General Information

This Release Note describes changes included in the 4202 GFC firmware version 2.31. The new firmware files for the 4202 GF controllers are included with Firmware Loader version 2.21. The expected availability of Firmware Loader version 2.21 is May 08, 2006.

Software and Hardware Relevant to this Release

Firmware Loader version 2.2.1 contains firmware version 2.31 for the 4202 GF controllers. RealFLO version 6.1.1. (Application and Flow Computer) is the currently released version of RealFLO.
TelePACE Ladder Logic version 3.00 is the currently released version of TelePACE.
ISaGRAF Workbench Extensions version 2.10 is the currently released version of ISaGRAF.
SCADAPack 32 C++ Tools version 1.75 is released in conjunction with this firmware release.

4202 GFC Firmware 2.30 Issues Resolved

The following issues identified in the 4202 GFC firmware version 2.30 have been resolved in the current release:

  • Broadcast commands for adjusting and setting the Real Time Clock in the controller is now allowed.
  • Issue causing a frame within a multi-fragmented DNP response to be repeated within the same transaction has been corrected.
  • The POW function in ISaGRAF can now be used without the controller losing its program.
  • Issue causing the controller to randomly enter a security lock state has been corrected.
  • Controller running firmware 2.31 no longer loses its ID and firmware options randomly.
  • Corruption of controller DNP configuration no longer occurs by simply reading the configuration into a new TelePACE program.
  • Changing the Flow Computer real time clock using the Set Clock Modbus command or DNP Time sync commands would no longer corrupt the flow computer records.
  • Controller is now able to handle a repeatedly increasing number of DNP errors without crashing.
  • When DNP event buffers have large numbers of events (> 5000 events), communication failures can occur when reporting these events to a master. This issue has been resolved.
  • I/O module errors are no longer detected and displayed simply by downloading an ISaGRAF application to the controller. I/O module errors are now displayed if there is an actual IO error with the physical I/O module.
  • The Controller will now log the total number of events as listed in its specifications. A related issue preventing another controller from polling a 4202, when the latter's event buffer is full, although the number of recorded events is still less than specifications, has been resolved.
  • When several expansion I/O modules are mapped to the controller's I/O database, the controller would occasionally display I/O module errors even though the physical modules are not in error. This issue has been resolved.

Firmware Upgrade Procedure

*Note: All application programs and data associated with the application programs are lost when the firmware is upgraded.
If you are planning to upgrade the firmware in your 4202 GFC to take advantage of the features and changes described above, it is recommended that the following steps be used. If you have any questions or concerns regarding this procedure contact Control Microsystems Technical Support using the information in the footer of this document.

1. Obtain Firmware Loader 2.2.1.

Send an email to INFOCenter@controlmicrosystems.com. You will be contacted with the information you need to obtain this release.

2. Save your Current Application

Installing new firmware in a controller completely removes any application programs that may be running in the controller.
If you do not have a copy of the application program running in the target controller you will need to read the application from the controller before installing new firmware.
Note: C and C++ programs cannot be read from a controller. You must have a copy of the program before installing new firmware.

Saving Your TelePACE Logic Program:
  • Open TelePACE and from the Communication menu select PC Communication Settings.
  • In the PC Communications dialog configure the settings to establish a serial or Ethernet connection with the target controller.
  • From the Communications menu select Read From Controller.
  • Once the file is read from the controller select Save from the File menu to save the application program.
Saving Your ISaGRAF Program:
  • In order for ISaGRAF programs to be uploaded from the controller the program must have been compiled with the Embed source code for upload option enabled.
  • From the File menu in the Project Management window select the Upload Project command.
  • Click the Setup button and configure the serial or Ethernet connection with the target controller.
  • Click the Run button to upload the program.
Saving Your RealFLO Configuration File:
  • Open RealFLO and open your current RealFLO configuration file.
  • Establish a serial or Ethernet connection with the target controller.
  • From the RealFLO Flow Computer menu select Setup.
  • In the Flow Computer Configuration section of the Setup dialog check the selection for Controller Configuration, Flow Run Configuration, MVT Configuration and Process I/O Configuration and click the Read button. Then click the OK button to close the dialog.
  • From the RealFLO Flow Computer menu select Read Logs/History. In the Read Logs/ History dialog select each of the available items by clicking your mouse on the white box beside each item.
  • Click the OK button to read the Logs/History from the Flow Computer.
  • Save the RealFLO file by selecting Save from the File menu. This will save the current configuration, the alarm and event logs and the hourly and daily flow totals.

3. Install New Firmware in Target Controller

  • Open the Firmware Loader and establish a serial or Ethernet connection with the target controller.
  • Click the Update Firmware button and select C:\Program Files \ Firmware Loader \ Firmware in the Look in: entry box.
  • Select the firmware file, appropriate for the controller you are using, and with the version listed above and then click the OK button.
  • Read the Confirm Update dialog to ensure you are loading the desired firmware and then click the Yes button to complete the firmware installation.

4. Re-Load Your Application

Once the new firmware has been installed in the target controller you will need to reload the application program.

Re-Load Your TelePACE Logic Program:
  • Open TelePACE and open your TelePACE Ladder program.
  • In the PC Communications dialog configure the settings to establish a serial or Ethernet connection with the target controller.
  • From the Communications menu select Write To Controller.
  • Once the file is written to the controller select Run from the Operation menu to start running the program in the target controller.
Re-Load Your ISaGRAF Program:
  • Open the ISaGRAF project saved in step 2 or the ISaGRAF project for the target controller that is saved on your PC.
  • Use the Link Setup command in the Debug menu to establish a serial or Ethernet connection with the target controller.
  • From the Make menu select Make Application to re-compile the program.
  • From the Debug menu select Debug to open the Debugger window. In this window select Download from the File menu to download the application to the target controller.
Re-Load Your RealFLO Configuration File:
  • Open the RealFLO configuration file that was saved in the first step above.
  • Select Setup from the Flow Computer menu.
  • In the Flow Runs section of the Flow Computer Setup ensure the Number of Runs and the Flow Computer ID boxes contain the correct information and click the Write button.
  • In the Flow Computer Configuration section of the Flow Computer Setup dialog check the Controller Configuration and Flow Run Configuration boxes. In addition to these two boxes if you are using MVT's check the MVT Configuration box and if you are using process I/O check the Process I/O Configuration box. Then click the Write button.
  • Click the OK button in the Flow Computer Setup dialog to close the dialog.
  • Select Real Time Clock from the Flow Computer menu. In the Real Time Clock Setting dialog set the controller time using the PC time or an entered time.
  • From the Flow Computer menu select the Calculation Control command and start the calculations for each meter run.
  • To monitor the current flow calculation readings select the Update Readings command from the Flow Computer menu.
Re-Load Your C/C++ Applications:
  • For TelePACE applications open TelePACE and from the Communication menu select PC Communication Settings.
  • In the PC Communications dialog configure the settings to establish a serial or Ethernet connection with the target controller.
  • From the Controller menu select C\C++ Program Loader.
  • In the File window of the C\C++ Program Loader dialog browse to the location of your C/C++ application.
  • Click the Write button to write the application to the target controller.
  • Once the application has been written to the controller click the Run button to start the application running in the controller.
  • For ISaGRAF applications open an ISaGRAF project and use the Link Setup command in the Debug menu to establish a serial or Ethernet connection with the target controller.
  • From the Tools menu select Controller and then select C/C++ Program Loader.
  • In the File window of the C\C++ Program Loader dialog browse to the location of your C/C++ application.
  • Click the Write button to write the application to the target controller.
  • Once the application has been written to the controller click the Run button to start the application running in the controller.