Hi all,
We have a machine with a 1756-L61S/1756-LSP processor. The programme is stored on a compact flash card inserted inside the L61S.
The processor is set at revision 19.011 and the RSLogix software being used is version 19.01.
Over the weekend, the processor suffered some kind of fault (I'm unsure what the fault was as the people on shift dealt with it without calling for engineering support). The people on shift wrote in their log that the processor had a flashing red 'OK' led. To recover the situation, they installed a new L61S, inserted the Compact Flash card and then toggled the key switch from PROG to RUN and then to REM and the system came back to life.
However, the machine HMI showed an alarm which they traced to a limit switch, but the only way they could get it to clear was by removing the cable from this limit switch input. The machine then could run and has been running since.
The line engineer today has attempted to go online using a Windows 10 PC connected to the machine via our site Ethernet network to try and determine why the alarm message relating to the limit switch would not clear after the programme was reloaded. However, every time he tries to go online via the EN2T Ethernet card in the rack, the new processor crashes (Major Fault) and he cant get online to find out why or what the Major Fault is (the OK LED flashes red, as per the weekend).
I then got involved and I tried to go online via another Ethernet card in the rack, a 1756-ENBT (a different network to the EN2T card) and the same thing happens.
I then thought it maybe the PC, so tried to go online using a Windows 7 Laptop, but the same thing happens when attempting to go online via either of the two Ethernet cards. The system can always be recovered by moving the key switch PROG, RUN, REM
From both the PC and the laptop, I can Ping Ethernet both cards from Command Prompt and I can see the controller properties from RSLinx
The error that comes up in RSLogix on both machines is "Failed to go online with controller. Can't communicate with RSLinx". The error number is 701-80042535.
So I dont really understand why we cant go online with this PLC.
This machine has a sister machine with exactly the same hardware config and more or less the same software (the controller version is the same) and we can get online with this no problem.
The only difference I can see is that both the original processor from the affected machine and the processor in the sister machine say on the side F/W Rev 1.10. The new processor says F/W Rev 1.9.
Can any of you help? I dont really know how to tackle this.
We have rung Rockwell UK today and they have pointed to some knowledgebase articles suggesting that deleting harmony files etc from the PC/Laptop might help, but why would we have the same problem on 2 programming terminals?
Thank you for any suggestions you have.
We have a machine with a 1756-L61S/1756-LSP processor. The programme is stored on a compact flash card inserted inside the L61S.
The processor is set at revision 19.011 and the RSLogix software being used is version 19.01.
Over the weekend, the processor suffered some kind of fault (I'm unsure what the fault was as the people on shift dealt with it without calling for engineering support). The people on shift wrote in their log that the processor had a flashing red 'OK' led. To recover the situation, they installed a new L61S, inserted the Compact Flash card and then toggled the key switch from PROG to RUN and then to REM and the system came back to life.
However, the machine HMI showed an alarm which they traced to a limit switch, but the only way they could get it to clear was by removing the cable from this limit switch input. The machine then could run and has been running since.
The line engineer today has attempted to go online using a Windows 10 PC connected to the machine via our site Ethernet network to try and determine why the alarm message relating to the limit switch would not clear after the programme was reloaded. However, every time he tries to go online via the EN2T Ethernet card in the rack, the new processor crashes (Major Fault) and he cant get online to find out why or what the Major Fault is (the OK LED flashes red, as per the weekend).
I then got involved and I tried to go online via another Ethernet card in the rack, a 1756-ENBT (a different network to the EN2T card) and the same thing happens.
I then thought it maybe the PC, so tried to go online using a Windows 7 Laptop, but the same thing happens when attempting to go online via either of the two Ethernet cards. The system can always be recovered by moving the key switch PROG, RUN, REM
From both the PC and the laptop, I can Ping Ethernet both cards from Command Prompt and I can see the controller properties from RSLinx
The error that comes up in RSLogix on both machines is "Failed to go online with controller. Can't communicate with RSLinx". The error number is 701-80042535.
So I dont really understand why we cant go online with this PLC.
This machine has a sister machine with exactly the same hardware config and more or less the same software (the controller version is the same) and we can get online with this no problem.
The only difference I can see is that both the original processor from the affected machine and the processor in the sister machine say on the side F/W Rev 1.10. The new processor says F/W Rev 1.9.
Can any of you help? I dont really know how to tackle this.
We have rung Rockwell UK today and they have pointed to some knowledgebase articles suggesting that deleting harmony files etc from the PC/Laptop might help, but why would we have the same problem on 2 programming terminals?
Thank you for any suggestions you have.
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