SOP – Xovis Firmware Upgrade from 4.x to 5.x
Primarily applies to the PC2S/PC2 series in Vemcount environments • English version • 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 5.9.1-737182e679, 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
The procedure is written primarily for the PC2S/PC2 series and Vemcount environments.
It assumes that the sensor is supported by the target 5.x firmware and that a compatible firmware file exists for the specific hardware revision.
Older sensors or very old firmware branches may require a local intermediate upgrade before migration to 5.x is possible.
If there is any doubt about hardware compatibility, always test on one sensor first before rolling out the change broadly.
3. Prerequisites
Sensor: Xovis PC2S or related PC2 model with a supported hardware revision.
Access to the sensor web interface.
Stable power and network connectivity throughout the entire upgrade process.
Administrator rights in Vemcount.
A local fallback option if remote migration does not succeed.
Document the current setup before the upgrade: scenes, lines, zones, calibration, height filter, multisensor relationships, passwords, and push configuration.
4. Version check before you start
Before upgrading, identify the sensor’s current firmware and follow the correct path forward:
Current version | Recommended path | Note |
4.7.1 or later | Add the v5 remote connection and then migrate to 5.x. | This is usually the most direct route. |
4.0 – 4.7.0 | First upgrade locally to 4.7.1, then continue to 5.x. | Reduces the risk of migration errors. |
3.1.x / 3.x | Use the verified bridge version: upgrade directly to 5.5.9 and then continue to the desired newer 5.x version. | As a general rule, avoid using 4.7 as an intermediate step for 3.x sensors. |
5. Step-by-step procedure: 4.x → 5.x
5.1 Confirm the firmware version
Log in to the sensor web interface.
Check the sensor firmware version.
If the version is lower than 4.7.1, first perform a local firmware upgrade to 4.7.1.
Also confirm the hardware version to make sure the selected 5.x firmware matches the sensor.
5.2 Prepare the sensor
Take screenshots or notes of the existing configuration before making changes.
If the sensor contains old recordings, it may be helpful to clean them up before a major version jump.
Ensure stable PoE/power and avoid upgrading over an unstable connection.
5.3 Add the v5 remote connection
Go to the sensor’s Remote Connection Settings under Network.
Add a new connection using the values shown below.
Save the change.
Wait until the sensor shows a green status, for example “Migration OK”.
If the status does not turn green, do not start a remote firmware push yet.
Field | Value |
URL | |
Token | vemcount |
5.4 Upgrade to firmware 5.x
Once the sensor is green, perform the firmware upgrade via Vemcount / IBEX.
Select the desired 5.x version, for example 5.9.1-737182e679 or the version approved in your environment.
If remote upgrade is not possible, the upgrade can be performed locally via the sensor web interface using the correct firmware file.
Do not interrupt power or network connectivity during the upgrade itself.
5.5 After the upgrade
Confirm that the sensor is now running the expected 5.x version.
The height filter may not be inherited correctly from firmware 4; reconfigure it manually if relevant.
Perform a new calibration, or at minimum validate the calibration.
If multisensor / stitching is used, check passwords and relationships and reconfigure them if needed.
Review logics and data push. Use the new 5.x format and avoid legacy configurations where possible.
Disable or remove old legacy settings if they are no longer required.
6. Special note on firmware 3.x → 5.x
If the sensor is still running firmware 3.x, treat the migration as a special case. Based on practical experience in Vemcount environments and internal verification, a working path for 3.1.x sensors is to upgrade directly to 5.5.9 and then continue to a newer 5.x version, for example 5.8.3.
Verified migration path for 3.1.x: 3.1.x → 5.5.9 → desired newer 5.x version.
Version 5.5.9 is relevant in this context because it can handle both the AI and non-AI tracks and therefore functions as a bridge version for older 3.x sensors.
As a general rule, avoid going through 4.7 for 3.x sensors. In practice, this has caused issues because 4.7 was the first version in the AI track and is therefore not the most robust intermediate path for these older sensors.
Once the sensor is stable on 5.5.9, it can be upgraded further to a newer 5.x version using the same principle as other 5.x upgrades.
Still test on a single sensor first before upgrading multiple sensors with the same starting point.
After each step, verify that the sensor comes online correctly, keeps access to the web interface, and continues to push data as expected.
Important note on 3.x: Practical experience in Vemcount environments shows that 3.1.x sensors can be migrated via 5.5.9 as a bridge version and then further to newer 5.x builds, for example 5.8.3. As a general rule, 4.7 should not be used as the intermediate step for these older sensors.
7. Validation after upgrade
Confirm the firmware version in the sensor status view.
Confirm that the sensor is online and uploading data to Vemcount without errors.
Check count lines, zones, scenes, and any API/logics pushes.
Compare live data and historical patterns to verify that the sensor counts plausibly.
For critical installations, a short manual validation or recording is recommended after the upgrade.
8. Troubleshooting
Problem | Possible cause | Solution |
Sensor does not turn green / does not show “Migration OK” | Port 3002 is blocked, the URL/token is incorrect, or the sensor loses connectivity. | Check internet access, firewall rules, URL, and token. Restart the sensor and add the connection again. |
“Token invalid” or “Unauthorized” | Incorrect token or a configuration error in the connector URL. | Re-enter the values exactly and save again. |
Migration stays at “in progress” | The sensor is not actually ready for migration or still runs too old a 4.x version. | First upgrade locally to 4.7.1, remove the remote connection, restart, and try again. |
Firmware cannot be pushed remotely | The sensor is not green or the v5 remote connection is not active. | Check the status, or perform a local firmware upgrade via the web interface. |
No data in Vemcount after the upgrade | Legacy push/logics are still in use, or the configuration has not been updated. | Review the logics and change the data push to the correct 5.x format. |
Calibration is inaccurate after the upgrade | The height filter, mounting height, or calibration was not restored correctly. | Perform a new calibration and verify mounting height, tilt, and scene configuration. |
Multisensor does not work as expected | Passwords or stitching relationships were not carried over correctly. | Review the multisensor setup, passwords, and any remaining legacy elements. |
9. Practical recommendations
Avoid upgrading many old sensors in the same wave without first testing one representative sensor.
Prefer using a version plan so you know exactly which sensors require intermediate versions.
If a sensor is business critical, schedule the upgrade during a low-traffic window.
Document both the before and after state so troubleshooting is faster if counts change afterwards.
10. Public references and note
There is limited public documentation covering the exact Vemcount-specific migration path from older Xovis firmware branches. The following references are relevant as background:
Xovis compatibility matrix (June 2019) describing firmware families and sensor series.
Xovis product pages for the PC2 series / PC2SE showing continued focus on Firmware 5 in newer generations.
Practical experience in Vemcount environments should still be weighted highly, especially for 3.x and early 4.x sensors.
Version and changelog
v1.0 – Original SOP text.
v1.1 – English version with language tightening, decision table, and dedicated section on 3.x → 5.x.
v1.2 – The 3.1.x section was updated with the verified migration path 3.1.x → 5.5.9 → newer 5.x and a note to avoid 4.7 as the intermediate step for these sensors.