AutoStore Software & Firmware Update Instructions

TABLE OF CONTENTS

• AutoStore Software & Firmware Update Instructions
• Firmware Updates
  • Firmware Programming Matrix
  • Hardware Config
  • AVR Programming Tool
    • General Procedure for all Applicable Modules 
    • Programming a Robot Radio 2.4GHz Using the AVR
    • Photos of Common Programming Locations in Different Modules
  • Updating the ASIO Via the Web Interface
  • Updating Firmware Via the Service Console
    • Updating Robot CPUs
    • Updating Access Points
• Software Updates
  • Service PC Software Updates
    • Consoles
  • Controller PC Software Updates
    • Driver
    • Planner
    • Router
    • XHandler
    • Charge Manager
    • Hub
    • Port Manager
  • Application Server Software Updates
    • Interface
    • Unify Connect
    • Log Publisher
    • Backup
• Checking Version Information

Firmware Updates

Firmware Programming Matrix

The diagram below outlines by what method each AutoStore module's firmware can be updated.

Hardware Config

Hardware Config is an AutoStore Application which allows you to update firmware of modules such as ports and robots via an ethernet cable connected to a computer equipped with the Hardware Config application.

Important Notes:

• The computer using Hardware Config must be set to the following IP address: 192.168.0.253 (see step 2 below)
• An ethernet cable is required to connect the computer to the module receiving the update.
• The AutoStore system may remain running during this update, but the module cannot be used during this update.
• The example below shows the process for updating a Carousel Port controller. 

1. Change your PC's IP address
   1. In the Start Menu, search for “Control Panel”
   2. Under "Network and Internet", click "View network status and tasks"
   3. In the left panel, click "Change adapter settings"
   4. Double click "Ethernet"
   5. Click "Properties"
   6. Click "Internet Protocol Version 4 (TCP/IPv4)"
   7. Change the IP address to 192.168.253. Subnet mask can be set to 255.255.255.0. Click "OK"
2. Open the AutoStore Controller cabinet and find the cable for the port to be updated. They should be labeled.
   1. NOTE: You may also connect directly to the port's controller via the port's control panel. Simply unplug the ethernet cable going into the port's control panel and plug in another ethernet cable from your laptop to the port control panel.
3. Unplug the port and plug it into your PC
4. Launch the Hardware Config app
5. In the white box labeled “Network Connection,” click the “Connect” button.
   1. After a few seconds, the configuration settings for the port you’ve plugged in should appear.
   2. If it does not connect, try power cycling the port via the power button on the port.
6. Once the settings appear, click the folder icon next to the "Select File" text box
7. Select the corresponding .hex file
8. Press the "Update" button
9. Wait for the controller to update
10. Return the port cable back to its place in the switch.
11. Repeat for additional ports.
12. Close Hardware Config.
13. Change your PC’s IP address back to what it was before.

AVR Programming Tool

Some modules require the AVR Programming Tool to complete firmware updates. The AVR programming method may also be used if other methods of programming fail. Refer to the programming matrix in Section 1 to see which modules can be programmed via the AVR.

The AVR update method should be used as a last resort, as it is the most difficult and finicky method of updating.

IMPORTANT INFORMATION:

• The AVR programmer requires the use of Microchip Studios software. It can be downloaded for free here: https://www.microchip.com/en-us/tools-resources/develop/microchip-studio#Downloads
• Each Module/Device has its own fuse settings. Fuse documentation is included in the BOOT folder in the module FW (firmware) folder in PDF format.
  1. PCBs may have different “Device” signatures. The information (which Device must be chosen) is listed in the "Fuse Settings" document 
• Each module has different programming pin connections
  1. Example PROG connection locations in Section 3.3: Photos of Common Programming Locations 
  2. Make sure that the white wire of the AVR programming cable is close to "PROG" sign on the board 
• AVR tool will have a green and red LED active when connected to the module
  1. Both AVR LEDs will turn green while programming FW 
• If the device does not read or reach the target voltage for operation, please evaluate connections or power distribution to the module.

General Procedure for all Applicable Modules 

If programming a Robot Radio 2.4GHz, please see information in Section: Programming a Robot Radio 2.4GHz Using the AVR

1. Download FW from the AutoStore Download Center in the CRM Portal
2. Power off the module
3. Connect AVR-Programmer from your PC to PROG pins of device
   1. Picture below shows an example of a PROG pin from an R5 Robot CPU board
4. Power on the module
5. Ensure Safety features aren’t cutting power to the device (Estop, safety hatch, etc.)
6. Start the application Microchip Studio for AVR® and SAM Device to program:
   1. Module main firmware file
   2. Module boot file located in firmware folder
7. Start the application Microchip Studio for AVR® and SAM Device
8. Start the device programming tool under the tools tab of the start page
9. Select the tool "Atmel-ICE" and the processor name from the "Device" list
   1. Use the default "Interface" value
10. Click the "Apply" button
11. Click "Set" on the default frequency clock
12. Click the "Read" button under "Device Signature"
    1. If device error message is displayed, check the following items and try again: 
       1. AVR programming cable is reversed 
       2. There is no power on programmable module
       3. Chosen device setting is not correct, check Fuse Settings Document for the correct device
13. Make sure "Fuses" settings are the same as in the document provided in the FW file for the module
14. Click the “Programming” button to save fuse settings.
15. Program the main FW file
    1. Browse and select the main FW file
    2. Ensure field “Erase device before programming” is marked
    3.  Click the “Program” button
16. Program the BOOT file
    1. Ensure field “Erase device before programming” is NOT marked
    2. Browse and select the boot file
    3. Click the "Program" button
17. Once the module has been upgraded:
    1. Turn off the module
    2. Disconnect the AVR

Programming a Robot Radio 2.4GHz Using the AVR

IMPORTANT INFO: 

• The ATM and RF chips can be programmed in any order. It is important when programming each chip, the main firmware file is flashed before the boot file
• The radio needs to be connected to the robot with the robot powered on for the radio to receive power for programming. Keep the radio connected to the robot at all times
•  When programming the ATM chip, the jumper goes on the right-side pins of the “PROG-RF” connection, please see the photo below. Connect the AVR programmer to the “PROG-ATM” chip pins
• When programming the RF chip, the jumper goes on the right-side pins of the “PROG-ATM” connection. Please see the photo below.
  • Connect the AVR programmer to the “PROG-RF” chip pins
  •  "Device" setting needs to be set to ATmega128RFA1 instead of ATmega128A

IMPORTANT: Once finished, be sure to place the jumper back on one pin only, so that it is no longer jumping any pins, but will stay with the radio for any future programming attempts.

Photos of Common Programming Locations in Different Modules

Updating the ASIO Via the Web Interface

IMPORTANT INFORMATION:

• This process only applies to the ASIO 3.0 and newer
• If the ASIO has been powered on for more than 60 minutes, it needs to be power cycled before you can access its web interface

1. On a PC connected to the same network as the ASIO (the Service PC or Controller PC), open a web browser and type in 192.168.0.252
2. Click on "Firmware" in the left panel
3. Select the correct firmware file and upload it.
4. Press the "Restart" button in the web interface.

Updating Firmware Via the Service Console

IMPORTANT INFORMATION:

• Update via the Service Console (desktop icon is a blue gear). The Customer Console (green gear icon) does not have the ability to program.
• When updating robots, only update ~10 robots at a time, that way, if there is an issue, there are fewer robots to correct.

Updating Robot CPUs

1. Place robots to be updated in Console mode
   1. Go to the “Robot” tab
   2. Mark all robots by typing a range of robot IDs in the text box at the bottom of the screen. The marked robots will be highlighted yellow.
      1. The example below shows robots 1-18 marked and highlighted
2. Under “Robot Mode” in the drop down box labeled “Marked Robots:”, click “Console” and click the play button. This changes all the robots to Console mode, which will allow you to manually move the robots
3. On the right panel, click "Viewer". A new window will open.
4. Click and drag to highlight the cells where you want the robots to move. It is recommended to line the robots up near the service area. This makes it easier to access the robots in the event of an update failure.

5. Right click the highlighted area, click “Marked Robots”, and then click “Move to Cells”. The robots will move to the highlighted cells

6. On the right panel, click "Programming"

7. A popup will open. Choose "Robot" and select "2.4 GHz". Click "Next".

   1. NOTE: When updating the Robot Radios, choose "Robot Link" and "2.4 GHz"

8. Click “Get Marked Robots”. This will select the previously marked robots for programming.  
   1. The example below shows 1-9
9. Click “Next”
10. Click "Upload File" and select the appropriate .hex file. Click "Program".
    1. NOTE: When updating the Robot Link or Access Points (ASAPs), you must upload both the ATM file and the RF file. Ensure you upload each into the correct place (it is labeled)
    2. 
11. When the Notice pops up, click "Yes"
12. Wait for Upload, Boot Mode, and Program statuses change to “OK” and turn green.
13. Click “Finished”.

    1. If a robot fails, retry the process for that robot alone.

14. Once the robots have been updated, switch them back to "Planner" mode.

15. Repeat this process for all robots.

Note: If a robot gets stuck in "programming" mode (shows under Mode and e-stop light on robot flashes), try pushing the firmware to that robot again. If it still remains in "programming" mode, power cycle the robot to clear the error.

Updating Access Points

Follow the same procedure as with other modules. When you get to the step that says "type in the units to be programmed," note that Access Points are numbered beginning with 21. 

i.e. If your system has 3 access points, you'll type in 21, 22, 23 (or 21-23)

Software Updates

Service PC Software Updates

Consoles

(Applies to Passive, Customer, and Service Console applications)

Update via the Service PC

1. Double click the .exe installer file
2. Click “Next”
3. Select the file path to the existing Console installation (this should auto-fill)
4. Check “Create a desktop icon” and click “Next”
5. Check “Launch AutoStore Console” and click “Finish”
6. Uninstall the previous version and/or move it to another folder

Controller PC Software Updates

To access the Controller PC:

1. In the Start Menu on the Service PC, search for “Remote Desktop Connection”
2. Open the app. The text box should be auto-filled with 192.168.0.230
3. Click “Connect”

To transfer the update files onto the Controller PC, you can either:

1. Plug a jump drive into the Service PC and copy the files and paste them onto the Controller PC desktop.

OR

2. Plug a jump drive directly into the Controller PC (into the USB port found in the same door where the Controller PC power button is located).

NOTE: It is a good idea to ensure all services are running after performing any update on the Controller PC.

Driver

Update via the Controller PC

1. Minimize the Remote Desktop Connection to return to the Service PC desktop.
2. In the Console, click the Stop button to stop the system.
3. Return to the Controller PC via the Remote Desktop Connection. (Click the computer icon on the toolbar at the bottom of the screen.
4. Double click the .exe file
5. In the File Explorer, navigate to Local Disk (C:) > AutoStore > AS Driver and delete the old AS Driver file.
   1. It may also be a good idea to save the previous version to a separate folder in case a rollback is ever needed.
6. Again, minimize the Remote Desktop Connection to return to the Service PC desktop
7. Start the AutoStore system by clicking the Start button

Planner

Update via the Controller PC

IMPORTANT: Close the Windows Services and Windows Task Manager applications before running the installer.

1. Stop the AS system via the “Stop” button in the Console.
2. Double click the installer file
3. Follow the instructions in the guided installation process.
4. Start the AS system via the “Play” button in the Console.

Router

Update via the Controller PC

IMPORTANT: Close the Windows Services and Windows Task Manager applications before running the installer.

1. Stop the AS system via the “Stop” button in the Console.
2. Double click the installer file
3. Follow the instructions in the guided installation process.
   1. Existing running services will be stopped while the updates are installing and the services will be restarted at the end of the installation.
4. Start the AS system via the “Play” button in the Console.

XHandler

Update via the Controller PC

IMPORTANT: XHandler must not be handling an error while updating. To ensure this, either perform the update during a production break time or stop the system.

Windows Services and Windows Task Manager must be closed when running the installer.

1. Open Windows Services (search for it in the Windows Start menu)
2. Stop the AutoStore XHandler service
3. Close Widows Services
4. Double Click the installer file
5. Follow the instructions in the guided installation
6. Ensure Xhandler is running in Windows Services.

Charge Manager

Update via the Controller PC

IMPORTANT: Charge Manager may be installed while the system is running.

1. Double click the installer file
2. Click “Install”
3. Click “Finish”

Hub

Update via the Controller PC

IMPORTANT: Windows Services and Windows Task Manager must be closed before running the installer.

1. Double click the installer file
2. Follow the instructions in the guided installation

Port Manager

Update via the Controller PC

IMPORTANT: Ports that are being managed by PortManager (ex. Fusion Ports) will not be operational during the update. These ports may require operator intervention (i.e. hard restart/power cycle) once the update has finished.

1. Close PortManager (if the application is running)
2. Overwrite the existing executable with a new version
3. Restart PortManager

Application Server Software Updates

*Ensure the AutoStore system is stopped and Driver is closed before beginning updates on the Application Server.

Interface

Update via the Application Server.

1. Double click the .exe file
2. Type in the AS Driver IP address (this is the b-net address for the AS Controller) and click "Next"
3. Click "I accept the agreement" and click "Next"
4. On the "Select Destination Location" screen, click "Next"
5. Click "Install"

Unify Connect

Update via the Application Server

1. Double click the .exe file
2. Enter the Client Key and click "Next". The client key can be found on the AS CRM portal under your site's Grid information or in the Commissioning Checklist from the Kardex handover documents. If you cannot find it, contact Kardex.
3. Enter the AS Driver IP address (this is the b-net address for the AS Controller) and click "Next"
4. Click the "Test" button to test the connection. Click "Next".
5. Check "Send crash reports" and click "Next"
6. Click "I accept the agreement" and click "Next"
7. On the "Select Destination Location" screen, click "Next"
8. Click "Install"

Log Publisher

Update via the Application Server

1. Double click the .exe file
2. Enter the AS Driver IP address (this is the b-net address for the AS Controller) and click "Next"
3. Enter the Client Port and Bin Offset values and click "Next"
   1. Ensure these values have been communicated with the WMS provider
   2. Typically, Bin Offset is kept at 0.
4. Check all the boxes and click "Next"
5. Click "I accept the agreement" and click "Next"

Backup

Update via the Application Server

1. Uncheck both boxes and click "Next"
2. Fill in the database settings which correspond to the SQL server where the AutoStore database is located
3. Enter the AS Driver IP address (this is the b-net address for the AS Controller) and click "Next"
4. On the "Select Destination Location" screen, click "Next"
5. Click "Install"

Checking Version Information

To check all modules’ software and firmware version information, go to the “Overview” tab in the Console and click on the icon displaying a clock and computer chip (pictured below).

The “Modules” tab shows all the current AutoStore software version information. The “Last Updated” column does not always reflect the true date of the most recent update; rather, it displays the last time the version number was checked.

The version information may be exported to a .csv file via the “Export All” button in the bottom right 

The “Robots” tab displays the robot CPU and radio firmware information.

The “Ports” tab displays the firmware version information for port controllers and drivers