Rockwell 1756-61 Firmware Upgrade Failure

Hi,

I was upgrading the firmware of 2 1765-61 controllers. I upgraded the first one with no problem but during the second upgrade the controller timed out and not it cannot be seen in RSLinx. I searched the posts and saw someone had a similar problem with upgrading a different module and it seemed the outcome of that was the module needed to sent back to Rockwell. Does anyone have any suggestions or know why it may have timed out? Below is the error from the ControlFLASH log.
Thanks!
-Cindy

03/31/10 16:30:19 [SUCCESS] Load Driver: C:\Program Files\Common Files\Rockwell\AB_ASA.DLL

03/31/10 16:30:19 [SUCCESS] Initialize Driver: C:\Program Files\Common Files\Rockwell\AB_ASA.DLL

03/31/10 16:31:56 [SUCCESS] Device Identity: Path = RSLinx API!AB_ETH-1 16 12 49 57 50 46 49 54 56 46 49 46 49 49 1 4 2 2 1 0, Instance = 1,
VID=0x0001, PT=0x000E, PC=0x0036, Maj Rev=01, Min Rev=09, SN=0x00632397

03/31/10 16:32:05 [SUCCESS] Validate:
VID=0x0001, PT=0x000E, PC=0x0036, Maj Rev=01, Min Rev=09

03/31/10 16:32:05 [SUCCESS] Authorization: Bypass cookie used.
Key: PN-70324

03/31/10 16:32:09 [SUCCESS] Load Script: C:\Program Files\ControlFLASH\0001\000E\0036\PN-70324.nvs

03/31/10 16:32:09 [SUCCESS] Program: Catalog Number = 1756-L61/B LOGIX5561, Serial Number = 00632397, Num Updates = 1, Size = 1720204 byte(s).

03/31/10 16:32:09 [SUCCESS] Update: Instance = 3, Size = 1720204 byte(s), Chunk Size = 128 byte(s), Major Rev = 255, Minor Rev = 255

03/31/10 16:35:31 [FAILURE] Reset: Error #11003: Unconnected Send timed out waiting for a response.
GS=0x01, ES=0x0204

03/31/10 16:41:35 [FAILURE] Reset:

03/31/10 16:41:38 [FAILURE] Device Identity: Error #11003: Unconnected Send timed out waiting for a response.
GS=0x01, ES=0x0204

Disconnect the battery and cycle power twice without a battery.

This will bring controller to bootloader mode and you should be able to re-flash it again.

I see you flashing over Ethernet to 192.168.1.11. bridged to controlnet (?) to controller
why bridging via controlnet?
If this redundancy system?

Yes, this is a redundant system. It has a redundant chassis pair and a rack of I/O. I tried disconnecting the battery and power cycling twice, and it still isn't being seen by RSLinx. Is it the way the comm is set up? I didn't have an issue with the firmware upgrades for other modules on both chassis before this.

Never flash controlelrs with SRM or RM module present in the same chassis

- Put controller into your I/O chassis and flash there
or
- Remove SRM, insert ENBT instead and flash locally

All L6x controllers have bootloader and you should be able to recover them by cycling power without a battery

I also can say that controlnet node numbers (1 and 2) you have for redundand pair are in violation of redundancy rules:
Redundand pair must have highest node address and can't be node 1 and 2.
Also you must have at least two I/O rack nodes for redundancy to function correctly

Thank you! I was able to update the firmware by removing the SRM on the chassis and placing the ethernet module on it. I also changed the node addresses for the Controlnet. I have to schedule the Controlnet connections again and configure the modules in the program, but for some reason I was having issues getting online with the RSNetworx and now RSLinx does not see the controller and CNB on the second chassis. I would have stuck with it a little longer to figure out the connection problem but I had to step away from it before I get too frustrated for the day. As you can tell I'm not very experienced with Rockwell/Allen Bradley products. Thanks again for the help!,

1756-61 rev. 16.54 firmware upgrade

I think I may have resolved some of the issues. However, I'm getting an error in RSLogix5000 "the project has redundancy enabled. Redundancy is only supported in controller revisions where the minor revision is .50 or higher". The firmware revision in my controllers now are 16.22 and I cannot find the revision 16.54 on the Rockwell website. I cannot upgrade to revision 17 or 18 because of the compatibility of my RSLogix5000 and RSLinx. Does anyone know where I can get the firmware upgrade of .5 or higher for major rev. 16?

You have to use redundancy bundle for FW site
http://support.rockwellautomation.com/ControlFlash/
Current ver 16.57

It is not enough to flash controllers, you must flash every module to a specific rev from the bundle
See: http://support.rockwellautomation.com/controlflash/FirmwareFiles/1756-RN628K-EN-E.pdf

That took care of it! Thanks for the help!