We are experiencing intermittent communication issues with this PLC, with three different sources reporting problems - two Rockwell Logix PLCs, one "Safety" PLC, and our PI-OSI Interface which is used for data archiving. This suggests a problem with the Rockwell 6000 8-port Switch, the wire connecting the switch to the PLC, or even the Ethernet card in the PLC chassis. Although we initially tried replacing the wire, the communication errors have persisted. Considering that the switch has already been replaced, we are considering swapping out the Ethernet card in the chassis. Can this be done seamlessly with another card from one of the Chiller Bays, which are similar in setup except for their IP addresses? We are wondering if any re-configuration would be necessary, or if the card would automatically adjust in the PLC system.
I have successfully hot-swapped the 1756-ENBT module on numerous occasions. After configuring the spare with the correct IP address and firmware, I simply remove the old module and install the new one. While the swap may temporarily disrupt any connections dependent on the module, it is a reliable process. Through our experience, we have learned that updating the firmware to the latest version can resolve various issues. As a precaution, we always keep a few spare modules on hand for quick replacements when needed.
When it comes to the physical hardware, these components are hot-swappable without causing harm to any circuit boards. However, the amount of configuration required will vary depending on the exact replacement and the module setup within the PLC. Setting the IP address is the minimum requirement, as recommended by @joseph_e2.
When it comes to hot-swapping the 1756-ENBT module, it is a process that can be done smoothly by ensuring the spare module is properly set up with the correct IP address and firmware. While swapping the modules, any connections that rely on the module being swapped will experience interruptions, but this method works effectively. In certain situations, upgrading the firmware to the latest version has proven to resolve various issues, so it is recommended to keep a couple of spare modules ready for quick replacement if needed. The physical hardware of the modules is hot-swappable without causing damage to circuit boards. However, depending on the exact replacement and configuration in the PLC, some reconfiguration may be necessary, such as setting the IP address. In a scenario where multiple Chiller Bays have EtherNet/IP Cards communicating with PLCs, swapping the cards between bays to troubleshoot communication errors may require changing the IP addresses in real-time via ControlLogix Software. Since there are no spare devices or lab environment for pre-configuration, initially swapping the cards may result in data being sent to the wrong destination. It is important to consider whether the PLC will recognize this and how to prevent any potential issues. Despite the possibility of shutting down both bays to avoid these issues, it is preferred not to disrupt operations. The PLC hardware in all three bays was installed at the same time, making it identical in nature. The PLC experiencing communication errors is not directly controlling a chiller but serves as an interface between the Vendor package for the chiller and two other Rockwell PLCs. This means that the Ethernet/IP Cards used are interchangeable between bays due to their uniformity.
Colt Hero noted that the three Chiller Bays are essentially identical, with each equipped with an EtherNet/IP Card communicating with the other two PLCs - "Supervisor" and "Safety." To troubleshoot communication errors, he proposed swapping the EtherNet/IP Cards between Bays to test if the issue persists. He also considered changing the IP addresses in real-time using ControlLogix Software, which would not require a re-download. Due to the lack of a lab environment for pre-IP configuration and the absence of spare cards, Colt Hero acknowledged that initially swapping the cards would result in incorrect IP addresses. This could potentially lead to data originally intended for one Chiller Bay being sent to another. He questioned whether the PLC would be able to detect this misdirected data. It was mentioned that shutting down both Bays to avoid issues could be an option, although not preferred. Despite all three Bays having similar PLC hardware installed simultaneously twelve years ago, the Bay experiencing communication errors is not directly controlling a Chiller but rather interfacing with vendor software and other Rockwell PLCs. Considering the uncertainty surrounding the PLC card configurations, including message instructions and produced/consumed tags, it was advised against swapping cards without adjusting IPs unless a thorough understanding of the program is obtained. Changing the IP address of a card can be done without a download, even through RSLinx without accessing ControlLogix. For conducting a swap test, the recommendation was to assign dummy IPs to both cards, swap them, and then input the correct swapped IPs.
Swapping out the Ethernet card is indeed a viable option. However, you will likely need to reconfigure it to match your specific system setup. Ethernet cards usually don't just auto-adjust on system level upon swapping. Pay specific attention to settings such as IP address, subnet mask, and gateway. Ideally, make sure to back up your PLC program before modifying the hardware. As a failsafe, you might want to consider setting up a secondary communication path to avoid downtime during the troubleshooting.
Based on my experience, swapping out the Ethernet card from the Chiller Bays should be quite doable, but it won't be a seamless process. Remember, hardware and network settings are often intrinsically linked, specifically, the IP address in your case. After you've replaced the card, you'll need to manually adjust the PLC system to recognize the card's IP address. Check the OEM's guide to properly reconfigure the settings. Also, ensure that this new card's IP doesn't clash with any existing device on your network. Hope this helps!
It sounds like you've already done a good job troubleshooting the issue! Swapping the Ethernet card from the Chiller Bays could work, but it's essential to check if the firmware versions match; otherwise, you might run into compatibility issues. As for reconfiguration, while some settings may auto-adjust, it’s best to verify the IP address and other configurations manually to avoid any potential conflicts. Just make sure to document any changes you make—it's always good to have a record!
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Answer: - No, Ethernet cards in a Logix5571 PLC cannot be hot swapped. It is recommended to power down the PLC before replacing the Ethernet card to avoid any potential damage.
Answer: - Before swapping out the Ethernet card in the PLC chassis, it is important to ensure that the replacement card is compatible with the PLC model and firmware version. Additionally, make sure to have a backup of the PLC program and configuration settings.
Answer: - Yes, re-configuration will be necessary after replacing the Ethernet card in the Logix5571 PLC. The new card will need to be configured with the appropriate IP address, subnet mask, and other network settings to ensure proper communication within the system.
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