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How to recover the drive after a failed firmware update

There are several reasons that can cause a failed firmware update on your Everest drive and that you should try to avoid all the time:

  • Having the public firewall in your computer ON during the firmware update
  • Powering off the drive during the firmware update
  • Disconnecting the Ethernet cable during the firmware update
  • Not waiting until the drive gets back to Init state when performing the firmware update through FoE
  • Performing an FTP bootloader update while having TwinCAT connected
  • And more

An easy way to detect that the drive has not updated the firmware successfully is because the LEDs state changes from its normal operating conditions. If you are unsure of how the LEDs look like during normal operation, please check the How to interpret drive LEDs section of the manual. After a failed firmware update, the LEDs will be left looking like the following:

  • LED4 → blinking red very slowly (~1 Hz)
  • LED5 → off
  • LED6 → solid green

Besides the LEDs state, other clear signs that the update process has not been completed successfully are:

  • You cannot connect to the drive in MotionLab3 directly in the IP if you are using CANopen firmware
  • You cannot scan the drive in TwinCAT

However, this situation is 100% recoverable by performing some additional steps:

  1. In most cases, the only thing that you will have to do to recover the drive is to perform an additional FTP bootloader to the CANopen/EtherCAT version that you want to use. Therefore, power cycle the drive and close and open MotionLab3 again and use the FTP bootloader tool directly without scanning the drive. The firmware update process should be able to start and finish successfully. After that, you should be able to operate as before.
  2. If the FTP bootloader update does not work at the first time, some additional steps will be needed:
    1. Power off the drive 
    2. Make a connection between pins 12 and 13 of the I/O connector of your Everest XCR board (J2 connector on the Connectors Guide)
    3. Power on the drive
    4. Perform the FTP bootloader firmware update as described in step #1. This time it should work fine and it should complete successfully.
    5. Power off the drive again
    6. Remove the connection between pins 12 and 13
    7. Power on the drive again. Now everything should be working as before.

Do the connection of the pins CAREFULLY

It is extremely important to make the connection between pins 12 and 13 carefully and with the drive off.

Do not do it while the drive is powered and double-check that you are doing the connection to the correct pins. 

Not following this can lead to permanent no recoverable damage to the drive. 

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