Issue:
This FAQ covers key points regarding the process of upgrading an M580 PLC from firmware version v3.x to v4.x.
Product:
M580 controllers
Environment:
EcoStruxure Control Expert software (previously Unity Pro)
Resolution:
Use the following manual as a reference for upgrading the PLC firmware, and keep in mind the key points listed below.
Title => "Modicon M580 Controller Firmware, Installation Guide"
General Information Regarding Firmware Upgrades
- When performing a firmware upgrade, make sure to connect directly to the PLC using USB or Ethernet. Performing the upgrade remotely can lead to latency issues, resulting in packet loss and an incomplete firmware download. In such cases, the PLC may need to be sent for recovery.
- Disconnect from Control Expert and stop the PLC before starting the upgrade. Ideally, perform the firmware upgrade on a test bench rack. If this is not possible, ensure there is no network traffic going through the PLC. Disconnect other Ethernet cables and leave only the cable connected to the PC for the firmware upgrade.
- For HSBY M580 PLCs, in most cases, a firmware upgrade will require a full application retransfer. Even if you upgrade one PLC at a time and select the “Allow firmware mismatch” option, depending on the firmware versions and project configuration, synchronization issues may occur. For example, if one PLC is upgraded to v4.x while the other remains at v3.x, both PLCs may fail to sync, requiring a full project download, which means stopping the PLC.
Information regarding the PV and FW version
- Keep on mind that to go to a v4.x firmware you need a PV greater than v3.0:
From: Modicon M580 Controller Firmware, Installation Guide P.31
- Also keep on mind that to downgrade from v4.x to v3.x it requires a specific procedure, if this is the case please contact the technical support of your region.
Information Regarding the Procedure from v3.x to v4.x Firmware (Based on the Manual)
- When upgrading from v3.20 to v3.99 (intermediate firmware), keep in mind that the EADM software will fail due to the change from FTP to HTTPS implemented in v4.x firmware on the M580. This behavior is normal.
Do not restart the PLC in this state, as doing so will revert it back to firmware v3.20. Also note that the PLC IP address will change to the default:
10.10.x.x (where x represents the last two octets of the M580 MAC address converted to decimal).
To confirm the PLC is in v3.99, perform a ping to the default IP address. If successful, the PLC is likely in v3.99.
Note: (Remember to change your computer’s Ethernet port IP range to match 10.10.x.x/255.255.255.0, for example.)
- Once in v3.99 state, in EADM, Add a new device as BME***(MODERNIZED).
- Check the Secure box.
- Use the default IP address of the PLC.
- You should see a yellow light in the Status column, indicating EADM detects the PLC.
- Log in with the following credentials:
- User: loader
- Password: fwdownload
- Trust the certificate.
- When the Status turns green, you can continue as usual.
- After upgrading to v4.x, you will always use the BME***(MODERNIZED) device type.
- Ensure the following ports are open on your computer:
- 21 (FTP)
- 443 (HTTPS)
- 80 (HTTP)
The above points summarize the relevant information. Please read all steps carefully and refer to the manual for details. If you have any further questions, do not hesitate to contact your regional technical support.
