S7-300 Defective PLC when going online, PLCSIM too...

[adfox]

Hi I've got very strange problem.
I have a project for CPU 317-2 DP.

1.I download hardware config to PLC - it's ok.
2.I download OB1 with contents

L 0
T MB2 - it's still OK.

3.I go online in OB1 - PLC stops and diag buffer says PLC Defective.

This happens in PLCSIM (5.4+SP6).

I've found this in diag buffer (attached):

Event 9 of 10:  Event ID 16# 530D
New startup information in STOP mode
Startup prevented by:
Loading user program or internal inconsistency detected
 (SDBs less than 200 incomplete, superfluous, or incorrect)
- STOP request exists
- Keyswitch set to STOP
- Cold restart or warm restart necessary
Startup information: 
- Time for time stamp at the last non backed up power on
- Single processor operation
Current/last startup type:
- No startup type/following memory reset
Permissibility of certain startup types: 
- Manual startup not permitted, corrections in parameter assignment, submodule, etc. necessary
- Automatic startup not permitted, corrections in parameter assignment, submodule, etc. necessary
Last valid operation or setting of automatic startup type at power on:
- No startup type/following memory reset
Operating mode: STOP (internal)
Incoming event
07:47:42.668 PM  08/01/2016
(Coding: 16# 530D  FF04  C777  0161  0000  1100)

How can I find the source of error ?
I'm linking the project file to dropbox as it's quite big multi-PLC (5 MB).

https://www.dropbox.com/s/9usdb4utvxi1bs0/Calc_6.14.zip?dl=0

It's the plc named Sivacon.

I'm really confused. I'd be really glad if someone could point me in the right direction.

 

[Mike_RH]

Recompile your hardware config, then download it again.
Make sure no monitor functions are active when you do the download.
Then download your program blocks.

 

[adfox]

Hi, did this numerous times already. Recompiled hw, netpro and existing software ( not called since empty OB1 alone is enough for PLC to die ).

 

[Mike_RH]

The error / diagnostic message indicates inconsistent system data.
This can be caused by downloading hardware with a debug (monitor) function active.

 

[adfox]

No online functions active, more over after plc sim dying - i need to close it and open it again as it stops to function, with real PLC i need to take power down, and power it up in stop mode to be able to download again.

 

[Mike_RH]

Ok, then post an archive of your project.
What are the versions of your software andthe OS?

 

[adfox]

Link to the project is in the fist post ( dropbox ) as it's too large to fit forums limit.

Windows 7 SP1 64
Step 7 5.5 + SP4
PLCSim 5.4 + SP6

Thank You.

 

[KalleOlsen]

Have you tried to rebuild the hw from scratch in a new project?

It might be an evil ghost hiding in the old configuration

.

Kalle

 

[Mike_RH]

Not sure if this is good news or bad -
The project also causes
I am on Win 7 / 64 bitmy PLCSIM to crash.

Step 7 V5.5 SP4 and PLCSIM 5.4 SP5.

 

[Mike_RH]

If I download hardware only, no crash.
The same of only HW + OB1.

 

[adfox]

Download HW + OB1 and enter online in OB1 - instant crash.
KalleOlsen : Doing it right now - its 128 dp slaves to copy paste ))

 

[Lare]

its 128 dp slaves to copy paste

128?
Have you 2 dp masters on PLC?

p.s 317-2DP...

 

[adfox]

2 DP networks on PLC, 2 additional CP 342-5 and 2 343-1 ethernet cps.

Ok... i've mostly copy-pasted slaves from defective project, added CPs with copy-paste,
manually created connections in netpro - and it works like nothing happened.

Thanks for investigating - but I still don't know what caused this behaviour.

 

[adfox]

Ok, i've found the solution.
It can be used as a nice job interview puzzle.

1st screen - my CPU properties, notice Process Image size.
2nd screen- my DP network, I had to add 2 new 3WL circuit breakers, so as my first 3WL was at PIW/PWQ 300 and first simocode on 512, i added them up front.

And voila.
Thanks for the help