factory field upgrade

CK721-A Network Controller factory field upgrade version 3.1 build 25 24-10025-75 Revision B October, 2013

Copyright 2013 Johnson Controls, Inc. All Rights Reserved No part of this document may be reproduced without the prior permission of Johnson Controls, Inc. If this document is translated from the original English version by Johnson Controls, Inc., all reasonable endeavors will be used to ensure the accuracy of translation. Johnson Controls, Inc. shall not be liable for any translation errors contained herein or for incidental or consequential damages in connection with the furnishing or use of this translated material. Due to continuous development of our products, the information in this document is subject to change without notice. Johnson Controls, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with furnishing or use of this material. Contents of this publication may be preliminary and/or may be changed at any time without any obligation to notify anyone of such revision or change, and shall not be regarded as a warranty. Other Manufacturers Documentation Johnson Controls does not duplicate documentation of other equipment manufacturers. When necessary, Johnson Controls provides documentation that supplements that of other manufacturers. When unpacking your equipment, keep all original manufacturer documentation for future reference. Technical Support Johnson Controls authorized dealer representatives can call the Field Support Center at (800) 524-1330 or (414) 524-5000 and use options 6, 1, 7. System users that need information on maintenance contracts or on-site field support can call a local Johnson Controls sales or service office. Acknowledgment Metasys and Johnson Controls are trademarks of Johnson Controls, Inc. All other company and product names are trademarks or registered trademarks of their respective owners. Declaration of Conformity This product complies with the requirements of the EMC Directive 2004/108/EC and the Low Voltage Directive 2006/95/EEC. This equipment must not be modified for any reason and it must be installed as stated in the Manufacturer s instruction. If this shipment (or any part thereof) is supplied as second-hand equipment, equipment for sale outside the European Economic Area or as spare parts for either a single unit or system, it is not covered by the Directives.

FACTORY FIELD UPGRADE This document describes how to upgrade CK721-A controllers in the field to Version 3.1 Build 25. This is the only supported method for upgrading CK721-A controllers when a P2000 host update fails and the controller constantly reboots or fails to come back online with the host. For standard CK721-A controller firmware upgrade procedures, refer to the CK721-A Software Release Notes. The upgrade method described in this document does not require the host. NOTE: Procedures described in this document use the Tera Term Pro terminal emulation software version 2.3. Use of other terminal emulation programs may require different steps. SYSTEM REQUIREMENTS You need the following hardware and software to perform the factory field upgrade of the CK721-A controller firmware: A computer running Microsoft Windows XP Professional or higher, or Windows 2000 Professional NOTE: You are required to change various Microsoft Windows settings on this computer. To minimize any future issues you may encounter as a result of these changes, we recommend keeping track of your customer settings using Table 1 and restoring them after the upgrade. RS232 Null Modem Cable (DB9F/F), for example, Black Box EYN257T- 0015-FF or equivalent 10/100Base-T CAT5 Ethernet crossover cable or a standard CAT5 straightthrough cable if connecting to a hub/switch, for example, Black Box EVCRB82-0020 or equivalent The CK721a_Factory_FieldUpdate_FW_3-1Buld25.exe self-extracting archive file located on the CK721-A Version 3.1 Upgrade CD, or on the following FTP site: ftp://cardkey:cardkey2000@ftp2.johnsoncontrols.com/cardkey-out/ CK721A/CK721A_3p1/CK721A_3p1Build25_Release 1

Terminal Emulation Software (Tera Term Pro Preferred). To use the free Tera Term Pro software, download and install Version 2.3 from the following site: http://hp.vector.co.jp/authors/va002416/teraterm.html Cable Wiring Null Modem Cable The null modem cable provides an RS-232 serial connection from the CK721-A controller RS232C A port to the computer s COM port. Connector 1 Pinout Connector 2 Pinout 3 TX 2 RX 2 RX 3 TX 7 RTS 8 CTS 8 CTS 7 RTS 5 SG 5 SG 6 DSR 4 DTR TX = Transmit RX = Receive RTS = Request to Send CTS = Clear to Send SG = Signal Ground DSR = Data Set Ready DTR = Data Terminal Ready 4 DTR 6 DSR Ethernet Crossover Cable The Ethernet crossover cable provides an network connection from the CK721-A controller Ethernet port directly to the computer s network port. Connector 1 Pinout Connector 2 Pinout 1 RX+ 3 TX+ 2 RX- 6 TX- 3 TX+ 1 RX+ TX = Transmit RX = Receive 6 TX- 2 RX- Ethernet Straight-through Cable The Ethernet straight-through cable provides an network connection from the CK721-A controller Ethernet port to the computer s network port via a hub or switch. 2

Connector 1 Pinout Connector 2 Pinout 1 TX+ 1 RX+ 2 TX- 2 RX- 3 RX+ 3 TX+ TX = Transmit RX = Receive 6 RX- 6 TX- COMPUTER TO CK721-A CONTROLLER CONNECTION To connect the computer to the CK721-A controller: 1. Connect one end of the RS232 Null Modem Cable to the COM 1 or COM 2 port of the computer (see Figure 1). Connect the other end to the RS232C A port of the CK721-A controller. CK721-A Controller Power RS232C A Serial Port Ethernet Port RS232 Null Modem Cable (DB9F/F)* COM 1 or 2** 10/1000Base-T CAT5 Ethernet Crossover Cable* (Use straight-through Ethernet cables if connecting to CK721-A via a hub/switch.) Computer Ethernet * Maximum Distance: 15 m (50 ft.) ** Baud Rate: 115200 Figure 1: Connections between Computer and CK721-A Controller 3

2. Connect one end of the Ethernet cable to the network port of the computer. Connect the other end of the cable to the Ethernet port CK721-A controller. COMPUTER CONFIGURATION Once you have properly connected the computer to the CK721-A controller, you are ready to configure the computer as follows: Copy and run the CK721-A Version 3.1 self-extracting archive file (see page 5) Enable file and printer sharing for Microsoft networks Change the computer s IP address (see page 6) Disable computer firewall software Configuring the computer takes approximately 2 minutes and must only be performed once. Installing the CK721-A controller firmware takes approximately 15 minutes per controller. IMPORTANT: Before changing the IP address settings of your computer, write down the current settings (see Table 1). This information enables you to reconfigure the computer with the original settings once you have finished upgrading the CK721-A controller(s). Failure to revert to the original settings may result in computer network issues or other problems related to the configuration changes. The following table provides a quick reference of the required computer configuration changes: Table 1: Computer Settings Computer Settings Current Settings Change to... File and Printer Sharing for Microsoft Networks Enabled IP Address 192.168.2.1 Subnet Mask 255.255.255.0 Windows XP Professional with Service Pack 2 was used in the development of these instructions. Older versions of Windows XP Professional differ. 4

To copy and run the CK721-A Version 3.1 self-extracting archive file: 1. Copy the CK721a_Factory_FieldUpdate_FW_3-1Build25.exe file to the computer s C:\ directory. 2. Double-click the archive file. The WinZip Self-Extractor dialog box appears. 3. Verify that C:\ is listed in the Unzip to folder field. 4. Click Unzip. The self-extracting archive file saves the CK721-A firmware files in the following directory: C:\ck721a The following files are available in the ck721a subdirectories:./ck721a/step1: 1image-721a-factory-field-ftpd001.bin load.bat load1.bat load2.bat sendnto.exe./ck721a/step2: 2image.bin fs.tar step2b.sh step2a.bat step2a.ftp 5. Click OK when the Files successfully extracted message appears. 5

To change the computer s IP address: 1. In the Local Area Connection Properties dialog box, select Internet Protocol (TCP/IP). 2. Click Properties. 3. In the Internet Protocol (TCP/IP) Properties dialog box, click Use the following IP address. 4. Enter the following IP Address: 192.168.2.1 5. Press the <Tab> key. 6

6. Verify that the following Subnet mask appears: 255.255.255.0 7. Click OK and close the window. TERA TERM PRO CONFIGURATION This section provides instructions on configuring Tera Term Pro. If your configuration settings currently match the settings required to perform the upgrade, you may skip this section. The required settings are: Setting Value Connect to serial port COM1 or COM2 (depending on the COM port you are using) Serial port baud rate 115200 Scroll buffer 10,000 lines Once you configure Tera Term Pro according to the following instructions, the settings take effect each time you launch the application. 7

To configure Tera Term Pro: 1. Open Windows Explorer. 2. Access the following directory: C:\Program Files\TTERMPRO 3. Delete the TERATERM.INI file. 4. Launch Tera Term Pro. 5. In the Tera Term: New connection dialog box, select Serial and COM1 or COM2 port, depending on the COM port you are using. Click OK. 6. From the menu bar, select Setup > Serial Port. 7. On the Tera Term: Serial port setup dialog box, select 115200 from the Baud rate drop-down list. Click OK. 8

8. From the menu bar, select Setup > Window. 9. On the Tera Term: Window setup dialog box, change the number of Scroll buffer lines to 10,000 and click OK. 10. From the menu bar, select Setup > Save setup. 11. On the Tera Term: Save setup dialog box, navigate to C:\Program Files\TTERMPRO and click Save. 9

NOTE: Use Tera Term Pro to view the current controller configuration settings. Write down the current settings. You need to restore these settings when you complete the firmware upgrade (see Restoring the Controller s Configuration Settings). FIRMWARE VERSION 3.1 INSTALLATION Once you set up the computer and Tera Term pro, you are ready to install the CK721-A firmware. IMPORTANT: The CK721-A controller will not be operational until the firmware is successfully installed. This condition poses a high security risk to the building and its occupants. Before proceeding, discuss the potential security issue with the building s Security Manager. Configuring the computer takes approximately 2 minutes and must only be performed once. Installing the CK721-A controller firmware takes approximately 15 minutes per controller. To install the CK721-A Version 3.1 firmware: 1. Launch Tera Term Pro to establish a Telnet logon session to the CK721-A controller. 2. Cycle power to the CK721-A controller by unplugging the power connector and then re-plugging it into the CK721-A controller power port (see Figure 1). If the controller is already powered down, simply plug in the connector to power up the controller. 3. When the following message appears, press <S> within 10 seconds. 10

If this message does not appear, the CK721-A controller cannot be updated due to a hardware problem. Contact Johnson Controls Technical Support at (805) 582-3117 between the hours of 8:00 a.m. to 5:00 p.m. Pacific Time, Monday through Friday, for assistance. If the 10 second time period expires before pressing <S>, cycle the power on the CK721-A controller. Wait for the message to appear again and press <S>. If you press <S> within the specified time, a Download now message appears. 4. Close Tera Term Pro. The Tera Term Pro program must be closed in order to free the COM port for the initial firmware download. 5. Open a DOS window by selecting the following: Start>Programs>Accessories>Command Prompt 6. At the DOS prompt, enter the following command and press <Enter>: cd c:\ck721a\step1 11

7. If the computer is connected to CK721-A via COM 1, enter the following command and press <Enter>: load1.bat Or, if the computer is connected to CK721-A via COM 2, enter the following command and press <Enter>: load2.bat A Percent Complete message appears. 12

8. When the load1.bat or load2.bat procedure is completed, launch Tera Term Pro soon after to establish a serial port session to the CK721-A controller. 9. Using the previously opened DOS window, type the following command and press <Enter>: cd c:\ck721a\step2 13

10. Transfer the CK721-A controller Firmware Update files to the CK721-A controller by entering the following command and pressing <Enter>: step2a 14

11. In the Tera Term Pro window, at the prompt enter: cd /ramdisk 12. In the Tera Term Pro window, at the prompt enter: ls -la Verify the size of the following firmware update files: File Name 2image.bin fs.tar tep2b.sh File Size Approximately 1 MB Approximately 14 MB Approximately 9 MB If the three files are missing or are the wrong size, verify the IP address in the ftp scripts (192.168.2.2) and the connected computer s ethernet IP address (192.168.2.1). Also, review the log output for FTP transfer error messages or warning messages (step 10). See Troubleshooting on page 18 for further help if needed. Then, start over by rebooting the CK721-A controller and downloading the CK721-A firmware installer image files (see Firmware Version 3.1 Installation on page 10). 13. Using the Tera Term Pro window, invoke the CK721-A Controller Firmware Installer script. At the prompt, enter: sh step2b.sh 15

14. The final logging of the CK721-A controller firmware installation actions appears in the Tera Term Pro window. Verify that you see the same data as shown in the following figure. 16

When the firmware installation process is completed, the CK721-A controller reboots and a Login prompt appears on Tera Term Pro window. If Tera Term Pro window does not display a Login prompt, the firmware installation has failed (see Troubleshooting for more information). 15. Verify the CK721-A controller firmware version number. If the installation was successful, the firmware version is listed as 3.1 Build 25. The CK721-A firmware version appears a few lines above the Login prompt (see the highlighted area of the previous screen capture). 17

If the version number is not 3.1 Build 25, then the firmware installation failed (see Troubleshooting for more information). 16. Repeat the steps in this section for each controller you are upgrading. Troubleshooting If the firmware installation fails, answer the following troubleshooting questions: Are you are using the correct cable types? For example, are you using the correct network cable (straight-through versus crossover)? Check the pin connections if you constructed the cables yourself. See Cable Wiring on page 2 for more information. Did you correctly connect the serial null modem and network cables to the CK721-A controller and computer? See Figure 1 for reference. Does your computer have Firewall software installed (besides Windows XP Firewall)? If so, you must disable it in order to successfully upgrade the CK721-A controller firmware. Did you correctly configure your computer? Review the required changes to your computer settings as listed in Table 1. Verify the settings on your computer are correct. If the firmware installation still fails after performing the previous troubleshooting steps, the CK721-A controller has experienced a hardware failure. Return the defective controller to Johnson Controls by initiating a Return Material Authorization (RMA). To do this, contact your Johnson Controls Representative or enter an RMA at this Employee Portal site: http://spcweb.cg.na.jci.com/rma 18

RESTORING THE CONTROLLER S CONFIGURATION SETTINGS Use Tera Term Pro to configure the upgraded CK721-A controllers for operation. You must configure each controller before connecting it to the Johnson Controls Security Management System (SMS). When preparing a CK721-A controllers for operation, you must: Enter the IP address of the CK721-A Enter the netmask of the CK721-A Enter the IP address of the P2000 server Configure the Download Port number, the Upload Port number, and the Priority Port number to match those defined at the P2000 Server. The default values are: Port Type Port Number Download Port 41014 Upload Port Number 41013 Priority Port Number 41012 Once the IP addresses are assigned at the controller, they cannot be changed from the P2000 software. Modify the network polling rate, if needed Modify the route information, if needed Modify the network polling delay, if needed Once each controller has been configured for operation, reconnect each controller to the P2000 host. For details on preparing a CK721-A controller for operation and connecting to the host, refer to the CK721-A Network Controller Installation and Operation Manual. CK721-A VERSION 3.1 DATABASE DOWNLOAD After you reconnect the updated CK721-A to the P2000 host (controller is online), download all databases to the controller. Refer to the P2000 Software User Manual and the CK721-A Software Release Notes for details. The controller is now ready for normal operation. 19

To ensure that the downloaded databases remain in the controller in the case of a power and battery failure, you may want to invoke the controller s write to flash feature. After writing to flash, the controller will reboot. Refer to the P2000 Software User Manual for details on how to invoke the controller s write to flash feature. NOTE: Always wait at least 5 minutes after the host download has been completed (that is, after the download queue count goes down to 0), before performing a write to flash operation. RE-CONFIGURING THE COMPUTER After the databases have been downloaded to the controller and the system appears to be operating normally, re-configure your computer and return it to its original settings (see Table 1). You have finished the firmware upgrade procedure. 20

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