updating HotStandby Premium PLC
Object of this
Chapter
This chapter describes how to update a Premium PLC with an Ethernet CoProcessor module. This procedure is applicable to the following modules :
3 TSXH5724M
3 TSXH5744M
however, the upgrade procedure is the same for Hot Standby processors .
Warning
For updating Premium PLCs with an Ethernet Co-Processor it is imperative

that the update be carried out in the following order :
3 Make sure to have stored the program application on your computer. In
case you are not sure its is present on your computer, it is possible to
upload it from the PLC.
3 Update the Ethernet coprocessor module (Phase 1)
3 Download program application because in most cases it can be lost.
3 Each phase is described in the following procedure
29
Updating
Standby PLC
with Primary
PLC in RUN
The module upgrade can be done with the two PLC in STOP but you may
keep the process active and update separately both PLC following
these recommendations :
3 Before starting verify that the logic mismatch between both PLC is
allowed in application. For this the bit %SW60.4 must be set to 1 by
program. This condition is mandatory to keep primary active when
updated standby PLC will be reconnected .
3 Disconnect the standby PLC coprocessor Ethernet cable to update.
3 Update the Ethernet coprocessor module (see Phase 1)
3 Update the PLC Operating System (see Phase 2)
3 Download program application because in most cases it can be lost.
3 Re connect the standby PLC coprocessor Ethernet cable with primary
3 Set stand by PLC in RUN
3 On primary PLC see content of %SW61 in an animation table or
processor information screen to verify that standby PLC is seen OK, then
you can create a switch over by setting %SW60 to 0..
3 Update now the new standby PLC as already done.
Phase1 and phase 2 are described in the following procedure
Update the
Ethernet Coprocessor
This phase is fully described in Appendix 2 of this document.

Once done update the PLC operating system.
30
Updating the
Processor
As the Ethernet Co-Processor module of the Premium PLCis now updated it

is time to update the Operating System according to the latest version
available. This download does not need an Ethernet connection but the PC
has to be connected to the TER port of the processor
will not be repeated here.
Update the processor according to its type. Note that in our example (TSX
P57 5634M) the file will be downloaded from the following directory :
Premium\Processors_modules\Unity_Upgrade\ :
31
7. Restoring a Premium PLC from Unity to PL7
Object of this
Chapter
This chapter describes how to restore a Premium PLC from Unity to PL7. The
screens shots given below show how to restore a TSX P57 254 (Unity) to
TSX P57 253 (PL7).
Warning
Restoring a PLC from Unity to PL7 requires to perform three main phases :
3 Phase 1 Restore the PLC to PL7 with an intermediate OS
3 Phase 2 - Power OFF then ON the PLC
3 Phase 3 Restore the PL7 Operating System with the appropriate file
Each phase is described in the following procedure
Connecting the
PC to the PLC
This phase is fully described in the chapter 1 of this document.
32
Launching the
OS loader
The OS Loader (installed with Unity allows the user to download the
Operating System to the PLC. To open it click on Start/Progam/SchneiderElectric/Unity-PRO/OS loader
The next steps are fully described later in this document.
Select the com

munication
protocol

button. The
button.
33
Select the
Target Device
Select the
Download
Function
From the screen described above press the

is proposed : select Download OS to device
button. A new screen
34
Select the file to

be downloaded

Click on the
PLC. In this example we will restore the OS from TSX P57 254 to TSX P57
253 version V5.9. For that select the folder :
Premium\Processor_modules\Unity_to_PL7\ :
Then select TSXP57254_to_253 (in your case, select the folder according to
your processor)
Select the OS version to download (V5.9 in our example)
Valid the choice SV5.9
35
Select the file to

be downloaded
(cntd)
To restore the OS from Unity to PL7, two binary files can be sectioned :
3 Unity_to_PL7_253.bin (allows to format the processor to PL7)
3 TSXP57253_V59.bin is the OS that will finally be download in the
processor
In our example we have to format the processor (remember, we still are in
the Phase 1) then select and Valid Unity_to_PL7_253.bin.
button.
36
Download the
intermediate
OS
Once the previous screen validated a warning is displayed
Click the
button. Two screens that give information
regarding the file, the processor and the download are now displayed :
Warning : If the system detects a discrepancy on the hardware or on the OS

version, the download will not be possible. This is indicated by a red cross
and the
on the
to launch the download of the intermediate OS file

37
Download the
intermediate
OS file (cntd)
disconnect the Ethernet cable nor shut down the OS loader. If
unfortunately it happens, the PLC may have lost some important files and
therefore be unable to run correctly and must be returned back for repair.
Click twice on the
then ON or reset the PLC).
button and go to the Phase 2 (Power OFF
38
Reset the PLC
Once the download of the intermediate binary file completed, the PLC has to
be initialized. This task can be performed by one of the two following actions:
documentation
Once the PLC restarted, go to Phase 3 : download the final PL7 OS
Presentation
The final binary file TSXP57XXX_VZZ.bin where XXX represents the

processor type (253, 353, 453, .) and ZZ the OS version, has to be
downloaded.
For that, follow the same procedure as the one described in the Phase 1.
Download
procedure
As all the actions necessary to download the final PL7 OS have been already
fully described in the Phase 1, they are shortly reminded here after :
1
Open the OS loader (the PC should be still connected to the PLC)
Select the Protocol (UNTLW01) Refer to Phase 1

Select the target device and click on the
screen appears after few seconds.
button. The next
39
button and select (for our example) the file

Click on the
TSXP57253_V59.bin located on the CD OS. Then valid this screen
4
Select the operation to perform (Download OS to device) and press

on the
Download
procedure
(cntd)
button
At this stage, and as no functional Operating System is present in the

PLC the screen displays the string ??? in the field OS Version
to validate this message
and an error message. Click
Then click on the
button.
40
Click on
and validate the warning message displayed on
the screen to download the final OS file.
7
During the download (roughly 10 to 15 mn) the remaining time is

displayed
Warning : During the download, do not power OFF the PLC,

neither disconnect the Ethernet cable nor shut down the OS
loader. If unfortunately it happens, the PLC may have lost some
important files and therefore be unable to run correctly and must be
returned back for repair.
Once the download successfully completed, the screen below is
displayed.
Click twice on the

button to exit the OS loader tool.
Reset or power OFF then ON the PLC.
41
Checking
version
(optional)
3 Click on
3 Click on
,
.
In our example, the CPU has been restored to TSX P57 253 and the OS
version is V5.9
42
Appendix 1 : ETY Module Upgrade Procedure

Purpose
The upgrade of the ETY and Ethernet Port modules are completed 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.
Applicable Modules
TSXETY4102 V2.0 or V2.1
TSXETY4103 V3.0 or higher
TSXP572623M Ethernet Port
Resulting Module after upgrade

TSXETY4103 BootRom V3.1, Exec V4.1
TSXP571634M Ethernet Port BootRom V3.1, Exec V4.1
Overview
The upgrade of an ETY module is a multi-step process. Two components must be considered to
be upgraded, the BootRom and the Exec version. Steps 6, 7 and 8 describe the various files used
to upgrade the modules. Not all steps may be required depending on the version of the ETY
module before this upgrade procedure is started.
Note - For Premium configurations TSX P57 2623M / TSX P57 3623M / TSX P57 1634M /TSX
P57 2634M / TSX P573634M, it is imperative that the update be carried out in the following
order:
- Update of Ethernet Port.
- Update of processor Operating System.
Step1
Ensure the ETY module to be upgraded is listed in the Applicable Modules section of this
document. Refer to the ETY module web pages for version numbers.
43
Step2
Install the ETY module in a system consisting of only the PLC CPU, Power Supply, Rack and
ETY module. Configure the PLC system with an empty program containing only the ETY IP
address configuration.
Ensure the ETY module must be installed in a PLC rack with a configured IP address.
The CPU module must be in STOP mode and the ETY must have NO TCP traffic.
Step3
The PC must be running OS Loader V2.2 or higher. To identify this, the first screen of the OS
Loader should look like the screen below.
Select Next
Version to be updated V4.1
Step4
Select the FTP Driver.
Select Next
44
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.
Select Next
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.
45
Step6
Select Operation Download OS to Device
Select the filename to download based on the Current Module Version in the following table.
If module not listed proceed to Step7.
If module is listed select the correct file and click Next.
Current Module
File to Select
Resulting Module
Version
TSXETY4102
Premium\Ethernet_modules\Pl7_to_U TSXETY4103 Boot V2.1 Exec
Exec V2.0 or V2.1 nity\TSXETY4102_to_4103\TSXETY V3.0
4103_V300.bin
TSXP572623M
Premium\Processor_modules\Pl7_to_ TSXP572634M Ethernet Port
Ethernet Port
Unity\TSXP572623_to_2634\Eth_OS\ Boot 2.1 Exec V3.0
TSXP572634_EtyPort_V300.bin
TSXP573623M
Premium\Processor_modules\Pl7_to_ TSXP573634M Ethernet Port
Ethernet Port
Unity\TSXP573623_to_3634\Eth_OS\ Boot 2.1 Exec V3.0
TSXP573634_EtyPort_V300.bin
46
The following Screen will appear
Both Hardware ID and OS Version must be followed by a green tick.

Select Next and then Download
After the download is completed the following screen will appear.
47
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.
Restart this procedure from Step 1 and continue to Step7.
Step7
Select the filename to download based on the Current Module Version in the following
table.
Current Module
File to Select
Resulting Module
Version
TSXETY4103 Boot Premium\Ethernet_modules\Pl7_to_ TSXETY4103 Boot V3.1
V2.1 and Exec V3.0 Unity\TSXETY4102_to_4103\TSX Exec V3.0
ETY4103_V310_BOOT.bin
Premium\Processor_modules\Unity TSXP571634M Ethernet
TSXP571634M
_Upgrade\TSXP571634\Eth_OS\TS Port Boot 3.1 Exec V3.0
Ethernet Port Boot
V2.1 and Exec V3.0 XP571634_EtyPort_V310_BOOT.b
in
48
Premium\Processor_modules\Pl7_to TSXP572634M Ethernet

TSXP572634M
_Unity\TSXP572623_to_2634\Eth_ Port Boot 3.1 Exec V3.0
Ethernet Port Boot
V2.1 and Exec V3.0 OS\TSXP572634_EtyPort_V310_B
OOT.bin
Premium\Processor_modules\Pl7_to TSXP573634M Ethernet
TSXP573634M
_Unity\TSXP573623_to_3634\Eth_ Port Boot 3.1 Exec V3.0
Ethernet Port Boot
V2.1 and Exec V3.0 OS\TSXP573634_EtyPort_V310_B
OOT.bin
The following screen will appear.
The Hardware ID and OS Versions must be both followed by green ticks. If an error
message regarding hardware ID is received ensure you have completed all previous steps
correctly and contact your local Schneider office for assistance if required.
Click Next and Download
49
Following the download the screen above will appear.

Select close and exit the OS Loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Boot Files.
This process will be complete once the module again shows the RUN and STS LEDs
on solid for at least 30 seconds continuously.
If the RUN and STS LEDs do not come on continuously after 2 minutes but instead the
RUN led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing
power cycle the module. After completion restart this procedure and proceed to Step8.
Step8
table.
Current Module Version
TSXETY4103 Boot V3.1,
Exec V3.0 or higher
File to Select
Premium\Ethernet_modules\U
nity\TSXETY4103\TSXETY4
103_V400.bin
Resulting Module
TSXETY4103 Boot V3.1
Exec V4.0
Comment: TSXETY 4103

Boot V3.1, Exec V3.0 can
be directly upgraded to
Exec V4.0. If users want
to use an early version, it
50
also can be upgraded

directly.
TSXP571634M Ethernet
Port Boot V3.1 and Exec
V3.0 or higher
Comment:
Port Boot V3.1 Exec V3.0
can be directly upgraded
to Exec V4.0. If users
want to use an early
version, it also can be
upgraded directly.
V3.0 or higher
Comment:
upgraded directly.
V3.0 or higher
Premium\Processor_modules\
Unity_Upgrade\TSXP571634\
Eth_OS\TSXP571634_EtyPort
_V400.bin
_V400.bin
_V400.bin
Comment:
upgraded directly.
51

The Hardware ID and OS Versions must be followed by green ticks.

The Device Boot Loader Version must be V3.1. If an error message regarding hardware
ID is received ensure you have completed all previous steps correctly and contact your
local Schneider office for assistance if required.
Following the transfer the following screen will appear.
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Select Close and exit the OS loader.

Allow the ETY module at least 60 seconds to reboot and implement the new Exec Files.
power cycle the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with
the OS Loader.
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Appendix 2: Premium Ethernet CoProcessor Upgrade

Procedure
Applicable Modules
TSXP574634M
TSXP575634M
TSXP576634M
TSXH5724M
TSXH5744M
Overview
The upgrade of the CoProcessor Ethernet 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 not be
configured and it will default to its default IP address (as defined by the MAC address).
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
converted in decimal.
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
Step1
The Ethernet coprocessor to be upgraded must be listed in the Applicable Modules
section of this document. Refer to the Ethernet port web pages for version numbers.
Step2
Install 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.
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Ensure the Ethernet coprocessor has a configured IP address.
Step3
The PC must be 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
Step4
Select Next
55/70
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.
Select Next
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
56/70
57/70
Step6
table.
Module Version
TSXP574634M
V2.2 or higher
File to Select
Premium\Processor_modules\Unity_Up
grade\TSXP57x634\Eth_OS\TSXP5746
34_EthCopro_V260.bin
Resulting Module
Eth Embedded link
V2.6
Current Module
Version
TSXP575634M
V2.2 or higher
File to Select
Resulting Module
Eth Embedded link

V2.6
Current Module
Version
TSXP576634M
V2.4 or higher
File to Select
Resulting Module
Eth Embedded link

V2.6
Current Module
Version
TSXH5724M
V2.5 or higher
File to Select
Resulting Module
grade\TSXH5724\Eth_OS\TSXH5724_
EthCopro_V28.bin
Eth Embedded link

V2.8
Current Module
Version
TSXH5744M
V2.5 or higher
File to Select
Resulting Module
grade\TSXH5744\Eth_OS\TSXH5744_
EthCopro_V28.bin
Eth Embedded link

V2.8

58/70
Ensure that both the Hardware ID and OS Version are followed by a green tick.
59/70

Allow the Ethernet coprocessor at least 60 seconds to reboot and implement the new
Exec Files. This process will be complete once the module again shows the RUN and
STS LEDs on solid for at least 30 seconds continuously.
power cycle the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with
the OS Loader.
60/70
Appendix 3 : FactoryCast ETY 510 Module Upgrade

Procedure
Purpose
The upgrade of the ETY 510 module is completed 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.
Applicable Modules
TSXETY5102 V2.0 or V2.1
TSXETY5103 V3.0 or higher
Resulting Module after upgrade

TSXETY5103 BootRom V3.1, Exec V4.5
Overview
The upgrade of an ETY module is a multi-step process. Two components must be
considered to be upgraded, the BootRom and the Exec version. Steps 6, 7 and 8 describe
the various files used to upgrade the modules. Not all steps may be required depending on
the version of the ETY module before this upgrade procedure is started.
Note
OS Version numbers displayed in screenshots of following steps are only examples.
Step1
Ensure the ETY module to be upgraded is listed in the Applicable Modules section of this
document. Refer to the ETY module web pages for version numbers.
Step2
Install the ETY module in a system consisting of only the PLC CPU, Power Supply,
Rack and ETY module. Configure the PLC system with an empty program containing
only the ETY IP address configuration.
Ensure the ETY module is installed in a PLC rack with a configured IP address.
Ensure the only devices connected to the Ethernet network are the PC running the OS
Loader and the ETY module.
The CPU module must be in STOP mode and the ETY must have NO TCP traffic.
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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
Step4
Select Next
62/70
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.
Select Next
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.
63/70
64/70
Step6
table.
Current Module
Version
File to Select
Resulting Module
TSXETY5102 Exec Premium\Ethernet_modules\Pl7_t TSXETY5103 Boot V2.1 Exec

o_Unity\TSXETY5102_to_5103\T V3.0
V2.0 or V2.1
SXETY5103_V300.bin
If device name is TSXETY5103 proceed to Step8.
Ensure that both the Hardware ID and OS Version are followed by a green tick.
65/70
If this screen does not appear recheck each step and contact your local Schneider office
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.
Restart this procedure from Step 1 and continue to Step7.
Step7
table.
Current Module
File to Select
Resulting Module
Version
TSXETY5103 Boot Premium\Ethernet_modules\Pl7 TSXETY5103 Boot V3.1 Exec
V2.1 and Exec V3.0 _to_Unity\TSXETY5102_to_5 V3.0
103\TSXETY5103_V310_BO
OT.bin
66/70
Ensure that the Hardware ID and OS Versions are both followed by green ticks. If an
error message regarding hardware ID is received ensure you have completed all previous
steps correctly and contact your local Schneider office for assistance if required.
67/70
Following the download the screen above will appear.

Select close and exit the OS Loader.
Allow the ETY module at least 60 seconds to reboot and implement the new Boot Files.
power cycle the module. After completion restart this procedure and proceed to Step8.
Step8
table.
68/70
Current Module
Version
File to Select
Resulting Module
TSXETY5103 Boot
V3.1, Exec V3.0 or
higher
Premium\Ethernet_modules\Pl7_t
o_Unity\TSXETY5102_to_5103\
TSXETY5103_V400.bin
TSXETY5103 Boot V3.1 Exec

V4.0
Comment: TSXETY
5103 Boot V3.1, Exec
V3.0 can be directly
upgraded to Exec V4.0.
If users want to use an
early version, it also
can be upgraded
directly.
OR
Premium\Ethernet_modules\Unit
y\TSXETY5103\TSXETY5103_
V400.bin

Ensure that the Hardware ID and OS Versions are both followed by green ticks. Ensure that the
Device Boot Loader Version is V3.1. If an error message regarding hardware ID is received
ensure you have completed all previous steps correctly and contact your local Schneider office

Following the transfer the following screen will appear.

Allow the ETY module at least 60 seconds to reboot and implement the new Exec Files. This
process will be complete once the module again shows the RUN and STS LEDs on solid for
at least 30 seconds continuously.
If the RUN and STS LEDs do not come on continuously after 2 minutes but instead the RUN
led is flashing and the STS led is on or the RUN, STS and ERR led's are flashing power cycle
the module.
Verify the Boot and Exec versions by viewing the web pages or connecting again with the OS
Loader.
70/70

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PLC Operating System

Upgrade and Update Procedure

Edition V0.3 - March 2011

Why this Documentation?

1. Prepare a Premium update

This chapter describes how to prepare a Premium PLC in order to update or

The following software are required :

Two possibilities can be proposed to connect the PC to the PLC :

2. Upgrading a Premium PLC from PL7 to Unity

This phase is fully described in the chapter 1 of this document.

Select the com

From the main screen of the OS loader, click on the

On the Device Type field, select Processor

Get the PL7

Knowing which PL7 version is installed on the processor could be useful if

Note this version number to avoid compatibility issues between the

button to return back to the OS update process

button. A new screen is proposed : select Download

Select the file to

button in order to select the file to download into the

In our example we have to format the processor (remember, we still are in

Once done click on the

Once the previous screen validated, a warning is displayed

Warning : If the system detects a discrepancy between the hardware or the

button becomes not available.

button launches the download of the intermediate OS file

During the download (roughly 15 to 20 mn) the remaining time is displayed

button and go to the Phase 2 (Power OFF

Reset the PLC

The final binary file TSXP57254M_V240.bin (in our example) has to be

Open the OS loader (the PC should be still connected to the PLC).

Select the Protocol (UNTLW01) Refer to Phase 1

button. The next

button and select (for our example) the file

Select the operation to perform (Download OS to device) and press

At this stage, and as no functional Operating System is present in the

to validate this message

Then click on the

During the download (roughly 35 to 45 mn) the remaining time is

Warning : During the download, do not power OFF the PLC,

Click twice on the

3. Updating a Premium PLC from Unity to Unity

This phase is fully described in the chapter 1 of this document

Select the com

From the main screen of the OS loader, click on the

On the Device Type field, select Processor

Get the Unity

Note this version number to avoid compatibility issues between the

button to return back to the OS update process

button. A new screen is proposed : select Download

Select the file to

button in order to select the file to download into the

Then, select the binary file TSXP57454M_V240.bin

Once done click on the

Warning : If the system detects a discrepancy between the hardware or the

button becomes not available.

During the download (roughly 45 to 55 mn) the remaining time is displayed

Click twice on the

Reset the PLC