Johnson Controls CK721-A Quick start guide

Factory Field Upgrade
CK721-A
Network Controller
Version 3.0, August 2010
24-10025-59 Revision –

Copyright 2010
Johnson Controls, Inc.
All Rights Reserved
[phone]
www.johnsoncontrols.com
No part of this document may be reproduced without the prior permission of Johnson Controls, Inc.
These instructions are supplemental. Often they are supplemental to other manufacturer’s
documentation. Never discard other manufacturer’s documentation. Publications from Johnson
Controls, Inc. are not intended to duplicate nor replace other manufacturer’s documentation.
If this document is translated from the original English version by Johnson Controls, Inc., all
reasonable endeavors will be used to ensure the accuracy of translation. Johnson Controls, Inc.
shall not be liable for any translation errors contained herein or for incidental or consequential
damages in connection with the furnishing or use of this translated material.

CK721-A VERSION 3.0
FACTORY FIELD UPGRADE MANUAL
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This document contains confidential and proprietary information of Johnson Controls, Inc.
© 2010 Johnson Controls, Inc.
INTRODUCTION
This document describes how to factory field upgrade the CK721-A controller firmware to
Release 3.0. This is the only supported method for upgrading CK721-A controllers in the
field when a P2000 host update has failed and the controller constantly reboots (the
controller does not come back online with the host). For standard CK721-A firmware
upgrade procedures, refer to the CK721-A Version 3.0 Software Release Notes. The upgrade
method described in this document does not require the host.
SYSTEM REQUIREMENTS
The following hardware and software are required to factory field upgrade the CK721-A
firmware:
PC running Microsoft® Windows® XP Professional or higher, or Windows 2000
Professional
NOTE
You will be required to change various Windows settings on this PC. To
minimize any future issues you may encounter as a result of these
changes, we recommend using a substitute computer (i.e. not the PC you
use day-to-day).
RS232 Null Modem Cable (DB9F/F) – Black Box EYN257T-0015-FF or
equivalent
10/100Base-T CAT5 Ethernet Cross-over Cable (or a standard CAT5
straight-through cable if connecting to a hub/switch) – Black Box EVCRB82-0020
or equivalent
The CK721a_Factory_FieldUpdate_FW_3-0.exe self-extracting archive file
located on the CK721-A Version 3.0 Upgrade CD or on the following FTP site:
ftp://cardkey:[e-mail]/cardkey-out/CK721A/
CK721A_3p0/CK721A_3p0Build41_Release

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Terminal Emulation Software (Tera Term Pro Preferred) – To use the free Tera
Term Pro software, download and install Version 2.3 from the following site:
http://hp.vector.co.jp/authors/VA002416/teraterm.html
NOTE
The Tera Term Pro terminal emulation software was used in the
development of this document. Use of other terminal emulation programs
may differ.
Cable Wiring
Null Modem Cable
The null modem cable provides an RS-232 serial connection from the CK721-A
RS232C A port to the computer’s COM port.
Connector 1 Pinout Connector 2 Pinout
TX = Transmit
RX = Receive
RTS = Request to Send
CTS = Clear to Send
SG = Signal Ground
DSR = Data Set Ready
DTR = Data Terminal Ready
3 TX 2 RX
2 RX 3 TX
7 RTS 8 CTS
8 CTS 7 RTS
5 SG 5 SG
6 DSR 4 DTR
4 DTR 6 DSR
Ethernet Cross-over Cable
The Ethernet cross-over cable provides an network connection from the CK721-A
Ethernet port directly to the computer’s network port.
Connector 1 Pinout Connector 2 Pinout
TX = Transmit
RX = Receive
1 RX+ 3 TX+
2 RX- 6 TX-
3 TX+ 1 RX+
6 TX- 2 RX-

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Ethernet Straight-through Cable
The Ethernet straight-through cable provides an network connection from the
CK721-A Ethernet port to the computer’s network port via a hub or switch.
Connector 1 Pinout Connector 2 Pinout
TX = Transmit
RX = Receive
1 TX+ 1 RX+
2 TX- 2 RX-
3 RX+ 3 TX+
6 RX- 6 TX-
Figure 1: PC to CK721-A Controller Connections
PC TO CK721-A CONTROLLER CONNECTIONS
To connect the PC to the CK721-A controller:
1. Connect the RS232 Null Modem Cable to the PC’s COM 1 or COM 2 port
(see Figure 1). Connect the other end of the cable to the CK721-A’s
RS232C A port.
2. Connect the cross-over Ethernet cable to the PC’s network port. Connect the
other end of the cable to the CK721-A’s Ethernet port. (Use a cross-over
Ethernet cable to connect the PC directly to the CK721-A. Use
straight-through Ethernet cables to connect to the CK721-A via a switch or
hub.)
PC
CK721-A Controller
RS232 Null Modem Cable
(DB9F/F)*
COM 1 or 2**
Ethernet
RS232C A
Serial Port Ethernet Port
10/1000Base-T CAT5 Ethernet
Cross-over Cable*
(Use straight-through Ethernet cables if
connecting to CK721-A via a hub/switch.)
Power
* Maximum Distance: 15 m (50 ft.)
** Baud Rate: 115200

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PC CONFIGURATION
Once you have properly connected the PC to the CK721-A controller, you are ready to
configure the PC. Configuring the PC consists of the following steps:
Copying and running the CK721-A Version 3.0 self-extracting archive file (see
page 5)
Verifying file and printer sharing for Microsoft networks is enabled
Changing the computer’s IP address (see page 5)
IMPORTANT
If firewall software is installed on your computer, you must disable it before
proceeding with the firmware upgrade.
NOTE
Configuring the PC takes approximately 2 minutes and must only be
performed once. Once the PC has been configured, installing the CK721-A
firmware takes approximately 15 minutes per controller.
IMPORTANT
Before changing the IP address settings of your PC, write down the current
settings (see the following table). This enables you to re-configure the PC
with the original settings once you have finished upgrading the CK721-A
controller(s). Failure to revert to the original settings may result in PC
network issues or other problems related to the configuration changes.
The following table provides a quick reference of the required PC configuration changes:
PC Setting Current Setting Change to . . .
File and Printer Sharing for
Microsoft Networks
Enabled
IP Address 192.168.2.1
Subnet Mask 255.255.255.0
NOTE
Windows XP Professional with Service Pack 2 was used in the
development of these instructions. Older versions of Windows XP
Professional will differ.

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To Copy and Run the CK721-A Version 3.0 Self-Extracting Archive
File:
1. Copy the CK721a_Factory_FieldUpdate_FW_3.0.exe file to the PC’s C:\
directory.
2. Double-click the archive file.
The WinZip Self-Extractor dialog box appears.
3. Verify that C:\ is listed in the Unzip to folder field.
4. Click Unzip.
The self-extracting archive file will save the CK721-A Version 3.0
firmware files into the following directory structure:
C:\ck721a
The following files will be available in the ck721a subdirectories:
./CK721a/Step1:
1image-721a-factory-field-ftpd001.bin
load.bat
load1.bat
load2.bat
sendnto.exe
./CK721a/Step2:
2image.bin
fs.tar
step2b.sh
step2a.bat
step2a.ftp
5. Click OK when the files successfully extracted message appears.
To Change the Computer’s IP Address:
1. On the Local Area Connection Properties dialog box, select Internet
Protocol (TCP/IP).

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2. Click Properties.
3. On the Internet Protocol (TCP/IP) Properties dialog box, select the Use the
following IP address radio button.
4. Enter the following IP Address: 192.168.2.1
5. Press the <Tab> key.
6. Verify that the following Subnet mask appears: 255.255.255.0
7. Click OK.
8. Windows XP Users: Click Close.
Windows 2000 Users: Click OK.

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TERA TERM PRO CONFIGURATION
This section provides instructions on configuring Tera Term Pro. If your configuration
settings currently match the settings required to perform the upgrade, you may skip this
section. The required settings are:
Connect to serial port: COM1 or COM2 (depending on the COM port you are
using)
Serial port baud rate: 115200
Scroll buffer: 10,000 lines
NOTE
Once Tera Term Pro is configured according to the following instructions,
the settings will take effect each time you launch the application.
To Configure Tera Term Pro:
1. Open Windows Explorer.
2. Access the following directory: C:\Program Files\TTERMPRO
3. Delete the TERATERM.INI file.
4. Launch Tera Term Pro.
5. On the Tera Term: New connection dialog box, select the Serial radio
button and the COM1 or COM2 port, depending on the COM port you are
using. Click OK.
6. From the menu bar, select Setup>Serial Port.

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7. On the Tera Term: Serial port setup dialog box, select 115200 from the
Baud rate drop-down list. Click OK.
8. From the menu bar, select Setup>Window.
9. On the Tera Term: Window setup dialog box, change the number of Scroll
buffer lines to 10,000 and click OK.
10. From the menu bar, select Setup>Save setup.

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11. On the Tera Term: Save setup dialog box, navigate to C:\Program
Files\TTERMPRO and click Save.
NOTE
Use Tera Term Pro to view the current controller configuration settings.
Write down the current settings. You will need to restore these settings
when you complete the firmware upgrade (see “Restoring the Controller’s
Configuration Settings” on page 16).
FIRMWARE VERSION 3.0 INSTALLATION
Once you set up the PC and Tera Term pro, you are ready to install the CK721-A Version 3.0
firmware.
IMPORTANT
If the firmware upgrade fails, the CK721-A controller will not be
operational until the firmware can be successfully installed. This poses a
high security risk to the building and its occupants. Before proceeding,
discuss the potential security issue with the building’s Security Manager.
NOTE
Configuring the PC takes approximately 2 minutes and must only be
performed once. Once the PC has been properly configured, installing the
CK721-A firmware takes approximately 15 minutes per controller.

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To install the CK721-A Version 3.0 firmware:
1. Launch Tera Term Pro to establish a Telnet login session to the CK721-A
controller.
2. Cycle power to the CK721-A by unplugging the power connector and then
re-plugging it into the CK721-A power port (see Figure 1 on page 3).
If the controller is already powered down, simply plug in the connector to
power up the controller.
3. When the following message appears, press <S> within 10 seconds.
If this message does not appear, the CK721-A controller cannot be updated
due to a hardware problem. Contact Johnson Controls Technical Support at
[phone] between the hours of 8:00 a.m. to 5:00 p.m. Pacific Time,
Monday through Friday, for assistance.
If the 10 second time period expires before pressing <S>, cycle the power
on the CK721-A controller. Wait for the message to appear again and press
<S>.
If you press <S> within the specified time, a “Download now” message
appears.

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4. Close Tera Term Pro.
The Tera Term Pro program must be closed in order to free the COM port
for the initial firmware download.
5. Open a DOS window by selecting the following:
Start>Programs>Accessories>Command Prompt
6. At the DOS prompt, enter the following command and press <Enter>:
cd c:\ck721a\step1
7. Enter one of the following commands and press <Enter>:
load1.bat (if PC is connected to CK721-A via COM 1)
load2.bat (if PC is connected to CK721-A via COM 2)

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A Percent Complete message appears.
8. When the load1.bat or load2.bat procedure is completed, launch Tera Term
Pro soon after to establish a serial port session to the CK721-A controller.
9. Using the previously opened DOS window, type the following command
and press <Enter>:
cd c:\ck721a\step2

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10. Transfer the CK721-A Firmware Update files to the CK721-A by entering
the following command and pressing <Enter>:
step2a
11. In the Tera Term Pro window, at the prompt enter:
cd /ramdisk
12. In the Tera Term Pro window, at the prompt enter:
ls -la

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Verify the size of the following firmware update files:
2image.bin (appx.1 MB)
fs.tar (appx. 14 MB)
step2b.sh (appx. 9 KB)
If the three files are missing or are the wrong size, verify the IP address in
the ftp scripts (192.168.2.2) and the connected PC’s ethernet IP address
(192.168.2.1). Also, review the step 10 log output for ftp transfer error
messages or warning messages. See “Troubleshooting” on page 16 for
further help if needed.
Then, start over by rebooting the CK721-A controller and downloading the
CK721-A firmware installer image files (see “To install the CK721-A
Version 3.0 firmware:” on page 10).
13. Using the Tera Term Pro window, invoke the CK721-A Firmware Installer
script. At the prompt, enter:
sh step2b.sh

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14. The final logging of the CK721-A firmware installation actions appears in
the Tera Term Pro window. Verify that you see the same data as shown
below.
When the firmware installation process is completed, the CK721-A will
reboot and a Login prompt will appear on Tera Term Pro window.
If Tera Term Pro window does not display a Login prompt, the firmware
installation has failed (see the “Troubleshooting” section for more
information).
15. Verify the CK721-A firmware version number. If the installation was
successful, the firmware version will be listed as 3.0 Build 41. The
CK721-A firmware version appears a few lines above the Login prompt
(see the highlighted area of the previous screen capture).
If the version number is not 3.0 Build 41, then the firmware installation
failed (see the “Troubleshooting” section for more information).
16. Repeat the steps in this section for each controller you will be upgrading.

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Troubleshooting
If the firmware installation fails, answer the following troubleshooting questions:
1. Are you are using the correct cable types?
For example, are you using the correct network cable (straight-through vs.
cross-over)? Check the pin connections if you constructed the cables
yourself. See “Cable Wiring” on page 2 for more information.
2. Did you correctly connect the serial null modem and network cables to
the CK721-A and computer?
See Figure 1 on page 3.
3. Does your computer have Firewall software installed (besides Windows
XP Firewall)?
If so, you must disable it in order to successfully upgrade the CK721-A
firmware.
4. Did you correctly configure your computer?
Review the required changes to your PC settings on page 4. Verify the
settings on your computer are correct.
If the firmware installation still fails after performing the previous troubleshooting
steps, the CK721-A controller has experienced a hardware failure. Return the
defective controller to Johnson Controls by initiating a Return Material
Authorization (RMA). To do this, contact your Johnson Controls Representative or
enter an RMA at this Employee Portal site:
http://spcweb.cg.na.jci.com/rma
RESTORING THE CONTROLLER’SCONFIGURATION
SETTINGS
Use Tera Term Pro to configure the upgraded CK721-A controllers for operation. You must
configure each controller before connecting it to the Johnson Controls Security Management
System (SMS). When preparing a CK721-A for operation, you must:
Enter the IP address of the CK721-A
Enter the netmask of the CK721-A
Enter the IP address of the P2000 server
Configure the Download Port number, the Upload Port number, and the Priority
Port number to match those defined at the P2000 Server. The default values are:
Download Port Number 41014
Upload Port Number 41013
Priority Port Number 41012
Modify the network polling rate, if needed

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Modify the route information, if needed
Modify the network polling delay, if needed
NOTE
Once the IP addresses are assigned at the controller, they cannot be
changed from the Johnson Controls SMS.
Once each controller has been configured for operation, reconnect each controller to the
SMS host. For details on preparing a CK721-A controller for operation and connecting to the
host, refer to the CK721-A Network Controller Installation and Operation Manual.
CK721-A VERSION 3.0 DATABASE DOWNLOAD
After the updated CK721-A controller has reconnected to the SMS host (controller on-line),
download all databases to the updated controller. Please refer to the respective host’s user
manual for details on how to download the databases to a controller.
The controller is now ready for normal operation.
To ensure that the downloaded databases remain in the controller in the case of a power and
battery failure, you may want to invoke the controller’s “write to flash” feature. After writing
to flash, the controller will reboot. Please refer to the respective host’s user manual for
details on how to invoke the controller’s “write to flash” feature.
NOTE
Always wait at least 5 minutes after the host download has been
completed (that is, after the download queue count goes down to 0),
before performing a “write to flash” operation.
RE-CONFIGURING THE PC
After the databases have been downloaded to the controller and the system appears to be
operating normally, re-configure your PC and return it to its original settings (see page 4).
You have finished the firmware upgrade procedure.

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