UPS Firmware Version 3.13 and 3.14 Update{7620} Caterpillar

Uninterruptible Power Supply:

UPS 250 (S/N: APZ250-UP)

UPS 300 (S/N: CNJ300-UP)

UPS 301 (S/N: CSY301-UP)

UPS 500 (S/N: CSE500-UP)

UPS 600 (S/N: CTX600-UP)

UPS 750 (S/N: CPM750-UP)

UPS 900 (S/N: CRY900-UP)

Introduction

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Risk of electric shock or energy hazard. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.

A new version of firmware for the UPS 300 series has been released. The current UPS 300 series requires periodic firmware upgrades to the existing system. These upgrades are essential in maintaining the performance requirements of the machine. The firmware may also incorporate an operational enhancement.

The service technician will need to obtain an electronic copy of the update for the firmware from the SIS web site prior to performing the actual upgrade. The service technician will also be required to ensure that the UPS View 2.5 software is installed in the laptop computer that will be used to perform the upgrade. UPS View 2.5 is available as an upgrade on SIS Web, or the complete software package can be purchased. The UPS 3.13 and 3.14 firmware updates are only able to be executed by using the UPS View 2.5 version software.

The update for firmware should be performed at the time of commissioning procedure or for machines currently in operation at the next scheduled interval. The firmware version of a UPS can be determined by connecting the UPS to your laptop computer while utilizing the UPS View 2.5 software and performing a CTRL N. function.

Table 1

Software and Firmware Files that are Required
Application	Description	Caterpillar Part Number
UPSView 2.5 Software	Upgrade	222-3478
UPSView 2.5 Software	Single User License	203-3971
UPSView 2.5 Software	Multiple User License	203-3976
UPS Firmware 3.13	Single Module System Update	243-2252
UPS Firmware 3.14	Multi Module System Update	243-2253

The SIS Web download .exe firmware files will contain all of the appropriate firmware update files needed for your UPS.

Note: There are two files which only apply to a purchased UPS. There are the ZZA FPGA firmware file and the PCC FPGA firmware files. If your UPS does not have these particular options, then there is no requirement in order to update these firmware files.

In order to perform the UPS Firmware 3.13 or 3.14 update, your UPS must currently be operating at firmware version 2.4 or newer. If your UPS does not have firmware version 2.4 or newer, you must upgrade your existing UPS firmware to Revision 2.45 before proceeding. You can obtain the 2.45 Firmware upgrade Caterpillar file numbers 2065418 .exe, 2065410 .exe 2298308 .exe) from SIS Web.

For reference, further instructions regarding the firmware updating procedure can be found in Systems Operation, Testing and Adjusting, RENR2476, "UPS 250, UPS 300, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supply".

To provide a more efficient way of performing firmware updates, the Autoloader Utility feature was created. The Autoloader simplifies the firmware update procedure, reduces downtime, and eliminates operator induced errors.

The Autoloader Utility is a Windows based application that will prompt the technician for information. When the technician satisfies the system prompts, the autoloader will initiate the Firmware Update automatically. To have a better understanding of the Autoloader Utility the following information is provided. Refer to Illustration 1.

• The first text window in Illustration1 is the command window. The window will provide the technician with a current status of the firmware update.

• The COM Port pull down window is the area that the technician selects the appropriate COM Port of the serial output device on the laptop computer.

• The Connect button will establish communications over the selected COM Port between the appropriate UPS MMU/SMU and the technicians laptop computer.

Procedures

UPS 3.13 or 3.14 Firmware Update Utilizing the Autoloader Utility Feature

Once communication has been established, the User Name and Password windows will be activated. Once the User Name is active and once the Password is active, the technician will enter the appropriate data. The technician will click the Start button.

The lower text window contains detailed information on the current process. The window displays four columns of data. The first column is the Target. The second column is the IS Rev. The third column is the ShB Rev column. The fourth column is the Reporting Status.

• The Target column will have a (>) pointing to the current target being updated

• The IS Rev column displays each of the target's current revision prior to the Firmware Update being performed.

• The ShB Rev column displays the firmware version that each of the target's should be changed to.

• The status column may contain one of five statements:

Not Applicable (NA) - The UPS did not detect this equipment (option) in the UPS. A firmware update is not required for this target.

Force - The UPS will update this file regardless of the current version.

Updating - This target is in the process of being updated.

Pending - The target is programmed when the target sequence is reached.

Skipped - This file is at the current revision. A firmware update is not required.

The following procedures apply to performing the UPS 3.13 or 3.14 Firmware update utilizing the Autoloader Utility Feature.

1. Ensure that your laptop computer has the current UPSView 2.5 software installed.

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Illustration 1	g01104377

2. Ensure that you have downloaded the appropriate electronic firmware update version from SIS Web to either your laptop computer hard drive or to another storage media device.

3. Place the UPS key in the bypass position. If the UPS is a MMS, place the system switch in the bypass position.

4. Connect the laptop computer to the RS-232 connector located on the system I/O board for a SMS or to the PCI board.

5. For MMU systems, begin by selecting MMU number 1 via the PCI rotary selector switch. You must index the PCI rotary switch to the next sequential MMU number in the system in order to perform the firmware update for that specific MMU cabinet.

6. Start the UPSView 2.5 software and establish communications for that specific MMU cabinet.

7. Select "Enter Password."

8. Type the appropriate User Name and Password.

9. Click OK .

10. Perform an ALT Z and write down all the Operating Parameters that are default parameters.

11. Click on the Clear Password menu item.

12. Terminate your communications link between your laptop computer and the UPS. Select the Connection item and then click the Disconnect option.

13. From the electronic media storage location, where you have the new 3.13 or 3.14 firmware update file stored, locate the Autoload_2_0.exe file.

14. Double click on the Autoload_2_0.exe file.

15. The Autoloader Utility will be initialized and a screen prompt will appear.

16. Enter the appropriate COM Port information.

17. Click on the Connect button.

18. Once you have established communications, the Autoloader Utility will begin to prompt you for specific information. Enter the required information accordingly.

19. If the system incurs a problem during the Autoload process, a message dialog box will appear. You will then have one additional opportunity to execute the Autoload process.

20. To re-initialize the Autoload process as a result of a system incurred problem, repeat Step 14. If the Autoload Utility process fails this time, you will need to perform the firmware update manually.

21. A successful Autoload process will yield a message dialog box indicating that the firmware update was successful.

22. Remember, if you are working with a MMS type system, you must perform the firmware update for each MMU. You must index the PCI rotary switch to the next sequential MMU number in the system in order to perform the firmware update for that specific MMU cabinet. Repeat Step 7 to Step 20.

23. Upon successfully completing the firmware update process, you will now need to perform a CTRL R and then answer Y to confirm the operation request.

24. Press the EXIT icon.

25. Now utilizing the UPSView 2.5 software, you will need to monitor the reboot process. If there are any Bad Values the UPS system will identify them by providing a yellow text message indicating the reason for the notification.

    Note: A Bad Value is an Operating Parameter which has never been assigned a value before.

26. All Bad Value statements must be acknowledged and all Bad Value statements must be cleared. You will need to write down all Bad Value statements. Then access the appropriate Operating Parameter Menu via UPSView 2.5.

27. Select the Operating Parameter. A new window will appear asking for a new value.

28. If you are unable to locate the appropriate Operating Parameter Menu to correct the correlating displayed Bad Value, this may be due to the Operating Parameter being outside of your Password Authorization. In this event, you can set the default value to all the restricted parameters by selecting the Command Menu. From the Command Menu, click on the line that reads "Load Restricted Default Params to Flash". This will set all of the restricted parameters to their default value.

29. You will now need to re-enter the ALT <Z> Operating parameters you obtained from Step 10. Compare the parameters and correct any differences to match the values you obtained in Step 10.

30. After you have updated your ALT <Z> Operating Parameters, perform another ALT <Z> to ensure that the Operating Parameters have been set. Confirm that the new ALT <Z> listing is the same as that obtained in Step 10.

31. The firmware update has now been completed. Perform a CTRL <N> and confirm that the Revision History report matches Table 2 or Table 3, as applicable.

32. Upon completion of the firmware update, there will be two New Operating Parameter messages. The two messages will be: "Disch Full Load pH Shift is at 0.000 Degrees, default is 5.000" and "Disch No Load pH Shift is at 0.000 Degrees default is 1.000".

    These two parameters are typically utilized when the system output has a large inductive load characteristic. These two parameters do not have to be altered. A change to these specified default parameters will be applications dependent. If you require a change to these parameters, you will need to obtain a High level password. In order to obtain this High level password, you will have to contact the Active Power Product Support Group at 1-800-288-5081 and submit your request.

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    Table 2

    SINGLE MODULE SYSTEM
    	File Name	Program Target	PWA Board
    Boot Monitor	APC1_Boot4_00.mot	Byte-wide Power or PC Monitor	APC
    Application	SMS_APC1_CMP_APP_3_13.mot	PowerPC	APC
    Internal Flash	SMS_APC1_INT_1_34.mot	Internal PowerPC	APC
    APC FPGA	sms_mms_apc1_fpga_117.ttf	APC FPGA Firmware	APC
    ZZC	zzc_102.ttf	ZZC FPGA Firmware	ZZC

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    Table 3

    MULTIPLE MODULE SYSTEM
    	File Name	Program Target	PWA Board
    Boot Monitor	APC1_Boot4_00.mot	Byte-wide Power or PC Boot Monitor	APC
    Application	SMS_APC1_CMP_APP_3_14.mot	Power PC	APC
    Internal Flash	SMS_APC1_INT_1_41.mot	Internal PowerPC	APC
    APC FPGA	sms_mms_apc1_fpga_117.ttf	APC FPGA Firmware	APC
    ZZC	zzc_102.ttf	ZZC FPGA Firmware	ZZC
    PCC	ppc_110.ttf	PCC FPGA Firmware	PCC

    In the event that the Autoloader Utility does not function properly, you will have to perform the firmware update manually.

    The firmware files that you will have to enter manually are listed in Table 2 or Table 3, depending upon your application. The ZZC firmware file is only applicable to 4-wire UPS systems. The PPC firmware file is only applicable to MMS type UPS. If your UPS does not have either of these particular options, then there is no requirement for you to update these firmware files. They can therefore be disregarded.

    Before performing a Manual Firmware update, an explanation of the Firmware Update Dialog box needs to be reviewed. Refer to Illustration 2.

    • The "Select Target to be Programmed" pull-down menu allows you to select the appropriate firmware file to be updated.

    • The "Browse for Target File to be Used" field will display the selected firmware file and its location in your PC.

    • The "Download Firmware Progress" field provides you with a current completion status of the selected firmware file being updated. This field will provide an incremental percentage value from 0 to 100.

    • The "Program" button initiates the selected firmware update procedure when a valid target has been selected and the files has been found on your PC.

    • The" Exit" button is used after all the appropriate firmware files have been updated and you need to terminate the use of the Firmware Update Utility.

    • The "Advanced" button will no longer be utilized for firmware updates of 3.13 and 3.14 or newer. The check boxes contained within this function box menu, should now be unchecked.

    • The "Browse" button is utilized to search and select the appropriate firmware file to be updated from your PC.

    • The "Reload Device" button is utilized to reboot the selected target without having to cycle the UPS control power. It is required to reboot all devices after the devices have the new Firmware is installed.

    • The" Read Back" button is no longer utilized for firmware updates of 3.13 and 3.14 or newer.

    The Following procedures apply to performing the UPS 3.13 or 3.14 Firmware update manually from a PC terminal.

UPS 3.13 or 3.14 Firmware Update Manually from a PC Terminal

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Illustration 2	g01104887

1. Ensure that your laptop computer has the current UPSView 2.5 Software.

2. Ensure that you have downloaded the appropriate electronic firmware update version from SIS Web to either your laptop hard drive or to another storage media device.

3. Place the UPS Key switch in the bypass position. If the UPS IS mms, place the system key switch in the bypass position.

4. If possible on SMS UPS models, place the UPS in maintenance bypass.

5. Connect the laptop computer to the RS-232 connector located on the System I/O board for a SMS or to the PCI board.

6. For MMU systems, begin by selecting MMU #1 via the PCI rotary selector switch. You will have to index the PCI rotary switch to the next sequential MMU number in the system in order to perform the firmware update for that specific MMU cabinet.

7. Start the UPSView 2.5 software and establish communications.

8. Select "Enter Password."

9. Type in the appropriate user name and password.

10. Click OK.

11. Perform an ALT<Z> and write down all the Operating Parameters that are default parameters.

12. Click on the UPS Settings Menu and select the firmware file "PCC FPGA Firmware."

13. If you are updating a Single Module System (SMS), go to Step 20.

14. For a Multiple Module System (MMS), select the firmware file "PCC FPGA Firmware" from the pull down menu

    Note: The "PCC FPGA Firmware" file may also be indicated as "Serial Flash PCC FPGA" if you have a version of firmware older than 2.4

15. Click on the "Browse" button.

16. Locate the appropriate firmware file to match the file name selected in Step 4. Refer to Table 3.

17. Click on the "Program" button.

18. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and no errors were found. If an error occurred, document the error message and then retry the firmware file update.

19. Click the "Reload Device" button to reboot the PCC firmware file.

20. If you have a 3-wire UPS, proceed to Step 28.

21. For a UPS with the appropriate 4-wire option circuitry, select the firmware file ZZC FPGA Firmware from the pull down menu.

    Note: The ZZC FPGA Firmware file may also be indicated as Serial Flash PCC FPGA if you have a version of firmware older than 2.4.

22. Click on the "Browse" button.

23. Locate the appropriate firmware file to match the file name selected in Step 21. Refer to Table 2 or Table 3.

24. Click on the "Program" button.

25. The "Download Firmware Progress Display " begins to increment and indicate the completion status level of the firmware file.

26. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and no errors were found. If an error occurred, document the error message and then retry the firmware file update.

27. Click the "Reload Device" button to reboot the ZZC firmware file.

28. Select the firmware file "Byte-wide Flash Power PC" from the pull down menu.

    Note: The "Byte-wide Flash Power PC" file may also be indicated as "Boot Monitor" if you have a version of Firmware older than 2.4

29. Click on the "Browse" button.

30. Locate the appropriate firmware file to match the file name selected in Step 28. Refer to Table 2 or Table 3.

31. Click on the "Program" button.

32. The Download firmware progress display will begin to increment and indicate the completion status level of the firmware file.

33. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and an error message was not found. If an error occurred, document the error message and then retry the firmware file update.

34. Click the "Reload Device" button to reboot the Byte-wide Flash Power PC file. With the main window for UPSView as the active window, press CTRL I when you see the text message "Pausing for Operator Input." If you perform this step correctly, the text window will display "IDLED." If this step is not performed correctly, you will need to repeat this step until you obtain an "IDLED" condition statement in the text window.

35. Select the firmware file "Power PC" firmware from the pull down menu.

36. Click on the "Browse" button.

37. Locate the appropriate firmware file to match the file name selected in Step 45. Refer to Table 2 or Table 3

38. Click on the "Program" button.

39. The Download Firmware Progress display will begin to increment and the Download Firmware Progress display will begin to indicate the completion status level of the firmware file.

40. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and no error message and then retry the firmware file update.

41. Select the firmware file "Internal Flash" from the pull-down menu.

42. Click on the "Browse" button.

43. Locate the appropriate firmware file to match the file name selected in Step 41. Refer to Table 2 or Table 3.

44. Click on the "Program" button.

45. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and no errors were found. If an error occurred, document the error message and then retry the firmware file update.

46. Select the firmware file "Internal Power PC Firmware" from the pull-down menu.

47. Click the "Browse" button.

48. Locate the appropriate firmware file to match the file name selected in Step 46. Refer to Table 2 or Table 3.

49. Click on the "Program" button.

50. Upon successfully completing the firmware file update, the "Download Firmware Progress" display will indicate that the firmware was completely updated and no errors were found. If an error occurred, document the error message and then retry the firmware file update.

51. Click the "Reload Device" button to reboot the Power PC Application, Internal Power PC, and APC FPGA firmware files.

52. For a Single Module System (SMS), the firmware update procedure is now completed.

53. For a Multiple Module System (MMS), you will have to index the PCI rotary switch to the next sequential MMU number in the system and perform the firmware update for that specific MMU cabinet. When all the MMU's have been updated, the Firmware Update procedure is complete. It is not necessary to perform the update to the PCC or ZZC firmware files for each MMU. The firmware update for the PCC and ZZC files only need to be performed for MMU1.

54. Upon successfully completing the firmware update process, you will now need to perform a CTRL <R> and then answer Y to confirm the operation request.

55. Press "EXIT".

56. Now utilizing the UPSView 2.5 software, you will need to monitor the reboot process. If there are any Bad Values the UPS system will identify them by providing a yellow Text message indicating the reason for the notification.

57. All Bad Value statements must be acknowledged and all Bad Value statements must be cleared. You will need to write down all of the Bad Value statements provided. Then access the appropriate Operating Parameter through UPSView 2.5.

58. When you select the Operating Parameter, a new window will appear asking for a new value. The new value that you are to enter will be the same as the default value displayed.

59. If you are unable to locate the appropriate Operating Parameter menu to correct the correlating displayed Bad Value, this may be due to the Operating Parameter being outside of your password authorization. In this event, you can set the default value to all the restricted parameters by selecting the Command menu. From the Command menu, click on the line that reads "Load Restricted Default Params to Flash". This will set all of the restricted parameters to their default value.

60. You will now need to re-enter the ALT <Z> Operating Parameters you obtained in Step 11. Compare teh parameters and correct any differences to match the values you obtained in Step 11.

61. After you have updated your ALT <Z> Operating Parameters, perform another ALT <Z> to ensure that the Operating Parameters have been set. Confirm that the new ALT <Z> listing is the same as that obtained in Step 11.

62. The firmware update has now been completed. Perform a CTRL <N> and confirm that the Revision History report matches Table 2 or Table 3, as applicable.

63. Upon completion of the firmware update, there will be two new message. The two messages will be:
    • "Disch Full Load pH Shift is at 0.000 Degrees, default is 5.000".

    • "Disch No Load pH Shift is at 0.000 Degrees default is 1.000".

64. These two parameters are typically utilized when the system output has a large inductive load characteristic. These two parameters do not have to be altered. A change to these specified default parameters will be application dependent. If you require a change to these parameters, you will have to obtain a High Level password. In order to obtain a High Level password, you will have to contact the Active Power Product Support Group at 1-800-288-5081 and submit your request.