Downloading Ci854 firmware on a running controller. Failed with "Application Present in Controller"
I have placed an addtional Ci854 on a PM866 controller while our process was offline for a short period. I found that the firmware on this card was causing communication issues due to not being at same version as in controller. I proceeded to perform a Remote Sytems>Firmware upgrade to the current library version .57. However, the download would fail with error due to an application in the controller. One solution that was provided was to clear the application from the controller and do the upgrade. Another solution was to use compact control builder through a spare controller to update the CI854 then insert it (hot swap) on the running controller. This is the path I took. Is this typical that when upgrading firmare that the application needs to be removed and process offline? I now have a warning not an error that the CI854 is not at the Perferred Version but the card is functioning. The compact control builder supplied was at a newer version of CI854 than in the 800xa system.
Yes, controller should not have running applications for a firmware upgrade. Procedure you have done is correct, however you should have verified if compact controller builder and control builder have same CI854 FW versions. You can again repeat the procedure, if you can get matching version of Compact control builder.
There is also a possibility (in later 800xA systems) to do a online (firmware) upgrade. That works only if you have a redundant system. (I.e. redundant pair of CPU's and communication interface redundancy).
In your case, you have to have a pair of redundant PM's, to be able to run the application. If you need the fieldbus communication to be up, you also need a redundant pair of CI854's.