Procedure for Using the Automatic Flash Update Tool for a UPS System{4480, 7620} Caterpillar

Uninterruptible Power Supply:

ES12F (S/N: CZE1-UP)

UPS 120 (S/N: CNK1-UP)

UPS 150 (S/N: CPC1-UP)

UPS 250 (S/N: CNM1-UP; APZ1-UP)

UPS 300 (S/N: CNJ1-UP; CPZ1-UP)

UPS 301 (S/N: CSY1-UP)

UPS 500 (S/N: CSE1-UP)

UPS 600 (S/N: CTX1-UP)

UPS 750 (S/N: CPM1-UP)

UPS 900 (S/N: CRY1-UP)

UPS 1000S (S/N: CZS1-UP)

UPS 1200S (S/N: CZT1-UP)

Introduction

This Special Instruction addresses the procedure for using the Automatic Flash update Tool in order to automatically program a UPS system. Refer to ""Procedure" " in order to perform an update to the existing firmware with the following revisions:

• UPS 3.30

• UPS 3.31

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

Automatic Flash Update Tool

The Automatic Flash Update Tool is a Windows application that will prompt the technician for information. When the technician has satisfied the system prompts, the autoloader will initiate the update for firmware automatically. Refer to Illustration 1.

"Command/Status" Window

Illustration 1	g01432806
"Command/Status" Window (1) "COM Port Pull Down" window (2) "Connect" button (3) "User Name" window (4) "Password" window (5) "Start" button (6) "Target" column (7) "IS Rev" column (8) "ShB Rev" column (9) "Status" column

The "Command/Status" window provides the technician with a current status of the update of firmware and requests for command prompts.

"COM Port Pull Down" Window

The "COM Port" pull down window (1) allows the technician to select the appropriate serial COM port of the serial output device on the laptop computer.

"Connect" Button

The "Connect" button (2) will establish communication over the selected serial COM port between the appropriate UPS system and the technician's laptop computer.

Once communication has been established, the following windows will be activated:

• "User Name"

• "Password"

Once the "User Name" window (3) is active and once the "Password" window (4) is active, the technician will enter the appropriate data. The technician will click the "Start" button (5) .

"Autoload Firmware Update Status" Window

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

"Target" Column

The "Target" column will have a "(>)" pointing to the current target that is being updated.

"IS Rev" Column

The "IS Rev" column displays each of the target's current revision prior to the update of firmware that is being performed.

"ShB Rev" Column

The "ShB Rev" column displays the version of firmware that should be selected for each of the targets.

"Reporting Status" Column

The "Reporting Status" column may contain one of the following statements:

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

Procedure

1. Determine the date of bearing installation for your UPS system.

   During this update for firmware and during future updates, you will be required to enter the "Bearing Install Date". If you do not know the correct date of bearing installation, contact Activepower with one of the following methods:

   • 1-800-288-5081

   • "apservice@activepower.com"

2. Ensure that your laptop computer has the current UPSView software. The current software is version 2.7.

3. Ensure that you have downloaded the appropriate electronic update for the firmware version from SISWeb to the following areas:
   • Laptop computer

   • Device for storing media

4. Place the keyswitch for the UPS system in the Bypass position.

   Note: If the UPS is a multiple module unit (MMU), place the keyswitch for the system in the Bypass position.

5. If the single-module system (SMS) is equipped with a maintenance bypass, place the system in maintenance bypass.

6. For a single-module system, connect the laptop computer to the RS-232 connector that is located on the system I/O board.

   Note: For a MMU system, connect the laptop computer to the RS-232 connector that is located on the board for the Parallel Cabinet Interface (PCI).

7. For a MMU system, select "MMU #1" via the rotary switch (PCI).

   Note: You will need to index the rotary switch (PCI) to the next sequential number for the MMU in the system in order to perform the update of firmware for that specific MMU cabinet.

8. Start UPSView and establish communication.

9. Select "Enter Password".

10. Type the appropriate username. Type the appropriate password.

11. Click "OK".

12. Perform an "ALT <Z>" on your laptop computer. Write down all of the operating parameters that are not default parameters.

13. Click on the "Clear Password" menu item.

14. Terminate your communication link between your laptop computer and the UPS. Select the "Connection" item. Click the "Disconnect" option.

15. Locate the "Autoload_2_0.exe" file from your location for media storage on your laptop computer.

16. Double click on the "Autoload_2_0.exe" file.

    The autoloader utility will be initialized. A series of screens with prompts will appear. Refer to Illustration 2.

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Illustration 2	g01434619
"Automatic Flash Update Tool" Window

17. In order to continue, the "Yes, the UPS in bypass?" box must be checked. Verify that the UPS system is in bypass mode by checking the box.

    Illustration 3 will appear as the next prompt.

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Illustration 3	g01434625
"Command/Status" Window

18. Enter the appropriate information in the "COM Port Pull Down" window (1) .

19. Click on the "Connect" button (2)

20. Once you have established communications, the autoloader utility will begin to prompt you for specific information. Enter the required information accordingly.

    If the system incurs a problem during the autoloader process, a communication dialog box will appear. You will have one additional opportunity to execute the autoloader process.

    Repeat Step 14 in order to initialize the autoloader process again.

21. For a single-module system (SMS), the procedure is complete. A successful autoloader process will yield a communication dialog box that indicates that the update for firmware was successful.

    Note: For a multiple module system (MMS), you will need to index the rotary switch (PCI) to the next sequential number for the MMU in the system in order to perform the update of firmware for that specific MMU cabinet. When all of the multiple module units have been updated, the procedure for updating the firmware is complete.

22. Perform a "CTRL <R>" on your laptop computer. Select the answer "Y" in order to confirm the request for operation.

23. Press "Exit".

24. Utilize the UPSView version 2.7 software and monitor the boot process.

    If there are any "Bad Value" statements, the UPS system will identify the statements by providing a yellow text message. The yellow text message will indicate the reason for the notification.

    All "Bad Value" statements must be acknowledged and all "Bad Value" statements must be cleared.

25. Enter the "ALT <Z>" Operating Parameters that were obtained in Step 12. Compare the parameters and correct any differences.

26. After updating your "ALT <Z>" Operating Parameters, perform an "ALT <Z>" on your laptop computer. Ensure that the Operating Parameters have been set. Confirm that the new "ALT <Z>" listing is the same value that was obtained in Step 12.

    The update for firmware has now been completed.

27. Perform a "CTRL <N>" on your laptop computer. Confirm that the "Revision History" report matches Table 1 and Table 2.

    A new user command of "Set Bearing Install Date" has been added. The command sets the operating parameters for the "bearing install date" to the current date that has been entered. Use this command for the following actions:

    • Start-up mode

    • Installation of new service replacement bearings

    The "Bearing Install Date" parameter consists of the following sequence: Year, Month and Day.

28. Enter the new date for the bearing installation. Refer to Step 1.

    Note: The firmware for UPS will not accept an incorrect date for the bearing installation. A red text message will appear in UPSView that states "Invalid Bearing Install Date".

If the Autoloader Utility does not function properly, manually perform the update for firmware. Refer to Special Instruction, REHS4463 for the procedure for manually programming a UPS system.