How to Increase the ION Setup Meter Firmware Upgrade Timeout

Issue
During a meter firmware upgrade, the meter power cycles to initialize the new firmware. On a slow or unstable network, the meter may take longer than expected to reconnect to ION Setup, causing the firmware upgrade to report a failure.

Product Line
PowerLogic ION Setup
Legacy PowerLogic ION meters using UPG firmware files

Environment
ION Setup
Meter firmware upgrade
Local Area Network
Wide Area Network
Remote meter connection
UPG firmware file

Cause
ION Setup waits for the meter to transition between firmware upgrade stages and reconnect after the firmware is installed.

When the upgrade is performed across a slow or unstable network, the meter may not reconnect before the timeout defined in the UPG file expires.

The UPG file contains two timing parameters:

• TriggerTime controls how long ION Setup waits for the meter to transition from the Idle state to the Download state.
• CRCTime controls how long ION Setup waits for the meter to reconnect after the firmware upgrade.

If ION Setup reports “Attempting to reconnect ethernet connection” and the upgrade times out, the applicable value is CRCTime.

Resolution
Warning: Incorrectly modifying a firmware upgrade file can cause the upgrade to fail and may affect meter operation. Back up the original UPG file before making any changes.

Whenever possible, perform the firmware upgrade using the latest version of ION Setup and a direct connection between the computer and the meter or its associated gateway.

Before starting the firmware upgrade:

1. Confirm that the firmware file is correct for the exact meter model and hardware revision.

2. Back up the meter template and any required meter settings or data.

3. Temporarily disable communication to the meter from PME or other monitoring applications.

4. Use a stable, direct Ethernet connection whenever possible.

5. Keep the original UPG file unchanged as a backup.

For older PowerPC-based meters that use the UPG firmware format, open a copy of the UPG file in a plain-text editor.

The beginning of the file may contain values similar to the following:

PML: Device = 8650
PML: Firmware Version = 004.040.001
PML: TriggerTime = 60000
PML: CRCTime = 80000

The timing values are specified in milliseconds.

If the firmware upgrade times out while ION Setup displays “Attempting to reconnect ethernet connection,” increase the CRCTime value in the copied UPG file.

CRCTime controls how long ION Setup waits for the meter to reconnect after the firmware upgrade.

Example:

Original value:

PML: CRCTime = 80000

Updated example:

PML: CRCTime = 120000

In this example, the reconnection timeout is increased from 80 seconds to 120 seconds.

Do not change TriggerTime for a post-upgrade reconnection timeout. TriggerTime applies to the transition from the Idle state to the Download state, not the reconnection stage.

After changing CRCTime:

1. Save the modified UPG file under a new file name.

2. Open ION Setup and reconnect to the meter.

3. Start the firmware upgrade using the modified UPG file.

4. Monitor the upgrade log for the following messages:

Ethernet Connection Disconnected
Attempting to reconnect ethernet connection

5. Allow the upgrade to complete without interruption.

6. Confirm that ION Setup reconnects to the meter.

7. Verify the installed firmware version.

8. Confirm that the meter measurements, communications, framework, and configuration operate correctly.

Note: Increasing CRCTime provides additional reconnection time but does not correct an unstable network connection. If the upgrade continues to fail, use a direct local connection or contact Schneider Electric Technical Support before attempting additional firmware changes.