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PLC totally stuck

Created by: Kragic at: 8/11/2012 11:00 AM (16 Replies)

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8/11/2012 11:00 AM	Rate (0)
Kragic Posts: 18 Rating: (1)	I received a dozen of CPU 1211 AC / DC / Rly with firmware version 3.0. During transfer operations and run all looked good. Next day after power on, PLC display LED indication: RUN / STOP yellow, continuously ERROR red, continuously MAINT yellow, flashing Such LED indication I don't found in books or on the forums. PLC is not available online, transfer with empty MC card does not help (also, other combinations with card). I just can't get reset to factory settings. Even on other PLCs appeared the same symptom, while the other half works fine with the same program. The error appeared accidentally and without rules, but allways after power-on cycle. My program uses a Web server and data logging.Previously I was developing a program using PLC S7-1212 and made a 'change device' in the TIA-portal before downloading.Maybe it was better to open a brand new project for the new PLC's, and move programs from old project. Perhaps the cause of these errors lies in data logging. I use the internal PLC storage. For the simulation, i write to data log frequently and continuously, triggered with timer- every 2 seconds, therefore memory corruption may occur during power-off phase. -What is the explanation of these LED indications? -Would it help to dowload firmware via MC card? -Can anyone help?
Kragic Posts: 18 Rating: (1)
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8/12/2012 2:05 AM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 4/9/2021 Posts: 10421 Rating: (1722)	Kragic I received a dozen of CPU 1211 AC / DC / Rly with firmware version 3.0. During transfer operations and run all looked good. Next day after power on, PLC display LED indication: RUN / STOP yellow, continuously ERROR red, continuously MAINT yellow, flashing Such LED indication I don't found in books or on the forums. PLC is not available online, transfer with empty MC card does not help (also, other combinations with card). I just can't get reset to factory settings. Even on other PLCs appeared the same symptom, while the other half works fine with the same program. The error appeared accidentally and without rules, but allways after power-on cycle. My program uses a Web server and data logging.Previously I was developing a program using PLC S7-1212 and made a 'change device' in the TIA-portal before downloading.Maybe it was better to open a brand new project for the new PLC's, and move programs from old project. Perhaps the cause of these errors lies in data logging. I use the internal PLC storage. For the simulation, i write to data log frequently and continuously, triggered with timer- every 2 seconds, therefore memory corruption may occur during power-off phase. -What is the explanation of these LED indications? -Would it help to dowload firmware via MC card? -Can anyone help? If you logon to the plc and view the online diagnostic buffer, what do you find? Do you have a diagnostic fault handler to keep the plc from crashing for most hardware and software problems? Did you devote a bit more communication time from the default of 20% to maybe more like 40%? Any reason your demanding application is using the least capable low-end PLC?
	science guy
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8/12/2012 9:18 AM	Rate (0)
Kragic Posts: 18 Rating: (1)	If you logon to the plc and view the online diagnostic buffer, what do you find? I said that the PLC can no longer be accessed over the network. I tried pinging with no results. I also scanned the network with the Advanced IP Scanner v2 - with no results. Why use a low-end PLC: it will be installed over 100 PLCs for the simple purpose of just pieces counting on several machines. Obviously not all PLC's will be on the same network. Server service takes over the cyclic data-logging CSV files and write into the database. At this point you should find an explanation of the LED indications It is not clear to me that Siemens can't provide exit from this catastrophic bugs.
Kragic Posts: 18 Rating: (1)
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8/12/2012 1:16 PM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 4/9/2021 Posts: 10421 Rating: (1722)	Kragic If you logon to the plc and view the online diagnostic buffer, what do you find? I said that the PLC can no longer be accessed over the network. I tried pinging with no results. I also scanned the network with the Advanced IP Scanner v2 - with no results. Why use a low-end PLC: it will be installed over 100 PLCs for the simple purpose of just pieces counting on several machines. Obviously not all PLC's will be on the same network. Server service takes over the cyclic data-logging CSV files and write into the database. At this point you should find an explanation of the LED indications It is not clear to me that Siemens can't provide exit from this catastrophic bugs. I would urge you to submit a Support Requestand see if they can get your systems back online. I am just a regular end-user like yourself, so I also want to see your issue resolved too -before it happens to one of my deployed CPU's using FW3.0. The firmware is upgraded via the profinet port, so unfortunately, I am not aware of any MMC method available to perform a firmware update or CPU reset via the memory card. Try updating the system overhead to 40% for testing on one of the remaining PLCs and see if it helps those remaining PLCs, plus add a diagnostic error handling OB to help avoid most shutdown issues.
	science guy
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8/13/2012 11:53 AM	Rate (0)
Kragic Posts: 18 Rating: (1)	Thankshuggy_d1 I have sent my submit on Support Request. It seems there is nobody on this forum who can correctly answer. In any case I will post how I solved this problem. One solution is to return the goods, but we'll see...
Kragic Posts: 18 Rating: (1)
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8/13/2012 1:46 PM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 4/9/2021 Posts: 10421 Rating: (1722)	Kragic Thankshuggy_d1 I have sent my submit on Support Request. It seems there is nobody on this forum who can correctly answer. In any case I will post how I solved this problem. One solution is to return the goods, but we'll see... The PLC is new, and the status LEDs do not match the manual's descriptions. Easy to understand that someone has to be first at finding the [new]problems. I'm sorry it had to be you.
	science guy
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8/13/2012 4:14 PM	Rate (0)
Kragic Posts: 18 Rating: (1)	They called me from the Siemens Technical Support ... Unfortunately I'm not the only one with this problem ... Development Department has taken steps to solve this problem I hope that everything will be fine at the end
Kragic Posts: 18 Rating: (1)
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8/13/2012 4:43 PM	Rate (0)
spokiir Posts: 13 Rating: (0)	please update here what was the solution when you have it. gl
spokiir Posts: 13 Rating: (0)
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8/13/2012 4:44 PM	Rate (0)
0_Einstein Diamond Expert Joined: 7/7/2010 Last visit: 4/9/2021 Posts: 10421 Rating: (1722)	Kragic They called me from the Siemens Technical Support ... Unfortunately I'm not the only one with this problem ... Development Department has taken steps to solve this problem I hope that everything will be fine at the end Thanks for the update. I am using one of the FW 3.0 S7-1215's with more being integrated this week and planning more in the future. Hopefully FW 3.1 will fix this problem. (I am simply assuming it can be corrected with a firmware change and they will issue a 3.1 instead of a 3.0.1) Please keep us updated of progress on this. What is the reason for the LEDs? Something they need to document in the system manual, or something they need to fix, or both?
	science guy
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8/13/2012 5:09 PM	Rate (0)
Kragic Posts: 18 Rating: (1)	huggy_d1 you're not in danger They told me that the problem was recorded only in family 1211 and 1212 (in principle the same CPU) This LED indication is not planned, and come as a result of an unknown state of the CPU
Kragic Posts: 18 Rating: (1)
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