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Very strange error

Created by: trenders at: 5/31/2012 5:33 PM (6 Replies)

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5/31/2012 5:33 PM	Rate (0)
trenders Posts: 6 Rating: (0)	Hi everybody, I'm getting a very strange (and annoying) error on my S7-1200: About once a week my installation goes to stop mode. In the event log it says: Hardware configuration error - Removal of hardware component restricted - CPU switches to stop Event ID:16#02:4042 This happens while everything is running in a locked cabinet?!? so I don't think a hardware removal is even remotely likely I'm running a 1214 CPU firmware version 2.2.0 I have some screenshots as attachment (it's actually a .rar file instead of a .zip) If anyone has a solution (or even an idea to what is happening), it would be very much appreciated Tim Attachment New folder.zip (287 Downloads)
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5/31/2012 6:27 PM	Rate (0)
LarryAm Silver Member Joined: 9/19/2011 Last visit: 10/11/2024 Posts: 140 Rating: (33)	For some reason I cannot download the file. What is your system configuration?

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5/31/2012 6:57 PM	Rate (1)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 11/8/2024 Posts: 15388 Rating: (2443)	From the diag buffer image it appears as if your connected modules are disconnecting or not fully connecting, causing the plc to halt. If you create a diagnostic error interrupt OB, it should stop the plc from going into stop mode, but it will not correct the problem with the hardware disconnecting. Those slide connectors may be vibrating loose or the din rail captive ends may not be fully tightened.
	science guy
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6/1/2012 4:32 PM	Rate (0)
trenders Posts: 6 Rating: (0)	CPU 1214 AC/DC/Rly 2x SM 1223 DC/Rly 3x SM 1222 Rly 24V power supply
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6/1/2012 4:39 PM	Rate (0)
trenders Posts: 6 Rating: (0)	I considered a loose/faulty connection, but all wires are firmly attached. Wiggling and/or shaking the whole setup (and I admit; even hitting the thing) doesn't result in a disconnection. Whenever the plc goes to stop all modules give "status green" Could it be noise or HF-signals on the power/ground lines?? If i create an error-catching OB, do I have to do something specific with it or can I just leave it empty? (never needed one before) Thanks for the quick replies, Tim
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6/1/2012 5:13 PM	Rate (1)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 11/8/2024 Posts: 15388 Rating: (2443)	trenders I considered a loose/faulty connection, but all wires are firmly attached. Wiggling and/or shaking the whole setup (and I admit; even hitting the thing) doesn't result in a disconnection. Whenever the plc goes to stop all modules give "status green" Could it be noise or HF-signals on the power/ground lines?? If i create an error-catching OB, do I have to do something specific with it or can I just leave it empty? (never needed one before) Thanks for the quick replies, Tim Ok, based on the testing you've done for the physical install, it sounds like it's noise or RF causing the plc to "think" it lost a connection to an external device. Once had a similar problem with a plc within 10cm of a drive. About once a week the plc would halt and the program would require reloading most of the time as it actually corrupted the plc code, or at least the plc thought so. Moved the drive and plc further apart and the problem magically went away. Perhaps you are seeing something similar or have a bad grounding problem or noisy power supply or field device periodically failing causing a power spike. All kinds of problems once you eliminate the easy As to the diag ob, no code is required, however, if you put in logic to detect the problem, you can cause the plc to more gracefully recover, or simply generate a hardware fault and shutdown, log it, and so on. Hope that helps get it fixed.
	science guy
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6/3/2012 1:02 PM	Rate (0)
trenders Posts: 6 Rating: (0)	huggy_d1 trenders I considered a loose/faulty connection, but all wires are firmly attached. Wiggling and/or shaking the whole setup (and I admit; even hitting the thing) doesn't result in a disconnection. Whenever the plc goes to stop all modules give "status green" Could it be noise or HF-signals on the power/ground lines?? If i create an error-catching OB, do I have to do something specific with it or can I just leave it empty? (never needed one before) Thanks for the quick replies, Tim Ok, based on the testing you've done for the physical install, it sounds like it's noise or RF causing the plc to "think" it lost a connection to an external device. Once had a similar problem with a plc within 10cm of a drive. About once a week the plc would halt and the program would require reloading most of the time as it actually corrupted the plc code, or at least the plc thought so. Moved the drive and plc further apart and the problem magically went away. Perhaps you are seeing something similar or have a bad grounding problem or noisy power supply or field device periodically failing causing a power spike. All kinds of problems once you eliminate the easy As to the diag ob, no code is required, however, if you put in logic to detect the problem, you can cause the plc to more gracefully recover, or simply generate a hardware fault and shutdown, log it, and so on. Hope that helps get it fixed. Thank you for the feedback! Not exactly the 'quick fix' I was hoping for, but I didn't really expect there to be one. Since there's no HF source nearby that I know of, I'll be checking all ground connections first, install the ob and change startup options to 'Warm restart -RUN'. Consider this thread closed till further notice
trenders Posts: 6 Rating: (0)
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