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Learn to Upgrade Orbitor Software in a FLASH!

Article Number: H003
Article Type: HowTo
Modified: September 26, 1999

SUMMARY

Upgrading the software in an Orbitor product is a simple, easy-to-follow process. However, if you don't know the process, what then?

The instructions provided in this article are also located in the Orbitor reference manual and can be referenced there.

There are two methods that may be used to upgrade the software of an Orbitor. The first method uses the console of the Orbitor and the Z-MODEM protocol commonly used in many terminal emulation programs readily available. The second method, which is much faster and less tedious, uses TFTP, an IP-based protocol available in application form for your PC.

The instructions to follow describe the steps for both methods. You may chose the method that is best suited for your environment.

Note: Failure to follow these instructions can result in failure of the unit requiring return to Develcon for servicing. Please follow the instructions provided carefully.

• Z-MODEM - A method to load software through the console of an Orbitor
• TFTP - A method to load software over a LAN or WAN connection

MORE INFORMATION

Using the Console Method

Before proceeding, make sure that you have saved the configuration of the router such that it may be restored properly after the upgrade. See the Reference section below for details.

To complete this method of upgrade, you will need to have at your disposal a PC with a terminal emulation package that has the Z-MODEM protocol available. Software programs such as Windows HyperTerm, Procomm, Telix, X-Talk and many others are capable of supporting this protocol.

Once logged into the console of the Orbitor, you should proceed to the Load FLASH Set-Up Menu and select the Console Load option. Do not be alarmed, but this action will reset the router and place it in "Console load" mode.

Once the router is in Console load mode, the "flash.lda" and "flash.fcs" files may be sent using the Z-MODEM transfer protocol.

Current versions of Orbitor system software use a different file structure that previous versions. This current form uses a <version>.all filename. In all cases listed below, the files flash.lda and flash.fcs shall also refer to <version>.all. Consult the Software Updates web page for details.

The Console load mode may only be used with a direct connection to the serial console port of the router.

The Load Flash operation may be aborted (before, during, and after the loading of the file "flash.lda", but not during the loading of the file "flash.fcs") by aborting the ZMODEM transfer and then entering 5 control-X characters "^X" from the console keyboard. After the control-X characters are sent, the router will display a limited menu system. Choose the Abort Load option from the Load FLASH Set-Up menu. This will cause the router to reset and return to normal operations operating from the existing software.

If the ZMODEM transfer operation needs to be restarted after it has been canceled or after loading the first file, simply choose the Console (ZMODEM) option from the Load FLASH Set-Up menu once again.

Note: When the router is placed in Console load BOOT mode, the LAN interface and both WAN interfaces will be disabled. The router will only accept information from the console management port.

The BOOT code of the Orbitor may be upgraded by performing a load of the "flash.lda" and "flash.fcs" files from the BOOT Code diskette. Upgrading the BOOT code will allow the Orbitor to load compressed system code in future upgrades.

Using the Network Method

Before proceeding, make sure that you have saved the configuration of the router such that it may be restored properly after the upgrade. See the Reference section below for details.

Proceed to the Load FLASH Set-Up Menu and select the Network Load option. This resets the router and places it in Network Load mode. Once the router is in Network Load mode, a TFTP connection may be made to the router to upgrade to a new version of software. Make sure to disconnect any telnet sessions to the router before starting the TFTP transfer

The TFTP application must be in "octet" or "binary" mode for software upgrade transfers.

This option must be confirmed before operation by typing "yes" when prompted.

Procedures for performing a Flash Load to upgrade the operating software of the router:

Execute the Network (TFTP) command from the Load FLASH Set-Up menu. Confirmation is required. Enter "yes" to proceed. Start the TFTP application to be used for transfers to the router. (The IP address of the router may be found in the Internet Set-Up menu.) Put the file "flash.lda" to the router from the Operational Code diskette. (Any router not in Network Load BOOT mode will respond with an access violation error.) Put the file "flash.fcs" to the router from the Operational Code diskette. The router will verify the file "flash.lda" in memory, program and verify the FLASH, clear the configuration to default values (except: IP Address, IP Routing state, IP Forwarding state, WAN Environment, Link 1 & 2 State, the Switch Type, Directory Numbers, SPIDs, and Password), and then reset. After the reset, the router will operate normally using the newly upgraded software. In some upgrade situations the Directory Numbers and SPIDs may be corrupted after the upgrade and will need to be re-entered. The router may take up to two (2) minutes to program and verify the FLASH. The console will not respond during this time period. To check on the router’s current state during this process, get the file "status.txt" from the router. This file will report the router’s state: the mode and version if no errors have occurred, or an error message. Note: On the rare occasion that during the programming of the FLASH something happens to the router (power hit or hardware reset), causing the FLASH to become corrupted, the router will restart in ZMODEM receive mode only. If the router does not start in ZMODEM receive mode, follow the procedures presented in the section Recovery of a Failed Software Load further in this article.

The Load Flash operation may be aborted (before, during, and after the loading of the file "flash.lda", but not during the loading of the file "flash.fcs") by re-connecting to the console of the router and choosing the Abort Load option from the Load FLASH Set-Up menu. This will cause the router to reset and return to normal operations operating from the existing software.

When the router is placed in Network (TFTP) load BOOT mode, the router will restart and then remain idle.

When performing a TFTP software download to a remote Orbitor and that remote Orbitor router had been configured to make an automatic ISDN call to another device, this call will not be made. A manual ISDN call must be placed to the Orbitor and then the TFTP transfer may proceed.

When the Orbitor restarts in network load mode, the security settings will be at the default values. When upgrading Orbitors via TFTP in a network that is using security it may be easier to use one of the Orbitors to initiate the manual ISDN call to the remote Orbitors one at a time. Disable security on the Orbitor that is chosen to establish the manual calls. After each remote Orbitor is upgraded, the configuration may be restored and security may be started. Upgrading in this method should reduce any security holes that may appear if security is disabled for the entire network of Orbitors and then the upgrades performed.

Recovery of a Failed Software Load

In the event that the software load is interrupted or it fails for some reason, the unit may be left in a state where it is expecting a Z-MODEM load through the console. If the router does not start in ZMODEM receive mode, follow the procedures presented below:

1. Power down the Orbitor
2. Open the case cover
3. Remove the jumper shorting plug on pins 2-5 of strap W1
4. Power up the Orbitor. It shouldn now restart in Z-MODEM receive mode.
5. Power down the Orbitor
6. Re-install jumper on W1 pins 2-5
7. Replace the case cover and power up the Orbitor.

Please refer to the reference manual for detail regarding this strap.

1. Power down the Orbitor
2. Open the case cover
3. Remove the jumper shorting plug on pins 5-6 of strap J1
4. Power up the Orbitor. It shouldn now restart in Z-MODEM receive mode.
5. Power down the Orbitor
6. Re-install jumper on W1 pins 2-5
7. Replace the case cover and power up the Orbitor.

Please refer to the reference manual for detail regarding this strap.

1. Power down the Orbitor
2. Remove the case cover
3. Remove the jumper on pins 3-7 of strap W9
4. Power up the Orbitor and wait until it has completed initialization (approximately 30 seconds)
5. Power down the Orbitor
6. Re-install jumper on W9 pins 3-7
7. Replace the case cover and power up the Orbitor.

The Orbitor should now restart and be in ZMODEM receive mode.

1. Power down the Orbitor
2. Remove both WAN modules
3. Power up the Orbitor and wait until it has completed initialization (approximately 30 seconds)
4. Power down the Orbitor
5. Re-install the WAN modules
6. Power up the Orbitor

The Orbitor should now restart and be in ZMODEM receive mode. Refer to the Changing Link Interfaces section in the Installation & Applications Guide for information on removing and inserting the WAN modules.

1. Power down the Orbitor
2. Open the front and remove the main board
3. Change strap W4 to position 1-2
4. Install the main board and power up Orbitor

The Orbitor should now restart and be in ZMODEM receive mode. After the software has been loaded using ZMODEM mode follow these steps:

1. Power down the Orbitor
2. Open the front and remove the main board
3. Change strap W4 back to the 2-3 position
4. Install the main board and power up the Orbitor

The Orbitor should now restart in normal operational mode. Refer to Orbitor Reference manual for information on strap settings.

REFERENCES

Before proceeding with any software upgrade, the configuration of the Orbitor should be saved to a backup file. To perform a configuration backup, you may reference the following Knowledge Base article:

HOWTO: Orbitor Configuration Dump/Restore Procedures §

Copyright © 1999 Develcon Electronics Ltd.  All Rights Reserved.