Content chapters
1. General information – Which Update is necessary?
In the first How To “How To update SAFEX-C.1x firmware - Part 1/2” the basic information for updating a SAFEX-C.1x firmware are shown and are prerequisite for this Part 2 of the update description “How To update SAFEX-C.1x firmware Part 2/2”.
Part 1/2 - The following points you can find there and are referenced in the update steps below:
Background Information for updating a SAFEX-C.1x via serial connection
Key file explanation
Key file ordering information
Update steps via serial firmware download of CPU-A/B and FPGA at USB port XF09
Error messages during update process, tips & tricks
Factory default settings of SAFEX-C.1x
Part 2/2 - describes:
The released different hardware and firmware versions
Several prerequisites and notes to be followed
The “2 step update procedure” from 1.0.1.19 /../ 1.0.1.29 to 1.0.1.53
The final update procedure in one step with µSD card firmware >=1.0.1.45
Handling and usage of the µSD card (Appendix A.1)
New µSD card diagnostics and Hints (Appendix A.3, A.3)
Outlook
[callout type="warning" text="An update via fieldbus EoE on EtherCAT at primary Interface XF28/29 or PROFINET on secondary interface XF30/31 is not possible in any combination and not supported!"]
Released HW/FW/SW Versions
Latest releases for ctrlX SAFETY SAFEX-C.1x are:
SAFEX-C.1x hardware – AN1
SAFEX-C.1x firmware 1.0.1.53 – FPGA 221
ctrlX SAFETY Engineering 1.8.3.10207
Available at the Collaboration room ctrlX SAFETY for Software distribution.
[callout type="info" text="Please refer the ctrlX SAFETY release notes of your installed firmware in the SAFEX-C.1x safety control. You will find out which exact ctrlX SAFETY Engineering Version must be used!" link-label="ctrlX SAFETY release notes" link-href="https://docs.automation.boschrexroth.com/iirds/cdp-metadata.boschrexroth.de~iiDC~Product-ctrlX-SAFETY/"]
[callout type="hint" text="Firmware 1.0.1.45 – FPGA 212 is not available on the collaboration room for download and “self-update” in the field. The minimum firmware 1.0.1.53 – FPGA 221 must be used for each update of the SAFEX-C.1x."]
Decide which update is possible
The reference table below shows the possible updates of different hardware and firmware combinations which are and have been delivered from Bosch Rexroth with the actual release at delivery time.
Some SAFEX-C.1x just may be updated in the past at OEM or customer side or repaired which may have higher Firmware, then it must be followed the column FW-Version and FPGA for the proper update procedure.
Start the verification with the Change Index on your SAFEX-C.1x type shield, described here: LINK: Fig. 4.: Electronic type shield SAFEX-C.12
Table entry with grey background color.
Refer online connected to your SAFEX-C.1x the "System Info" which firmware is running:
1.0.1.x --> proceed with table entries in violet color.1.0.0.x --> update only by factory, cause the “Bootloader” must be exchanged which is only at manufacturing factory possible.
Contact Bosch Rexroth Service for clarification how to proceed with an exchange.
Table entry with violet background color.
The so called “2 step update procedure” must be performed to update from 1.0.1.19 – 1.0.1.29 to 1.0.1.53.
First update step for CPU-A and CPU-B at once via USB serial connection.
Second update step for FPGA via µSD card.
Described in Chapter 2.
Table entry with green background color.
From firmware 1.0.1.45 CPU-A, CPU-B and FPGA can be updated in one step with µSD card.
Described in Chapter 3.
Preparation steps for update
Before starting the update process, ensure the following steps are completed:
Establish a serial connection to the control SAFEX-C:1x using a USB-C cable.
Switch ON the control voltage (+24 V).
Start the ctrlX SAFETY Engineering and establish a connection to the control (“connect”).
Start the diagnostic and screenshot the “System Info” register.
There you find the running firmware version, FPGA version and serial number.
Create a backup of your current project and save a renamed copy for use after the update.
[callout type="info" text="We recommend putting at the end of the project name the ctrlX SAFETY Engineering version build number. For example …._Eng10207.spl2"]
[callout type="info" text="Before an update, please always refer to the Blogs “How To update SAFEX-C.1x firmware – Part n/n” with the latest Part Number in the How To area!"]
[callout type="warning" text="The 2 step update procedure with the jump to 1.0.1.53 is recommended to be done outside of the machine. Only supply with 24V at XG31-17/18, XG32-17/18 and XG33-17/18.
The corrected periphery in a machine cabinet leads to “Alarms” LED PF01 flashing red or “Fatal Errors” LED PF01 red, during the certain update situations. We give no warranty on failures during 2 step update in the machine cabinet. Spare part RTB connector sets are available for connecting 24V and the cabling of the machine need not to be changed: SAFEX-C.12: R911414364 - XACC-3-CSRTB12_H and SAFEX-C.15 R911414365 XACC-3-CSRTB15_H"]
[callout type="warning" text="After firmware download from the ctrlX SAFETY Engineering a 24V OFF/ON power reset POR is necessary. The boot sequence recognizes new firmware files and perform the update before startup the SAFEX-C.1x.
This POR reboot is not allowed via unplug and plug the RTBs XG31-17/18, XG32-17/18 and XG33-17/18
àplease switch off your 24V power supply for the POR."]
[callout type="hint" text="The “2 step update procedure” need the SF40 push button function. We recommend evaluating its function with following steps before update is started:"]
Generate an “Alarm” with short-circuit from 24V to one of the inputs on XG31
PF01 is flashing red for the “Alarm 51xx”
Press SF40 push button for reset the “Alarm”
--> If the program restart is working – PF01 LED is flashing green, you may proceed with the update.
--> If the PF01 is still flashing red, SF40 is not working. In this case the update will not work, cause the „reset password“ step cannot be performed ! The SAFEX-C.1x must be sent to the Bosch Rexroth service. Please report this in the error report for your exchange of warranty.
Where do I get the firmware, Key file ctrlX SAFETY Engineering?
Download runtime firmware 1.0.1.53 from the Collaboration room SAFETY_Runtime_Apps
Request a Key file from your supporting technician from Bosch Rexroth in your region.
Refer How To update SAFEX-C.1x firmware - Part 1/2 chapter 2.1 Firmware update – Request a Key file.
For the “2 Step update procedure” two Key files must be ordered.
First Key file for updating the CPU-A/B to 1.0.1.53, FPGA keeps the installed one.
Second Key file for updating the FPGA to 221.
Please add this information to your request mail to Bosch Rexroth
For Update 1.0.1.45 FPGA 212 to 1.0.1.53 FPGA 221 one Key file for both steps at once has to be ordered.
Download ctrlX SAFETY Engineering 1.8.3.10207 from the Collaboration-room SAFETY_Engineering_APPS and install it on your PC parallel to your actual version in use. You need both for the “2 step update procedure”.
2. “Two step update procedure” for SAFEX-C.1x – FW 1.0.1.19 /../ 1.0.1.29
2.1 Background Information
The “2 step update procedure”, a major improvement for the update of an SAFEX-C.1x, is possible with the support of the µSD card launched with firmware version 1.0.1.45.
To take advantage of this, the update to 1.0.1.53 is separated in 2 steps.
Step-by-step guide
First step – update of SAFEX-C.1x – CPU-A and CPU-B to firmware 1.0.1.53 to get the µSD card slot supported
Second step – update of the FPGA using the µSD card
The update step 2 of the FPGA by using µSD card, is much faster (ca. 5min) compared to the serial download update via USB (ca.1h10min depending on PC). Additionally, the stability with the update internally of the SAFEX-C.1x via µSD card is much less risk of losing the control, caused by communication interrupts during the long serial download process.
2.2 First step - Update CPU-A/B via XF09 USB-C serial interface
2.2.1 Procedure
This Update step via the USB-C serial interface XF09 is documented in the How To update SAFEX-C.1x firmware - Part 1/2 chapter 3.2 Download firmware to ctrlX SAFETY control.
Start the first step with the ctrlX SAFETY Engineering Version which fits to the installed firmware on your SAFEX-C.1x.
After successful firmware download:
Power on reset POR, SEE POR NOTE BELOW
Update of CPU-A/B internally is processed by the firmware
SAFEX-C.1x performs an automatic restart
PF01 is continuous red – F2254 is diagnosed
The SAFEX-C.1x control is running with firmware 1.0.1.53
[callout type="warning" text="To switch OFF the 24V power supply - do not perform the POR on the so called RTB plug XG32 of the SAFEX-C.1x!"]
From now you need the proper ctrlX SAFETY Engineering 1.8.3.10207 which fits to 1.0.1.53 firmware
open 1.8.3.10207
open a new default project with your Type of SAFEX-C.1x
select your serial interface in “connection settings”
go online by “connect” and enter your serial number
open “Diagnostics”
select online “System Info” to check the firmware in the control is 1.0.1.53.
Update of CPU-A/B firmware was successful.
The µSD card slot is now working.
2.2.2 Device password
Launched by firmware 1.0.1.45 and higher a hardware password protection for the SAFEX-C.1x is implemented.
All Controls in the field get the default password “boschrexroth” with the update to >=1.0.1.45 within the firmware update file. During firmware update it must be enabled one time in the SAFEX-C.1x EPROM.
After successful update of the CPU-A/B to 1.0.1.53 the “password reset” must be performed. Use the following steps at ctrlX SAFETY Engineering in Online mode connected to the SAFEX-C.1x:
Select „Connection”, pull down “Security”, “Reset Password“
Attention with performing this Reset Password selection the SF40 hast to be pushed for a short moment within 10s.
Best result gave:Select „Reset Password“
count up to 5
press SF40 short
Refer the messaging window, it was successful when the „Password reset“ is shown
May be this procedure has to be repeated several times ;-)
Secure login
After „Reset Password“, the “boschrexroth“ password is usable from firmware 1.0.1.45.
Select the new icon „Secure“ to get the new „password Dialog“ for log in.
Enter: "boschrexroth"
Download the default project including only your control type SAFEX-C.12 or SAFEX-C.15
After download of the default project the SAFEX-C.1x automatically starts the safety program. After the LED PF01 is blinking yellow during the startup, it appears green blinking when the reboot is ready and the SAFEX_C:1x is in RUN.
2.3 Second step - Update FPGA via µSD card
2.3.1 Preparation
The procedure starts with preparation of the µSD card with the requested firmware
Prepare your µSD card with the correct directories, new firmware “data file” and Key file.
Refer Appendix A.1 beelow
Plug in your µSD card into the SADFEX-C.1x
2.3.2 Procedure
Power ON the 24V supply
The Initialization is starting just
After yellow blinking – white flashing is signaling the chance to update via the files from the µSD card
Press SF40 and hold it until the PF01 flashing color changes from white to yellow
[callout type="error" text="Update procedure is running - don´t touch and DO NOT REMOVE POWER DURING UPDATE! keep 24V ON!"]
Update steps shown in next figure are performed automatically
Refer the signaling steps during the Update process!
Finally, PF01 LED shows
--> Green flashing
--> Update of the FPGA is finishedCheck extended “System Info” diagnostic of your SAFEX-C.1x online in ctrlX SAFETY Engineering 1.8.3.10207
Fig 9: System Info with final updated firmware for CPU-A/B and FPGA Confirm the successful update of FPGA firmware version, open diagnostic “System Info” – FPGA 221 which fits to 1.0.1.53
Create a screenshot of the "System Info" and send it to the person who gave you the Key files.
He must finalize the Key file request ticket in ADS and set the ticket to DONE
2.3.3 Load machine project to updated SAFEX-C.1x
Final last task is to load the renamed machine project to the control. From ctrlX SAFETY Engineering 1.8.3.10207 the manual project conversion is no longer necessary anymore. The ctlX SAFETY Engineering automatically makes the elements up to date.
The project is after first safe or download to the SAFEX-C.1x no longer possible to be managed with former ctrlX SAFETY Engineering versions.
[callout type="confirm" text="SAFEX-C.1x firmware update to 1.0.1.53 – FPGA 221 is Ready"]
[callout type="warning" text="Warning: After updating the configuration data, validation for each project on a machine must be performed once to ensure that all safety functions work correctly. The control can then be locked accordingly."]
3. SAFEX-C.1x one step update with µSD card – FW >= 1.0.1.45
From firmware 1.0.1.45 FPGA 212 the update is performable in one step by using the µSD card for the whole update.
The Firmware and the one Key file for both update pats CPU-A/B and FPGA at one time have to be loaded on the µSD card, FAT32 formatted.
The “Preparation steps for update” in chapter 1 General information have to be followed. Then the update using a µSD card can be done by next steps.
Prepare your µSD card with the correct directories, new firmware “data file”, “Key file” and load the password from SAFEX-C.1x to the µSD card.
All described in Appendix A.1-3 below
Then proceed with the same steps like in chapter 2.3 Second step - Update FPGA via µSD card described.
[callout type="hint" text="The sequence of the PF01 LED colours blinking may differ, cause both update steps CPU-A/B and FPGA are performed directly after each other. The update is ready when the System Info shows the correct Firmware 1.0.1.53 - FPGA 221 an PF01 is flashing green"]Follow the chapter 2.3.3 Load machine project to updated SAFEX-C.1x
[callout type="success" text="SAFEX-C.1x firmware update to 1.0.1.53 – FPGA 221 is Ready"]
Please do not forget to send the “System Info” screenshot after the successful update back to your Bosch Rexroth technical support.
Appendix
A.1 µSD card for SAFEX-C.1x - usecase update
This chapter describes how to prepare the µSD card for firmware update. The µSD card size may be 8,16 or 32GB and must be formatted as FAT32.
It is recommended to use a flexible μSD card extension for convenient μSD slot access. This renders access easier for a cabinet mounted ctrlX SAFETY device.
A.1.1 Directories on the µSD card
A.1.2 Generate µSD card directories structure
The µSD card folder structure can be found in the SAFEX-C_DataFile_V1.0.1.53_FPGA221.zip file from the
Refer to unpacked directory “SD_CARD_Folder_Structure”.
Copy all directories to an empty formatted µSD card.
The one file firmware SAFEX-C_V1_0_1_53_FPGA_V221.frm for CPU-A/B and FPGA is just located in the “Datafile” directory. And the default password “boschrexroth” is just in the directory “Securityfiles”.
The Key file you get from your responsible technical support you put in the directory “Keyfiles” under “Updatefiles”
A.1.3 Generate SAFEX-C.1x customers password on µSD card
To retrieve password from the SAFEX-C.1x to the µSD card is not necessary for the 2 step update procedure. Cause updated SAFEX-C.1x from 1.0.1.19-29 to 1.0.1.45/53 or factory new SAFEX-C.1x have the default password “boschrexroth”. Setup the µSD card from chapter “A.1.2 Generate µSD card using distributed structure from Collaboration room” above.
A.2 Additional diagnostics for µSD card support FW >= 1.0.1.45
A.3 Tips & Tricks for µSD card support
In cases of multiple SAFEX-C.1x update from firmware 1.0.1.x – FPGA 2xx to firmware 1.0.1.53 – FPGA 212, it is possible to put more than one Key file for FPGA-update to the µSD card directory „updatefiles\keyfiles“ at once.
Successful updates with 2 and 9 Key files at one time on the µSD card had been performed in the field.