Service Procedure

CAPM4/5 Software
Installation
Nu-Lec Industries Pty Ltd
(A Schneider Electric Company)

35-37 South Street

LYTTON 4178
Queensland
Australia

ACN 085 972 425

Tel: + 617 3249 5444

Fax: + 617 3249 5888

No: SP_006
Service Procedure CAPM4/5 Software Installation

Notices
Scope
This document describes certain procedures that may require to be conducted on in-
service switchgear.
Regardless of the switchgear type, the procedures in this document apply for:
! CAPM4 Software Versions 21-01.00 or higher.
! CAPM5 Software Versions 25-01.00 or higher.
Limitations
This document is copyright and is provided solely for the use of the purchaser. It is
not to be copied in any way, nor its contents divulged to any third party, nor to be
used as the basis of a tender or specification without the express written permission
of Nu-Lec Industries Pty Ltd.
Disclaimer
The advisory procedures and information contained within this Service Procedure
have been compiled as a guide to the safe and effective service support of products
supplied by Nu-Lec Industries Pty Ltd.
It has been prepared in conjunction with references from sub-assembly suppliers
and the collective experience of industry qualified Nu-Lec Industries Pty Ltd
personnel.
In-service conditions for use of the products may vary between customers and end-
users. Consequently, this Service Procedure is offered as a guide only. It should be
used in conjunction with the customers own safety procedures, maintenance
program, engineering judgement and training qualifications.
No responsibility, either direct or consequential, for injury or equipment failure can be
accepted by Nu-lec Industries Pty Ltd resulting from the use of this Service
Procedure.
Copyright
2001 by Nu-Lec Industries Pty Ltd.
All rights reserved. No part of the contents of these documents may be reproduced
or transmitted in any form or by any means without the written permission of Nu-Lec
Industries Pty Ltd.
Revision Record
LEVEL DATE AUTHOR COMMENT
R01 09/05/01 Chris Maher First release
R02 24/05/01 Chris Maher Include "-low" command
R03 19/06/01 Chris Maher Include "-debug" command

No: SP_006 Notices

 Service Procedure CAPM4/5 Software Installation

CAPM4/5 Software Installation

1.1. PURPOSE 1

1.2. SAFETY 1
1.2.1. Compatibility of Software and WSOS 1

1.2.2. Isolation of TRIP and CLOSE solenoids 1

1.3. EQUIPMENT REQUIRED 1

1.4. REFERENCES 1

1.5. PROCEDURE 2
1.5.1. Preparation 2

1.5.2. Connecting the Personal Computer (PC) 2

1.5.3. Transfer Existing Switchgear Configuration Settings 3

1.5.4. Understanding the Software Command Configuration 4

1.5.5. Saving the Software File to the PC Hard-Drive 5

1.5.6. Software File Download using the MS Dos Prompt Screens 5

1.5.7. Common Faults 7

1.5.8. Alternative File Transfer Rate 8

1.5.9. Creation of a Debug File 8

1.5.10. Confirmation of Data 9

1.5.11. Upload Switchgear Configuration Settings 10

1.5.12. Compare On-Line and Off-Line Files 11

1.5.13. Restore to Service 11

No: SP_006 Table of Contents

 Service Procedure CAPM4/5 Software Installation

CAPM4/5 Software Installation

1.1. Purpose
The following procedure explains how to install the latest revision software over an
existing version of CAPM4/5 software, whilst retaining all previous control and
protection settings.
! It may also be used to reconfigure the switchgear after a CAPM card has been
replaced.

1.2. Safety
1.2.1. Compatibility of Software and WSOS
Each software version release is supported by a Windows Switchgear Operating
System update.
Any attempt to load a recent software release using a superseded version of WSOS
may result in incorrect file transfer or an inability to communicate with the switchgear.
Always ensure that you have the latest release WSOS and that it is compatible with
the release version of software being installed.
Download from www.nulec.com.au

1.2.2. Isolation of TRIP and CLOSE solenoids

The solenoids must be isolated, when prompted, before the software file transfer is
commenced.
Ensure that the solenoids are not enabled until after the Event Log has been
checked for pickup events.
Enabling the solenoids before confirming that a pickup event has not been generated
may result in incorrect or hazardous switchgear function.

1.3. Equipment Required

! Nu-Lec Industries Pty Ltd Serial Cable, Part No: N05-902
! Laptop Personal Computer (32 bit system) with Version 3.16 or later Windows
Switchgear Operating System (WSOS) installed.
! The replacement software file.
! The cap5load.exe file.

1.4. References
A. Windows Switchgear Operating System User Guide Document No: N00-218

No: SP_006 Section 1 - Page 1

 Service Procedure CAPM4/5 Software Installation

1.5. Procedure

1.5.1. Preparation
It is strongly advised that you read and fully understand the following procedure
before commencing the software installation.
Confirm that you have satisfactory communications with network control personnel
before commencing the procedure.
If you have any doubts as to the procedure or require further clarification of
explanations provided, please contact our Service Department before commencing
the procedure.
Additional reference should be made to the user guide specified at Ref A.

1.5.2. Connecting the Personal Computer (PC)

1 Setup the PC:
! Create a temporary directory file on the PC hard-drive as appropriate to the
installation, ie: Software.
! It may also be beneficial to create a default file for each individual device within
the network.
Connect the PC to the control cubicle at port P9 using the serial cable, Part No:
N05-902:
! If possible, connect the PC end of the cable to the COMM 1 port.
2 If the specified serial cable is not
available, a suitable cable may be
fabricated using the diagram at right
and the table below as a guide.

Male Female Note:

Db 25 Db 9
Pin No: Pin No:
2 2 Rx data to PC
3 3 Tx data from
PC
7 5 Signal earth
and cable
screen
Not 1,4,6,8 Pins shorted
connected together

No: SP_006 Section 1 - Page 2

Service Procedure CAPM4/5 Software Installation

1.5.3. Transfer Existing Switchgear Configuration Settings

1 Open the WSOS programme:
! Select the name of the device from
the Switchgear Device drop down
file.
! Select OK.

Note: "Example" is used only as a

reference file throughout the remainder
of this procedure.
2 The WSOS "Example" Control and
Monitoring OFF-LINE screen is now
displayed:
! Select the ON-LINE button.
A password is required to make
the connection:
! Enter your user defined password if
programmed. If not, enter the
default password (NULEC).
! Select OK to go ON-LINE.
3 WSOS is now ON-LINE:
! Select OPTIONS at the menu
toolbar.
! Select "Read Switchgear Settings
from the Switchgear" at the drop
down file.
! Select YES to save to the default
file.
4 A "Read Switchgear Settings"
confirmation request is now displayed:
! Select YES.

No: SP_006 Section 1 - Page 3

Service Procedure CAPM4/5 Software Installation

5 The "Upload Status" screen advises of

the file transfer progress:
! This may be cancelled at any time
during the file transfer by selecting
the CANCEL button.

6 The "Upload Status" screen remains on

display to advise when the file transfer
is complete:
! Select OK.
New software may now be
installed on the CAPM:
! Select OFF-LINE at the menu
toolbar.

1.5.4. Understanding the Software Command Configuration

Individual software file names consist of ten digits and a sub letter ie: 10864024.05a
The command dialogue contains specific functionality that is affected by system
capability ie: cap5load -1 -force 10864024.05a is configured as follows.
cap5load -1 -force CCCCCHVV.RRX
DOS command Comm Port 1 Initialises the Software file name:
used with 32 bit Note that if CAPM4/5 CCCCC = configuration number
systems: Comm Port 2 internal
database and H = hardware type
Windows 95 is used, the
Windows 98 erases all VV = software version number
entry will be
Windows 2000 -2. settings. RR = software release number
Windows NT X = A (All)
= R (Range)
= S (Specified List)
Note that single character spaces must exist after:
! the last character in the DOS command,
! the comm port, and
! the force command.
The file transfer will not proceed unless the character spaces are entered in the
command configuration as specified.

No: SP_006 Section 1 - Page 4

Service Procedure CAPM4/5 Software Installation

1.5.5. Saving the Software File to the PC Hard-Drive

The new software file may be provided by e-mail or on a 3.5" diskette.
To save the file to the hard-drive:
! Copy the CAPM Software File into the temporary directory created earlier.
! Copy the cap5load.exe file into the same directory.

1.5.6. Software File Download using the MS Dos Prompt Screens

Software file download is conducted using the Windows MS DOS Prompt program:
! Select Start \ Programs \ MS-DOS Prompt.
! Open the DOS prompt and select the drive containing the CAPM Software File
created earlier ie: C:\Example
! At the DOS Prompt, enter: cap5load 1 force CCCHVV.RRX (software file
name) as shown at Figure 1, Step 1.
! Ensure that both of the isolating switches are switched OFF (Figure 1, Step 2).
! Enter (y) to confirm that TRIP and CLOSE are isolated (Figure 1, Step 3).

Figure 1 - Screen View 1 DOS Prompt

! The screen display will now update to advise that the software is downloading
(transfer occurring at the default rate).

No: SP_006 Section 1 - Page 5

Service Procedure CAPM4/5 Software Installation

Figure 2 Software Transfer Status

! The download is shown as an increasing percentage (Figure 2, Step 4) until
100% complete (Figure 3, Step 5).
! The screen display will now change to advise that the software database is being
downloaded (Figure 3, Step 6).
! The screen display updates to advise Download completed OK (Figure 3, Step
7). The CAPM will restart after a delay of up to 3 seconds.

Figure 3 Configuration Transfer Status

No: SP_006 Section 1 - Page 6

Service Procedure CAPM4/5 Software Installation

1.5.7. Common Faults

! If the serial cable is incorrectly installed or either of the two isolating switches are
not switched OFF, the screen display will update to indicate the fault condition.
! Check the cable and switches and then repeat Para 1.5.6.

Figure 4 Cable/Isolating Switch Fault

! If WSOS is still "On-Line", the screen display will update as follows.
! Return to the WSOS main screen, select "Off-Line" and then repeat Para 1.5.6.

Figure 5 On-Line Fault

No: SP_006 Section 1 - Page 7

Service Procedure CAPM4/5 Software Installation

1.5.8. Alternative File Transfer Rate

If the software transfer has still not been completed successfully at this point, it may
be re-attempted using a slower transfer rate than the default rate.
Another command may be entered into the Software Command Configuration to
slow down the transfer rate as follows:
! Refer to Step 1.5.6.
! Enter the following command when prompted, ensure character spaces are
included where shown;
cap5load -1 -force -low CCCCCHVV.RRX (software file name)
The new command "-low" enforces the slower transfer rate (allow up to 25 minutes to
complete).

1.5.9. Creation of a Debug File

In the event that the software transfer is still not successful at this point, it may be
advantageous to create a "debug file" for analysis by our Service Department.
To create the file, a new command is entered into the Software Command
Configuration as follows:
! Refer to Step 1.5.6.
! Enter the following command when prompted, ensure character spaces are
included where shown;
cap5load -1 -force -debug CCCCCHVV.RRX (software file name)
The additional command "-debug" causes a communications log of transactions
between the CAPM and the PC to be saved to disk The log file is automatically
saved to the source folder that the software was loaded from as "debug.tmp".
Once saved, the file may be forwarded by e-mail or other means:
! Be aware that the actual file size may increase up to 13MB.
! If forwarded by e-mail, it is recommended that the file be compressed using
WinZip which will reduce the file size to a maximum size of 1.3MB.

No: SP_006 Section 1 - Page 8

Service Procedure CAPM4/5 Software Installation

1.5.10. Confirmation of Data

1 The Date and Time Group (DTG) page at the Operator Control Panel (OCP) must
be reset as a result of the CAPM restarting at the completion of the software file
transfer:
! The switchgear data will be invalid until the CAPM has completed its initial
"switchgear settings read" upon restarting.
To reset the date/time group:
! At the OCP - Press the Panel ON button to activate the display and reset the
DTG using the SELECT and arrow keys. Then press the MENU key to raise the
Fault Flags display.
! From WSOS - Raise the "Example" Controller Status screen and reset by
selecting the Date/Time field and then entering the required DTG when
prompted.
2 Return to the WSOS " Example Control and Monitoring OFF-LINE" screen:
! Select ON-LINE at the menu toolbar.
! The password is not required unless the WSOS programme has been closed.
3 The "Example" Control and Monitoring
screen now shows that WSOS is ON-
LINE:
! Select STATUS at the menu toolbar
to raise the Example Controller
Status screen. Note that the Trip
Solenoids are shown as being
isolated.
! Select the DTG field. Enter the
password and follow the prompts to
enter the correct DTG. WSOS
should enter the DTG as per the
PC.
! Select the Switchgear Data button.
4 This is the "Example" Switchgear
Data screen:
! Confirm that the switchgear data is
shown as valid.
! Select the EXIT button to return to
the previous screen.
! Then select the EXIT button at that
screen to return to the "Example"
Control and Monitoring screen.

No: SP_006 Section 1 - Page 9

Service Procedure CAPM4/5 Software Installation

1.5.11. Upload Switchgear Configuration Settings

1 At the WSOS File Screen:
! Select OPTIONS at the menu toolbar.
! Select "Write Settings to the Switchgear" at the drop down file.
2 A warning message is displayed
advising confirmation of settings
in the off-line file:
! If in any doubt, confirm the settings.
! Select YES to continue.

3 A "Write Switchgear Settings"

confirmation request is now displayed:
! Select YES.

4 The "Write Status" screen advises of

the transfer progress:
! This may be cancelled at any time
during the file transfer by selecting
the CANCEL button.
! If cancelled, be aware that a partial
transfer of settings may have
occurred. These settings cannot
be used and must be over-written.
5 The "Write Status" screen is displayed
when the file transfer is complete:
! Select OK to complete the process
and return to the Main WSOS
menu.

No: SP_006 Section 1 - Page 10

Service Procedure CAPM4/5 Software Installation

1.5.12. Compare On-Line and Off-Line Files

1 At the Main WSOS screen:
! Select OPTIONS at the menu toolbar.
! Select "Compare Switchgear Settings" from the drop down file.
2 This message appears advising that the
switchgear settings must be read
before the files can be compared:
! Select Yes to continue.

3 The switchgear settings will be read as

for Para 1-5-2, Steps 4, 5 and 6:
! Select Yes to commence the read.
! Observe the Upload status as the
read is in progress.
! Select OK once "Read Settings" is
completed.

4 This is the Example Comparison screen

which displays any differences between
the On-Line and Off-Line files.
In the event that no differences
between the two files are detected, this
screen will be as shown.
If the file comparison is acceptable after
comparing differences, exit from
WSOS.

CAUTION
IF IN DOUBT, CONFIRM THE REQUIRED SETTINGS BEFORE PROCEEDING

1.5.13. Restore to Service

1 Go to the Operator Control Panel:
! Press the MENU button to raise the Event Log.
! Confirm that a Pickup Event has not been generated
2 Enable the Trip and Close solenoids:
! Return both switches to the Enable position.
3 Disconnect and store the computer and serial cable.

No: SP_006 Section 1 - Page 11