Hello everyone, I need help with an issue I'm experiencing after upgrading my L32E V16 controllers to L33ER V31.011. The problem arises when the DCS communication link to the L33ER controller (which communicates via an ALE111 card over ethernet/IP) is lost intermittently, resulting in a fault on the DCS (A320 - 'connection shutdown when transmitting to the connected socket'). This issue only occurs with the updated L33ER controllers, while the previous L32 controllers had no such problems. Despite the communication loss between the PLC and DCS, I can still ping the PLC and ALE cards without any issues, and Studio5000 does not disconnect. Additionally, there are no fault counts in the controller diagnostics that indicate any issues. Upon further investigation, I noticed recurring messages in the advanced diagnostics section of the controller's webpage, specifically 'CipStatus: Generated on device' and 'Connection timeout notification'. These messages appear every 52 minutes but do not seem to directly correlate with the DCS communication fault. I tried upgrading the firmware to the latest version V33, but the recurring messages persist. Interestingly, re-downloading the properties of the ALE111 card temporarily stops the spamming of these messages and resolves the communication dropouts on the DCS. However, cycling the power to the PLC clears the event log but reintroduces the recurring messages and DCS communication issues. I am uncertain if the event log spamming is a normal occurrence or a sign of an underlying issue. Any insights or suggestions would be greatly appreciated. Thank you, SJ.
Are there any obstacles preventing you from testing or using the most recent version, 33? While there may not be a quick solution to the issue at hand, exploring the newest update could provide valuable insights and improvements.
Thank you for your response. I attempted using V33 in the controller and installed a new ALE111 card in the DCS, but unfortunately, I am still encountering issues. Despite triggering a different DCS fault, I am consistently observing the same event log messages in the PLC through the web browser.
Are you equipped with an Ethernet TAP to collect Wireshark traces and troubleshoot issues effectively?
I have not had the opportunity to check it yet, as I am currently off site. However, I will address this issue soon. If anyone has any prior knowledge or experience with the messages in the event log of the L33ER controller, it would be greatly appreciated.
The log indicates a timeout error with the connection. There are numerous factors that could contribute to this issue, making it difficult to determine a specific cause. Additional information is needed to accurately diagnose the problem.
Hello SJ, it seems like a complex issue. One thing I've noticed while working on L33ER before is that if you change ALE Manual View from "UES" to "Device Properties", you can sometimes get more detailed information about what's causing the fault. Regarding the recurring messages, it's difficult to conclude whether it's directly causing the communication loss or not. It's crucial to check the correct configurations set within the DCS and the PLC. If you can temporarily stop the recurring messages and the DCS communications functions well, then this might be the cause. Also, you could try a complete factory reset or replacing the ALE111 card to exclude that as a potential source of the issue. Just throwing out some possibilities; hope it helps and you find a resolution soon!
Hi SJ, your predicament sounds challenging, and I can understand your concern. The behavior you're observing is not typical, and I suspect it might be a compatibility issue stemming from the upgrade. It would be helpful if you could check the compatibility of the ALE111 card with the L33ER Controller V31.011. You have mentioned that re-downloading the properties of the ALE111 card seems to temporarily mitigate the issue - suggesting that the card and controller might be having difficulty synchronizing. As a troubleshooting step, try replacing the existing Ethernet cable and check if any firewall settings were unintentionally changed post upgrade. In parallel, consider reaching out to Rockwell's customer support for further technical assistance.
Hey SJ, it appears you've approached this issue from several valid angles. The symptoms you're observing seem to point to a possible incompatibility between the new controllers and the old equipment, or even a firmware bug. One step you might try, if you haven't already, is thoroughly checking your Ethernet/IP settings. While you can ping the PLC and ALE cards without issue, there might be some optimizations needed for the continuous flow of information. Also, consider reaching out directly to the manufacturer's technical support, as they may have additional insights or a possible patch if it's indeed a bug in the firmware. And lastly, it's worth checking if any other users have encountered a similar problem in online user groups or forums. They might have found workarounds or solutions for this issue. Good luck!
Hey SJ, sounds like a complex problem. Given that the issue appears after the upgrade, there might be some compatibility issues between the newer L33ER controllers and the DCS. Double-check if the DCS can fully support these controllers and whether there are patches or updates available on the DCS side. Also, consider reaching out directly to Rockwell for support. They may have more information about this specific issue, especially if it's something they have encountered before. Another thing to look into is your router and switch, since they also play a crucial role in maintaining a stable connection. Just some thoughts - hope that helps.
Hey SJ, it sounds like you’re really deep into troubleshooting this issue! Given that the problem started after upgrading to the L33ER, it might be worth checking if there are any compatibility notes or known issues between the DCS and the new controller firmware. Since re-downloading the ALE111 properties provides a temporary fix, it could point towards how the configuration of that card interacts with the new firmware. I’d also suggest looking at the Ethernet settings on both the L33ER and the DCS; perhaps there’s a timeout or keep-alive setting that needs adjustment. Hopefully, you can get it sorted out soon!
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Answer: Answer: The intermittent communication loss could be related to the firmware update or the properties of the ALE111 card. There may be issues with compatibility or configuration settings causing the problem.
Answer: Answer: Troubleshooting steps could include checking for recurring messages in the advanced diagnostics section of the controller's webpage, upgrading firmware to the latest version, and re-downloading the properties of the ALE111 card to temporarily resolve communication dropouts.
Answer: Answer: These messages may indicate underlying issues causing the recurring communication faults. It's essential to investigate further to determine the root cause and potential solutions to prevent communication disruptions.
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