Hello everyone! I'm reaching out today because I'm struggling to solve a recurring issue with a site I'm associated with. Their SLC 5/03s keep losing their programs. Despite replacing all the batteries, the problem persists. The 5/03 is connected to a PanelView 550 via the DH485 port, and a drive via the RS232 port. I have a UIC and CP3 cable set. Since this site is remote, they sent me the PLCs to reprogram. I can successfully download the program using either the UIC or CP3. However, after downloading the program, I receive a message stating, "you will lose communications from both ports." Subsequently, I am unable to connect to the PLC on either port using DF1 or DH485 through the UIC and CP3. I have provided a picture displaying the program comms settings and the error warning. The issue arises when they install the PLC back into their rack, as it fails to communicate with the HMI or drive. While programming in my rack, there are no faults, but once installed at the site, the FLT light starts flashing along with the DH485 green light solid. I'm struggling to identify the cause of this issue and need to resolve it before flying out to the site. Apologies for the lengthy explanation, but my query remains - does anyone have insight into what could be causing this fault and how I can establish an online connection with the processor post-download.
Navigate to the Channel 0 user tab to display the configuration settings.
To demonstrate the configuration, simply click on the Channel 0 user tab as requested by geniusintraining. Explore the settings further by clicking to expand the options.
The configuration for channel 0 is specifically optimized for processing ASCIILets. Moving on, what is currently connected to the processor at this particular location?
During the discussion, geniusintraining mentioned that channel 0 is assigned to ASCIILets. To further understand this, what specific equipment is connected to the processor at that particular spot? It turns out that the channel is linked to an Introl Design DC100A as detailed in the manual found here: https://www.introldesign.com/Uploads/Documents/DC100LCP/DC100A-LCP%20Manual%20collated.pdf. This information sheds light on the configuration and functionality of the system in question.
Unfortunately, the CP3 is not compatible as the DB9 settings must remain in ASCII mode. However, after the download process, communication cannot be established through ASCII. Instead, utilize the DH485 port (RJ45) with the UIC protocol, designated as Channel 1. Navigate to the Channel 1 tab and provide a screenshot for further assistance.
Hey there! It sounds like quite a predicament you're facing. Despite your thorough explanation, it's difficult to diagnose this remotely without seeing the full system setup, but one possible issue could be the UIC-CP3 configuration. The UIC and CP3 are designed to work on separate ports - UIC on DH485 and CP3 on DF1 respectively. Double-check to ensure that you aren't overloading one port by using both cables. Also, given that your SLC 5/03 is losing its program despite battery replacements, it's worth checking if there's any issue with the base unit itself. Sometimes, a faulty base can cause such unexplained issues. Lastly, don’t rule out the possibility of an issue with the internal power supply. Power fluctuations can cause programs to disappear and can also interfere with communication. Given the complexity of the issue, I highly recommend the assistance of an on-site automation engineer, if feasible.
Just off the top of my head when seeing these symptoms, it seems like the PLC might be booting into RUN mode post-download, which could be causing the communication ports to become inactive. Try booting it in PROGRAM mode and see if that solves the communication issue. Additionally, you should check your control system's configuration, any discrepancy like baud rate or parity could impede smooth communication. Lastly, ensure that both the PanelView and drive can communicate at the same baud rate as the processor. Otherwise, these secondary devices may need their baud rate set manually as well. Hope this helps! Safe travels to the site.
From your detailed explanation, it seems like you're dealing with a tricky situation here. One possibility could be a issue with the order of operations during start-up. When you first power up, the 5/03 might try to establish communication with the PanelView 550 or the drive before its own program is fully loaded, leading to lost communication. As for post-download, the issue could be with the DF1 and DH485 protocols. Check if your PLC and the devices it's connecting to are compatible with the same versions of these protocols. It might also be worth checking the baud rate settings - you'd be surprised how many times mismatched speeds can cause similar issues. Finally, inspect for any grounding issues. Electrical noise from other equipment can sometimes cause these PLCs to act up, particularly in a high noise environment. Hopefully this gives you a starting point to troubleshoot.
Hi there! So, it seems like there might be a few things in play here. One possibility could be that the DH485 network itself is causing the fault, especially if the PLC is fine in your rack but shows fault upon installation at the site. Another possibility could be settings mismatch or noise interference. A close check on the baud rate, parity, and stop bits between PLC and HMI might help, making sure they match appropriately. In case of noise, check if all the PLC and HMI communication cables are shielded properly. For the program loss, however, you may want to verify if the software ‘download' procedure includes a step to ‘store' the program to permanent memory (EEPROM), it sounds like it might only be going to RAM and is lost when power is cycled. Lastly, it wouldn't hurt to check the power supply at the installation site, a voltage fluctuation or interruption might be causing the issue. All the best for your troubleshooting!
It sounds like a frustrating situation! One possibility could be that there are communication settings on the PLC that are not matching what the HMI and drive expect once it's back in the rack. Double-check the static IP or addressing configured in the program versus what's set on-site. Also, ensure all ports are enabled and that you're not unintentionally changing settings during the download process. Sometimes, firmware mismatches or the environment (like noise on the communication lines) can cause issues too. If possible, try downloading the program with the PLC powered directly from the site’s power supply, as this might change how the hardware behaves compared to your setup. Good luck!
It sounds like a frustrating issue! One possibility that comes to mind is that there might be a mismatch in the communication settings between the PLC and the HMI or drive once they're back in the rack—make sure the baud rates and node addresses are consistent across all devices. Another thing to check is if there are any grounding issues or interference that could be throwing off the communication after being installed on-site. Sometimes, pulling a configuration backup or checking for hardware damage, particularly on connectors and cables, can also reveal hidden problems. Good luck, and I hope you find a solution soon!
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Answer: Answer: The issue could be related to communication settings, hardware connections, or compatibility between devices.
Answer: Answer: This message could indicate a disruption in communication protocols that need to be addressed to establish a stable connection.
Answer: Answer: Investigate the hardware connections, check communication settings, and ensure compatibility between devices to resolve the communication problems.
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