How To update ctrlX SAFETY firmware

1. General information

In the following, we show to you how to update the SAFEX-C.1x ctrlX SAFETY firmware.

Versions used

All the screen shots are based on:

ctrlX SAFETY Engineering version >= 1.7.1.8198
SAFEX Firmware version >= 1.0.0.1 (first certified version)
SAFEX FPGA >= 16
SAFEX-C1.12 Hardware – Change index index AA1, AB1, AD1

Prerequisites

A connection to the ctrlX SAFETY control via USB serial cable is successfully established. Switch on the control voltage +24 V.
As well, start the engineering tool ctrlX SAFETY Engineering

Notes

The update process is still under construction. Enhancements are continuously implemented in the ctrlX SAFETY ENGINEERING Tool, ctrlX SAFETY Firmware and as well in ctrlX SAFETY Hardware.

- Within hardware index AE1 controls, the boot loader will be stabilized for more robustness.

- The firmware update workflow may change with the next “FW
Milestone”.

- Additional Steps during update may be necessary.

- Update via Ethernet – only over EtherCAT (EoE) – is planned.

Please refer always before an update to the Blog “How to update ctrlX SAFETY“ with the latest Version Number in the HowTo area. LINK einfügen AUF das gelb hinterlegte wenn das How to dort liegt!

2. Background information for update of ctrlX SAFETY

2.1 Firmware update – shares, files and procedure

The possibility to update the ctrlX SAFETY firmware is available within ctrlX SAFETY Engineering.

Firmware parts

In principal, the ctrlX SAFETY control firmware contains two code parts.

CPU-A + CPU-B version parts
FPGA version part

Normally the firmware update is performed with both together. In some circumstances it may be good enough to update only one of them CPU-A+CPU-B or FPGA.

CPU-A + CPU-B version parts have to be updated always together!

FW update with enable key

The firmware download is locked in order to secure that it is only possible to update approved controls. An update of an SAFEX-C.1x hardware has to be registered at BoschRexroth ctrlX AUTOMATION Support.

For the update purpose, the user needs two files. The “firmware data file” and a so called “key-file”.

The key-file enables the download. For every update, a key-file is essentially necessary.

Fig. 1.: Firmware update – two files needed

Bosch Rexroth ctrlX AUTOMATION Support generates the key-file if an update of the ctrlX SAFETY Firmware is recommended or necessary.

Examples:

Firmware data file:
SAFEX_Cxx_V1.0.0.5_FPGA19.frm

Key file:
KeyC12_ver1_0_0_3_FPGA19_to_ver1_0_0_5_FPGA19_SN_12000188.key

Fig. 2.: Firmware Update - key file contains versions and serial number of the SAFEX-C.1x to be updated

Request a Key File

Following information are necessary to request and generate a key file:

Please generate a Key-File:
For: < Customer >, < Engineer >
Application: < Example STS Workshop SAFETY 2/3 >
Machine: < ctrlX DRIVE Production line >
Update Reason: < new or which fixed functionality needed >
BoschRexroth
Engineer: < Name > supports customer above mentioned
Online electronic type shield:
< enter “System Info” screenshot here >
Hardware-Type plate information:
Production Date FD: < 00w21 >
Change-Index: < A_1 >
New requested Firmware:
FW version: < 1.0.0.5 >
FPGA version: < 19 >

Find the current “FW version” and “FPGA version” online within the ctrlX SAFETY Engineering “Diagnostics” register “System Info”:

Fig. 3.: Electronic type shield SAFEX-C.12 – information for key-file ordering

The manufacturing date and HW-Index you find on the type plate.

Fig. 4.: Electronic type shield SAFEX-C.12 – Information for key-file ordering

Please send this information per mail to your local ctrlX SAFETY sales technician in order that he can order at Bosch Rexroth Germany Lohr using the so called DC-AE ctrlX AUTOMATION Support to generate the key-file for you.

Remark (only for local ctrlX SAFETY Bosch Rexroth sales technician)
For more information: see Bosch Rexroth internal WebSeminar ctrlX SAFETY (Part 2/3) and (Part 3/3) LINK
Use this link to order a key-file: LINK

When your update is finished successfully, please send a screenshot of your ctrlX SAFETY online “System Info” to your local ctrlX SAFETY sales technician to give feedback to DC-AE ctrlX AUTOMATION Support.

3. Update of ctrlX SAFETY in steps

3.1 First preparation steps before updating a ctrlX SAFETY

3.1.1 Recommendations

Attention:
During update, several recommendations need to be followed to avoid unsuccessful updates!

During the update process, the USB connection must not be interrupted at any time!

Update the ctrlX SAFETY control with the key-file and data file on your local PC – not from the office network
Prevent the screensaver or power save mode during the update. This interrupts the USB connection to the ctrlX SAFETY control.
Do not work in parallel during the update download process with Windows Applications like Office tools, Outlook or any Browser!
Keep the “Firmware Update” Dialogue always on top of your desktop – and keep the focus on this frame.

Attention: Plan your Update, it will last nearly 1h!

Update Firmware CPU-A and CPU-B - ca. 12 minutes
Update FPGA - ca. 40 minutes

Attention:
After successful download, one or more POR power on resets have to be performed. During different long waiting times, the firmware is taken over in the memory and/or FPGA. Do not switch OFF the 24V power supply during this waiting periods.
Follow exactly the steps, described below.

3.1.2 Configurations at ctrlX SAFETY Engineering for update

Settings for update

Generate a new empty project with the ctrlX SAFETY control type you want to update!

Before you connect to the ctrlX SAFETY, change the Timeout setting from default 5000 to 15000 – 15s!

This is necessary for memory copy processes during the update mainly with the FPGA update.

Fig. 5.: Firmware Update – Engineering Setting

Now select the button “Connect” in order to go online with the ctrlX SAFETY, which has to be updated.

Attention!

With the latest ctrlX SAFETY Engineering, the selection of the Firmware update button is not blocked, if the Diagnostics is open and running.

The update will not work when “Diagnostics” is communicating from the PC to the ctrlX SAFETY.

(BLM Error 2 appears!)

Fig. 6.: Firmware Update – Stop “Diagnostics” before

3.2 Download firmware to ctrlX SAFETY control

Start Update

During online connection, the firmware update may be started with the “Firmware Update” button in the online menu band.

Do not forget to switch off your “Diagnostics” before.

Fig. 7.: ctrlX SAFETY Engineering menu band – online status

The “Firmware Update” control dialog for the file download appears modal.

Fig. 8.: ctrlX SAFETY Engineering – firmware update control dialogue

Select update steps and files

You may select the required Update Steps CPU-A + CPU-B (always together) and/or FPGA, dependent on your Key-file you have.

Select under “Firmware File” the firmware data file.

Select under “Key-file” the suitable key-file to your selection for update steps.

Attention:
An update step by step is not possible with one key-file. You have to perform exactly the selections, which the key-file contents, in one update step!

Example for update the CPU-A + CPU-B

The following example describes an update of the control in chapter 2.1 Firmware update – shares, files and procedure mentioned above, from Firmware 1.0.0.3 to Firmware 1.0.0.5. Both CPUs are updated, which has always to be performed in one-step.

Fig. 9.: Example update - CPU-A + CPU-B, firmware and key-file selection

With selection “Start Update” the download process will start.

An abortion is not possible at the very moment– Mind to not select OK during file download!

The Firmware is switching to the download mode.

PF01 light pipe signaling download by blinking yellow

The light pipe PF01 at the SAFEX-C.1x is changing from green or green blinking at RUN mode to yellow blinking during the firmware download.

Fig. 10.: Firmware download – PF01 light pipe signaling yellow blinking

Fig. 11.: Firmware download Step 1 – Erases CPU-A and Downloads CPU-A

Fig. 12.: Firmware download Step 2 – Erases CPU-B and Downloads CPU-B

Fig. 13.: Firmware download Step 3 – Succeeded

The download is ready.

Select the “Close Connection” button to switch the ctrlX ENGINEERING OFF from SAFEX-C.1x

3.3 Reboot Power On Reset (POR) after download

After the successful download, a reboot is necessary.

Note depending on the update type, several points have to be paid attention to – refer to next two chapters!

Forbidden:
Do not POR by unplugging and re-plugging the RTB terminal plugs XG31, XG32, XG33 of the ctrlX SAFETY! Switch of the 24V power supply.

3.3.1 Update only CPU-A + CPU-B

After POR, the SAFEX-C.1x needs ca. 15s to update the new firmware.

Attention:
After POR, the SAFEX-C.1x may be switched OFF earliest 15s later only. – Not before!
Otherwise, the SAFEX-C.1x has to be sent back to Bosch Rexroth for service.

PF01 light pipe signaling during update yellow blinking

The light pipe PF01 at the SAFEX-C.12 after POR is dark for some few seconds. Then a yellow blinking is starting during the firmware update. Ca.12 times.

With a short break in the blinking frequency, it is recognizable that the update of the firmware for CPU-A + CPU-B is performed.

After another 6 yellow blinks during the initialization boot, the SAFEX-C.12 is in RUN mode. PF01 light pipe is blinking or solid green. It tries to get in same state than before the update was started.

Follow next steps in chapter 3.3.3 Feedback the successful update of your ctrlX SAFETY!

3.3.2 Update with FPGA

In case of update both firmware parts or only the FPGA, after POR the SAFEX-C.1x first needs ca. 15s to update the new firmware – AND – FPGA load additionally behind.

Inside the FPGA the NIOS kernel has to be loaded too, which needs additional time of 2 minutes!

Attention:
When updating FPGA, after POR the SAFEX-C.1x may be switched OFF earliest 3 minutes later only. – Not before!
Otherwise, the SAFEX-C.1x has to be sent back to Bosch Rexroth for service.

PF01 light pipe signaling during update yellow blinking

The light pipe PF01 at the SAFEX-C.12 is dark after POR for some few seconds. Then a yellow blinking is starting during the firmware update. Ca.12 times.

With a short break in the blinking frequency, it is recognizable that the update only of the firmware for CPU-A + CPU-B is performed.

After another 6 yellow blinks during the initialization boot, the SAFEX-C.12 is in RUN mode. PF01 light pipe is blinking or solid green – in the state before the update was started. FPGA just follows!

Attention:
When PF01 light pipe is blinking green?? or solid green the update IS NOT READY at this moment!
Updating FPGA is still in progress for another 2 minutes!

PF01 light pipe signaling green during FPGA load

At the very moment, it is just possible to connect to ctrlX SAFETY ENGINEERING and check the status of the FPGA copy with the “Diagnostics” in the register “System Info”.

It may display behind “FPGA version” “0” or “1” – in this case the copy is not ready, yet.

Fig. 14.: FPGA load – intermediate state 0 (sometimes 1)

The user has to wait until the old “FPGA version” from before the update is displayed. Then the FPGA load is finished.

Select the “Close Connection” button to switch the ctrlX ENGINEERING OFF from SAFEX-C.1x.

After a second POR the SAFEX-C1.x is initializing and booting to RUN .

3.3.3 Feedback the successful update of your ctrlX SAFETY

Check the update success with the “Diagnostics” in the register “System Info”. Take a screenshot and send this to your local ctrlX SAFETY sales technician to get the feedback to DC-AE ctrlX AUTOMATION Support that the information is changed in the quality record of your SAFEX-C.1x control.

Fig. 15.: Firmware update CPU-A + CPU-B successful – feedback

3.4 Error messages during update process, tips & tricks

3.4.1 Update error messages

BLM error

There are several error messages possible during the firmware update.

BLM error

description

…

“Diagnostics” ON during firmware update

…

key-file invalid (data in key-file not readable)

key-file invalid (Checksum in key-file not correct)

key-file does not fit to SAFEX-C.1x ID

key-file does not fit to serial number of SAFEX-C.1x

key-file does not fit to firmware running at SAFEX-C.1x

Download error

The update is starting but after CPU-A+CPU-B download during FPGA download after ca 21 minutes the following error appears:

Error sending FPGA File

--> Timeout is wrong (5000 instead of 15000)

3.4.2 Remedy in case of a failed firmware download

In case of an interrupted firmware download, firmware files are only partly downloaded.

Do not switch OFF the 24V power of your ctrlX SAFETY!

There is a possibility available to restart the download again.

In most cases the USB connection between ctrlX SAFETY Engineering PC and the SAFEX-C.1x was interrupted by e.g. the operating system of the PC.

However, the PF01 light pipe is still blinking yellow, which signals the download mode.

Follow the next steps to get the possibility to repeat the download:

Restart your ctrlX SAFETY Engineering.
Open your default project including the correct SAFEX-C.1x type control.
Select the “Device Interface” to switch the Engineering to “Online mode” menu.
Select the correct COM port and press the “Connect“ button to switch the ctrlX SAFETY Engineering after password entering to the SAFEX-C.1x.
Select the “START” button in the menu bar. (3^rd from left).
At this moment, the download modus is switched to RUN mode.
By selecting the “Firmware Update” button, you are able to restart the “Firmware Update control dialogue” again.

330497

4. Factory default setting of ctrlX SAFETY

The ctrlX SAFETY gets the “Factory default settings” by downloading an empty project with only the SAFEX-C1.x control type on the working desk in the “Terminal Scheme” register.

Steps for factory default setting

Generate a new empty project with the ctrlX SAFETY control type.
Connect to SAFEX-C.1x.
Download the project by “send configuration”.
After download, the SAFEX-C.1x control is automatically booting into the RUN – Status present before the download.
The light pipe PF01 is signaling RUN by blinking green or solid green like present before the download.

Fig. 17.: Factory default setting – only ctrlX SAFETY type in the project