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S7-1200 CPU fails to RUN

Created by: RahulYeasir at: 3/14/2011 5:44 PM (9 Replies)

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3/14/2011 5:44 PM	Rate (0)
RahulYeasir Posts: 4 Rating: (0)	I'm facing a strange problem with a micro-automation project done in Siemens S7-1200 PLC. The small program I wrote compiles perfectly, and downloads successfully. But the CPU does not go into RUN mode. Diagnostics buffer shows "New startup inhibit information - Current CPU operating state: STOP". Also reports, "Pending startup inhibit(s): - HW configuration inconsistent (TIA portal activity) - Manual warm start required." I did the HW configuration alright, I know. Diagnostics status shows "The loaded configuration and the offline project are not identical. The online and offline module configuration data are different. Order number: 6ES7 214-1AE30-0XB0 Configured order number: 6ES7 214-1AE30-0XB0" The reported numbers are exactly same, I can't see why it's saying that the configurations are different. I tried to press the "RUN" button in online panel, I saw network activity in the CPU (Rx/Tx LEDs), RUN/STOP, Error, Maint LEDs blink. But the CPU does not start and repeats the above messages in diagnostics. I tried memory reset (MRES in online panel) also. Same result. I also tried to download a new project. That also behaved in this way. Most importantly, I changed the CPU, and the new CPU also did this same thing, which surprised me very, very much. Anyone experienced similar behavior? All helps are appreciated. Regards Rahul Attachment error.JPG (1743 Downloads)
RahulYeasir Posts: 4 Rating: (0)
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3/14/2011 5:55 PM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 9/12/2024 Posts: 15180 Rating: (2417)	Some of things to look at.. 1. With the memory card, you can update the firmware. If you already did so, wonderful. 2. With the memory card, it stops the CPU and attempts to run programs on the card. Do not load programs to the memory card - at least for the small program you are running. 3. The hardware, do you have any additional modules? 4. Do you have any of the PLC I/O configured to detect things like power, wire break, short circuit, over/under range? Uncheck all those boxes. It does not appear to be the cause of the problem, but just one thing to be aware of. 5. When you look at the PLC, do you have an error indicator? 6. The best suggestion though is to delete the CPU, and add it back. Compile ALL (not just software), and reload. My guess is the hardware compile has an error or a problem. Lastly, in your attached image, your "MAIN" OB shows it is different than the online version. That does not match what your original post indicates. Just something to think about as it may be you think you loaded successfully but in fact did not. Look at the errors when you compile and when you load. If there are any, it may not switch to RUN mode.
	science guy
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3/15/2011 3:18 AM	Rate (1)
primus 1 Posts: 45 Rating: (4)	As they say a picture is worth a thousand words. I see that at the bottom right of the picture you have anit virus installed double click on the shield and verify your firewall is off and go to control panel and check the firewall. Try this, check your computer and see if you have a firewall active. When active the computer establishes minimum communications. For me norton firewall was active deactivating allowed me to upload the CPU configuration and down load the program. Then go to run mode. Have A Good Night Tom
primus 1 Posts: 45 Rating: (4)
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3/15/2011 6:27 PM	Rate (0)
RahulYeasir Posts: 4 Rating: (0)	Thanks much Tom, for your advice on firewall. I've checked the firewall settings, and it was OFF. I've disabled the anti-virus also. The issue has not been solved, though.
RahulYeasir Posts: 4 Rating: (0)
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3/15/2011 6:38 PM	Rate (0)
RahulYeasir Posts: 4 Rating: (0)	Thanks huggy_d1 for your time. >> 1. With the memory card, you can update the firmware. If you already did so, wonderful. I have not yet upgraded the CPU firmware, which is 1.0.0. Version 1.0.2 is available in Siemens site. Will there be any issue with TIA 10.5 if I upgrade CPU firmware? TIA 10.5 only shows version 1.0 in the hardware catalog. >> 2. With the memory card, it stops the CPU and attempts to run programs on the card. Do not load programs to the memory card - at least for the small program you are running. Ok. >> 3. The hardware, do you have any additional modules? No, there are no additional modules. >> 4. Do you have any of the PLC I/O configured to detect things like power, wire break, short circuit, over/under range? Uncheck all those boxes. It does not appear to be the cause of the problem, but just one thing to be aware of. No. >> 5. When you look at the PLC, do you have an error indicator? The ERROR led goes yellow. Does not blink, and does not go red. >> 6. The best suggestion though is to delete the CPU, and add it back. Compile ALL (not just software), and reload. I have tried deleting the CPU, and adding back. Did not work. However, how do I do a "Compile ALL"? >> My guess is the hardware compile has an error or a problem. Is there any way to explicitly download the "hardware configuration" into the CPU? I thought that happens automatically, after everytime I edit the configuration.
RahulYeasir Posts: 4 Rating: (0)	Last edited by: RahulYeasir at: 3/15/2011 6:40 PM
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3/15/2011 9:04 PM	Rate (2)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 9/12/2024 Posts: 15180 Rating: (2417)	I would urge you to update the firmware. If you right click on the cpu project, you get the options to compile all, and download all. If you are getting good feedback on the "info" window at the bottom of the portal software with no errors or warnings, your firmware may be out of date and not allow an instruction. Last thing would be to make sure you have the latest service pack (SP2) installed. The antivirus might be the problem, but it is not likely if you have ever been successful at communicating with the PLC.
	science guy
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3/16/2011 7:36 PM	Rate (0)
RahulYeasir Posts: 4 Rating: (0)	huggy_d1 If you right click on the cpu project, you get the options to compile all, and download all. That has done the trick Compile ALL and Download ALL has solved my problem. Thanks a lot Huggy. I was under the impression that, when I edit the hardware configuration of the project, TIA portal automatically downloads this new hardware config into the CPU. If not automatically, then atleast during the next software download. But, that's not the case. Thanks everyone for helping me out here.
RahulYeasir Posts: 4 Rating: (0)
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3/17/2011 3:38 PM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 9/12/2024 Posts: 15180 Rating: (2417)	Glad you got it loaded and running!
	science guy
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4/11/2022 11:03 AM	Rate (0)
electronicsengine... Member Joined: 3/23/2022 Last visit: 4/11/2022 Posts: 1 Rating: (0)	thanks tom I did what you said and the problem was solved.

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9/30/2022 12:44 PM	Rate (0)
alex_g89 Member Joined: 6/14/2022 Last visit: 1/30/2023 Posts: 1 Rating: (0)	Thanks! I had the same issue and solved it this way.

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