SCADAPack E

Firmware Update Technical Reference

Version: 8.14.3
Date: August 2017
Table of Contents
1 Legal Information
.....................................................................................................................................................5
2 Technical Support
.....................................................................................................................................................6
3 Safety Information
.....................................................................................................................................................7
4 Introduction
.....................................................................................................................................................10
5 RTU FLASH Memory & Boot Monitor Diagnostics
.....................................................................................................................................................11
6 Loading Compressed RTU Firmware
.....................................................................................................................................................13
6.1 "Binary
............................................................................................................................................13
Difference" and "Compressed Binary" Files
6.2 Firmware
............................................................................................................................................13
Difference Generator
7 Updating rPAC or RTU Operating System Firmware
.....................................................................................................................................................18
7.1 Offline
............................................................................................................................................18
SCADAPack E Configurator Firmware Update Wizard
7.2 Offline
............................................................................................................................................18
Firmware Updates
7.3 Online
............................................................................................................................................18
Update of RTU Firmware
7.3.1 Online..........................................................................................................................18
SCADAPack E Configurator Firmware Update Wizard
7.3.2 Online..........................................................................................................................18
Firmware Updates
7.3.3 Updating
..........................................................................................................................18
Firmware by Manual Commands

7.4 Firmware
............................................................................................................................................18
Update System Status Codes
8 Updating rPAC or RTU Boot Monitor Firmware
.....................................................................................................................................................33
8.1 Offline
............................................................................................................................................33
SCADAPack E Configurator Boot Monitor Update Wizard
8.2 Online
............................................................................................................................................33
Update of Boot Monitor Firmware
8.2.1 Online SCADAPack E Configurator Boot Monitor Update
..........................................................................................................................33
Wizard
8.2.2 Updating RTU or rPAC Boot Monitor Firmware Using Manual
..........................................................................................................................33
Commands
9 Updating I/O Operating System Firmware
.....................................................................................................................................................42
9.1 Updating
............................................................................................................................................42
SCADAPack ES Remote I/O Firmware
9.1.1 Updating
..........................................................................................................................42
SCADAPack ES Remote I/O Firmware
9.1.2 Updating
..........................................................................................................................42
SCADAPack ES Remote I/O Boot Monitor Firmware

9.2 Updating
............................................................................................................................................42
SCADAPack ER I/O Processor Firmware
9.2.1 Updating
..........................................................................................................................42
I/O Processor Firmware Using Manual Commands

2
 9.3 Updating
............................................................................................................................................42
6000 Series I/O Firmware
10 Updating 6000 Series I/O Boot Monitor Firmware
.....................................................................................................................................................49
11 Hardware Specific Features
.....................................................................................................................................................51
11.1 SCADAPack
............................................................................................................................................51
ES & SCADAPack ER Dynamic RAM Test

3
 Firmware Update Technical Reference

4 8.14.3
Firmware Update Technical Reference Legal Information

1 Legal Information
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not intended
as a substitute for and is not to be used for determining suitability or reliability of these products for
specific user applications. It is the duty of any such user or integrator to perform the appropriate and
complete risk analysis, evaluation and testing of the products with respect to the relevant specific
application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be
responsible or liable for misuse of the information contained herein. If you have any suggestions for
improvements or amendments or have found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means, electronic or mechanical,
including photocopying, without express written permission of Schneider Electric.

All pertinent state, regional, and local safety regulations must be observed when installing and using this
product. For reasons of safety and to help ensure compliance with documented system data, only the
manufacturer should perform repairs to components.

Trademarks
Schneider Electric, ClearSCADA, SCADAPack, Trio, Modbus, and StruxureWare are trademarks and
the property of Schneider Electric SE, its subsidiaries and affiliated companies. All other trademarks are
the property of their respective owners.

Address
Schneider Electric

415 Legget Drive, Suite 101, Kanata, Ontario K2K 3R1 Canada
Direct Worldwide: +1 (613) 591-1943
Fax: +1 (613) 591-1022
Toll Free within North America: 1 (888) 267-2232
www.schneider-electric.com

© 2014 - 2017 Schneider Electric Canada Inc.

All rights reserved.

8.14.3 5
Technical Support Firmware Update Technical Reference

2 Technical Support
Questions and requests related to any part of this documentation can be directed to one of the following
support centers.

Technical Support: Americas, Europe, Middle East, Asia

Available Monday to Friday 8:00am – 6:30pm Eastern Time
Toll free within North America 1-888-226-6876
Direct Worldwide +1-613-591-1943
Email supportTRSS@schneider-electric.com

Technical Support: Australia

Inside Australia 1300 369 233

Email au.help@schneider-electric.com

6 8.14.3
Firmware Update Technical Reference Safety Information

3 Safety Information
Important Information
Read these instructions carefully and look at the equipment to become familiar with the device
before trying to install, operate, service, or maintain it. The following special messages may
appear throughout this documentation or on the equipment to warn of potential hazards or to
call attention to information that clarifies or simplifies a procedure.

The addition of this symbol to a Danger or Warning safety label indicates

that an electrical hazard exists, which will result in personal injury if the
instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, can result in
death or serious injury.

CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can
result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.

8.14.3 7
Safety Information Firmware Update Technical Reference

Please Note
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel.
No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this
material.

A qualified person is one who has skills and knowledge related to the construction, installation, and
operation of electrical equipment and has received safety training to recognize and avoid the hazards
involved.

Before You Begin

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-
of-operation guarding on a machine can result in serious injury to the operator of that machine.

WARNING
EQUIPMENT OPERATION HAZARD
· Verify that all installation and set up procedures have been completed.
· Before operational tests are performed, remove all blocks or other temporary
holding means used for shipment from all component devices.
· Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in death or serious injury.

Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future reference.

Test all software in both simulated and real environments.

Verify that the completed system is free from all short circuits and grounds, except those grounds
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to help prevent accidental equipment damage.

Operation and Adjustments

The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English version
prevails):
· Regardless of the care exercised in the design and manufacture of equipment or in the selection and
ratings of components, there are hazards that can be encountered if such equipment is improperly
operated.
· It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. Always use the manufacturer’s instructions as a guide for functional adjustments. Personnel
who have access to these adjustments should be familiar with the equipment manufacturer’s
instructions and the machinery used with the electrical equipment.
· Only those operational adjustments actually required by the operator should be accessible to the
operator. Access to other controls should be restricted to help prevent unauthorized changes in
operating characteristics.

8 8.14.3
Firmware Update Technical Reference Safety Information

Acceptable Use
SCADAPack E remote Programmable Automation Controllers (rPACs), Remote Terminal Units (RTUs)
and input/output (I/O) modules are intended for use in monitoring and controlling non-critical equipment
only. They are not intended for safety-critical applications.

WARNING
UNACCEPTABLE USE
Do not use SCADAPack E rPACs, RTUs, or I/O modules as an integral part of a
safety system. These devices are not safety products.
Failure to follow this instruction can result in death or serious injury.

CAUTION
EQUIPMENT OPERATION HAZARD
When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.

Use only Schneider Electric software or approved software with Schneider Electric
hardware products.

Failure to follow these instructions can result in minor or moderate injury.

8.14.3 9
Introduction Firmware Update Technical Reference

4 Introduction
The SCADAPack E RTU provides a Boot Monitor component within firmware. In conjunction with RTU
hardware it provides the ability to re-load RTU operating system firmware.
Reloading firmware can be done through an RTU serial port (locally), or it can be done remotely from
across network communication media.
The SCADAPack E firmware contained in hardware Flash memory contains the RTU operating system.
A separate boot loader containing a Flash re-programming Boot Monitor controls the process of starting
the RTU and re-programming the RTU operating system firmware.
The SCADAPack E RTU runs the Boot Monitor from its Boot ROM or Boot FLASH sector at start-up
(depending on RTU hardware model). Its purpose is to validate and run the RTU operating system
firmware already stored in Flash memory, or update the RTU operating system firmware.

The Boot Monitor can be notified to update RTU Operating System Firmware or Boot Monitor Firmware
by connection of a local PC initiating a firmware upgrade, or by the user initiating a remote RTU firmware
update. For the SCADAPack ES and SCADAPack ER the user can also select hex switch modes on
the RTU hardware to force firmware upgrade options.

At startup, if an Operating System Firmware upgrade or Boot Monitor Firmware upgrade is not initiated,
the Boot Monitor will validate the RTU operating system firmware by scanning the RTU’s Flash memory
and comparing a computed CRC-32 value with one stored in the Flash memory. Should the operating
system firmware be validated, the Boot Monitor will begin executing it. Otherwise the Boot Monitor will
remain active, waiting for a new RTU operating system firmware image to be loaded to it, locally.

10 8.14.3
Firmware Update Technical Reference RTU FLASH Memory & Boot Monitor Diagnostics

5 RTU FLASH Memory & Boot Monitor Diagnostics

RTU Flash Memory
The RTU firmware is stored in non-volatile FLASH memory.
The SCADAPack E RTU hardware supports local and remote flash loading for the following firmware:
§ Boot Monitor firmware
§ Operating System Firmware
In addition, the SCADAPack ER RTU hardware supports local and remote flash loading for the following
firmware:
§ I/O Processor Firmware
The Boot Monitor firmware also provides RTU start-up information that may assist diagnosing potential
conditions affecting start-up.

Boot Monitor Port

The SCADAPack E RTU Boot Monitor can use a specific RTU port to load firmware during the RTU
startup phases.
The following port is used by the Boot Monitor for offline firmware update connection during the startup
phases of the RTU.
Some RTU models also support diagnostics on this Port at RTU start-up. If any unexpected behavior is
encountered at RTU start-up, it may help to view these diagnostics. This port is known as the BOOT
MONITOR PORT.

Firmware update Boot Diags on

RTU Type Boot Monitor Port
on this Port? this Port?

SCADAPack ES PORT 4 Yes Yes

SCADAPack ER PORT 4 Yes Yes

SCADAPack 312E PORT 2 (COM2) Yes No

SCADAPack 313E PORT 2 (COM2) Yes No

SCADAPack 314E PORT 2 (COM2) Yes No

SCADAPack 330E PORT 3 (COM3) Yes No

SCADAPack 333E PORT 3 (COM3) Yes No

SCADAPack 334E PORT 3 (COM3) Yes No

SCADAPack 337E PORT 3 (COM3) Yes No

SCADAPack 350E PORT 3 (COM3) Yes No

SCADAPack 357E PORT 3 (COM3) Yes No

SCADAPack 530E PORT 4 (Serial4) Yes No

SCADAPack 535E PORT 4 (Serial4) Yes No

8.14.3 11
RTU FLASH Memory & Boot Monitor Diagnostics Firmware Update Technical Reference

Boot Monitor Diagnostics (SCADAPack ES and SCADAPack ER only)

SCADAPack 300E, SCADAPack 530E and SCADAPack 535E RTUs do not provide Boot Monitor
Diagnostics at startup.
To view boot monitor diagnostics on SCADAPack ES and SCADAPack ER RTUs, use HyperTerminal, or
another terminal emulation program, set-up as follows:
1. Connect using an RTU serial cable to the Boot Monitor Port detailed in the table above (Boot
Monitor Port 11 )
2. Set-up terminal emulator as 57600 bps, 8 Data-bits, No Parity, 1 Stop-bit
3. Restart the RTU
4. Boot Monitor diagnostics will be displayed

Typical Boot Monitor start-up diagnostics are as follows:

>Flash Monitor Loaded - Version 2.10
>Validating Program
>Valid Program
>Execute Program

Following completion of Boot Monitor start-up, the SCADAPack E RTU operating system firmware is
started.
Depending upon the port configurations, the port to which you connect may display RTU firmware start-
up diagnostics.
The default firmware configurations for the RTU serial port (after the Boot Monitor starts the main
Operating System Firmware) are 9600 bps (8-N-1) with Cmd Line functions. These may be reconfigured
by the user to a different data rate, or different port functionality than the default. It is possible that the
boot monitor may output its diagnostics at 57600 bps, and the firmware output its startup diagnostics at
a different rate, or possibly not start-up.

12 8.14.3
Firmware Update Technical Reference Loading Compressed RTU Firmware

6 Loading Compressed RTU Firmware

Updating the RTU firmware using either a “compressed” binary image (.BIZ) or “compressed difference”
binary patch file (.BIP) is an efficient mechanism provided by the SCADAPack E architecture to allow
loading a new operating system version remotely. These compressed binary images are derived from a
complete binary ".bin" file.
A compressed binary image is identified as a “.biz” file and can be used to update to the new firmware
irrespective of the existing firmware in the RTU.

· SCADAPack ES, SCADAPack ER and SCADAPack 300E RTUs support .bin, .biz and .bip
files.
· SCADAPack 530E and 535E RTUs support .biz files only. They do not support .bin or .bip files.

Tip: By default, firmware images will be installed to: C:\Program Files\Schneider Electric\SCADAPack E
\Firmware

A “difference” file is identified as a “.bip” file and can only be used to update from one specific version to
another.
Refer to Section “Binary Difference” and “Compressed Binary” File Utility 14 for more information on
these compressed files and how they can be generated.

Loading compressed RTU firmware is supported through three methods:

· Offline locally using SCADAPack E Configurator Firmware Update Wizard connected to the
RTU's Boot Monitor port (see SCADAPack E Configurator Update Firmware Wizard 19 ).
· Online locally or remotely using SCADAPack E Configurator Firmware Update Wizard via remote
DNP3 communications (see Remotely Updating RTU Firmware 24 )
· Remotely using file transfer and DNP3 commands (see Remotely Updating RTU Firmware 24 )

8.14.3 13
Loading Compressed RTU Firmware Firmware Update Technical Reference

6.1 "Binary Difference" and "Compressed Binary" Files

The “differences” between two given firmware binary (.bin) files can be determined and a “binary
difference” file (*.BIP) can be generated that characterizes the differences between the two given binary
images. The resulting “.BIP” difference file can be downloaded and applied as a firmware upgrade to the
RTU through SCADAPack E Configurator locally, SCADAPack E Configurator remotely, or via manual
commands.
Using a .BIP firmware upgrade to patch an older firmware version effectively replaces the old firmware
with the new firmware.

The greatest advantage of the binary difference .BIP format is realized when the increment between two
firmware versions is small, resulting in a relatively small *.BIP (binary difference file), as opposed to a
comparatively large *.BIZ file (complete compressed binary image).
This is particularly useful for remotely patching outstation firmware when communications is via low-
speed links.

See Online Update of RTU Firmware 24 for more information regarding remote firmware patching.

The Schneider Electric SCADAPack E Installer includes a software utility that can generate both .BIP
files and .BIZ files. This utility is a Microsoft Windows® application, as detailed in the following sections.

SCADAPack 530E and 535E RTUs support .BIZ files only.They do not support .BIN or .BIP files.

Firmware Difference Generator 15

14 8.14.3
Firmware Update Technical Reference Loading Compressed RTU Firmware

6.2 Firmware Difference Generator

The Windows Difference Generator application provides a mechanism for generating SCADAPack E
firmware .BIZ and .BIP files from operating system firmware binary image .BIN files.

The Firmware Difference Generator is used with SCADAPack ES, SCADAPack ER and SCADAPack
300E RTUs. It is not used with SCADAPack 530E and SCADAPack 535E rPACs.

If you are using the Windows 10 operating system, you need the ability to run applications as
administrator to use the Firmware Difference Generator.
To Start the Firmware Difference Generator
· Select the Start or Windows menu, then navigate to the Schneider Electric folder and select
SCADAPack E > Difference Generator.

If you are using the Windows 10 operating system, right-click on Difference Generator and select
Run as administrator.
The Firmware Difference Generator is displayed, as shown below.

Figure 4.1: Firmware Difference Generator Interface

To Generate a .BIZ Compressed Firmware File

1. In the Firmware Difference Generator, select Generate BIZ.

2. In the Generate Compressed Firmware File dialog, select the controller type.
3. Click Browse to locate the .BIN firmware file to compress.
4. Click Browse to select the folder and filename for the compressed target .BIZ file.
5. Click Generate.
The progress bar shows the conversion progress.

8.14.3 15
Loading Compressed RTU Firmware Firmware Update Technical Reference

Figure 4.2: BIZ file Generation

To Generate a .BIP Firmware Binary Difference File

1. In the Firmware Difference Generator, select Generate BIP.

2. In the Generate Firmware Difference File dialog, select the controller type.

16 8.14.3
Firmware Update Technical Reference Loading Compressed RTU Firmware

Figure 4.3: BIP file Generation

3. Click Browse to select the .BIN firmware file for the existing RTU firmware version.
4. Click Browse to select the .BIN firmware file for the RTU firmware version you want to upgrade to.
5. Click Browse to select the folder and filename for the firmware difference .BIZ file.
6. Click Generate.
The progress bar shows the conversion progress.

8.14.3 17
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

7 Updating rPAC or RTU Operating System Firmware

Loading & re-programming new SCADAPack E RTU operating system firmware in FLASH memory is
managed by the Boot Monitor.
The Boot Monitor can also load & re-program new Boot Monitor firmware (i.e. replace itself).
Operating System firmware upgrade can be activated in one of the following ways:

· Offline locally using the SCADAPack E Configurator Transfer | Update System Firmware menu
command to access the Firmware Update Wizard while connected to the Boot Monitor Port of
the RTU (See Offline SCADAPack E Configurator Firmware Update Wizard 19 )
· Online locally using the SCADAPack E Configurator Firmware Update Wizard while connected to
a DNP3 communication port of the RTU (See Online SCADAPack E Configurator Firmware
Update Wizard 25 )
· Online remotely using SCADAPack E Configurator Firmware Update Wizard across a DNP3
communication link (See Online SCADAPack E Configurator Firmware Update Wizard 25 )
· Online remotely via DNP3 file transfer of compressed RTU operating system image into an
operating RTU (See Updating Firmware by Manual Commands 29 ) - e.g. by Master Station
See also

· Offline Firmware Updates 22

· Online Firmware Updates 28

Updating Boot Monitor Firmware

Boot Monitor firmware upgrade can be activated in one of the following ways:

· Offline locally using the SCADAPack E Configurator Transfer | Update Boot Monitor command
to access the Boot Monitor Update Wizard while connected to the Boot Monitor Port of the RTU.
(NOT SUPPORTED BY SCADAPack 300E, SCADAPack 530E and SCADAPack 535E RTUs).
· Online locally using the SCADAPack E Configurator Boot Monitor Update Wizard while
connected to a DNP3 communication port of the RTU. (See Online SCADAPack E Configurator
Boot Monitor Update Wizard 38 )
· Online remotely using the SCADAPack E Configurator Boot Monitor Update Wizard across a
DNP3 communication link. (See Online SCADAPack E Configurator Boot Monitor Update Wizard
38 )

· Online remotely via DNP3 file transfer of the compressed RTU operating system image into an
operating RTU (See Updating Boot Monitor by Manual Commands 39 ) - e.g. by Master Station
See also

· Updating Boot Monitor Firmware 33

· Online Update of Boot Monitor Firmware 37

18 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

7.1 Offline SCADAPack E Configurator Firmware Update Wizard

The SCADAPack E RTU may have its Operating System firmware upgraded Offline using the
SCADAPack E Configurator “Firmware Update” Wizard and selecting Local Serial Port as the update
method. This locally transfers a Firmware Binary Image (.BIN file), a Compressed Binary Image (.BIZ
file), or a Firmware Patch (difference) Image (.BIP file) to the RTU through the PC’s serial port and via the
RTU’s Boot Monitor port. See Boot Monitor Port 12 for more information.
· SCADAPack ES, SCADAPack ER and SCADAPack 300E RTUs support .BIN, .BIZ and .BIP
files.
· SCADAPack 530E and 535E RTUs support .BIZ files only. They do not support .BIN or .BIP files.
Offline firmware updates can only be performed locally, and results in complete initialization of the RTU.
Also see:

· Offline Firmware Updates 22

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating firmware, make sure you are connected to the correct
SCADAPack E RTU.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a firmware update. Hazardous situations can
occur if the system state is not confirmed prior to performing a firmware update.
Failure to follow these instructions can result in death or serious injury.

Using the Firmware Update Wizard for Offline Updates

Start the Wizard through the SCADAPack E Configurator “Transfer” menu by selecting “Update System
Firmware”.

Select the Local Serial Port update method and follow the Wizard instructions, which will guide you
through setting up the link to the RTU and starting the firmware update process.

8.14.3 19
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Reloading RTU Firmware interrupts the operation of the RTU during the Flash re-
programming process, and resets the RTU configurations. Offline firmware updates
clear the RTU configuration, including IEC 61131-3 application(s).
Before reloading the firmware, save a copy of the RTU configuration information,
user-created applications, logs and other data to an external drive so it can be
reloaded when then the firmware reloading is complete.
Failure to follow these instructions can result in equipment damage.

Figure 5.1: SCADAPack E Configurator Firmware Update Wizard

For updating RTU Operating System firmware Offline locally (i.e. plugged in to the Boot Monitor serial
port on the controller), select the Local Serial Port option. Then follow the wizard instructions.

20 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

Figure 5.2: SCADAPack E Configurator Firmware Update Wizard Instructions

8.14.3 21
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

7.2 Offline Firmware Updates

This section details how to update the RTU Operating System firmware offline by local connection to an
RTU serial port.

With firmware update techniques detailed for local updates the RTU configuration is NOT
retained.

If it is necessary to update the firmware and retain configurations, applications and database values, it is
recommended that the firmware is updated using one of the “online” techniques used for remote firmware
updates. See Online Update of RTU Firmware 24 .

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating firmware, make sure you are connected to the correct
SCADAPack E RTU.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a firmware update. Hazardous situations can
occur if system state is not confirmed prior to performing a firmware update.
Failure to follow these instructions can result in death or serious injury.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Reloading RTU Firmware interrupts the operation of the RTU during the Flash re-
programming process, and resets the RTU configurations. Offline firmware updates
clear the RTU configuration, including IEC 61131-3 application(s).
Before reloading the firmware, save a copy of the RTU configuration information,
user-created applications, logs and other data to an external drive so it can be
reloaded when then the firmware reloading is complete.
Failure to follow these instructions can result in equipment damage.

The Boot Monitor Port on the RTU is utilized by the Boot Monitor to allow Local transfer of new Operating
System firmware into the RTU Flash memory.
For SCADAPack 300E RTUs, the Boot Monitor keeps the "RUN" LED OFF while it is running (RTU's
"POWER" LED is ON).

22 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

For SCADAPack ES, SCADAPack ER, SCADAPack 530E and SCADAPack 535E RTUs: Upon starting,
the Boot Monitor blinks the “Run” LED on the RTU quickly (about 2 flashes per second). This flash rate is
faster than when the RTU is operating normally.
Transferring new operating system firmware to the RTU “locally” requires the use of SCADAPack E
Configurator with a PC Com Port connected to the Boot Monitor Port on the RTU (See section Boot
Monitor Port 12 ).
Binary images, or compressed binary image files for the RTU are provided by Schneider Electric.
Compared with standard binary image files, using the compressed (.BIZ) files are a preferred way of
updating firmware due to the smaller file size and the hardware specific information included in the
compressed binary file.
Firmware updates are also possible using difference binary images (.BIP) that allow the firmware to be
updated from one specific version to another.
· SCADAPack ES, SCADAPack ER and SCADAPack 300E RTUs support .BIN, .BIZ and .BIP
files.
· SCADAPack 530E and 535E RTUs support .BIZ files only. They do not support .BIN or .BIP
files.
See Loading Compressed RTU Firmware 13 for more information regarding binary difference files.
At RTU startup, the Boot Monitor waits 2 seconds, as part of its normal boot sequence, for connection
with the SCADAPack E Configurator Firmware Update Wizard.
Thus the RTU needs to be powered OFF prior to commencing the upgrade procedure.

Updating Operating System Firmware Offline

1. Start the SCADAPack E Configurator Firmware Update Wizard by selecting Transfer | Update
System Firmware.
2. Select the Local Serial Port connection on the update wizard and follow the wizard instructions to
prepare the serial connection to the RTU.
3. Power ON the RTU when instructed by the Wizard.
Once communications is established with the RTU Boot Monitor, the following firmware update
sequences occur automatically:
· Operating System Flash memory in RTU is erased
· Firmware Image is transferred to the RTU in blocks
· Each block is verified for data integrity and blocks are programmed into the Flash memory
· Blocks are transferred and programmed into the Flash memory until the complete binary image is
transferred
· When programming a SCADAPack 300E RTU with a .BIP (binary compressed patch) file, a two-
phase transfer and burn process takes place to establish update integrity. This part of the
process can take longer than if using a .BIZ or .BIN file for upgrade.
· Upon completion, the user is prompted for the RTU to be restarted

SCADAPack ES and SCADAPack ER Local Firmware Updates

If the RTU hex switches on a SCADAPack ES or SCADAPack ER RTU are set to “FF” (Flash Firmware
transfer mode), the Boot Monitor waits indefinitely for a firmware update.

If not set to “FF” mode, the Boot Monitor waits 2 seconds on startup, as part of its normal boot
sequence, for connection with the SCADAPack E Configurator Update Firmware Wizard as described

8.14.3 23
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

above.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Use of "FF" (Flash Firmware transfer mode) disables normal RTU operation.
Set the RTU hex switches to 00 for RUN mode.
Failure to follow these instructions can result in equipment damage.

In the case of the SCADAPack ES and SCADAPack ER RTU models, the RTUs may be restarted at
any time after "FF" mode is set, rather than having to have the unit powered down until the wizard
instructs a power up.

Set the Hex Switches then restart the RTU by one of the following methods:
· Power the RTU off & on
· Hardware reset the RTU
· Send a DNP3 Cold Restart command
· Send an RTU command line “RESTART RTU” command
· Send a SCADAPack E Configurator Commands > Restart RTU

7.3 Online Update of RTU Firmware

See the following sections describing how to upgrade Operating System firmware online:

· Online SCADAPack E Configurator Firmware Update Wizard 25

· Online Firmware Updates 28

· Updating Firmware by manual commands 29

24 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

7.3.1 Online SCADAPack E Configurator Firmware Update Wizard

The SCADAPack E RTU may have its Operating System firmware upgraded online using the
SCADAPack E Configurator Firmware Update Wizard and selecting DNP3 Connection as the update
method.

This transfers a Compressed Binary Image (.BIZ file), or a Firmware Patch (difference) Image (.BIP file) to
the RTU through a DNP3 connection. This connection may be local to the RTU, or remote across a
communications link.

· SCADAPack ES, SCADAPack ER and SCADAPack 300E RTUs support .BIN, .BIZ and .BIP
files.
· SCADAPack 530E and 535E RTUs support .BIZ files only. They do not support .BIN or .BIP
files.
An online firmware update will save and restore the configuration of the RTU as part of the upgrade
process. When upgrading by way of Firmware Patch, this includes preservation of ISaGRAF retained-
variable values. The ISaGRAF application state, ISaGRAF I/O lock states, and SCADAPack E RTU
output states are not preserved during an upgrade. Also see
· Online Firmware Updates 28

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating firmware, make sure you are connected to the correct
SCADAPack E RTU. Verify the CPU ID displayed in the SCADAPack E
Configurator matches the CPU ID of the RTU that firmware is intended to be
updated on.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a firmware update. Hazardous situations can
occur if system state is not confirmed prior to performing a firmware update.
Failure to follow these instructions can result in death or serious injury.

Using the Firmware Update Wizard for Online Updates

1. Start the Wizard through the SCADAPack E Configurator “Transfer” menu by selecting “Update
System Firmware”.

2. Select the DNP3 Connection update method and follow the Wizard instructions, which will guide you
through setting up the link to the RTU and starting the firmware update.

8.14.3 25
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

Figure 5.3: SCADAPack E Configurator Firmware Update Wizard

For updating RTU Operating System firmware online (i.e. via a local or remote DNP3 connection), select
the DNP3 Connection option. On SCADAPack 300E, SCADAPack 530E and SCADAPack 535E RTUs,
the USB Device (peripheral) port may be used. RTUs may use a DNP3 serial port or Ethernet interface
for this connection.

Follow the wizard instructions for connection:

26 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

Figure 5.4: SCADAPack E Configurator Online Firmware Update Wizard Connection

Instructions
1. Establish connection with the RTU. These use the same dialogs as establishing SCADAPack E
Configurator connection with RTUs. For more information see the SCADAPack E Configurator
User Manual.
2. Choose a compressed firmware image (.BIP or .BIZ file) when prompted.

8.14.3 27
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

7.3.2 Online Firmware Updates

Online update of the RTU's Operating System firmware is achieved using an RTU firmware compressed
binary image.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Reloading RTU Firmware interrupts the operation of the RTU during the Flash re-
programming process, and resets the RTU configurations. Offline firmware updates
clear the RTU configuration, including IEC 61131-3 application(s).
Before reloading the firmware, save a copy of the RTU configuration information,
user-created applications, logs and other data to an external drive so it can be
reloaded when then the firmware reloading is complete.
Failure to follow these instructions can result in equipment damage.

Typically, compressed binary files will be used to upgrade from a lower SCADAPack E firmware version
number to a higher firmware version number, though re-programming can also operate in the reverse
direction (from a higher version number to a lower version number) provided an appropriate “*.BIZ” or
“*.BIP” file is available.

· SCADAPack ES, SCADAPack ER and SCADAPack 300E RTUs support .BIN, .BIZ and .BIP
files.
· SCADAPack 530E and RTUs support .BIZ files only. They do not support .BIN or .BIP files.
Section “Binary Difference” and “Compressed Binary” Files 14 describes the Schneider Electric utility for
generating these files.

Typically a .BIP file, being the compressed changes for a firmware image, is a smaller size than a BIZ
file. On lower-speed network links the time to transfer a .BIP file can be considerably shorter than a .BIZ
file.

Online firmware update will save and restore the configuration of the RTU as part of the upgrade process.
When upgrading by way of Firmware Patch, this includes preservation of ISaGRAF retained-variable
values. The ISaGRAF application state, ISaGRAF I/O lock states, and SCADAPack E RTU output states
are not preserved during an upgrade.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating firmware, make sure you are connected to the correct
SCADAPack E RTU. Verify the CPU ID displayed in the SCADAPack E
Configurator matches the CPU ID of the RTU that firmware is intended to be
updated on.
Failure to follow these instructions can result in death or serious injury.

28 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a firmware update. Hazardous situations can
occur if system state is not confirmed prior to performing a firmware update.
Failure to follow these instructions can result in death or serious injury.
In the case of SCADAPack 300E RTUs, it takes longer to update the firmware from a .BIP file than a
.BIZ file. This is to establish update integrity in case of RTU power interruption during the update
process.

RTU configurations are restored following an online firmware update.

Following the remote issuing of a “RESTART PATCH” command, the RTU stores the following
information in the Boot Monitor Flash (non-volatile) memory:

· IEC 61131-3 (target 3 and target 5) kernel application files (if used)
· IEC 61131-3 Retained Variable values (For Target/Resource 1 & Target/Resource 2 if in use)
· RTU point database configuration including derived variable values
· RTU communication configuration parameters
· Profile Files
· NTP configuration file (ntp.conf)
The following information is NOT separately saved and restored following a remote firmware update, but
should persist in the RTU Flash file system:

· Trend sample Files (SF & SAMP files)

· Other files in the RTU file system
The following information is NOT restored following a remote firmware update:

· RTU Diagnostic mode settings (e.g. SYSDIAG, DNPDIAG, PLCDIAG, TCPDIAG, etc.)
· ISaGRAF application internal program states
· ISaGRAF application I/O Lock status

7.3.3 Updating Firmware by Manual Commands

The Operating System firmware can be upgraded online by manual commands. A Master Station may
also use this method.
This method can be carried out either locally or remotely. The compressed firmware image file needs to
first be transferred into the file system of an operational SCADAPack E RTU. This file transfer can be
done in one of 2 ways:

· FTP (File Transfer Protocol) – if IP connection to the RTU is available and FTP is enabled on the
RTU.
· DNP File Transfer.

NOTICE

8.14.3 29
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

UNEXPECTED EQUIPMENT OPERATION

Legacy DNP3 file transfers using Group 70 Variation 1 objects are not
communication-loss tolerant.
If file transfers are required in an environment that may experience communication
loss, consider using a more tolerant transfer mechanism such as the new DNP3 file
transfer (Group 70 Variation 2, 3, 4, 5, 6, 7 objects.)
Failure to follow these instructions can result in equipment damage.

A firmware update will save and restore the configuration of the RTU as part of the upgrade process. The
ISaGRAF application state, ISaGRAF I/O lock states, and SCADAPack E RTU output states are not
preserved during an upgrade.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating firmware, make sure you are connected to the correct
SCADAPack E RTU.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a firmware update. Hazardous situations can
occur if system state is not confirmed prior to performing a firmware update.
Failure to follow these instructions can result in death or serious injury.

To Remotely Reprogram Operating System Firmware

The following steps should be performed to remotely reprogram the RTU Operating System firmware:
1. Use FTP or SCADAPack E Configurator to transfer the compressed firmware image (.BIZ or .BIP)
file to the RTU.
· If you are using FTP, set the transfer mode to binary before transferring the file.
· If you are using SCADAPack E Configurator DNP file transfer, select Transfer > Write File from
the main menu.
2. Access the SCADAPack E RTU’s command line facility to activate the Firmware re-programming
process. Enter the following command:
restart patch filename.biz
or
restart patch filename.bip

The RTU’s command line facility can be accessed in one of several ways (listed as follows):

30 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Operating System Firmware

· direct connection to CMD LINE serial port (or ISaGRAF port via Command Line Shell when IEC
61131-3 Target 3 is enabled. Command line shell is not available with Target 5.)
· Remote Command Line
· TELNET connection
OR

1. From SCADAPack E Configurator menu bar, select Commands | Execute Command | Other …
2. Check DNP Address is set to RTU’s DNP address
3. Enter restart patch filename.biz or restart patch filename.bip in the Execution Line field
4. Click on OK to send the restart request.

The RTU will then restart and the firmware re-programming process is managed by the RTU Boot
Monitor.
The Boot Monitor will automatically restart the RTU operating system once the re-programming is
successfully.
Programming the FLASH EEPROMs may take up to 3 mins during which time communications with the
RTU will not be available.
Once the firmware patch is complete, re-establish communication with the RTU and use SCADAPack E
Configurator to read the General / Controller Status page to confirm that the firmware version number
reports the upgraded version number.
After a successful firmware update, the RTU configuration and ISaGRAF applications, etc., should be
properly restored. These should be checked.
Once the Operating System firmware memory is erased, the contents of the Flash EEPROM is invalid
until the re-programming process is complete. If an interruption occurs during the Operating System
Flash re-programming process, the Boot Monitor should not be affected. However, an Offline Firmware
Update 28 may then be required to load a valid operating system into the RTU. If re-programming is
unsuccessful and the SCADAPack E RTU will not boot, consult the Boot Monitor Diagnostics 12 . If this
does not restore the firmware, contact Schneider Electric Technical Support 6 .

8.14.3 31
Updating rPAC or RTU Operating System Firmware Firmware Update Technical Reference

7.4 Firmware Update System Status Codes

Unsuccessful firmware updates using compressed binary images may reported via the System Status
Code system point (system analog point 50020).
Table 6.1 32 below lists status codes that may result from updating firmware.

Table 6.1: Firmware Update Status Codes

Status Code Value Name Description

1050 Remote I/O Main Firmware The main firmware version number of the relevant
Mismatch SCADAPack ES Remote I/O RTU is different to
that of the Main Unit

1051 Remote I/O Boot Monitor The Boot Monitor firmware version number of the
Firmware Mismatch relevant SCADAPack ES Remote I/O Unit is
different to that of the Main Unit

1052 Main Firmware Model An attempt was made to patch the main firmware
Mismatch with a compressed image (*.biz or *.bip) which
had a different hardware ID to that required

1053 Boot Monitor Firmware An attempt was made to patch the Boot Monitor
Model Mismatch firmware which had a different hardware ID to that
required.

1054 Main Firmware Patch This indicates that the Boot Monitor could not
Unsuccessful patch the main firmware with a compressed
image (*.biz or *.bip). A possible cause for this
status code is that the *.bip file was not
generated using the correct “old” firmware binary
image.

1055 Main OS Firmware Patch This indicates that the SCADAPack 350E or
Incompatible SCADAPack 357E RTU has an incompatible
hardware version for the OS firmware patch used.
· For hardware versions 7.00 and later firmware
version 7.85 and later is required.
· For hardware versions 6.00 and earlier firmware
version 7.84 and earlier is required.
Use the command line VER command to
determine the hardware version.

3015 6000 Series I/O Firmware Reported when there is an unexpected issue
Update Incomplete during the firmware update on a 6000 series I/O
expansion module.
For example, this code may be reported if the
firmware binary image file was corrupted during
the file transfer.

32 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Boot Monitor Firmware

8 Updating rPAC or RTU Boot Monitor Firmware

The RTU Boot Monitor may be upgraded in one of the following ways:

· Using SCADAPack E Configurator Boot Monitor Update Wizard connected to the Boot Monitor
Port for a local offline update. See Offline SCADAPack E Configurator Boot Monitor Update
Wizard 35 . This method is not supported by SCADAPack 300E, SCADAPack 530E and
SCADAPack 535E RTUs.
· Requesting the main Operating System Firmware to update the Boot Monitor (online local or
remote update possible). See Online Update of Boot Monitor Firmware 37 .
The Boot Monitor firmware image includes a Hardware Identification field that indicates the target
hardware for the respective Boot Monitor firmware image file. Each supported hardware platform requires
its own Boot Monitor image for correct operation.
The supported hardware types are:

· SCADAPack 350E (with hardware version 7.00 or greater only Boot Monitors 2.30 and higher
are supported).
· SCADAPack 357E (with hardware version 7.00 or greater only Boot Monitors 2.30 and higher
are supported).
· SCADAPack 330E
· SCADAPack 333E (only Boot Monitors 2.31 and higher are supported).
· SCADAPack 334E
· SCADAPack 337E (only Boot Monitors 2.31 and higher are supported).
· SCADAPack 312E (only Boot Monitors 2.31 and higher are supported).
· SCADAPack 313E (only Boot Monitors 2.31 and higher are supported).
· SCADAPack 314E
· SCADAPack ES
· SCADAPack ER
· SCADAPack 530E
· SCADAPack 535E

Use the VER command from the command line to check the hardware version of your RTU.

8.14.3 33
Updating rPAC or RTU Boot Monitor Firmware Firmware Update Technical Reference

The following table lists the hardware types and the Boot Monitor filename syntax (for the appropriate
hardware).

Hardware Type Boot Monitor Filename Syntax*

SCADAPack 350E
mon_VVV_35xE.bin
SCADAPack 357E

SCADAPack 330E
SCADAPack 333E
mon_VVV_33xE.bin
SCADAPack 334E
SCADAPack 337E

SCADAPack 312E
SCADAPack 313E mon_VVV_31xE.bin
SCADAPack 314E

SCADAPack ES mon_VVV_586e.bin

SCADAPack ER mon_VVV_586m.bin

SCADAPack 530E
mon_VVV_53xE.bin
SCADAPack 535E

* where VVV represents the version number of the Boot Monitor, e.g. the filename of version 2.12 of the
SCADAPack ES Boot Monitor is “mon_212_586e.bin”.

The recommended method for updating the Boot Monitor Firmware is the SCADAPack E Configurator
online method (see Online SCADAPack E Configurator Boot Monitor Update Wizard 38 . This method
provides protection against inadvertent loading of the incorrect Boot Monitor Firmware image for the given
hardware type. This protection is not available when using the "local" update methods for SCADAPack
ES and SCADAPack ER RTUs.

34 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Boot Monitor Firmware

8.1 Offline SCADAPack E Configurator Boot Monitor Update Wizard

Offline Boot Monitor update is not available for SCADAPack 300E, SCADAPack 530E
and SCADAPack 535E RTUs.
The following information applies to SCADAPack ES and SCADAPack ER RTUs.

The SCADAPack E Configurator Boot Monitor Update Wizard transfers a Boot Monitor Binary Image
(.BIN file) to the RTU locally through the PC’s serial port via the RTU’s Boot Monitor port. See Boot
Monitor Port 11 for more information.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating the boot monitor, make sure you are connected to the correct
SCADAPack E RTU.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a boot monitor update.
Hazardous situations can occur if system state is not confirmed prior to performing
a boot monitor update.
Failure to follow these instructions can result in death or serious injury.

Using the Boot Monitor Update Wizard for Offline Updates

Start the Wizard through the SCADAPack E Configurator “Transfer” menu by selecting “Update Boot
Monitor”.
Select the Local Serial Port update method and follow the Wizard instructions, which will guide you
through setting up the link to the RTU and starting the Boot Monitor update process.

8.14.3 35
Updating rPAC or RTU Boot Monitor Firmware Firmware Update Technical Reference

Figure 7.1: SCADAPack E Configurator Boot Monitor Update Wizard (Offline)

For more information see the SCADAPack E Configurator User Manual.

36 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Boot Monitor Firmware

Local Boot Monitor Re-Programming

Local Boot Monitor firmware upgrade on the SCADAPack ES and SCADAPack ER RTUs uses special
Hex Switch setting "F9".
If Boot Monitor update is inadvertently activated through the “F9” hex-switch settings, the Boot Monitor
update mode will not affect the Flash memory unless user activates the SCADAPack E Configurator
“Update Boot Monitor” Wizard and commences the erasing and re-programming sequence.
To recover from accidental activation of the Boot Monitor update mode, power off the RTU processor
(check that the hex-switches not set in a special “Fx” mode - typically set them to "00"), power on the
RTU, and it will restart normally.
Once the Boot Monitor Flash memory is erased, the contents of the Flash EEPROM is invalid until the
re-programming process is complete. The RTU operating system firmware and configuration will not be
affected.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
If an interruption occurs during the Boot Monitor Flash reprogramming process, DO
NOT restart the RTU, or power it off. If you restart or power off the RTU, you will
have to return it to Schneider Electric for reprogramming.
Start the reprogramming process again. If reprogramming is unsuccessful and the
RTU does not boot, power off the RTU and contact Schneider Electric Technical
Support 6 .
Failure to follow these instructions can result in equipment malfunction.

8.2 Online Update of Boot Monitor Firmware

See the following sections describing how to upgrade Boot Monitor firmware online:

· Online SCADAPack E Configurator Boot Monitor Update Wizard 38

· Updating Boot Monitor by Manual Commands 39

8.14.3 37
Updating rPAC or RTU Boot Monitor Firmware Firmware Update Technical Reference

8.2.1 Online SCADAPack E Configurator Boot Monitor Update Wizard

The SCADAPack E RTU may have its Boot Monitor firmware upgraded online using the SCADAPack E
Configurator Boot Monitor Update Wizard and selecting DNP3 Connection as the update method.
This transfers a complete binary file (.BIN file) to the RTU through a DNP3 connection. This connection
may be local to the RTU, or remote across a communications link.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating the boot monitor, make sure you are connected to the correct
SCADAPack E RTU. Verify the CPU ID displayed in the SCADAPack E
Configurator matches the CPU ID of the RTU that the boot monitor is intended to be
updated on.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a boot monitor update. Hazardous situations
can occur if system state is not confirmed prior to performing a boot monitor
update.
Failure to follow these instructions can result in death or serious injury.

Using the Boot Monitor Update Wizard for Online Updates

An online firmware update will in most cases save and restore the configuration of the RTU as part of the
upgrade process.
Start the Wizard through the SCADAPack E Configurator “Transfer” menu by selecting “Update Boot
Monitor”.
Select the DNP3 Connection update method and follow the Wizard instructions, which will guide you
through setting up the link to the RTU and starting the firmware update

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Reloading RTU Firmware interrupts the operation of the RTU during the Flash re-
programming process, and resets the RTU configurations. Offline firmware updates
clear the RTU configuration, including IEC 61131-3 application(s).
Before reloading the firmware, save a copy of the RTU configuration information,
user-created applications, logs and other data to an external drive so it can be
reloaded when then the firmware reloading is complete.
Failure to follow these instructions can result in equipment damage.

38 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Boot Monitor Firmware

Figure 7.2: SCADAPack E Configurator Boot Monitor Update Wizard

For updating RTU Boot Monitor firmware online (i.e. via a local or remote DNP3 connection), select the
DNP3 Connection option.
Then follow the wizard instructions.

On SCADAPack 300E, SCADAPack 530E and SCADAPack 535E RTUs, the USB Device (peripheral)
port may be used. RTUs may use a DNP3 serial port or Ethernet interface for this connection.

· Establish connection with the RTU. These use the same dialogs as establishing SCADAPack E
Configurator connection with RTUs. For more information see the SCADAPack E Configurator
User Manual.
· Choose the Boot Monitor firmware .BIN image file when prompted.

8.2.2 Updating RTU or rPAC Boot Monitor Firmware Using Manual Commands

The Boot Monitor can be upgraded by manual commands if necessary. A Master Station may also use
this method.
This method can be carried out either locally or remotely. The boot monitor image file needs to first be
transferred into the file system of an operational SCADAPack E RTU. This file transfer can be done in
one of 2 ways

· FTP (File Transfer Protocol) – if IP connection to the RTU is available and FTP is enabled on the RTU.
· DNP File Transfer.

8.14.3 39
Updating rPAC or RTU Boot Monitor Firmware Firmware Update Technical Reference

WARNING
UNEXPECTED EQUIPMENT OPERATION
Before updating the boot monitor, make sure you are connected to the correct
SCADAPack E RTU.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNEXPECTED EQUIPMENT OPERATION
Evaluate the operational state of the equipment monitored and controlled by the
SCADAPack E RTU before performing a boot monitor update. Hazardous situations
can occur if system state is not confirmed prior to performing a boot monitor
update.
Failure to follow these instructions can result in death or serious injury.

To Remotely Reprogram Boot Monitor Firmware

The following steps should be performed to remotely reprogram the RTU Boot Monitor firmware:
1. Use FTP or SCADAPack E Configurator to transfer the Boot Monitor “.BIN” image file to the RTU.
· If you are using FTP, set the transfer mode to binary before transferring the file. The size of this
file is a multiple of 16k, and is 64k or greater.
· If you are using SCADAPack E Configurator DNP file transfer, select Transfer > Write File from
the main menu.
2. Access the SCADAPack E RTU’s command line facility to activate the Boot Monitor re-
programming process. Enter the following command:
restart bootmon filename.bin

The RTU’s command line facility can be accessed in one of several ways (listed as follows):
· direct connection to CMD LINE serial port (or ISaGRAF port via Command Line Shell when IEC
61131-3 Target 3 is enabled. Command line shell is not available with Target 5.)
· Remote Command Line
· TELNET connection

OR

From SCADAPack E Configurator menu bar,

1. Select Commands | Execute Command | Other …
2. Check DNP Address is set to RTU’s DNP address
3. Enter restart bootmon filename.bin in the Execution Line field
4. Click on OK to start the re-programming.

The RTU operating system firmware re-programs the Boot Monitor on-line and then restarts the RTU.

40 8.14.3
Firmware Update Technical Reference Updating rPAC or RTU Boot Monitor Firmware

Programming the Boot Monitor Flash EEPROM typically takes around 30 secs.
The status of the update will be indicated to the appropriate command line connection after this period.
The SCADAPack E RTU’s Command Line “VER” command and the SCADAPack E Configurator General
/ Controller Status indication of the Boot Monitor firmware version, will indicate a new version number
only after the RTU has been restarted.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
If an interruption occurs during the Boot Monitor Flash reprogramming process, DO
NOT restart the RTU, or power it off. If you restart or power off the RTU, you will
have to return it to Schneider Electric for reprogramming.
Start the reprogramming process again. If reprogramming is unsuccessful and the
RTU does not boot, power off the RTU and contact Schneider Electric Technical
Support 6 .
Failure to follow these instructions can result in equipment malfunction.

8.14.3 41
Updating I/O Operating System Firmware Firmware Update Technical Reference

9 Updating I/O Operating System Firmware

This section describes how to update firmware on:
· SCADAPack ES Remote I/O Units 42

· SCADAPack ER I/O processors 45

· Updating 6000 Series I/O Firmware 47

9.1 Updating SCADAPack ES Remote I/O Firmware

You can update the operating system and boot monitor firmware on SCADAPack ES Remote I/O Units:
· Automatically on every SCADAPack ES Remote I/O Unit when the firmware on the Main unit is
updated.
· Manually, using the restart patch command on individual SCADAPack ES Remote I/O Units.
For details, see Updating SCADAPack ES Remote I/O Firmware. 42

You can also update the boot monitor firmware on SCADAPack ES Remote I/O Units using the restart
bootmon command. For details, see Updating SCADAPack ES Remote I/O Boot Monitor Firmware 44 .

9.1.1 Updating SCADAPack ES Remote I/O Firmware

Automatic Remote I/O Firmware Update

The Boot Monitor firmware and Operating System firmware on SCADAPack ES Remote I/O Units
attached to a SCADAPack ES, SCADAPack ER, SCADAPack 530E or SCADAPack 535E are updated
automatically when a firmware update in the Main Unit is initiated. Remote updates are possible via both
serial and Ethernet communications to ES Remote I/O Unit(s).
The attached Remote I/O upgrade needs to be of a compatible type for a successful upgrade of units.
For example, a mix of ES Remote I/O Unit firmware versions will not successfully upgrade if a specific
.BIP version upgrade file is used to upgrade the Main Unit. Similarly a Boot Monitor firmware upgrade to
a mix of SCADAPack ES, SCADAPack ER, SCADAPack 530E and SCADAPack 535E models will not
be successful.
A range of analog system points has been created in the Main Unit from 54600 to 54704 to display the
current version of the Boot Monitor firmware and Operating System firmware for the 15 possible ES
Remote I/O Units. These system points will be updated each time an ES Remote I/O Unit is re-
configured by the Main Unit. See the Remote I/O Technical Reference Manual for details.
Updating the ES Remote I/O firmware is a transparent operation for the DNP Master station. The Main
Unit is responsible for distributing and executing the new binary to attached ES Remote I/O Units. This
operates as follows:
The DNP Master station or user downloads the new binary image to the Main Unit as normal. Upon a
successful completion of the transfer, a DNP File Exec “Restart Patch filename.biz” command is
issued to the Main Unit. When the Main Unit receives this command, it will perform some validation
checks on the “filename.biz” file and will reply to the Master with a successful response code.
The Main Unit will then begin a DNP file transfer of the new binary to each online ES Remote I/O Unit. As
each transfer is complete, the same DNP File Exec command string as was issued by the Master
station will be repeated to each ES Remote I/O Unit. After the DNP File Exec command is issued to the
last ES Remote I/O Unit, the Main Unit will commence an orderly shutdown and will then begin to
reprogram its own Flash memory with the new binary image.
After the Main Unit restarts, it will re-configure the ES Remote I/O Units. Part of this process will be to
collect the Boot Monitor and Operating System firmware versions so the user will be able to determine if

42 8.14.3
Firmware Update Technical Reference Updating I/O Operating System Firmware

the update was successful.

A SCADAPack ES or SCADAPack ER Main Unit compares both sets of firmware version numbers on
every SCADAPack ES Remote I/O Unit with those present on the Main Unit. A System Status code is
generated should they differ. This allows an alert to be raised at the Master station if an ES Remote I/O
firmware update is unsuccessful. However, if the Remote I/O Unit is a Serck 386 eNET model, the
firmware version numbers will not raise a System Status code.
The System Status codes are as follows:
Remote IO Firmware Version Mismatch = 1050
Remote IO Boot Monitor Version Mismatch = 1051

A SCADAPack 530E or SCADAPack 535E Main Unit will not compare the firmware versions of any
SCADAPack ES Remote I/O Units with its own and will not raise the above System Status codes.

The firmware update of the Main Unit will proceed regardless of the successful or unsuccessful ES
Remote I/O update(s).

If an upgrade to a Main Unit was attempted with firmware of the incorrect model type, a system status
code will be generated. The System Status code will be as follows.
Main unit Firmware RTU Model Mismatch = 1052

If the file validity check on the original File Exec command to the Main Unit is unsuccessful, the Main
Unit will respond to the command with the File Object Status field set to 1 [DOESN'T EXIST].

Individual ES Remote I/O Unit Firmware Update

It is also possible to update firmware on a selected ES Remote I/O Unit or on a Main Unit.
The process is the same as above, but the “unit number” is added as an additional parameter to the DNP
File Exec command.
The syntax is as follows,
restart patch firmware.biz [unit_no.]

Where “unit_no” is optional and has possible values of 0, 1, 2, 3... 15 or “r”

0 means the Main Unit
1 .. 15
Argument “r” updates remotes but does NOT upgrade the Main Unit.
The "unit no." parameter is not supported by SCADAPack 300E RTUs because they do not support
SCADAPack ES Remote I/O.

8.14.3 43
Updating I/O Operating System Firmware Firmware Update Technical Reference

9.1.2 Updating SCADAPack ES Remote I/O Boot Monitor Firmware

If there are any connected SCADAPack ES Remote I/O Units, the SCADAPack E Configurator wizard
and “restart bootmon” commands will also update these connected Remote I/O Units providing they are
of the same RTU type.
The “restart bootmon” command also supports an optional parameter as follows:
Restart bootmon filename.bin unit_number

where “unit_number” is optional and is one of 0, 1, 2, 3... 15 or “r”.

0 means update the boot monitor on the Main Unit only.
1 .. 15 means update a single Remote I/O Unit of the specified address
r means patch Remote I/O Units but leave the Main Unit unpatched.

If the boot monitor patch to the Main Unit was attempted with a boot monitor of the incorrect model type
a system status code will be generated. The system status code will be as follows.
Main unit Boot Monitor RTU Model Mismatch = 1053

Any updated Remote I/O Units will restart following a Boot Monitor firmware update.

44 8.14.3
Firmware Update Technical Reference Updating I/O Operating System Firmware

9.2 Updating SCADAPack ER I/O Processor Firmware

The SCADAPack ER I/O Processor firmware may be re-programmed by requesting the main Operating
System Firmware to update the I/O Processor Firmware. Only the SCADAPack ER hardware type is
supported.
The following table lists the hardware types and the SCADAPack ER I/O Processor Firmware filename
syntax.

Hardware Type Boot Monitor Filename Syntax

SCADAPack ER mon_XYZ_586m.bin*

* where XYZ represents the version number of the I/O Processor Firmware, e.g. the filename of version
1.01 of the SCADAPack ER I/O Processor Firmware is “mon_101_586m.bin”.

Reloading SCADAPack ER I/O Processor firmware interrupts the operation of the RTU's outputs during
the FLASH re-programming process. The FLASH upgrade runs at high priority and so the ISaGRAF scan
is stopped from executing during this process. Physical input event data isn't affected and will be
processed when the FLASH upgrade is complete.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
If an interruption occurs during the Flash reprogramming process, DO NOT restart
the RTU, or power it off. If you restart or power off the RTU, you will have to return it
to Schneider Electric for reprogramming.
Start the reprogramming process again. If reprogramming is unsuccessful and the
RTU does not boot, power off the RTU and contact Schneider Electric Technical
Support 6 .
Failure to follow these instructions can result in equipment malfunction.

The I/O Processor Firmware on the SCADAPack ER can only be reprogrammed by issuing manual
commands.

· Updating I/O Processor Firmware Using Manual Commands 46

8.14.3 45
Updating I/O Operating System Firmware Firmware Update Technical Reference

9.2.1 Updating I/O Processor Firmware Using Manual Commands

This method of updating firmware may be carried out locally or remotely.

The I/O Processor image file needs to first be transferred into the file system of the SCADAPack ER
RTU. This file transfer can be done in one of 2 ways:
· FTP (File Transfer Protocol) – if IP connection to the RTU is available and FTP is enabled on the
RTU.
· DNP File Transfer.
The following steps should be performed to re-program the SCADAPack ER I/O Processor firmware:
1. Use FTP or SCADAPack E Configurator to transfer the SCADAPack ER I/O Processor “.BIN” image
file to the SCADAPack ER RTU’s file system.
· If you are using FTP, set the transfer mode to binary before transferring the file.
· If you are using the SCADAPack E Configurator DNP file transfer, select Transfer > Write File
from the main menu.
2. Send the command
restart iofirm mon_XYZ_586m.bin
This can be done through the following methods:

· Locally. Enter the above RESTART command through the RTU’s command line.
· Remotely. Enter the above RESTART command through either a remote command line
connection, or through a FILE EXEC command.
The SCADAPack ER operating system firmware re-programs the I/O Processor online and then restarts
the I/O Processor, thereby activating the new I/O Processor image.
Programming the I/O Processor FLASH EEPROM typically takes up to 10 seconds to complete. The
status of the update will be indicated to the appropriate command line connection after this period.

NOTICE
UNEXPECTED EQUIPMENT OPERATION
Once the SCADAPack ER I/O Processor Flash memory is erased, the content of
the Flash EEPROM is invalid until the re-programming process is complete.
If an interruption occurs during the I/O Processor Flash reprogramming process,
DO NOT restart the RTU, or power it off. If you restart or power off the RTU, you
will have to return it to Schneider Electric for reprogramming.
Start the reprogramming process again. If reprogramming is unsuccessful and the
RTU does not boot, power off the RTU and remove the I/O Processor Flash memory
chip. A replacement chip should be installed, or the I/O Processor chip re-
programmed using external programming equipment. Contact Schneider Electric
Technical Support 6 .
Failure to follow these instructions can result in equipment malfunction.

46 8.14.3
Firmware Update Technical Reference Updating I/O Operating System Firmware

9.3 Updating 6000 Series I/O Firmware

The operating system firmware on 6000 series I/O modules can be updated locally or remotely, as
described below.

I/O Module Firmware Filename

6601 fw6601.bin

WARNING
LOSS OF CONTROL
During a firmware update, the 6000 series I/O module does not monitor or control
any of the devices to which it is connected. Before updating firmware:
· Confirm that you are connected to the correct rPAC.
· Evaluate the operational state of the devices that are monitored and controlled by
the I/O module.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNINTENDED EQUIPMENT OPERATION
Do not remove power from the rPAC during the firmware update.
Do not disconnect the 6000 series I/O module from the rPAC during the firmware
update.
If power is interrupted for any reason during the firmware update, contact Technical
Support 6 .
Failure to follow these instructions can result in death or serious injury.

NOTICE
INCOMPATIBLE FIRMWARE VERSIONS
Before installing a firmware update, check the Release Notes for the firmware
update to determine the most suitable firmware version for the rPAC firmware
version and the functionality you are using.
Failure to follow these instructions can result in equipment damage.

To Update 6000 Series I/O Firmware

1. Use FTP or SCADAPack E Configurator to transfer the file fw6601.bin to the rPAC file system.

8.14.3 47
Updating I/O Operating System Firmware Firmware Update Technical Reference

· If you are using FTP, set the transfer mode to binary before transferring the file.
· If you are using the SCADAPack E Configurator DNP file transfer capability, select Transfer >
Write File from the main menu.
2. Access the local or remote command line tool and type the following command:
restart iofirm fw6601.bin board_number
where board_number is the number of the I/O expansion module.
For 6601 I/O expansion modules, the board number is a number from 0 to 15.
Example: restart iofirm fw6601.bin 1

WARNING
UNINTENDED EQUIPMENT OPERATION
If the firmware update was unsuccessful, the I/O module will remain in a state
where it does not monitor or control any of the devices to which it is connected.

Carefully review the message indicating whether the firmware update was
successful or unsuccessful. Unsuccessful firmware updates are also reported
through analog system point 50020.
Failure to follow these instructions can result in death or serious injury.

3. After the device has restarted, select Read from Device in SCADAPack E Configurator, then go to
the Controller Status property page and verify that the 6601 I/O Ver. field was correctly updated.

48 8.14.3
Firmware Update Technical Reference Updating 6000 Series I/O Boot Monitor Firmware

10 Updating 6000 Series I/O Boot Monitor Firmware

The boot monitor firmware on 6000 series I/O modules can be updated locally or remotely, as described
below.

I/O Module Boot Monitor Filename

6601 bl6601.bin

WARNING
LOSS OF CONTROL
During a boot monitor update, the 6000 series I/O module does not monitor or
control any of the devices to which it is connected. Before updating the boot
monitor on the I/O module:
· Confirm that you are connected to the correct rPAC.
· Evaluate the operational state of the devices that are monitored and controlled by
the I/O module.
Failure to follow these instructions can result in death or serious injury.

WARNING
UNINTENDED EQUIPMENT OPERATION
Do not remove power from the rPAC during the boot monitor update.
Do not disconnect the 6000 series I/O module from the rPAC during the boot
monitor update.
If power is interrupted for any reason during the boot monitor update, contact
Technical Support 6 .
Failure to follow these instructions can result in death or serious injury.

NOTICE
INCOMPATIBLE FIRMWARE VERSIONS
Before installing a boot monitor update, check the Release Notes for the boot
monitor update to determine the most suitable I/O module boot monitor version for
the rPAC firmware version and the functionality you are using.
Failure to follow these instructions can result in equipment damage.

8.14.3 49
Updating 6000 Series I/O Boot Monitor Firmware Firmware Update Technical Reference

To Update 6000 Series I/O Boot Monitor Firmware

1. Use FTP or SCADAPack E Configurator to transfer the file bl6601.bin to the rPAC file system.

· If you are using FTP, set the transfer mode to binary before transferring the file.
· If you are using the SCADAPack E Configurator DNP file transfer capability, select Transfer >
Write File from the main menu.
2. Access the local or remote command line tool and type the following command:
restart iofirm bl6601.bin board_number
where board_number is the number of the I/O expansion module.
For 6601 I/O expansion modules, the board number is a number from 0 to 15.

Example: restart iofirm bl6601.bin 1

WARNING
UNINTENDED EQUIPMENT OPERATION
If the boot monitor update was unsuccessful, the I/O module will remain in a state
where it does not monitor or control any of the devices to which it is connected.

Carefully review the message indicating whether the boot monitor update was
successful or unsuccessful. Unsuccessful boot monitor updates are also reported
through analog system point 50020.
Failure to follow these instructions can result in death or serious injury.

50 8.14.3
Firmware Update Technical Reference Hardware Specific Features

11 Hardware Specific Features

Boot Monitor Firmware

Each type of SCADAPack E RTU requires a specific Boot Monitor firmware.
The required version will be indicated in the binary filename.

mon_VVV_3xxE.bin indicates that this is the Boot Monitor for one of the SCADAPack 300E RTUs.
mon_VVV_586e.bin indicates that this is the Boot Monitor for the SCADAPack ES.
mon_VVV_586m.bin indicates that this is the Boot Monitor for the SCADAPack ER.
mon_VVV_53xE.bin indicates that this is the Boot Monitor for the SCADAPack 530E or SCADAPack
535E.
See section Updating Boot Monitor Firmware 33 for more information on updating the Boot Monitor.

Operating System Hardware Identification

The compressed binary image (main OS firmware biz file) is identified internally for the target hardware,
i.e. SCADAPack 300E, SCADAPack ES, SCADAPack ER, SCADAPack 530E or SCADAPack 535E.
The Boot Monitor checks this hardware type before overwriting the flash memory, and if the hardware
type does not match, the firmware is NOT applied.
If the incorrect firmware was applied using a “restart patch” command, the command would be
unsuccessful, presenting an appropriate diagnostic to the caller, or an unsuccessful status response if
issued via a DNP file exec command.
The operating system firmware includes a signature for the hardware type but only when the firmware is
in compressed binary format, i. e. .biz file.Therefore it is recommended that firmware updates are issued
using the compressed binary (.biz file.)

8.14.3 51
Hardware Specific Features Firmware Update Technical Reference

11.1 SCADAPack ES & SCADAPack ER Dynamic RAM Test

The Bootloader Monitor for the SCADAPack ES and SCADAPack ER RTUs has the ability to run self-
diagnosis test on the Dynamic RAM (SDRAM).
The SDRAM test will not affect the RTU’s loaded configurations or ISaGRAF applications, but the main
Operating System will not be booted while the RTU is in “Memory Test” mode.

To perform a SDRAM memory test for SCADAPack ES and SCADAPack ER :

· Change the RTU’s Hex “Service Mode” switches to 'F8' and either hardware reset or power-up the
RTU.
· The memory tester outputs serial diagnostics out Port 4 at 57600 bps, but it is optional to view
these diagnostics.
· Diagnostic output will be similar to below:
>Flash Monitor Loaded - Version 2.15
Memory Tester loaded
Test start address: 0x80000
Passed data bus test
Address bus test passed
Memory increment/decrement test passed
Memory tests complete
When the RTU powers up, the Red "Run" LED should flash to indicate the test is running. After about 1
to 2 minutes, one of the other LED's should light up constantly. If a Red LED lights, there was a
memory fault detected. The diagnostic output should provide further information. The “detected memory
fault” indication LED on the SCADAPack ER is labeled as “ERR” or “UTIL” on the front panel.
If the Yellow LED lights, then the tester detected 64 MB of SDRAM and it tested ok. If the RTU under
test actually had 128 MB SDRAM loaded, then this would indicate a detected memory fault.
If the Green LED lights, then the tester found 128 MB of SDRAM, which tested ok.
· Once one of the LED's is on steady, the test is completed. Change the Hex switches back to
'00' and power cycle the RTU to end the memory test mode.

52 8.14.3
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