S7-400 PLC Fault

isteak007 · Nov 15, 2012

We have a S7-400 system.
which Power Supply (PS407 4A) is totally defective. So i replace it with
PS407 10A. after downloading the new hardware configuration to the CPU. CPU comes to run mode. but EXTF Led is on and BUS2F Led is Blinking
So i checked the diagnostics buffer. it seems to be a profibus fault.
Can anyone give me an idea?

Here is more information in attached file.

adfox · Nov 15, 2012

Go to HW config, open it in online - look for modules that are not present on the bus.

I/O access error, writing
P area, word access, Access address: 544
FC number: 3
Module address: 238

And also it a H system ? For the rest of errors like
I/O access error when transferring the process image to the output modules

Look there:

http://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=19661&Language=en

isteak007 · Nov 15, 2012

adfox said:
Go to HW config, open it in online - look for modules that are not present on the bus.

I/O access error, writing
P area, word access, Access address: 544
FC number: 3
Module address: 238

And also it a H system ? For the rest of errors like
I/O access error when transferring the process image to the output modules

Look there:

http://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=19661&Language=en

DP Slaves are all missing. but physically they are all present.

adfox · Nov 15, 2012

So, check why profibus nodes are out of the network.
Termination etc.

JesperMP · Nov 15, 2012

Something caused the PSU to become defective.
Could it be something that damaged other things ?
If you connect your PC to the DP port (*), can you see the CPU ?
Can you see the slaves ?

*: The DP connector in that port must have a piggy-back PG socket.

isteak007 · Nov 15, 2012

JesperMP said:
Something caused the PSU to become defective.
Could it be something that damaged other things ?
If you connect your PC to the DP port (*), can you see the CPU ?
Can you see the slaves ?

*: The DP connector in that port must have a piggy-back PG socket.

I guess DP port of the CPU is defective. Because I can't communicate with the
CPU using DP port. PC Adapter (Profibus) mode.

Any Idea?

JesperMP · Nov 15, 2012

Here is a suggestion for a fix if you dont have a spare CPU and you are desperate to get up and running:

You have a 412-2DP CPU.
It has an MPI/DP port and a DP port.
The MPI/DP port is setup for MPI, and all the i/o hangs on the DP port.
You can reconfigure the MPI/DP port to DP, and move all the i/o to that port. Depends on what else the MPI/DP port is used for, but it can be the solution.

KalleOlsen · Nov 15, 2012

isteak007 said:
I guess DP port of the CPU is defective. Because I can't communicate with the
CPU using DP port. PC Adapter (Profibus) mode.

Any Idea?

I have experienced a defective DP port ONCE. It was caused by 230V on the DP bus from a faulty terminated Simocode.

You must check the DP equipment thoroughly, measure, look and sniff.

Kalle

isteak007 · Nov 15, 2012

JesperMP said:
Here is a suggestion for a fix if you dont have a spare CPU and you are desperate to get up and running:

You have a 412-2DP CPU.
It has an MPI/DP port and a DP port.
The MPI/DP port is setup for MPI, and all the i/o hangs on the DP port.
You can reconfigure the MPI/DP port to DP, and move all the i/o to that port. Depends on what else the MPI/DP port is used for, but it can be the solution.

Well I am desperate to run it,
MPI /DP Port is used for HMI as MPI Network.
If i configure it to DP port. What will happened to HMI. Because HMI is using the MPI network

Production is Stop, lot of pressure, and everyone believe i am the responsible one

KalleOlsen · Nov 15, 2012

You would make it easier for us if you tell what kind of HMI it is.

But if you (still?) have overvoltage on the DP-bus, it will probably burn.

Kalle

JesperMP · Nov 15, 2012

Maybe switch the HMI to DP as well ?
And then run both i/o and HMI parallel on the same port.
What kinf of HMI is it ? Do you have the source for the HMI as well ?

isteak007 · Nov 15, 2012

JesperMP said:
Maybe switch the HMI to DP as well ?
And then run both i/o and HMI parallel on the same port.
What kinf of HMI is it ? Do you have the source for the HMI as well ?

Romaco HMI

Machine Name : Horn Noack Blister Machine
Pharmaceuticals Machine

JesperMP · Nov 15, 2012

Romaco seems to be the manufacturer of the machine, not the make of the HMI. Is it a Siemens ? Exactly what type is it ?

isteak007 · Nov 16, 2012

JesperMP said:
Romaco seems to be the manufacturer of the machine, not the make of the HMI. Is it a Siemens ? Exactly what type is it ?

HMI Model Number: GFO-57SQD-002
MSystem - Micro Innovation

JesperMP · Nov 16, 2012

OK, it is a HMI Panel with a proprietary software onboard.

Without the source code and the programming software you are stuck.

What you can do:
You can contact the original manufacturer of the machine and ask for help.
Or you can get a spare CPU asap. But... I am not 100% convinced that the problem is with the CPU, or with the CPU alone.

S7-400 PLC Fault

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