Part Number: 164700825

Revision: A00
21 October 2010

Eaton 9390 Firmware Flashing Quick Reference

The quick reference is an aid to the flashing procedure. If you are not comfortable using only this reference, please refer to the complete flashing
procedure available on the technical support web site, part number 164700603.

Firmware Upgrade Flashing Instructions

Materials

• The Eaton XCP Service Software Tool version 3.18.2 or newer.

• UPS Firmware
• ESS upgrade kit (optional)

Flashing Procedure

The 9390 UPS can be programmed with one of two software suites. Do not
upgrade the customer’s system to 5.XX firmware without a service ticket.
Upgrades to 5.XX firmware must be purchased.

Note: Firmware Suite 5.XX requires a CSB. If the system does not have a
CSB, you must use suite 2.XX and skip the CSB portion of this procedure.
Note: In parallel systems, only the system being flashed should be ener-
gized. Parallel units must have matching firmware. If flashing a reverse-
transfer system, skip the parallel portion of the steps below. Figure 1 XCP Service Software Tool Flash Tab

1. With the customer’s permission, transfer the load to the internal service
switch or maintenance bypass. If neither option is available, the load Table 1 Firmware Versions in Flashing Sequence
must be de-energized. 2.XX Suite 5.XX Suite
2. Command all UPSs to the shutdown mode.
3. If flashing a parallel system, disconnect J3 at each CAN Bridge Card. Processor Version Version
4. Connect to the UPS using the XCP Service Software Tool. LCD 1.10 1.10
5. Record all of the settings in the Options, Distributed Bypass, Events, and
Building Tabs of the XCP Service Software Tool. Gate Drive 1.12 1.14
6. Using the XCP Service Software Tool, download: CAN Bridge 1.14 1.14
• EEPROMs
• Calibration EEPROMs 1. DSP Bootloader 1.34 1.34
• Configuration Report 2. PLD 5 5
• History Log
3. DSP 2.12 5.06
7. If replacing a board, refer to the 9390 Service Manual, part number
164201537, Removal and Replacement Chapter and the other side of this 1. CSB Bootloader 1.34 1.34
sheet for additional details. 2. CSB INT 1.16 5.06

Note: If replacing the CSB while keeping the firmware at 2.XX, you must 3. CSB EXT 1.16 5.06
first flash the DSP to the 5.XX firmware suite and install the CSB. Then
downgrade the CSB to 2.XX and the DSP to 2.XX.
Table 2 Compatible Code Packages
8. Open the Flash Tab. DSP CSB Gate Drive
Note: If Mandarin or Korean is to be loaded, display part number 1.14 .94
103003706 must be installed in the unit. 1.18 1.00
1.22 1.00
9. Flash the unit firmware in the sequence shown in Table 1.
1.24 1.04
Note: Individual boards may be flashed. However, the firmware grouped 2.00 1.08
in Table 1 for the DSP and the CSB must be installed in sequence.
2.02 1.10 1.12
10. Perform a PCB Setup on the XCP Service Software Tool PCB Tab for 2.12 1.16 1.12
the DSP and CSB.
11. Set the Distributed Bypass and Battery parameters. Refer to FSB 606. 5.00 5.00 1.14
12. Restore any settings that were recorded in step 5.
13. Verify that the Configuration Error alarm has cleared from the Active 17. Calibrate the unit if necessary.
Events screen. 18. Start the unit and verify operation and transfers.
14. Cycle logic power twice. 19. De-energize the unit.
15. Verify that the firmware versions are correct on the unit display and 20. Repeat steps 3-19 for each UPS in the system.
the XCP Service Software Tool Flash Tab. 21. Connect J3 at each CAN Bridge Card.
16. If the control board was replaced: 22. Start the system and perform transfer tests.
• Load the calibration EEPROMs to the board. 23. Transfer the load from MBP to UPS.
• Write EEPROMs 372 and 373 to the new board (battery life data).

© 2010. Eaton Corporation. All Rights Reserved. Company Confidential.

 Part Number: 164700825
Revision: A00
21 October 2010

Eaton 9390 Firmware Flashing Quick Reference

Installing a New Control Board with 9155 HV Code Why the Three Code Packages Must Be Flashed In
Loaded Order
Requirements:
• XCP Service Software Tool 3.02 or newer The Bootloader, PLD, and DSP must be flashed in that order because
• 9390 bootloader 1.16 or newer of the way the integrated circuits on the control board and CSB oper-
• The CSB, if installed, must be compatible with the DSP version ate. This section provides an explanation of the function and interac-
to be flashed. See Table 2. tion of these code packages.

Procedure: Definitions:
1. Replace the control board using the 9390 Service Manual pro- Bootloader: The bootloader coordinates communication between
cedure. Do not apply logic power after installing the new board. the devices on the control board and the service port.
1. Disconnect the CSB CAN connection and install a jumper or re- Programmable Logic Device (PLD): The PLD is a digital I/O device.
move power from the CSB. It is similar to the BIOS in a computer. It translates all incoming and
2. Apply logic power. outgoing signals and is programmed to know the purpose of the de-
3. The unit display will not function and may display invalid char- vice’s inputs and outputs.
acters. Digital Signal Processor (DSP): The DSP controls calculation and
4. Connect the XCP Service Software Tool. unit control based on the many inputs and outputs to the device.
5. The tool will ask for a valid CTO number. Enter the CTO number
from the unit CTO label. Operation:
6. Open the Flash Tab in the XCP Service Software Tool. The bootloader is loaded first because it may have new functions
7. Flash the 9390 DSP bootloader. that enable the correct loading of the PLD and DSP. Older bootload-
8. If a CSB is not installed, cycle logic power when commanded by ers may not work with newer PLD and DSP firmware (see Table 2).
the XCP Service Software Tool. If the system does have a CSB, For this reason, the bootloader version may not change when the
do not cycle logic power. PLD and DSP versions are updated—it is only modified when neces-
9. Flash the 9390 PLD and DSP firmware packages. sary for the proper loading of new code packages. The bootloader
10. Flash the display. operates as the director, coordinating loading of the PLD and DSP
11. Flash the gate drive boards. firmware to the control board.
12. Using the XCP Service Software Tool PCB Tab, complete a DSP The PLD is loaded second. The XCP Service Software Tool commu-
PCB setup. nicates through the DSP to the PLD. EEPROMs are usually stored
• Verify that the unit kVA rating is correct on the CTO Tab. on the DSP and/or on an external chip. When the PLD is written, the
• If it is not correct, complete a kVA upgrade. Refer to the 9390 firmware must first be loaded to the DSP, corrupting the existing DSP
Service Manual for the procedure. code. The PLD code is then written from the DSP to the PLD. The
13. Flash the CAN bridge card if installed. bootloader directs this activity.
14. Connect the CSB. Finally, the DSP code is written to the DSP chip. If everything worked,
15. Flash the CSB bootloader, CSB INT, and CSB EXT files. all three code packages will have been updated on the control board
16. Complete a CSB PCB Setup on the XCP Service Software Tool and the unit will operate properly.
PCB tab.
17. Cycle logic power.
18. Verify that the firmware versions are correct on the unit display
and the XCP Service Software Tool.
19. Load the calibration EEPROMs to the board.
20. Write EEPROMs 372 and 373 to the new board (battery life Service Port
data). Laptop connection using the
21. Calibrate the unit if necessary. XCP Service Software Tool.
22. Start the system and perform transfer tests.
23. Restore the load to the system.

Error Messages When Flashing

XCP_ERR
When flashing, an XCP_ERR may appear in the flash console. This PLD DSP
alarm means that the XCP Service Software Tool was unable to write
to that address. The tool will attempt to rewrite the address. If the PLD Bootloader and DSP firmware
flashing process continues, then the rewrite was successful. If the firmware are stored here. PLD firmware is
write operation was unsuccessful, the flash process will abort. Re- stored here temporarily before
flash the processor. If that fails, replace the board. being transferred to the PLD.

C9 Error
C9 Errors occur when the tool briefly loses communication with the
unit. The XCP Service Software Tool will attempt to re-establish the Figure 2 Bootloader, PLD, and DSP Relationship
connection. Simply acknowledge the C9 error message and continue.
In rare cases, you may have to click on the CTO Tab to establish com-
munication with the machine before returning to the flash operation.

© 2010. Eaton Corporation. All Rights Reserved. Company Confidential.