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Author Topic: IO Error causes and fixes  (Read 66279 times)

BobO

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Re: IO Error causes and fixes
« Reply #15 on: May 04, 2015, 03:16:18 PM »
Quote from: CReese on May 04, 2015, 03:13:46 PM
So the obvious next question is: what is causing the crash in the controller? How do I debug?

Colin


Update the firmware. It's probably already fixed.
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CReese

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Re: IO Error causes and fixes
« Reply #16 on: May 04, 2015, 03:18:52 PM »
Message is "PLC rebooted following hardware watchdog timeout".

This can't be related to those AIN cards, can it?

Colin
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BobO

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Re: IO Error causes and fixes
« Reply #17 on: May 04, 2015, 03:20:28 PM »
Quote from: CReese on May 04, 2015, 03:18:52 PM
Message is "PLC rebooted following hardware watchdog timeout".

This can't be related to those AIN cards, can it?

Colin


Doubtful.

You are doing some custom TCP comms, right?
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BobO

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Re: IO Error causes and fixes
« Reply #18 on: May 04, 2015, 03:24:32 PM »
Oh wait...not TCP...but EMAIL?
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CReese

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Re: IO Error causes and fixes
« Reply #19 on: May 04, 2015, 03:25:46 PM »
Not really. Three MB TCP/IP clients, an internal serial client, and an unused SERIO card.

Firmware was all up to date.

The reboots happened every five seconds. If I reset the timer, won't it just continue to reboot every five seconds indefinitely?

C
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CReese

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Re: IO Error causes and fixes
« Reply #20 on: May 04, 2015, 03:26:18 PM »
No email here.
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CReese

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Re: IO Error causes and fixes
« Reply #21 on: May 04, 2015, 03:27:59 PM »
Log.
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BobO

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Re: IO Error causes and fixes
« Reply #22 on: May 04, 2015, 03:28:10 PM »
So it's still doing it when you put it back in RUN mode?
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BobO

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Re: IO Error causes and fixes
« Reply #23 on: May 04, 2015, 03:38:48 PM »
This smells a bit like a bug we fixed. SERIO card maybe...let me look up the details.
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CReese

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Re: IO Error causes and fixes
« Reply #24 on: May 04, 2015, 03:40:36 PM »
Quote from: BobO on May 04, 2015, 03:28:10 PM
So it's still doing it when you put it back in RUN mode?

It happens only sporadically. It has now decided to throw dozens of comm errors with no other change in configuration or connectivity on either side.

I'll see if it has the issue after I get it back online.

C
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CReese

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Re: IO Error causes and fixes
« Reply #25 on: May 04, 2015, 03:42:55 PM »
It's in RUN mode and working fine now. That's the frustrating part. Putting it back in RUN mode or power-cycling typically fixes the error immediately.

For now, I'm just going to have to leave the switch in RUN position as it's a critical PLC. I'm just curious what will happen when it watchdogs next time -- whether it will just continuously reboot or what.

C
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BobO

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Re: IO Error causes and fixes
« Reply #26 on: May 04, 2015, 03:46:55 PM »
There are some post mortem registers located at DST400-DST409. Throw those into a data view and send me a screen cap.
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CReese

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Re: IO Error causes and fixes
« Reply #27 on: May 04, 2015, 04:01:32 PM »
here you are.
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BobO

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Re: IO Error causes and fixes
« Reply #28 on: May 04, 2015, 04:51:38 PM »
This contains the last 4 reboot states and the current state.

518 = normal operation following a program update
806 = normal operation following a transition to run mode
413 = normal operation following a boot to program
801 = failed running user logic during the first scan

The top three are normal and expected. When you make a program change, you'll see 518. When you switch to run mode, you'll see 806. When you power up in program mode, you'll see 413.

The 801 is where the problem occurred. It failed during a transition to run mode, while running user logic the first time.

What I/O modules do you have in each slot?

What module configs do you have listed?
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CReese

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Re: IO Error causes and fixes
« Reply #29 on: May 04, 2015, 05:13:14 PM »
Here are some data. The device driver error is one I don't recognize.
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