Greetings,

I have recently run into a rather specific issue with AS-OS communication, in which previously working connections are stuck on the "is being set up" status (shown in NetPro for the AS projects).

First a little background:

The multiproject contains the following:

1) CLIENT project (two clients; one reference and one referencing)

2) AS1 (CPU 410-5H with CP 443-1)

3) AS2 (same)

4) AS3 (same)

5) ES project (never really used on site; used off site for OS simulation)

6) OPC station

7) SERVER project (one main and one redundant server pair)

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The project was first developed off site, without any work on the AS2 and AS3 project (planned for later years)

This worked without issue. AS1 was connected via one of the CP ports to the PLANTBUS making it part of the same subnet the servers and clients were on. An S7 connection was established between the AS and both OS (main and redundant) in NetPro. All PLANTBUS subnets from each individual project were merged into GLOBAL-PLANTBUS.

We took a copy of the on site project and continued developing the AS2 project. A new subnet was created, it was merged. On the day we replaced the on site project with the new updated project, S7 connections were added between AS2 and both OS. Everything was stopped, and all previous and new parts of the multiproject were compiled and downloaded.

Immediately something was not right:

1)The clients gave a green light for server pair connection, however none of the tags were available, not for AS1 nor AS2.

We then recompiled and redownloaded AS1 and OS projects.

2)AS1 functionality was restored, HOWEVER, clients were now reporting only the main OS server was OK. (redundant server was red in the interface you get when you click the server connection square in the upper right corner) There was still no communication between servers and AS2.

We then proceeded to recompile and redownload projects ad nauseam. Nothing changes.

AS1 has a running connection with mainOS and is stuck on "is being set up" with stbyOS.

AS2 is stuck on "is being set up" with both OS.

Clients report only mainOS OK.

Upon going to the redundant server and attempting to close and deactivate the project it hangs indefinitely during deactivation on "Data Manager RunTime".

This led me to the following post: postAboutOSRuntimeHangingOnDeactivation

I'm not sure if this applies to our project exactly since we use PCS7 V9.1 SP2 but trying the delete DCF procedure is something we will try the next time the plant stops (they are currently actively running AS1 for production).

Also, upon going to the mainOS I was greeted with the attached message. Could this actually be some kind of license issue? I am not aware of OS servers requiring special licenses for multiple AS connections. If this is the case, perhaps it only applies to S7 connections? Would switching to TCP/IP help?

Currently we are waiting for the next stand-still on site to actually do anything about this. In the meantime I would greatly appreciate any pointers. 

Best regards,

Nikola

I've realised now that one of the PCS7 manuals states that if multiple PC stations are communicating with a singular AS via S7 connection the named connections should all have the same name.

In NetPro the original two connections from AS1 to main and redundant OS never had the same name to begin with. This has previously worked however, so I am a little confused. (one was named OS_connection and the other stbyOS_connection).

Now that a second AS has hit the network, could this be causing some kind of collision or similar issue that would make the connections hang on "is being set up"? I presume these connection names cannot be changed and downloaded without putting the AS into STOP mode.

Again, any feedback is greatly appreciated.

Best regards,

Nikola.