SOP – Xovis Firmware Upgrade from 4.x to 5.x

Primarily applies to the PC2S/PC2 series in Vemcount environments. Updated with note on 3.1.x → 5.5.9 → newer 5.x.

Quick recommendation: If the sensor runs 4.7.1 or later, it can usually be migrated to 5.x via the new remote connector. If it runs early 4.x, first upgrade locally to 4.7.1. If it runs 3.1.x, a practically verified path in Vemcount environments is to upgrade directly to 5.5.9 and then continue to the desired newer 5.x version. As a general rule, avoid going through 4.7 for 3.x sensors.

1. Purpose

This procedure explains how to upgrade a Xovis sensor from firmware 4.x to firmware 5.x (for example 5.9.1) via the Vemcount Remote Connector / Xovis IBEX or locally through the sensor web interface. It also describes the recommended approach when the sensor is still running firmware 3.x.

2. Scope and limitations

• Written primarily for the PC2S/PC2 series and Vemcount environments.
• Assumes the sensor is supported by the target 5.x firmware and a compatible firmware file exists for the hardware revision.
• Older sensors or very old firmware branches may require a local intermediate upgrade before migration to 5.x.
• If in doubt about hardware compatibility, always test on one sensor first before broad rollout.

3. Prerequisites

• Xovis PC2S or related PC2 model with a supported hardware revision.
• Access to the sensor web interface.
• Stable power and network connectivity throughout the upgrade.
• Administrator rights in Vemcount.
• A local fallback option if remote migration does not succeed.
• Document the current setup first: scenes, lines, zones, calibration, height filter, multisensor relationships, passwords, and push configuration.

4. Version check before you start

• 4.7.1 or later: add the v5 remote connection and migrate to 5.x — the most direct route.
• 4.0 – 4.7.0: first upgrade locally to 4.7.1, then continue to 5.x. Reduces migration-error risk.
• 3.1.x / 3.x: use the verified bridge version — upgrade directly to 5.5.9, then continue to the desired newer 5.x. Avoid 4.7 as an intermediate step for 3.x sensors.

5. Step-by-step: 4.x → 5.x

5.1 Confirm the firmware version

• Log in to the sensor web interface and check the firmware version.
• If lower than 4.7.1, first perform a local firmware upgrade to 4.7.1.
• Confirm the hardware version matches the selected 5.x firmware.

5.2 Prepare the sensor

• Take screenshots or notes of the existing configuration.
• Clean up old recordings before a major version jump if present.
• Ensure stable PoE/power; avoid upgrading over an unstable connection.

5.3 Add the v5 remote connection

• Go to the sensor's Remote Connection Settings under Network and add a new connection.
• URL field: the Vemcount sensor connector v2 address — host xovis.vemcount.com, port 3002, path /sensorconnectorv2 (secure protocol).
• Token field: the standard Vemcount connector token.
• Save, then wait until the sensor shows a green status such as "Migration OK". If it does not turn green, do not start a remote firmware push yet.

5.4 Upgrade to firmware 5.x

• Once green, perform the upgrade via Vemcount / IBEX, selecting the approved 5.x version.
• If remote upgrade is not possible, upgrade locally via the sensor web interface with the correct firmware file.
• Do not interrupt power or network during the upgrade.

5.5 After the upgrade

• Confirm the sensor runs the expected 5.x version.
• The height filter may not be inherited from firmware 4 — reconfigure manually if relevant.
• Perform or validate calibration.
• If multisensor/stitching is used, check passwords and relationships.
• Review logics and data push — use the 5.x format and remove legacy settings no longer required.

6. Special note on firmware 3.x → 5.x

Treat 3.x migration as a special case. The verified path for 3.1.x sensors: 3.1.x → 5.5.9 → desired newer 5.x version (for example 5.8.3). Version 5.5.9 handles both the AI and non-AI tracks and functions as a bridge for older 3.x sensors. Avoid going through 4.7 for 3.x sensors — 4.7 was the first AI-track version and is not a robust intermediate for these older sensors. Test on a single sensor first, and after each step verify the sensor comes online, keeps web-interface access, and continues to push data.

7. Validation after upgrade

• Confirm the firmware version in the status view.
• Confirm the sensor is online and uploading to Vemcount without errors.
• Check count lines, zones, scenes, and any API/logics pushes.
• Compare live and historical data to verify plausible counting.
• For critical installations, do a short manual validation or recording.

8. Troubleshooting

• Sensor does not turn green / no "Migration OK": port 3002 blocked, wrong URL/token, or lost connectivity. Check internet access, firewall rules, URL and token; restart the sensor and re-add the connection.
• "Token invalid" or "Unauthorized": incorrect token or connector URL — re-enter the values exactly and save again.
• Migration stays "in progress": sensor not actually ready or running too old a 4.x — upgrade locally to 4.7.1, remove the remote connection, restart, retry.
• Firmware cannot be pushed remotely: sensor not green or v5 connection inactive — check status or upgrade locally.
• No data in Vemcount after upgrade: legacy push/logics still in use — review logics and switch the data push to the 5.x format.
• Calibration inaccurate after upgrade: height filter, mounting height, or calibration not restored — recalibrate and verify mounting height, tilt, and scene.
• Multisensor not working: passwords or stitching relationships not carried over — review the multisensor setup and remaining legacy elements.

9. Practical recommendations

• Don't upgrade many old sensors in one wave without testing one representative sensor first.
• Use a version plan so you know which sensors need intermediate versions.
• Schedule business-critical upgrades during low-traffic windows.
• Document before and after state for faster troubleshooting.

10. References and changelog

Public documentation on the Vemcount-specific migration path is limited; the Xovis compatibility matrix (June 2019) and Xovis PC2/PC2SE product pages are relevant background. Practical Vemcount experience should be weighted highly for 3.x and early 4.x sensors. v1.0 original SOP; v1.1 English version with decision table and 3.x section; v1.2 verified 3.1.x → 5.5.9 → newer 5.x path added.