s

Guideline of Uploading a Program to a Controller

&
Downloading Log Data from a Controller

Version: 1.1.2/07/20
 Sections Page
Introduction 1
Installation of the Smartkey Programmer Software for SmartKey on a PC 3
Upload a program from a PC to the SmartKey 5
Upload a program from SmartKey to the Controller 13
Installation of the pCoManager Software on a PC 15
Upload a program from PC to the Controller using Isolated USB-RS485 Converter 18
Check Controller’s ID 23
Unlock the Controller after updating the program 27
Load default on the controller. 28
Download log data from controller to PC using SmartKey 33
Download log data from controller to PC using pCO Manager 40

Contents

Contents

Version: 1.0.2/07/20
 Introduction
This manual will provide you a step-by-step guideline of uploading a program into a
controller, and below is the flow of the whole process.

Other than uploading a program to the controller, this manual also includes the guideline to
download logs data using pCO Manager.

1 Version: 1.0.2/07/20
 System Requirements: A PC/ Laptop with Windows 7/ 8/ 10

Tools/Devices Needed:
Method 1- SmartKey

1x SmartKey 1x RJ-12 Cable

(P/N: PCOS00AKY0)

1x pCO Smart Key USB adapter 1x USB-A to USB-B Cable

(P/N: PCOS00AKC0)
Method 2- pCOManager

1x Isolated USB- RS485 Converter 1x USB-A to USB-B Cable 1x RS-485 Cable

(P/N: CVSTDUMOR0)

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Installation of the Smartkey Programmer Software for SmartKey on a PC
(Skip this step if you did it before)

a. Obtain the Smartkey Programmer installer file from us CITEC, or download it from
http://ksa.carel.com (Requires Registration)
b. Open the zip file under the name Smartkey Programmer V2.10.3 and you will see 6 files inside
the zipped files. Click the SmartKey_setup_2.10.3 to begin the installation. (Note: Your version of installer
file may vary than what is shown in this manual)

Fig. 1 Files inside the SmartKey Programmer V2.10.3

c. Click Next to begin the installation followed by clicking “I Agree” to the License Agreement (after
reading all the contents of the agreement)

Fig. 2 Installation Setup Wizard Fig. 3 License Agreement Page

d. Click Install to finish up the installation. (Note: If you wish to change the installation location, you may click Browse
and select the location you wanted the software to install.)

Fig. 4 Install location window dialog

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e. When you see this window dialog (Fig. 5), the installation process is finish and you can close the

dialog by clicking Finish.

Fig. 5 Setup completed window dialog

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 Upload a program from a PC to the SmartKey
a. Connect smart key to P.C. via USB key adapter (Shown in Fig.6)

Fig. 6 Connection Setup

b. Click the Windows button, then click CAREL> SmartKey (Fig.7) to open the program and the program
will pop up (Fig.8) followed by a beep sound from the SmartKey. Set the parameters as shown in the Fig.8.

Select English

The program will

select COM3
automatically

Select WITH KEY

Fig. 7 Program Start Menu Fig. 8 SmartKey Programmer

c. Click “Go” to proceed to the next Configuration tab for the SmartKey.

Click this

Fig. 9 SmartKey Programmer with parameters set

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d. Set the parameters in the configuration page according to the parameters shown in the
Fig. 10 and click set Parameter

Select B- Write sw

Check this box if you

wish to enable
password protection
for the SmartKey Enter 2538 as it is the
from unauthorized password, which was
access. set for the controller

Note: We
recommend you to
jot down the
password if you wish
to enable it.

Fig. 10 Configuration page

e. Click the “Set Params” button to configure the SmartKey with the desired parameters
followed by clicking the Kit Definition tab to proceed to the next Kit Definition page
(Fig. 11). Note: If the “Set Params” button is grayed out, it means the current SmartKey is already configured
with your desired parameters and you may just proceed to the next Kit Definition page by clicking the Kit
Definition tab (Fig. 12).

Kit Definition tab Kit Definition tab

Click “Set Params” button

pCO Password that was SmartKey type that was

The “Set Params”
configured in the configured in the SmartKey
button is grayed out
Smartkey previously: 0 previously: Type: A

Fig. 11 Configuration page with parameter set Fig. 12 SmartKey is programmed with desired setting

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f. Set the parameters in the Kit Definition page according to the steps shown in the Fig. 13

Step II: Select the model of the controller Step III: Select the size/series of the
you wanted to load the program into controller (i.e. Small, Medium, Large,
(i.e. pCO5, pCO5+) Extra-Large)

Step I: Select the APP for

the Export file type

Step IV: Tick the Step V: Click

pLan Address “select” button
box and tick all of the
pLAN addresses
(0 to 31) in the
Step IV: Tick the dialog window.
Add BIOS box

Step IV: Click “…”

button to browse the
location of the BIOS
file (.OS files). Note:
The BIOS file is in the
zipped program file
sent out by CITEC.

Fig. 13 Kit Definition page

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g. Locate the folder where the program was extracted from a zipped file provided by CITEC.
(i.e. C:\Users\[Your User Name]\Desktop\CitecPCO5P_2.35\)

Step IV: Click “…”

button to browse the
location of the program
file

Fig. 14 Selecting program files for the kit

h. Select all the required files with file format of (.Bin, .grt, .iup, .lct .pvt) and add them to the
right column by clicking “ >> ” button.

The “>>” button

Fig. 15 Adding a kit

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i. All the required files are now added to the right column. After that, click “Save Kit” to save
all the files as a kit on your PC. The window dialog will prompt you to select the location to
save the kit and enter the file name you wish to save followed by clicking the “Save”
button.

Location for
Window Dialog
saving the kit

Right Column
“Save”
button

“Save Kit”
button
File name for
the kit

Fig. 16 Save the desired files as a kit Fig. 17 Selecting a location to save the kit

j. Once the kit is saved, a dialog window of “Kit saved successfully” will be popped out
(Fig. 18).

Fig. 18 The kit is saved successfully

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 k. Before you upload the program kit file (.app) to the SmartKey, do make sure there isn’t any
other program kit files inside the SmartKey - By clicking the Kit Download tab and check if
the SmartKey does contain other program kit file (.app) in the left column (Fig. 19).

Fig. 19 Checking the presence of other’s program kit

l. Remove the program kit file (.app) by adding it to the right column followed by pressing the
“Kit Erase” button (Fig. 20) and then you will see a window dialog of “Kit erase executed
successfully” after the kit file is fully removed (Fig. 21). NOTE: Skip this step if your
SmartKey doesn’t have any other program kit files inside it.

“Kit Erase”
button

Fig. 20 Select the program kit to be removed Fig. 21 The program kit is successfully erased

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m. Click the Kit Upload tab to upload the kit file to the SmartKey (Fig. 22).

Fig.22 The Kit Upload page

n. Press the “>>” button to add the kit file (i.e. 1.app) to the right column followed by clicking
the “Upload” button (Fig. 23). Once the upload process is completed, the window dialog of
“Kit upload executed successfully”, and then click “OK” button on the dialog to proceed
(Fig. 24).

Fig. 23 Adding desired program kit to the right column Fig .24 The kit is uploaded successfully to the SmartKey

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o. Verify the program kit file (.app) is successfully uploaded to the SmartKey by clicking the
Kit Download tab and you will see your program kit file on the left column (Fig. 25).

“Your latest
program kit
file”

Fig. 25 Verifying the program kit in the SmartKey

12 Version: 1.0.2/07/20
 Upload a program from SmartKey to the Controller
a. Disconnect the power source to the controller by turning off the Q2 breaker.
b. Disconnect the RJ12 cable from J10 port on the controller and also pLAN cable from
J11 port on the controller.

RJ12 Cable pLAN Cable

Fig. 26 The connection port of pLan

c. Plug the SmartKey thru the RJ12 cable into the J10 connector of the controller.

Fig. 27 The connection of the SmartKey with the controller

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d. Turn back on the power to the controller by flipping back the Q breaker and you will
hear the “beep” sound from the SmartKey, which indicates the SmartKey is connected
correctly. Once the “up” arrow key become solid green and you may begin the upload
process by clicking the “Start” button (Fig. 28).
Warning: Never disconnect the power source to the controller during
program uploading!

“Start”
button

“Up”-load
Arrow

Fig. 28 Beginning of the program uploading

e. Once the upload is completed, you will hear a “rapid beeping” sound for a few seconds
from the SmartKey, and you may press the “Start” button again to confirm the upload is
completed (the “rapid beeping” will sound after you press it).
f. Turn off the Q2 breaker followed by removing the SmartKey from the controller, and
also plug back the original RJ12 and pLAN cables to the controller.
g. Turn the Q2 breaker on and proceed to the “Load Default” Section.

14 Version: 1.0.2/07/20
 Installation of the pCoManager Software on a PC
(Skip this step if you did it before)

a. Obtain the pCOManager installer file from us CITEC, or download it from http://ksa.carel.com
(Requires Registration)
b. Open the zip file under the name pCOManager_2.9.1 and you will see 6 files inside the zipped
files. Click the prerequisites.exe to begin the installation. (Note: Your version of installer file may vary than what
is shown in this manual)

Fig. 29 Files inside the zipped file

c. Click Next to begin the installation followed by clicking Next on the popped-up window dialog of
“Welcome to the Device Driver Installation Wizard”. After the installation is completed, click Finish
on both window dialogs “Completing the Device Driver Installation Wizard” and “Completing the
Prerequisites 3.1.0 Setup Wizard”.

Fig. 30 The flow of installing the prerequisite software

15 Version: 1.0.2/07/20
a. Go back to the folder that you extracted the zipped file to, and click pCOManagerSetup_2.9.1.0
and then click Next to begin the installation followed by clicking “I Agree” to the License
Agreement (after reading all the contents of the agreement)

Fig. 31 The beginning of the software installation Fig. 32 The license agreement’s content

b. Select the features of pCO Manager you wish to install and then click Next. (Note: Uncheck the SmartKey Programmer if you had
installed it previously, or else check all of them.)

Fig. 33 The components selection

c. Click Install to continue the installation. (Note: If you wish to change the installation location, you may click Browse
and select the location you wanted the software to install.)

Fig. 34 The installation location

d. During the installation, a window dialog of “Welcome to pCO Log Converter 1.2.0.0 Setup

16 Version: 1.0.2/07/20
 Wizard” will pop out and click Next to continue the installation. (Note: Your window dialog version # might be
different than what is shown in this manual)

Fig. 35 The window dialog of pCO Log Converter

d. Click Install to continue the installation. (Note: If you wish to change the installation location, you may click Browse
and select the location you wanted the software to install.)

Fig.36 The installation location

e. When you see a window dialog of “Completing the pCO Manager 2.9.1.0 Setup Wizard”, the
installation process is finish and you can close the dialog by clicking Finish. (Note: Your window dialog
version # might be different than what is shown in this manual)

Fig.37 The software installation is completed

17 Version: 1.0.2/07/20
 Upload a program from a PC to the controller
a. Turn off the Q2 breaker and unplug the RJ12 cable from J10 port and RS485 cable from the J11 port on the
controller.
b. Connect the isolated USB-RS485 converter to the controller from PC (Shown in Fig. 38) and turn Q1 breaker back
on.

Fig. 38 The hardware connection

c. Click the Windows button, then click CAREL> pCO Manager (Fig.39) to open the program and the
program will pop up (Fig.40). Set the parameters as shown in the Fig.40

Fig. 40The parameter setting

Fig. 39 The start menu

Connection: Local

Baud Rate: Auto

Search Device: Auto (pLAN)

Device Password: 2538

Port Number: Wizard

18 Version: 1.0.2/07/20
d. Once you set the port number to wizard, a dialog window will pop up and you need to follow the instruction on
screen in order to detect the actual COMM port. (i.e. COMM 3 in Fig. 41)

Fig. 41 The flow of detecting the COMM port

e. Once the COMM port is detected, it will go back to the software and you will see the bottom left corner displays
ONLINE instead of OFFLINE. Meanwhile, the port number will be set automatically (i.e. COM3).

Port Number became

COM3

Click this

ONLINE

Fig. 42 The status of the connection

19 Version: 1.0.2/07/20
f. Click the upload tab on the left side and you will the page (Fig. 43). After that, check the
box under the BIOS and then click “…” button to browse the BIOS file (.os file). (The BIOS
file is in the folder where the program was extracted from a zipped file provided by CITEC.
(i.e. C:\Users\[Your User Name]\Desktop\CitecPCO5P_2.35\))

Check the box

Click here to browse

the BIOS file
Upload Tab

Fig. 43 Selecting the right BIOS file

g. Click “…” button and locate the folder where the program was extracted from a zipped file
provided by CITEC. (i.e. C:\Users\[Your User Name]\Desktop\CitecPCO5P_2.35\)

Click here to browse

the BIOS file

Fig. 44 Selecting the folder that contains the program files

20 Version: 1.0.2/07/20
 h. Once the location of the folder is selected, all the required files with file format of (.Bin,
.grt, .iup, .lct .pvt) will be added to the column automatically. Set the parameters as shown in
the Fig. 45 & 46

These files will be added

automatically and check the box of
whichever files you need.

Our recommendation is to check

all of them.

Check
this box

Select the .PVT

file

Check this box

Fig. 45 Selecting all the desired program files

Check this box

Select the .lct

file

Fig. 46 Selecting the logs configuration file

i. After all the parameters are set, the page will look like Fig. 47 and click
“Upload”button to begin the program upload process to the controller.
Warning: Never disconnect the power source to the controller during program uploading!

Fig. 47 The beginning of the program upload

21 Version: 1.0.2/07/20
j. The pCO Manager will begin uploading program files to the controller and it will pop
up a window dialog of “Upload succefully completed”. The controller will automatic
restart and you may need to wait at least 90 sec for it to get on-line (Fig. 48).

Uploading
process
started

Fig. 48 The process of the beginning to the completion of program

l d

k. Turn off the Q2 breaker after the controller get back on-line, and now you may
unplug the Isolated USB-RS485 converter from the J11 port on the controller.
Remember to plug back the orginal cables back (RJ12 cable and RS485 cable) to
J10 and J11 ports on the controller, and then turn the breaker back on.

22 Version: 1.0.2/07/20
 Check Controller’s ID

In order to obtain the unlock code, passcode and password to access level 3 for the latest
program, you need to provide us, CITEC with the Controller’s ID.

1. pGD1 display with Genius 3 or Genius 5 Controller

1)Press and both keys at the same

time (photo as below).

2)Press key and Select “Other

Information” then press key.

3)Select “ID/Product Code” and

press key.

23 Version: 1.0.2/07/20
2. pGD1 display with pCO 5 or 5+ Controller

Click the Prg key to enter

the main menu.

Press the down arrow key

until Level 1 and then press

enter key.

Enter the Level 1 Password

(Default Password: 0000)

Now you are in the Level 1

menu, press the down arrow

key to scroll down.

24 Version: 1.0.2/07/20
 Scroll until you see “Software
Version” and then press enter

key.

Jot down the Controller ID or

take a photo of the screen as a
record purpose.

25 Version: 1.0.2/07/20
3. pGDX display with pCO 5 or 5+ Controller

Press on the touch

screen to show out the menu list.

Press
on the menu list to enter to the
menu.

Press Software Version

on the menu to enter to the
software version page.

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 Unlock the Controller after updating the program

1. pGD1 display with pCO 5 or 5+ Controller

After upgrading the program to

the latest version, you will see
Enter Unlock Code: this screen when it boots up.
VVVVVVVVVVVVVVV

Key in the Unlock Code given

by CITEC
Enter Unlock Code:
VVVVBVEVVSSVGGV

1) The screen will show

“Correct Code!” if the
unlock code is keyed in
Enter Unlock Code:
VVVVBVEVVSSVGGV
correctly. (Note: It will show
“Wrong Code” if unlock code is wrong
Correct Code! and try it again.)

2) Turn off Q2 breaker and

wait for 5-10 sec before
turning the breaker back
on.

Voila! The program was

successfully unlocked and now
please proceed to Load
default on the controller
section

27 Version: 1.0.2/07/20
 Load default on the controller

1) Latest program with a hidden Level 3 for controller with a pGD1 display

Click the Prg key to enter

the main menu.

Press the down arrow

key until Level 2 and then press

enter key.

Enter the password given by

CITEC.

Contact CITEC if you have lost

the password

Enter the Pass Code given by

CITEC.

Contact CITEC if you have lost

the Pass Code.

28 Version: 1.0.2/07/20
 Now you are in the Level 3
menu, press the down arrow

key to scroll down.

Scroll until you see “Load

Default” and then press enter

key.

Now you are in the “Load

Default setting” page.

Press the down arrow button

to change the No to Yes

followed by pressing enter

key.

29 Version: 1.0.2/07/20
 The is undergoing the load
default setting process.

The load default setting

process is completed.

Change all the settings according to the

setting sheet.

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2) General program for controller with a pGD1, CGD2, or CGD3 display

Go to Level 3

Enter Password of
“8328

Go to Load Default
Menu and press
enter

Press up/ down

arrow to change
the “load default
setting” from no to
yes

Wait until the

“Please wait” is
gone

Change all the

settings according
to the setting sheet

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3) General program for controller with a pGDX pGDXA,or pGD-Touch display

Go to Factory
Setting

Enter Username of
“factory” and
password of
“cit5123”

Go to Load Default
Menu and press
enter

Press up/ down

arrow to change
the “load default
setting” from no to
yes

Wait until the

“Please wait” is
gone

Change all the

settings according
to the setting sheet

32 Version: 1.0.2/07/20
 Download log data from controller to PC using SmartKey

a. Connect smart key to P.C. via USB key adapter (Shown in Fig. 49).

Fig. 49 Connection Setup

b. Click the Windows button, then click CAREL> SmartKey (Fig. 50) to open the program and the
program will pop up (Fig. 50) followed by a beep sound from the SmartKey. Set the parameters as shown in the
Fig. 51.

Select English

The program will

select COM3
automatically

Select WITH KEY

Fig. 50 Start Menu Fig. 51 SmartKey Programmer

c. Click “Go” to proceed to the next Configuration tab for the SmartKey.

Click this

Fig. 52 SmartKey Programmer with parameters

t

33 Version: 1.0.2/07/20
d. Set the parameters in the configuration page according to the parameters shown in the
Fig. 53 and click set Parameter

Select D- Read logs

Check this box if you

wish to enable
password protection
for the SmartKey Enter 2538 as it is the
from unauthorized password, which was
access. set for the controller

Note: We
recommend you to
jot down the
password if you wish
to enable it.

Fig. 53 Configuration page

e. Click the “Set Params” button to configure the SmartKey with the desired parameters
followed by clicking the Kit Definition tab to proceed to the next Kit Definition page
(Fig. 54). Note: If the “Set Params” button is grayed out, it means the current SmartKey is already configured
with your desired parameters and you may just proceed to the next Kit Definition page by clicking the Kit
Definition tab (Fig.55).

Kit Definition tab

Kit Definition tab

Click “Set Params” button

pCO Password that was SmartKey type that was

The “Set Params”
configured in the configured in the SmartKey
button is grayed out
Smartkey previously: 0 previously: Type: A

Fig. 54 Configuration page with parameter set Fig. 55 SmartKey is programmed with desired setting

34 Version: 1.0.2/07/20
 f. Before you download the logs data to the SmartKey, do make sure there isn’t any other
logs data inside the SmartKey - By clicking the Logs tab to check if the SmartKey does
contain other logs data file (.LGS) in the left column (Fig. 56).

Fig. 56 Checking the presence of logs data

g. Remove the logs data file (.LGS) in by adding it to the right column followed by pressing
the “Log Erase” button (Fig. 57) and then you will see a window dialog of “File Erase
executed successfully” after the logs data file is fully removed (Fig. 58). NOTE: Skip this
step if your SmartKey doesn’t have any other logs data file inside it.

“Log Erase”
button

Fig. 57 Select the logs data to be removed Fig. 58 The logs data is successfully erased

35 Version: 1.0.2/07/20
h. Disconnect the power source to the controller by turning off the Q2 breaker.
i. Disconnect the RJ12 cable from J10 port on the controller and also pLAN cable from J11
port on the controller.

RJ12 Cable pLAN Cable

Fig. 59 The connection port of pLan

j. Plug the SmartKey thru the RJ12 cable into the J10 connector of the controller.

Fig. 60 The connection of the SmartKey with the controller

36 Version: 1.0.2/07/20
h. Turn back on the power to the connector by flipping back the Q2 breaker and you will
hear the “beep” sound from the SmartKey, which indicates the SmartKey is connected
correctly. Once the “Data” light and “Start” button become solid green and you may
begin the download process by clicking the “Start” button (Fig. 61).
Warning: Never disconnect the power source to the controller during
program uploading!

“Data”
Light

“Start”
button

Fig. 61 Beginning of the program uploading

i. Once the upload is completed, you will hear a “rapid beeping” sound for a few seconds
from the SmartKey, and you may press the “Start” button again to confirm the log
download is completed (the “rapid beeping” will sound after you press it).
j. Turn off the Q2 breaker followed by removing the SmartKey from the controller, and
also plug back the original RJ12 and pLAN cables to the controller.
k. Turn the Q2 breaker on.
l. Plug the SmartKey back to PC according to the step a.
m. Click the “Logs” Tab

Logs Tab

Fig. 62 Logs page

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n. Click “…” button to select the location you wish to save the logs data.
(i.e. C:\Users\[Your User Name]\Desktop\Logs\)

Fig. 63 Selecting a location to save your logs data

o. Add the logs data files you wish to download from the left column to the right column
followed by clicking the “Download” button.

Fig. 64 Adding the desired logs data

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p. After the download button is clicked, the bottom right will show the status of the
downloading.

Fig. 65 Beginning of the logs data download process

q. Once the downloading process is completed, it will pop up a window dialog of “Files
downloaded executed successfully” and now you may go to the folder you selected to
view the logs data. (i.e. C:\Users\[Your User Name]\Desktop\Logs\)

Fig. 66 Logs data is downloaded successfully

39 Version: 1.0.2/07/20
 Download log data from controller to PC using pCO Manager

a. Click the download tab followed by selecting the “pCO Logs” and “download” button.

Step 2: Select
“pCO Logs”

Step 3: Click
Step 1: “download”
Click the button to begin
Download
Tab

Fig. 67 Beginning of the logs data download process

b. After clicking the “download” button, the window dialog will prompt you to select the
location you wish to store the logs data . (i.e. C:\Users\[Your User Name]\Desktop\Log_Data\)

Fig. 68 Selecting a location to save your logs data

40 Version: 1.0.2/07/20
c. The pCO Manager is downloading the logs data from the controller and you can see the
status at the left bottom corner (Fig. 69)

Status: Downloading

Fig. 69 The status of downloading the logs data

d. The window dialog of “Download completed with success” and you click “Ok” button to close
the dialog. You may go to the folder you saved all the logs data and retrieve them.

Fig. 70 Logs data is downloaded successfully

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