Ninja Pirate
Member
Hi there,
Long time lurker posting for the first time.
TLDR: Trying to configure a small Point IO drop into an existing system, the point IO keeps faulting after a random amount of time.
Relevant Details
Network Layout: See attachment - Drive Comms.jpg (sorry for the low resolution)
Logix Code: See attachment - PM1_gpr_30_APR_2015.zip
This is a drive system for a small paper machine, all the hardware was installed before my time with the company and I only added a small subroutine to the software and the PointIO modules. The drives used are old Parker 590+ connected to a Link system. The CompactLogix PLC serves as a bridge of some sort to map between the newer Parker TS8000 HMI's and Wago IO modules, and the Link system. My additions to the system are a single PointIO adapter and one 4 channel analog module.
Processor: CompactLogix 1769-L32E Rev. 19.11
Switch: Siemens Scalance X-108 Unmanaged (that is what the CompactLogix and PointIO are connected to)
Remote IO:
1 of 1734-AENT/B - Revision 4.5
1 of 1734-IE4C - Revision 3.4
Preface.
I was tasked with putting a couple of analog signals (pressure readings) on to our historian system. To do so I decided to use an existing PLC (Compact Logix L32E), and add an remote IO drop (1734 modules) for the two pressure readings. Simple enough right? Just buy all the kit, configure the software, and wire everything up.
Ahahaha, no. It took me half a day and a few calls to Rockwell tech support to figure out that a) I needed to download an AOP for the PointIO adapter, and b) the bloody chassis size needed to be set properly!
Anyway, I did eventually get it 'working' and I could read the two pressure tags on the Historian software. All was well and good until I came back the next day.
Problem.
I came back the next day and noticed that the pressure readings were not updating. Loading up RSLogix showed that there was an I/O fault (green light blinking) and some yellow triangles on the Point IO modules. Power cycling the Point IO module got everything back up and running, fault cleared.
Checked it again the next day, same issue. This was a week ago and I am still having the same issues. I am unable to see most of the properties of the AENT module when it is faulted (just comes up with a time out error in Logix), and the only fault code that I can see is 16#0204.
Lights that are flashing on the modules:
* 1734-AENT - Network Status light flashing red
- Point Bus Status light flashing red
* 1734-IE4C - Network Status flashing green
What I have tried so far.
Based on a few conversations with Rockwell support I have tried the following:
* Check CPU Utilization - Utilization at ~100% Woah, that's probably not good. Turned out the attached Parker HMI's (see the diagram) were trying to poll too fast. Added a slight delay (100ms) to each of the HMI's and the utilization dropped to ~50%. Still the same issue with I/O dropping out.
* Try Pinging I/O when faulted - Cannot ping the 1734-AENT module. Also can't right click on any of the modules on RSLinx (it just freezes up).
* Checked the Ethernet cable - Using a cable tester, looks fine.
* Check Switch - Not really sure what to check on an unmanaged switch.
* Checked the Ethernet counters on the web browser - No errors logged.
* Checked driver diagnostics on RSLinx - Noticed that the Point I/O module had a lot of [10060] Connection timed out errors. Also noticed "Can't set port type to 288: no Harmony port for this IP address" show up at the end.
Rockwell has recommended I upgrade the firmware on the CPU and possibly on the PointIO modules as well to see if that fixes the issue. I will try this on Thursday when the machine is down.
Question.
Can anyone see any glaring issues with the software/hardware configuration?
What else should I check/try before upgrading the firmware on the CPU?
My own experience.
I am a graduate electrical engineer (well 2 years out of school now) with a focus in power systems but have recently been working more and more on industrial controls and programming (not something I really studied at school). I have not had any formal training in regards to any of the current platforms but have built up some basic hands on experience on the Allen Bradley PLC's (SLC and 5000 series), Parker SSD VFD's and HMI's, and a very old Alspa DCS system.
Thanks for reading, and apologies if this has already been asked 1000 times.
Long time lurker posting for the first time.
TLDR: Trying to configure a small Point IO drop into an existing system, the point IO keeps faulting after a random amount of time.
Relevant Details
Network Layout: See attachment - Drive Comms.jpg (sorry for the low resolution)
Logix Code: See attachment - PM1_gpr_30_APR_2015.zip
This is a drive system for a small paper machine, all the hardware was installed before my time with the company and I only added a small subroutine to the software and the PointIO modules. The drives used are old Parker 590+ connected to a Link system. The CompactLogix PLC serves as a bridge of some sort to map between the newer Parker TS8000 HMI's and Wago IO modules, and the Link system. My additions to the system are a single PointIO adapter and one 4 channel analog module.
Processor: CompactLogix 1769-L32E Rev. 19.11
Switch: Siemens Scalance X-108 Unmanaged (that is what the CompactLogix and PointIO are connected to)
Remote IO:
1 of 1734-AENT/B - Revision 4.5
1 of 1734-IE4C - Revision 3.4
Preface.
I was tasked with putting a couple of analog signals (pressure readings) on to our historian system. To do so I decided to use an existing PLC (Compact Logix L32E), and add an remote IO drop (1734 modules) for the two pressure readings. Simple enough right? Just buy all the kit, configure the software, and wire everything up.
Ahahaha, no. It took me half a day and a few calls to Rockwell tech support to figure out that a) I needed to download an AOP for the PointIO adapter, and b) the bloody chassis size needed to be set properly!
Anyway, I did eventually get it 'working' and I could read the two pressure tags on the Historian software. All was well and good until I came back the next day.
Problem.
I came back the next day and noticed that the pressure readings were not updating. Loading up RSLogix showed that there was an I/O fault (green light blinking) and some yellow triangles on the Point IO modules. Power cycling the Point IO module got everything back up and running, fault cleared.
Checked it again the next day, same issue. This was a week ago and I am still having the same issues. I am unable to see most of the properties of the AENT module when it is faulted (just comes up with a time out error in Logix), and the only fault code that I can see is 16#0204.
Lights that are flashing on the modules:
* 1734-AENT - Network Status light flashing red
- Point Bus Status light flashing red
* 1734-IE4C - Network Status flashing green
What I have tried so far.
Based on a few conversations with Rockwell support I have tried the following:
* Check CPU Utilization - Utilization at ~100% Woah, that's probably not good. Turned out the attached Parker HMI's (see the diagram) were trying to poll too fast. Added a slight delay (100ms) to each of the HMI's and the utilization dropped to ~50%. Still the same issue with I/O dropping out.
* Try Pinging I/O when faulted - Cannot ping the 1734-AENT module. Also can't right click on any of the modules on RSLinx (it just freezes up).
* Checked the Ethernet cable - Using a cable tester, looks fine.
* Check Switch - Not really sure what to check on an unmanaged switch.
* Checked the Ethernet counters on the web browser - No errors logged.
* Checked driver diagnostics on RSLinx - Noticed that the Point I/O module had a lot of [10060] Connection timed out errors. Also noticed "Can't set port type to 288: no Harmony port for this IP address" show up at the end.
Rockwell has recommended I upgrade the firmware on the CPU and possibly on the PointIO modules as well to see if that fixes the issue. I will try this on Thursday when the machine is down.
Question.
Can anyone see any glaring issues with the software/hardware configuration?
What else should I check/try before upgrading the firmware on the CPU?
My own experience.
I am a graduate electrical engineer (well 2 years out of school now) with a focus in power systems but have recently been working more and more on industrial controls and programming (not something I really studied at school). I have not had any formal training in regards to any of the current platforms but have built up some basic hands on experience on the Allen Bradley PLC's (SLC and 5000 series), Parker SSD VFD's and HMI's, and a very old Alspa DCS system.
Thanks for reading, and apologies if this has already been asked 1000 times.