Greetings to all readers! Our SMT line is equipped with a conveyor system that lost its programming due to a dead battery. Out of the three conveyors on the line, the one that needs reprogramming dates back to 1997, while the other two were manufactured in 1998. Each conveyor contains 90 Micros, specifically the IC693UDR005FP1 model. Our goal is to extract the program from a functioning conveyor and transfer it to the one in need of repair, as we unfortunately do not have backup copies of the programs.
Various attempts have been made to achieve this task, including using a USB to serial converter along with Proficy Machine 9.5 on a Windows 10 computer. While successful in uploading the hardware configuration, issues arise when attempting to transfer the logic or forced values, resulting in the error message: "Error 8097: Server Error - Transfer Error: Remote disconnect has occurred [0x6A][0x02]".
Another approach involved using LM90_9.05 on a VirtualBox VM running Windows XP, utilizing the DB9 serial port on the computer connected to a MOXA TCC-100I RS232 to RS422 converter and a custom cable to link to the PLC. Although able to access the configuration, connecting to the ladder logic or reference tables posed challenges, with LM90 displaying a "
If you are attempting to upload a program while the PLC is operational, it is recommended to only upload the program logic when the CPU is stopped. The error code referenced in the Proficy help file may indicate firmware issues with certain 90-30 models, although this may not be relevant to your specific situation. Are the project names consistent across all three conveyors? When troubleshooting this issue, did you create a new project folder from scratch or utilize an existing one? These questions stem from a potential concern that the folder being used may not correspond to the PLC model in use.
When the CPU is stopped and only the logic is uploaded, similar results are observed. To begin this process, a new TEMP folder was created. Although the three PLC program names are not identical, they share similarities.
Logicmaster's approach of using the project name "TEMP" to manage PLC uploads when the project name is unknown is a common practice. It is uncertain whether this method was retained in VersaPro and Proficy. For troubleshooting, consider accessing the "Status" window in Proficy to identify the PLC name and version. Additionally, determining the firmware version on the CPUs can help in identifying any known issues related to the problem at hand. It is crucial to note that if any of the three CPUs are unable to upload logic, the issue may be linked to the CPU with the failed battery, which may not have any viable data to upload. In cases where a PLC lacks a program due to a failed battery, the program name in Proficy's status window may display as "HHP".
Yes, you are correct that I was unable to upload from any of the three CPUs. It turns out that the program was still stored in the CPU despite the software fault. The CPU was set to start up in its last state, which caused it to begin in stopped mode each time the machine was powered on. To resolve the issue, I had to clear the fault, start the CPU, and power cycle the machine. Now it is back up and running. However, my objective remains to extract the programs from these CPUs. Additionally, we recently retrieved a 4th conveyor from storage, which was manufactured in 1998. When I connected the setup to this conveyor, I was able to successfully upload the entire program at once. It is noteworthy that this 4th conveyor's 90 micro is operating on "software version 3.01 build 31A1", while the other three conveyors are operating on "2.01 build 0". Could this difference in software versions potentially be causing the connection issue?
The release of 2.01 dates back to April 1996 and required Logicmaster software release 6.01 or higher. Release 3.01 dates back to August 1997 and required Logicmaster release 8.01 or higher. Both versions were originally programmed using Logicmaster software, as VersaPro was not introduced until 1999. Therefore, the most reliable option for successful uploads would be Logicmaster. According to the Logicmaster 9.02 release notes (GFK-1412E), it was specifically designed and tested to be compatible with Series 90 Micro release 2 and earlier. However, some of the new features in Logicmaster 9.02 may require CPU firmware upgrades for full functionality. I'm beginning to question the connection between your PC and the PLC. I have encountered difficulties using Logicmaster with a USB/serial converter in the past, and it seems like you are experiencing similar issues. It appears that the connection between the PC and the PLC is not being maintained long enough to complete the program upload or download. I am curious if your MOXA device is facing the same challenges.
Hey Chris, it sounds like you're in quite the pickle! One thing I've noticed is that your error messages seem to indicate an issue specifically with the data transfer during the process of the ladder logic upload. I'd keep an eye out for possible issues with the hardware involved in the data transfer, such as the cables or the USB to serial converter. I would also recommend double-checking the COM port settings in your software, as well as the parameters that your PLC requires for communication, as these settings could be off and causing problems in data transfer. Additionally, often batteries dying in PLCs can lose RAM memory, which usually contains the user program. Might be worth checking into the condition of those as well. Best of luck!
Hi Chris, Seems like you're dealing with quite a challenging issue here. If memory serves me right, the IC693UDR005FP1 is part of GE's 90-30 series, which got phased out quite a while ago. For your specific problem, it appears like the problem might lie in your connection setup. From your post, I infer your communication is dropping midway, which hints towards possible cabling or adapter-related issues. Before continuing with further technical troubleshooting, I'd recommend you cross-verify the integrity of your cables and adapters to see if they are working as expected. Also, it might help if you could test your setup on a different unit; sometimes, the problem lies not with the communication but the receiving PLC itself. However, the GE series you're dealing with could naturally present hurdles due to its age. If you don't get traction with the above suggestions, you might have to consider bringing in a specialist or contacting GE support for old models. Good luck with your attempts; remember, sometimes the simplest and most overlooked components turn out to be the culprits.
Hey Chris, it sounds like you’ve been dealing with quite the maze of communication errors! Have you tried checking the settings for your serial communication? Sometimes, mismatched baud rates or parity settings can cause the kind of disconnections you're seeing. Also, since the conveyors are relatively old, it’s worth making sure that all cabling is in good shape—bad connections could definitely affect your ability to transfer logic successfully. If you’re still stuck, consider reaching out to the manufacturer for legacy support; they might have insights unique to those specific models. Good luck, and I hope you get this sorted soon!
Hey Chris, it sounds like you're having a pretty tough time with those older conveyors! Have you tried checking the cabling and ensuring that all connections are secure? Sometimes, intermittent communication issues can stem from faulty cables or loose connections, especially with older hardware. Additionally, since you're working with older software versions, it might be worth experimenting with different serial port settings or even another USB to serial converter if you have one available—some have better compatibility across different setups. Lastly, since LM90 can be finicky, ensuring the virtual machine settings are optimized for communications might help as well. Good luck!
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Answer: Answer: The main issue is that the conveyor system lost its programming due to a dead battery, and now the goal is to transfer the program from a functioning conveyor to the one in need of repair.
Answer: Answer: Various methods have been tried, including using a USB to serial converter with Proficy Machine 9.5 on a Windows 10 computer, as well as using LM90_9.05 on a VirtualBox VM running Windows XP with a MOXA TCC-100I RS232 to RS422 converter.
Answer: Answer: Error messages such as "Error 8097: Server Error - Transfer Error: Remote disconnect has occurred [0x6A][0x02]" and "
Answer: Answer: Yes, communication dropping during ladder logic uploads has been a consistent issue, with messages like "S43 comms failed" or "Error during load; Program folder incomplete. Must reload or restore logic" being displayed.
Answer: Answer:
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