Carel Winload | 2024 |

Carel Winload is a legacy technical utility used to upload and download software (BIOS, BOOT, and application files) to Carel electronic boards, such as the pCO sistema family. While it has largely been superseded by modern platforms like , it remains a critical tool for field technicians working on older installations. Core Functionality Winload serves as the bridge between a PC and a Carel programmable controller. Its primary purpose is managing the low-level software components of a controller: BIOS Management: Updating the Basic Input/Output System that governs the controller's fundamental hardware interactions. Application Deployment: Loading specific HVAC/R control logic developed for units like chillers, heat pumps, or rooftop units. BOOT Files: Transferring the initial startup routines required for the controller to initialize correctly. System Architecture & Connection To perform a "load" or "download," Winload requires a physical interface between the PC and the controller: Hardware Interface: Typically requires a serial converter (RS485 to RS232/USB) or a dedicated Carel programming key. File Types: It handles specific extensions related to Carel's proprietary environment (often Communication Protocol: Uses Carel's serial communication standards to ensure data integrity during the transfer process. Procedural Overview The typical workflow for using Winload involves: Selection: Choosing the correct COM port on the PC and the target controller address. Validation: Matching the software version to the hardware model (e.g., ensuring a pCO3 application is not loaded onto a pCO1). Initiating the download, during which the controller is usually placed in a "standby" or "programming" mode to prevent operational conflicts. Modern Alternatives For newer projects, Carel has moved toward integrated development environments: A comprehensive suite that includes design, simulation, and commissioning environments, replacing the need for separate standalone utilities like Winload for modern hardware. APPLICA App Allows for parameter configuration and software updates in the field directly from a smartphone for compatible controllers. CAREL Industries For official technical manuals and specific software versions, refer to the CAREL Technical Documentation Carel CPQ Selection Tool for connecting Winload to a controller? Carel Software Download Instructions | PDF - Scribd

Technical Write-Up: Understanding winload in Carel pCO Controllers 1. Overview winload is not a standard Microsoft Windows component in this context. Instead, it refers to a specific file or bootloader process used by Carel Industries (an Italian manufacturer of HVAC/R control solutions) for their pCO series programmable controllers . In Carel’s ecosystem, winload is part of the proprietary firmware update or bootloader mechanism, often associated with:

pCO1, pCO2, pCO3, pCO5, and pCOsistema families Legacy controllers running a custom real-time OS (not Windows) Tools like pCOWin , pCOSoft , or pCOWeb

2. Purpose of winload The primary roles of winload in Carel devices are: carel winload

Bootloader execution – initializes hardware and loads the main firmware. Firmware recovery – allows reprogramming of a corrupted controller via serial (RS232) or USB. Application download – used by Carel’s development environment to transfer compiled .bin or .hex application code to the controller. Transition between modes – switches the controller from boot mode to run mode after validation.

It is not a file named winload.exe on disk, but rather a boot phase or a function call inside the controller’s bootloader. 3. Common Contexts Where winload Appears a. pCOWin / pCOSoft Download Process When uploading a program to a pCO controller via Carel’s IDE, the log or status window may show: Entering winload... Erasing flash... Writing application... Exiting winload...

This indicates the controller has entered the bootloader section responsible for accepting new firmware. b. Firmware Update Failure If a firmware update is interrupted, the controller may hang in winload mode. Recovery requires: Carel Winload is a legacy technical utility used

Using pCOWin with a specific recovery procedure Sending a “reset to bootloader” command via serial at 19200 baud, 8N1 Manually triggering the bootloader by shorting specific pins (for very old pCO1/pCO2)

c. Serial Bootloader Communication Carel’s proprietary protocol uses a handshake to enter winload . Typical sequence:

Controller powers on – runs user application. User sends break signal or specific byte sequence over serial. Controller jumps to winload section. Waits for new firmware or application via XMODEM or custom protocol. Its primary purpose is managing the low-level software

4. Troubleshooting winload Issues | Symptom | Likely Cause | Solution | |---------|--------------|----------| | Controller stuck in winload (LED pattern: slow blink) | Corrupted application or incomplete flash | Force re-download via serial recovery | | winload not responding to pCOWin | Wrong baud rate or serial cable (null modem required) | Set 19200 baud, 8 data bits, 1 stop, no parity, use Carel’s CAB series cable | | Error: “winload CRC mismatch” | Bad flash or incompatible firmware version | Use correct firmware file for exact pCO model | | Windows error “Carel winload failed” (when using USB-to-serial adapters) | Driver timing issues | Use native RS232 port or FTDI-based adapter at 5V logic | 5. Security Considerations

winload typically has no authentication in older pCO controllers (pCO1–pCO3), making them vulnerable to unauthorized firmware replacement via physical serial access. Newer pCO5+ introduced signed firmware and bootloader locking, but winload entry can still be forced if physical access is obtained. In critical HVAC systems (hospitals, data centers), disabling serial bootloader entry after commissioning is recommended via Carel’s “Boot Lock” parameter.