PC-less device replacement for ctrlX CORE

This How-To describes the required preparation to replace a ctrlX CORE without the need of using an engineering PC.
The PC-less device replacement requires a prior preparation, while the ctrlX CORE is still running the target application.

Too late? Your device is not available anymore, then read about hardware reset.

Prerequisites

• ctrlX CORE X3/X5/X7 is running and in operation the target application

• Engineering PC is connected to the ctrlX CORE

• User is logged in ctrlX OS web UI with administration rights

• A license dongle (SD card) with required licenses for the application is plugged in ctrlX CORE

• An USB stick minimum 4 GB and maximum 32 GB, formatted as FAT32

  • For ctrlX COREplus X5/X7: only including one GPT partition (GUID partition table). See "How to partition a disk as GPT & Restore ctrlX CORE X7".

• Current application is based on ctrlX OS >= 3.6

Prepare version independence (recommended)

The replacement ctrlX CORE already has to have system major version 3.x already installed if the backup restoration mechanism should be used only! To get version independent and also save a lot of time while restoration process, a system image has to be added to the corresponding USB device. More information see online documentation "Hardware reset".

1. Download the corresponding system image via the Collaboration Room

2. Connect the external data carrier to the engineering PC

3. Unzip the archive to the external data carrier

   • X3: "X3_Systemimage_x.x.x.zip" to the license µSD card or USB Stick

   • X5 and X7: "X5_X7_Systemimage_x.x.x.zip" to the USB stick

4. To prevent restoring the image to the same control

   1. Create directory /rescue/<serial number of control>

   2. There create a file .done (e.g. /rescue/726xxxxxxxxxx/.done)

      
      

Possibility 1: PC-less device replacement via license dongle µSD card (ctrlX CORE X3 only)

The PC-less device replacement only using the license dongle µSD card, is available for ctrlX CORE X3, ctrlX COREplus X3 and drive integrated ctrlX CORE X3.
Please check (again! 😜) the chapter "Prerequisites" before continuing.

The current device settings are put onto and the required licenses are assigned to the license dongle.

Create backup file on license dongle

1. In the ctrlX OS webUI: Open the “Settings” window and click on the tile “Storage”

   

2. Mount µSD card via corresponding button

   

3. Open the “Settings” window and click on the tile “Backup & Restore”

   

4. Click on the “Backup” tile

   

5. Enter/check backup setting:

   1. Select the device settings and resources to be added to the backup file (default all data is selected)

   2. Select the license dongle µSD card in the "Backup file storage"

   3. Tick setting "Force reboot after restore" in "Additional settings", so control will end up in OP after restoration

   4. Enter a password e.g. "secret" (mandatory to store the device certificates)

   

6. Click on the “Create”

7. A backup file [yyyy-mm-dd-XX-XX-XX_ctrlx-backup.zip] will be generated
   

Prepare the backup-file on license dongle µSD card

1. Open the file browser of the license dongle µSD card via “Settings” window and click on the tile “Storage”, then click "Open file browser"

   

2. To confirm that the backup file should be used for restoration:
   Rename the backup file to [yyyy-mm-dd-XX-XX-XX_ctrlx-setup.zip]

3. Create a file "setup.options.json"

4. Write password of the backup archive inside file "setup.options.json"

   Copy

   {
       "$password": "secret"
   }

5. To prevent restoring the backup to the same control, create a file "setup.<IP of control>.done" (e.g. /setup.726xxxxxxxxxx.done)

Your done! The license dongle can remain in the ctrlX CORE during operation.

Replace your device, PC-less

The device is defect? Too bad!

1. Replace the defect device through a replacement ctrlX CORE

2. Remove the license dongle from the defective device

3. Insert license dongle into the replacement devices µSD slot

4. Switch on the replacement device: The backup file will be recovered automatically
   

   [callout type="warning" headline="DO NOT REMOVE POWER DURING UPDATE!" text="While update, the ctrlX CORE is restarted multiple times and the operating system is initialized for the first time. The entire update, including an initial initialization, can take several minutes!"]

5. The new ctrlX CORE is ready and will boot up to operation!

   [callout type="info" text="Apps that are already installed in the correct version will be skipped during restoration.
On first login there could be a warning showing possible errors during restoration. See file "setup.log" on the µSD card for restoration details."]
   

Possibility 2: PC-less device replacement via license dongle µSD card and USB stick (all ctrlX CORE variants)

The PC-less device replacement via license dongle µSD card and USB stick is available for all variants of the ctrlX CORE device.
Please check chapter "Prerequisites" before continuing.

The current device settings can be saved to a backup file and stored on the USB stick. The required licenses are assigned to the license dongle.

Create backup file on the USB stick

1. In the ctrlX OS webUI: Open the “Settings” window and click on the tile “Storage”

   

2. Mount USB stick via corresponding button

   

3. Open the “Settings” window and click on the tile “Backup & Restore”

   

4. Click on the “Backup” tile

   

5. Enter/check backup setting:

   1. Select the device settings and resources to be added to the backup file (default all data is selected)

   2. Select the USB stick in the "Backup file storage"

   3. Tick setting "Force reboot after restore" in "Additional settings", so control will end up in OP after restoration

   4. Enter a password e.g. "secret" (mandatory to store the device certificates)

   

6. Click on the “Create”

7. A backup file [yyyy-mm-dd-XX-XX-XX_ctrlx-backup.zip] will be generated
   

Prepare the backup-file on the USB stick

1. Open the file browser of the USB stick via “Settings” window and click on the tile “Storage”, then click "Open file browser"

   

2. To confirm that the backup should be used for restoration:
   Rename the backup file to [yyyy-mm-dd-XX-XX-XX_ctrlx-setup.zip].

3. Create a file "setup.options.json"

4. Write password of the backup archive inside file "setup.options.json"

   Copy

   {
       "$password": "secret"
   }

5. To prevent restoring the backup to the same control, create a file "setup.<IP of control>.done" (e.g. /setup.726xxxxxxxxxx.done)

Your done! The USB stick and the license dongle can remain in the ctrlX CORE during operation.

Replace your device, PC-less

The device is defect? Too bad!

1. Replace the defect device through a replacement ctrlX CORE

2. Remove the USB stick and license dongle from the defective device

3. Insert license dongle into the replacement devices µSD slot

4. Plug the USB stick into the XF01C slot of the ctrlX CORE

5. Switch on the replacement device: the backup file will be recovered automatically

   [callout type="warning" headline="DO NOT REMOVE POWER DURING UPDATE!" text="While update, the ctrlX CORE is restarted multiple times and the operating system is initialized for the first time. The entire update, including an initial initialization, can take several minutes!"]

6. The new ctrlX CORE is ready and will boot up to operation!

   [callout type="info" text="Apps that are already installed in the correct version will be skipped during restoration.
On first login there could be a warning showing possible errors during restoration. See file "setup.log" on the USB Stick for restoration details."]

Related information

• Back up and restore

• Hardware reset in case of ctrlX CORE and ctrlX DRIVEplus with integrated ctrlX CORE

• ctrlX STORE on Collaboration Room

• How to partition a disk as GPT & Restore ctrlX CORE X7