S7 414-2 G03 to K05 replacement

Here is our situation:

We have a S7 414-2 (6ES7414-2XG03-AB0) Firmware V3.1 No memory card that has serious problems with the MPI and DP ports. I have personally soldered the ports back onto the board a few times just to keep us running.

I found a NEW sealed in the box S7 414-2 (6ES7414-2XK05-0AB0) Firmware V5.3 No memory card in our storeroom. I tried modifying our program (Replace Object) with the new CPU. then downloaded the program with hardware and all. 

But noticed that I have NO power on the Profibus cable connector with this CPU. The profibus connector has lights for PWR, TxD, Term, ERR but they are all dark no matter what I do. When going online none of the connected modules are available. The diagnostic data shows them as Configured but in "Current" shows not available.

I'm sure I have done something wrong, forgot to do something or this CPU might not work for a direct replacement.

Please someone just tell me what I've done wrong or what I need to do to get this to work!

Thank you in advance!!

Dear TKME,

Please share the program or the hardware configuration screen shots so that we can help you.

Thanks.

Person

Dear TKME,

Please share the program or the hardware configuration screen shots so that we can help you.

Thanks.

 This is the offline hardware config. I can only give you the offline because we currently have the old G03 back in the system after I soldered it again. When viewing this online on the K05 it is the exact same with the exception of every item having the red /  over the icon for each device on the Profibus DP network showing that they are not reachable.

I spoke with 2 different Siemens representatives. One told me that I should have NO problems with the K05, it is a direct successor and basically all I have to do is download the HW configuration and Program. Once that is done the PLC will enable the Profibus module and all will be good. But that is not what has happened. I downloaded everything and it all checks out except NO Profibus. 

The other representative said that because we don't have a memory card for the K05 that it will never work.

Both work for Siemens... I don't know what to think at this point. All I know is that I need something to work or my line will be down when this one decides to break again. I have soldered this thing 3 times now just to keep it running until I can get a working replacement.

A little more info:

The first attempt to replace this bad G03 was with a Refurbished G03 from one of our vendors. I was not able to communicate with it at all so we chalked it up to a bad refurbished part and sent it back. I then found this K05 in an obscure location in our storeroom, no one knew it was even there. I looked up the difference in the G03 and K05 and found a forum post on here that stated the K05 was a direct successor to the G03. 

So I tried it. After downloading the HW config and program to it I had no power to the Profibus. I noticed in the hardware configuration that it was still saying G03 for the CPU. So I saved project as a different name, to preserve the known good project, and then Replace Object to the K05 with the proper firmware that is on the K05 CPU. I then downloaded again and verified everything took. Still NO power to the Profibus. It's like it will not enable the module. I can't believe that I have a bad CPU; this was a NEW Sealed in the box K05. I broke the seal myself.

Once this did not work, and time was getting short for me to have the line back up and running, I decided to solder the G03 again and pray that it works. Once I finished soldering I connected everything up and turned it on. It immediately gave power to the Profibus, just like it has every other time after my repairs. Even without / before I download it. It to does not have a memory card with it. After downloading I was able to get it to work again but am desperately in need of a more permanent fix!

I then submitted a trouble ticket to Siemens and spoke with a representative that told me specifically that the K05 was a direct successor to the G03 and I should have no problems after downloading.

Another Siemens representative was at our facility for a separate project quote meeting, while I was not there, and my boss asked him about the K05. He told my boss that it will not work because we do not have the memory card. This didn't sit right with me because I can download everything and view it online. But because my boss heard it from a Siemens representatives' mouth directly...

We have a NEW Sealed in the box G03 coming in any day now, but I fear the same result with NO Power to the Profibus. My biggest concern is that I am missing something, that I am making a mistake and that it's me that is making this more difficult than it should be. If the first Siemens representative is correct and it should enable the Profibus once the HW config and program is downloaded then why does the Broken G03 power the Profibus with NO program? And why isn't the download enabling the Profibus? 

What am I missing???

Hi TKME

I don't know if you've managed to sort this problem out as it was posted a while back. I myself have just replaced some G03 cpu to K05 and it worked fine for me and none of them have memory cards in them. This is how i went about replacing it (although as you've said yours could be hardware related).

-Upload project from G03 (make a back up program as you did)

-Open hardware config, right click on the G03, replace object with K05 (insert version number), save and compile.

-Exit Hardware config.

-Click on CPU, then connections, this opens netpro. When is opened up it should show the cpu as orange. I save and compile and ask netpro to check everything. If this comes back that the connections are ok.

-Close netpro, highlight the simatic station and download and thats it.

Although ive used the above steps myself and its worked 99% of the time i have had a few issues where before downloading the simatic station ive had to download the connections first before exiting netpro and then downloading the station. Also ive changed a configuration before (a replace object from a K05 to a L07) opened up online for the program to still think it was a K05 to resolve this ive found it it better to open online a reset the cpu (to clear what is on the cpu and start a fresh)

Many thanks

Ant