We recently attempted to replace a 1769-L24ER-QBFC1B Series A controller with the newer Series B controller. The Series A controller had firmware version 20 installed, and the program was loaded onto the SD card along with the option to load both the program and firmware upon power up. When we inserted the SD card into the Series B controller and powered it up, the process failed, leaving the Series B controller in a nonfunctioning state. Subsequently, we converted the program offline in Studio 5000 to firmware version 31. Any endeavor to download the program to the Series B controller initiates a firmware upgrade from the factory 1.x version. Unfortunately, all attempts to upgrade the firmware have resulted in failure, displaying the message "Manually Reset module." Even using ControlFlash and ControlFlashPLUS have yielded the same outcome. While I was able to adjust the Series B controller's IP address using BOOTP and RSLinx, these actions do not seem to be related to updating the firmware or downloading the program. Is there a way to reset the Series B controller or restore it to a functioning state where the firmware can be updated and the program can be downloaded? I have come across suggestions of creating an SD card in a separate Series B controller with the correct firmware, but these discussions have not provided a definitive solution. I hope to avoid permanently damaging the Series B controller by inadvertently using an SD card with incompatible firmware. Although the controller bears a warning sticker regarding the risk of programming issues with wrong firmware, it is puzzling why the process of loading the wrong firmware onto the SD card did not simply fail, instead of leaving the controller inoperable.
Was the previous SD card used to load firmware version 20 onto the CPU? If so, consider loading the appropriate firmware from a new SD card. How long has the latest PLC been in use? It's likely that firmware version 34 or higher is required for optimal performance.
A user named geniusintraining asked if the old SD card loaded firmware V20 to the CPU. If so, they suggest trying to load the correct firmware from an SD. The age of the new PLC is also a factor, as it may require at least version V34 or newer. We successfully verified that the SD card with the v20 program loads on the series A PLC. However, when this card was used on the series B PLC, it failed due to compatibility issues with the lower version firmware. As a result, the series B PLC was unable to receive a firmware update from ControlFlash or ControlFlashPLUS. A new series B PLC is on its way with a v31 program ready to be loaded. The plan is to update this new PLC to V31, download the program, and burn an SD card with the option to load the firmware. It is hoped that inserting this SD card into the potentially "bricked" series B PLC will restore it to a working state. This is the final option left to attempt for fixing the PLC.
Although I don't use CMPL often, I'm wondering if there are any io expansion modules installed on this rack. According to information in the knowledge base, upgrading from series A to series B may result in a solid red LED if older expansion io modules are present. To troubleshoot this issue, consider removing all modules, replacing the endcap, and observing if there are any changes in the boot process.
When setting up a new Programmable Logic Controller (PLC), it is crucial to have firmware V34 or above to avoid potentially damaging the device. Be sure to verify this before proceeding to prevent any issues.
Finding information on compatible firmware for your device may not be as straightforward as expected. Attempting to load the wrong firmware or an incompatible version can result in a mismatch error. However, loading from an SD card may bypass this issue and attempt to load regardless of the version. In a similar situation, I mistakenly caused a L24er error but was able to recover it by creating a new SD card with a newer V34 version.
This sounds like a tricky situation you've gotten into. I've experienced similar issues with firmware updates on this series. From my understanding, these controllers are quite sensitive to firmware version discrepancies, which seems to be the root of your issue. Are you making sure to double-check the compatibility of the firmware version with the controller's series before updating? If a firmware update to a version that is not fully compatible with the controller is initiated, it could lead to the problems you're experiencing. In terms of your question about resetting the controller, there normally is a physical reset process outlined in the user manual — have you tried that yet? Also, contacting customer support might be a good idea, as they could provide specific insights relative to your device and issue. It's indeed a puzzle about why the procedure leaves the controller inoperable, rather than simply failing with incompatible firmware. Seems like there's a room for some refinement in their design process.
It sounds like you've done extensive work to get your Series B controller up and running. As far as your issue goes, restoring firmware on controllers can indeed be a tricky process. One thing you could try is performing a firmware recovery by booting the controller with the key in Program mode, then choosing SD fallback option. This might help to reset the controller to a working state by loading the original version of the firmware that came with the controller. Once your controller is in a functioning state, attempt to load a firmware version compatible with the controller via ControlFlash Plus, instead of directly using the SD card. But remember, always take a backup before proceeding with firmware updates to avoid permanent data loss.
It sounds like you're in a bit of a tricky spot. It's important to remember that Series A and Series B controllers, while similar, may have distinct firmware requirements. Unexpected issues often arise when swapping these, and a firmware upgrade attempt with incompatible firmware can lock a controller. Have you tried resetting the controller to factory defaults? This usually includes restoring the original firmware. Connect with technical support for the prescribed process. If a factory reset fails, it might be a hardware problem. Also, consider seeking help from a factory-trained technician who specializes in these controllers, as they may have appropriate tools and experience to tackle this issue without causing irreversible damage.
It sounds like you're in a bit of a bind with that Series B controller. Have you tried a full factory reset on the controller itself? Sometimes, that can clear out any issues caused by firmware mismatches and give you a clean slate to work from. Also, it’s worth checking if there are any firmware recovery options specific to your model on Rockwell’s support site. If all else fails, reaching out to their technical support might be your best bet; they might have some insights or procedures to recover your controller without risking permanent damage. Good luck!
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Answer: 1. How can I resolve firmware update failures on a CompactLogix 1769-QBFC1B Series B controller? - To resolve firmware update failures on the Series B controller, you may need to create an SD card with the correct firmware version and load it into the controller. Be cautious not to use an SD card with incompatible firmware to avoid damaging the controller.
Answer: - You can try resetting the Series B controller by manually resetting the module as prompted, or by exploring options within the programming software to restore it to a functioning state for firmware updates and program downloads.
Answer: - You can attempt to update the firmware and download the program by ensuring the correct firmware version is loaded onto an SD card and inserted into the Series B controller. Utilize programming tools like ControlFlash and ControlFlashPLUS to assist in the process.
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