Carel HQ, May 10th 2011

Object: pRack software upgrade via pRackManager

1. Introduction

The pRack firmware can be upgraded using a software utility named pRackManager.
With this software it is possible to upload a new software version on all pRack controllers without
losing the pRack configuration.

pRack Manager software can be downloaded from KSA website: http://ksa.carel.com, clicking on
item “x.x-pRackManager_full.zip”.

On the same web page of KSA also the pRack software revisions are available
(Bin_FLSTDMRC0E_x_x_yyyymmdd_Languages _devicemodel.zip).
Should you need to upgrade your pRack controllers, please contact Carel at the e-mail address
[email protected], specifying the following items:

• installation
• name of your customer
• number of installed pRack
• model, revision and manufacture date of the pRack (you can find all these info on the label
applied on the back of the devices)
• receiving date of the instruments
• reason of the upgrade
• any problems found

Our engineers will provide you all information about the last firmware version available according
to your application.

Note!
The SW upgrade of pRack has to be done only using pLAN connection.

2. Precautions for the update

Carel suggests to test the procedure, before proceeding with the software upgrade devices
installed in a real a plant. This will help you to get confidence with the procedure and avoid
troubles or delays on the field.

Before starting with the upgrade procedure carefully read the following advices:

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 • During the update process the controllers are completely off and they release all their
outputs: in particular all below features will be not managed
o Compressors and fans activation
o Safeties
o Monitoring
• The updating process requires at maximum 20 minutes each board (in case of parameter
list recovering)

It is recommended also to avoid any interruptions on the power supply during the upgrade.

IMPORTANT!

Should the upgrade process be interrupted for any reason, it will be possible to restart the
procedure from the beginning.

3. Tools required for the update

• Personal Computer with pRackManager already installed

• USB/RS485 converter cod. CVSTDUTLF0
• Telephone connectors cod. S90CONN*
• New pRack Firmware (zip.file)

4. Setting pRackManager

1. Install the last version of pRackManager software in your laptop or PC that you will use to
perform the update. Please, install also the USB drivers if they are not already installed on
your PC.

2. Download from KSA web site the .zip file containing the new firmware revision and the
related .zip file containing .2cf, .2cd and .2ct files (http://ksa.carel.com).

3. Copy the 3 files with extension .2cf, .2cd and .2ct in the folder “2CF”, where pRackManager
is installed (i.e.: C:\Programs\CAREL\pRack Manager\2cf). On this folder you could find
some other files related to the previous FW versions.

5. Full Updating procedure (without losing the configuration saved

inside the pRack)

1. Make sure that the unit is switched OFF (both suction line and condensing line) from user
interface or digital input or supervisor. I remember you that the default pRack password is
“1234”;

2. Disconnect the PGD1 user terminal from the pRack connector (J4 in case you are using a
pRack Compact size or J10 in case you are using a pRack S, M, L or XL size);

3. Connect the USB-RS485 converter (cod. CVSTDUTLF0) to one of USB ports of the PC where
the pRackManager was previously installed;

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4. Connect the other side of USB-RS485 converter to the user interface connector of pRack (J4
in case you areusing a pRack Compact size or J10 in case you are using a pRack S, M, L or
XL size);

Figure 1

5. If pRack is connected to a Serial Line RS485, please, disconnect the serial line from the BMS
connector;

6. Run the pRackManager double-clicking on its icon;

7. In panel “Connection Settings”, at top right corner of the screen, click on “Port Number”,
and select the COM port (Please, click on “Wizard” and follow the instructions to retrieve the
correct COM port), then set the BaudRate to “Auto” and set Search Device to “Auto(pLAN)”
(point 1 of figure 2);

8. In panel “Select the Device to connect with” (point 2 of figure 2) select the right software
version installed in the pRack you are going to upgrade (pay attention that this selection
has to be done to be sure that pRackManager will use the right 2cd, 2ct and 2cf files in
order to not lose any configuration);

9. Power ON the pRack that has to be uploaded;

10. At the beginning the pRack connected to the pRackManager will be offline (point 3 of figure
2);

11. Press Device Configuration button (point 4 of figure 2);

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 Figure 2

12. Wait until the ONLINE message will blink on the pRack Manager (please, see the point 5 of
figure 3). If it does not go online, turn off and turn on the pRack again and force a
disconnection/ connection pressing the related buttons on pRack Manager (point 6 of figure
3);

Figure 3

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13. Read the configuration from the pRack pressing the read button ” ” from
pRackManager (point 7 of figure 3);

14. Select “Read all variables” and wait that the end of the reading;

15. Save the pRack configuration exporting the configuration on a txt file. To do this, press
File>Export default settings to TXT … (figure 4);

Figure 4

16. At this point you can proceed with the firmware upgrade;

17. Select the pRackLoad button (point 8 of figure 5);

18. Insert the path where is saved the firmware you want upload and select the files:
• file .IUP (max. 2 languages)
• file .BLX
• file .BIN
• file CLEARALLx.DEV (this file is used to fully clear the memory of the pRack and to assign the
right pLAN address. i.e. Clearall1 assigns the pLan address 1, Clearall2 assigns the pLan
address 2 and Clearall3 assigns the pLan address 3 )

19. Flag also the “Update graphic resources” and “Enabled zipped Upload” (point 9 and 10 of
figure 5);

20. Press Upload button (point 11 of figure 5) and wait until the upload will be completed;

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 Figure 5

21. The below message will appear at the end of the procedure.

Figure 6
22. Wait that the device will be reset (the above message will disappear and the device will go
offline);

23. Turn off the controller, disconnect pCO from USB converter and reconnect the user
terminal;

24. Turn on the controller, and wait the startup procedure is completed;

25. Turn off the controller again;

26. Disconnect the terminal from pCO, reconnect the USB converter, with pRack Manager
running;

27. Turn on the controller;

28. Select Commissioning
Settings and in panel “Select the right Device to connect with”
select the new software version you have just upgrade (pay attention that this selection has
to be done to be sure that the pRackManager will use the right 2cd, 2ct and 2cf files) (point
13 and 12 of figure 8);

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 Figure 7

29. Select the Device Configuration button;

30. Import the txt file previously created. To do this, press File>Import default settings from
TXT …;

Figure 8

31. Wait that the configuration will be loaded;

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 32. Press Write variables button (point 14 of figure 10) “ ”;

33. Select Write all variables (point 15 of figure 10);

Figure 9

34. When the writing is completed, turn off the device;

35. Disconnect the USB converter from the pCO;

36. Connect the User terminal to the pCO;

37. Turn on the device;

38. Now the pRack has the new Firmware and is completed configured with the previous
settings.

Note!
The BMS RS485 connection can be used only to read/write parameters and in this case the pRack
will be on and it will continue to manage all the configured functions.

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6. Standard Updating procedure (without save the pRack
Configuration)

In this case is enough to follow only the steps: 1 ÷ 10, 12, 16 ÷ 24 of the previous procedure.

Should you need any further information or details, please, do not hesitate to contact Carel at
[email protected]

Best Regards.

Customer Solution Team

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