1747-AENTR, module fault code 16#0204

[pholonitch]

I am in the process of migrating an SLC5/04 system to CompactLogix using a 1747-AENTR. I have two 13-Slot SLC chassis populated as shown in the attached picture. Beginning with Slot 10 (1746-NO4I), there are yellow triangles next to the slot numbers. If I double click on the Slot 10 module, the pop-up box indicates fault code 16#0204 Connection Request Error. I compared the settings to the previous Slot 9 (also 1746-NO4I) and everything is identical. The Requested Packet Interval is at the default 20ms. Is that too fast? What else might cause this error?

The rest of the system:
Studio 5000 version 30
1769-L33ER flashed ver. 30
direct connected to 1747-AENTR
also connected to a PanelView
no other network connections

Let me know what other information is needed.

 

[joseph_e2]

I don't have the software open right now, but do you configure the chassis size when you add the -AENTR to the IO tree? If so, verify it's right. Starting with slot 10 hints to me that it's configured as a 10-slot chassis. I could be wrong, though.

 

[Ken Roach]

Welcome to the PLCTalk forum community, and thanks for the screenshots / photos.

I noticed that there are skipped slot numbers in the configuration; slots 3, 8, 12, 16, 22, and 23 are all unpopulated. Is that accurate ? They do seem to skip a slot in between groups of similar devices.

As you have seen, the 1747-AENTR makes a CIP "Module" connection to each I/O module individually instead of collecting up all the modules, or just the simple discrete ones, in an Assembly for the whole I/O chassis. That eats up I/O connections quickly, but the 1769-L33ER should support 32 EtherNet/IP connections and you're only showing 8 active.

The "split" between the functioning and non-functioning modules isn't the 13-slot backplane connection ribbon cable because it doesn't happen between Slots 11 and 12.

Go back to the 1747-AENTR configuration applet and the first tab, on which there's a Module Definition section. Double-check the "Chassis Size" value, because that will have a selectable 1747 chassis size, and it might be configured for a 10-slot chassis.

(Joseph beat me to it. Ignoring the connections to the subsequent modules strongly suggests that Chassis Size is set to 10, for a 1747-A10 chassis).

 

[pholonitch]

I don't have the software open right now, but do you configure the chassis size when you add the -AENTR to the IO tree? If so, verify it's right. Starting with slot 10 hints to me that it's configured as a 10-slot chassis. I could be wrong, though.

Looks like chassis size is correct at 25?

 

[pholonitch]

Screenshot attached.

 

[pholonitch]

Welcome to the PLCTalk forum community, and thanks for the screenshots / photos. Thanks, Ken. I've been a long time viewer but this is the first time I couldn't find a solid answer.

I noticed that there are skipped slot numbers in the configuration; slots 3, 8, 12, 16, 22, and 23 are all unpopulated. Is that accurate ? They do seem to skip a slot in between groups of similar devices. That is accurate. Slots were deliberately skipped for future additions.

As you have seen, the 1747-AENTR makes a CIP "Module" connection to each I/O module individually instead of collecting up all the modules, or just the simple discrete ones, in an Assembly for the whole I/O chassis. That eats up I/O connections quickly, but the 1769-L33ER should support 32 EtherNet/IP connections and you're only showing 8 active.

The "split" between the functioning and non-functioning modules isn't the 13-slot backplane connection ribbon cable because it doesn't happen between Slots 11 and 12.

Go back to the 1747-AENTR configuration applet and the first tab, on which there's a Module Definition section. Double-check the "Chassis Size" value, because that will have a selectable 1747 chassis size, and it might be configured for a 10-slot chassis.

(Joseph beat me to it. Ignoring the connections to the subsequent modules strongly suggests that Chassis Size is set to 10, for a 1747-A10 chassis).

I did see in another thread that someone had a similar issue and the "fix" was to delete the modules from the tree and then manually add them back in. I didn't know if this was the best way to fix the problem. I am worried about losing tags and/or Studio 5000 creating new tags if I re-add the modules. To make things worse, I won't have access to our customer's PLC again until it is time to get the system back up and running. So I'm hoping to go in with a bullet proof solution.

 

[Ken Roach]

Do you know the actual firmware revision of the 1747-AENTR ?

The original 1.001 firmware for that module only supported a maximum rack size of 13.

You should be able to get firmware and an Add On Profile (AOP) that allow you to select firmware 2.x in the Configuration dialog.

I'm working from the FAQ for the 1747-AENT(R) on the RA Knowledgebase:

https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/471083/loc/en_US#__highlight

 

[pholonitch]

Since I don't have access to the AENTR module at the moment, I'm not 100% sure, but I believe the label on the side of the module said FW 2.003.

I have version 30 of Studio 5000 so I most likely have the correct AOP, but this is definitely something worth looking at. While working offline, it appears that I am able to select version 2.x. As shown in the attached picture, it's probably configured as version 1.001 at the moment.

Thank you for the knowledgebase link. I appreciate your assistance.

 

[pholonitch]

SOLVED!

Just to follow up, I changed the 1747-AENTR firmware revision to 2.003 and downloaded. The problem with not connecting to half of the I/O modules persisted.

I tried the other approach I had read about and that did the trick. Basically, as I mentioned above, delete a module from the tree and then add it back in (to the same slot.) After dowloading, the communications problem went away. Also, I did not have to fiddle with any of the tags.

 

[James Mcquade]

thanks for posting the solution.
james