Hello everyone, I currently have numerous Micros deployed in the field, including models 810, 820, and a couple of 850, totaling about 12 units in operation 24/7. Recently, I encountered an issue with one of these units for the first time. This particular Micro is controlling a switching conveyor for lane sorting, which includes a 1 h.p. 600VAC motor on a VFD, two 24VDC magnets, a photoeye, and a signal from a checkweigher. Upon startup, it was discovered that the conveyor was not switching, and the Micro displayed a solid RED fault light. After attempting to power cycle the unit multiple times without success, I decided to replace it with a new unit, which has been running smoothly since. Now, with the failed Micro on my desk, I am unable to communicate with it. The ENET light is solid GREEN, indicating that it should have a configured IP address, but I am unable to locate it. Even after trying to ping the address assigned to it a year ago, setting the computer IP to the default 169.254.XXX.XXX with a subnet of 255.255.0.0, and checking with Wireshark, I am still unable to establish a connection. It is worth noting that the SD light is also on solid GREEN, despite the absence of an SD card in the unit. The controller seems to be in a bricked state, as it immediately goes to this state upon power up without attempting to enter run mode or flashing the ENET light. What are your thoughts on this situation?
One effective approach is to create an SD card containing specific information by making a file named "configmefirst.txt" in the root directory. The content of this file should be as follows: [PM][IPA=192.168.2.100][SNM=255.255.255.0][GWA=192.168.2.1][END]. Once the SD card is prepared, insert it into micro820, power cycle the device, and check if it is visible. Ensure your laptop is on the same network to establish a connection. Start by updating the firmware and proceed with testing. Best of luck!
I am going to give that a shot once I grab a MicroSD card. I will be sure to share my results after trying it out. Thank you for the helpful advice!
The image depicts the contents loaded onto the SD card. Despite multiple attempts, the issue persists with a solid RED fault light, a solid Green SD light, and a solid Green ENET light with no communication established. Thank you.
Are you connected directly to the programmable logic controller (PLC)? If your PC displays a network error in the corner of your screen, try connecting to a router. Access the router's website to check for active nodes. This troubleshooting method can help resolve connectivity issues efficiently.
I connected my PC directly to the Micro and also attempted to use a 5 port switch, however, it did not yield any noticeable results. I may try using a router in order to potentially salvage the unit, although I currently do not have one available. I will purchase a low-cost router with this capability soon. Thank you for your recommendations.
Hi there, it sounds like a tough situation. From what you've described, it seems like there might be an issue with the Micro's firmware which could lead to its failure to communicate and getting stuck in this 'bricked' state. Since it immediately goes to this state upon power up, it disregards the normal bootup and diagnosis process, making it hard to diagnose the problem. Additionally, the SD light remaining solid green without an SD card present might signal an issue with the Micro's internal controls. As a side note, have you checked that there's no physical damage to the Micro and its Ethernet port? If it's a firmware issue, it might be possible to do a firmware reset or update (if you can establish communication), but that's rarely a guarantee. Also, make sure to keep the replaced unit's settings documented just in case. It could be a one-off situation or point to recurring issues with these units deployed in similar environments or settings.
It definitely seems like there's some kind of internal issue with your Micro. The fact that you can't communicate with it, and the unusual SD light status, strongly suggest a hardware or internal firmware problem. I'd suggest reaching out directly to the manufacturer's technical support if you haven't already. They might guide you through a hard reset or firmware refurbishment, or possibly even identify a known issue with this specific model. It's also worth cross-checking with the other Micro units you have if they are behaving the same or differently. It would help in identifying if this is a standalone issue or the start of a possible sequence. Great troubleshooting so far, though!
It seems like you've tried most of the basic troubleshooting steps and it's quite strange that the ENET light is constant green even though you're unable to locate the IP. It's also peculiar that the SD light is also green without an SD card inserted. I suspect there might be an issue at the hardware level, possibly a fault in the controller board. You could try a factory reset to see if you're able to re-initialise the Micro. If not, being unable to communicate with the device will make further software troubleshooting steps nearly impossible. It might be more efficient to contact vendor support at this point, as they may be able to offer replacement if the unit is still within warranty.
It sounds like you've done a thorough job troubleshooting the microcontroller! Given that the ENET light is solid green but you're unable to communicate with it, it could be that the firmware is corrupted or some internal memory issue is happening. Have you tried performing a factory reset? Sometimes, units get locked up like this, and a reset can help clear things out. If the SD card light is also indicating a solid green, that could mean it's stuck trying to boot from a nonexistent card. If this continues, contacting tech support for a deeper dive might be worth considering—they may have specific recovery procedures for these situations. Good luck!
It sounds like you’ve done a thorough job troubleshooting that Micro! Since the controller is stuck in that bricked state and the ENET light is solid, it might be an issue with the firmware or internal corruption. Have you tried a factory reset, if that's possible for your model? Sometimes that can bring a unit back to life after a fault. Also, double-check if there are any firmware recovery modes specific to your model; some devices have hidden methods for restoring functionality. If all else fails, reaching out to the manufacturer's tech support could shed some light on this especially if it's still under warranty. Good luck!
It sounds like a frustrating situation! Given the solid GREEN SD light without a card could indicate that the firmware might be corrupted, leading to the controller's inability to boot up properly. Since you've already tried standard troubleshooting steps like pinging and checking the settings, I’d recommend checking if there's a way to perform a factory reset. Sometimes, connecting through a serial interface can also help regain access for troubleshooting. If all else fails, reaching out to the manufacturer's support could provide deeper insights or possible recovery options for that unit. Good luck!
It sounds like you've done your due diligence in troubleshooting that Micro! The solid GREEN ENET light usually suggests it's configured, but the lack of response is definitely puzzling. Since the SD light is also solid GREEN, maybe it’s a sign that the firmware is corrupted or the unit has entered a locked state due to some internal fault. Have you considered trying to do a hard reset, if that’s an option? Also, sometimes, manufacturers have specific recovery or reset procedures you can follow that might help re-establish communication. If all else fails, reaching out to tech support for a deeper dive could be beneficial; they might have seen similar issues before.
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Answer: - The conveyor not switching and displaying a solid RED fault light could indicate a critical issue with the unit that needs troubleshooting.
Answer: - If the Micro820 unit is unresponsive despite showing a solid GREEN ENET light, troubleshooting steps such as verifying the IP address, using Wireshark, and checking for connectivity issues can be attempted to establish a connection.
Answer: - The SD light being on solid GREEN despite the absence of an SD card could indicate a potential issue with the controller being in a bricked state, requiring further investigation and troubleshooting.
Answer: - The Micro820 unit immediately entering a bricked state upon power up without entering run mode could be caused by various factors such as internal hardware failures, software corruption, or configuration errors that need to be addressed for proper functionality.
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