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How to upload from my old s7 200 (which may be broken )

Created by: Louis Springer at: 11/5/2014 3:25 PM (10 Replies)

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11/5/2014 3:25 PM	Rate (0)
Louis Springer Posts: 10 Rating: (0)	Hello I have a Sawmill with an s7 200 controller. After 8 years of operation it started giving me nonsense messages on the TD200 panel, and stopped functioning properly. The manufacturer of the mill went out of business and can't help me. I purchased the Step 7 micro/win software, a new S7 200 224 dc/dc/dc PLC and a USB/PPI adapter (isolated). I got all that working - I can create/download/upload/run programs on the new S7 200. Now I need to get the original program uploaded from the old S7 200 that was in my sawmill. When I power up and connect to the old one it runs, but I can't talk to it. I see the Tx Rx lights going, but the red power light on the cable adapter is not on. I assume something is wrong with port on the old PLC, ( or old S7 200 PLCs don't support this isolated USB/PPI cable). Can anyone help me with this problem? It would take me a very long time to create a whole new program for the sawmill, I would hope I can get the original one out of the old PLC Thank You
Louis Springer Posts: 10 Rating: (0)
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11/5/2014 4:17 PM	Rate (0)
William_B Posts: 5225 Rating: (1204)	Louis, 1. How is the TD200 connected?.. is it powered by its own 24Vdc or does it receive power from the PLC? 2. If the TD200 is still able to communicate with the PLC - go to the system settings of the TD200 and check if you can see at what speed the TD200 is communicating with the PLC. I am expecting the default 9.6k baud. 3. Some PLCs require you to switch the PLC in TERM or STOP mode before allowing you to communicate with it. Do not use MultiMaster mode to communicate with the PLC. 4. Please tell us what PLC you are needing to communicate to. (CPU212 / CPU224 / ..) 5. Use the "communications" functions to see if you can link the PLC and PC. My friend Macjan will probably be able to add more thoughts. Coming back with your thoughts on the above will be helpful to us to asist you. Good luck. w
William_B Posts: 5225 Rating: (1204)
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11/6/2014 9:17 AM	Rate (1)
Marcjan Platinum Expert Joined: 4/22/2010 Last visit: 3/31/2025 Posts: 5697 Rating: (716)	Hello, Just want to add the port pinout so you can measure the 24V that is needed to power the adapter (partnumber ?) Regards, Marcjan Attachment s7200_com.pdf (735 Downloads)
	Problem solved? Please let us know! Please no technical questions by PM, use the forum sections for your questions.
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This contribution was helpful to 1 thankful Users William_B

11/6/2014 4:58 PM	Rate (0)
Louis Springer Posts: 10 Rating: (0)	1. How is the TD200 connected?.. is it powered by its own 24Vdc or does it receive power from the PLC? The only connection to the TD200 is the serial port, nothing on the power input 2. If the TD200 is still able to communicate with the PLC - go to the system settings of the TD200 and check if you can see at what speed the TD200 is communicating with the PLC. I am expecting the default 9.6k baud. Don't know if I can do this - I'll go to the sawmill and pull the TD200 out of the control box and bring it inside and see what I can do 3. Some PLCs require you to switch the PLC in TERM or STOP mode before allowing you to communicate with it. Do not use MultiMaster mode to communicate with the PLC. Will try later today ( but remember the red power light on the cable adapter doesn't come on ) 4. Please tell us what PLC you are needing to communicate to. (CPU212 / CPU224 / ..) S7 200 224 dc/dc/dc 5. Use the "communications" functions to see if you can link the PLC and PC. got this working fine with a brand new PLC
Louis Springer Posts: 10 Rating: (0)
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11/7/2014 7:31 AM	Rate (0)
William_B Posts: 5225 Rating: (1204)	Louis Springer 1. How is the TD200 connected?.. is it powered by its own 24Vdc or does it receive power from the PLC? The only connection to the TD200 is the serial port, nothing on the power input 2. If the TD200 is still able to communicate with the PLC - go to the system settings of the TD200 and check if you can see at what speed the TD200 is communicating with the PLC. I am expecting the default 9.6k baud. Don't know if I can do this - I'll go to the sawmill and pull the TD200 out of the control box and bring it inside and see what I can do 3. Some PLCs require you to switch the PLC in TERM or STOP mode before allowing you to communicate with it. Do not use MultiMaster mode to communicate with the PLC. Will try later today ( but remember the red power light on the cable adapter doesn't come on ) 4. Please tell us what PLC you are needing to communicate to. (CPU212 / CPU224 / ..) S7 200 224 dc/dc/dc 5. Use the "communications" functions to see if you can link the PLC and PC. got this working fine with a brand new PLC Hi. I would not classify the PLC as old.. CPU214 is old. From the questions I have asked I wanted to establish if the communication port of the PLC is still functioning. Marcjan has more positively moved into this direction with his post. Chances are there that there is a problem at the communication's port - the pin carrying 24V power does not supply power. That is the reason why your PPI programming cable is not working.. it it powered by the 24V and signal ground pins. Consider making up a short "adapter" cable between PLC and programming cable. Look at the PDF that Marcjan gave you in his post. The adapter cable will carry pins 1, 3 and 8 between PLC and PPI programming cable. Then on the PPI cable side: add signal ground (0Vdc) on pin 2 and 24Vdc on pin 7. PLC adapter PPI cable side cable side 1 ------------------ 1 3 ------------------ 3 8 ------------------ 8 Power Supply 0Vdc --------- 2 24Vdc -------- 7 I hope this helps you. w
William_B Posts: 5225 Rating: (1204)
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11/7/2014 10:17 PM	Rate (0)
Louis Springer Posts: 10 Rating: (0)	BIG PROGRESS MADE,BUT With your help I made a breakout cable and measured the 24 v coming out of my original s7 224 on the serial port . It measured about 22v, but when the usb/ppi cable was connected it dropped to 2volts. So there was obviously a problem there. I disconnected the plc end , connected a direct 24volts from the plc input power to the cable 24v. It worked! Had to change the baud rate, then I was able to communicate and upload the program...... SUBERB! BUT I can't view the program, it is password protected. "This POU is password protected from editing and viewing" . Will I still be able to download it to my brand new s7 224? Is there a way I can get around the password so I can see the program? It does let me see the Data Block, but not the program. thanks
Louis Springer Posts: 10 Rating: (0)
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11/8/2014 7:50 AM	Rate (0)
William_B Posts: 5225 Rating: (1204)	Louis Springer BIG PROGRESS MADE,BUT With your help I made a breakout cable and measured the 24 v coming out of my original s7 224 on the serial port . It measured about 22v, but when the usb/ppi cable was connected it dropped to 2volts. So there was obviously a problem there. I disconnected the plc end , connected a direct 24volts from the plc input power to the cable 24v. It worked! Had to change the baud rate, then I was able to communicate and upload the program...... SUBERB! BUT I can't view the program, it is password protected. "This POU is password protected from editing and viewing" . Will I still be able to download it to my brand new s7 224? Is there a way I can get around the password so I can see the program? It does let me see the Data Block, but not the program. thanks One of those good-news-bad-news situations. Louis, I am glad to hear you progress. The program you have uploaded seems to have "know how" protection. I call it a black-box program.. you can hook it up but can't see the inner workings. Make 100% sure if all the blocks are blanked off from view. Siemens standard libraries are blocked off by default. If the MAIN routine is blocked off, then it is difficult to add new program segements onto the program (not impossible.. check back if you need it). I am sure there are ways to crack open the block on the coding - but I will not help you on this. This is very usable. You can load it into the new CPU and use it. Caution: Make sure that there is no password loaded in the System Block before you load the program into the new PLC. You can download to the PLC and use as originally intended. My advice.. load the program on the new PLC and try to get the system running again. In the background you can prepare plan B - trying to get hold of the original builder(s). Plan C?.. re-engineer the control using any PLC of your choosing. My personal choice would be the S7-1200 when staying in the Siemens family. But there are some good choices in the other brands too. I hope my thoughts reach you positively. Greetings. w
William_B Posts: 5225 Rating: (1204)
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11/9/2014 2:15 AM	Rate (0)
Louis Springer Posts: 10 Rating: (0)	All is Good The POU password turned out to be the same as the password in the operational program ( which I did know), so I have been able to unlock the source code and view everything. The rest should be easy. I am so thankful that this forum exists! And I appreciate the help.
Louis Springer Posts: 10 Rating: (0)
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This contribution was helpful to 2 thankful Users Marcjan Min_Moderator

11/9/2014 6:45 AM	Rate (0)
William_B Posts: 5225 Rating: (1204)	Louis Springer All is Good The POU password turned out to be the same as the password in the operational program ( which I did know), so I have been able to unlock the source code and view everything. The rest should be easy. I am so thankful that this forum exists! And I appreciate the help.
William_B Posts: 5225 Rating: (1204)
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11/11/2014 3:21 PM	Rate (0)
Louis Springer Posts: 10 Rating: (0)	Hello again Can someone tell me what cable I need to connect my TD200 to my s7 200. The one in my mill is part of a cable bundle so I can't use it inside at my workstation. Thanks
Louis Springer Posts: 10 Rating: (0)
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11/11/2014 4:36 PM	Rate (0)
William_B Posts: 5225 Rating: (1204)	..it would be best if you make up your own cable. You can use what we have said before.. but attached is the official version (2004). This should do okay for testing offline to the machine the link between new PLC and TD200. Please note that there is no user program inside the TD200. The "program" comes from the PLC. w Attachment TD200_cable.pdf (437 Downloads)
William_B Posts: 5225 Rating: (1204)
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