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Author Topic: ModbusTCPServer - Possibly Locked up  (Read 79849 times)

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #30 on: May 21, 2021, 10:06:54 AM »
I plan on restarting the controller in a little while to see if it restores comms. Is there anything else you need me to do prior to this?

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #31 on: May 21, 2021, 10:22:40 AM »
I plan on restarting the controller in a little while to see if it restores comms. Is there anything else you need me to do prior to this?

I don't know anything else I can do without custom firmware. Restart it.
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #32 on: May 21, 2021, 12:21:32 PM »
Power cycle restored comms without additional action.

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #33 on: May 21, 2021, 03:00:55 PM »
I see some things I can't yet explain. Don't know if it is relevant, but it is certainly abnormal. Investigating.
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #34 on: May 21, 2021, 04:24:05 PM »
Just out of curiosity, of those having problems, do you have a Gateway defined for your primary Ethernet adapter, or not?
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #35 on: May 21, 2021, 04:32:08 PM »
The two systems I'm having trouble with have gateways defined for both. I work across different subnets and have to have the gateway defined.

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #36 on: May 24, 2021, 05:32:38 PM »
The two systems I'm having trouble with have gateways defined for both. I work across different subnets and have to have the gateway defined.

Well, I found a thing, not sure if it the thing.

When we added the ECOMEX, it required enabling code that enabled some routing functions. For outbound packets this is required, but it went the extra mile for us and enabled an internal gateway function which was causing legit havoc in certain conditions. I don't know exactly what those conditions are, but the trigger is for something to send a subnet broadcast, mostly likely to a subnet not configured on either the PLC's NICs. I won't bore y'all with the details, but basically the gateway function commits a faux pas and improperly forwards a broadcast packet. By itself, that's no big deal...but if he tells everybody, and everybody else tells everybody, etc., it's geometric. The TTL in the packet eventually extinguishes the flames, but not before annoying the stack greatly. The immediately obvious symptom is brief comm dropouts and $QueuesFlushed (ST145) getting set.

We'll get a fix out shortly.

As I said, I don't know if this fixes the Modbus issue, but it may well do it. I don't think the stack enjoys being assaulted repeatedly, and after weeks or months of abuse it might have leaked enough resources to become non-responsive.

For reference, the thing that was generating the subnet broadcast was a Win7 PC doing a NETBIOS name resolution. It could be about anything though.
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #37 on: May 24, 2021, 06:03:01 PM »
Would this cause issues with the EIP messaging? I assume it would.

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #38 on: May 24, 2021, 06:44:00 PM »
Would this cause issues with the EIP messaging? I assume it would.

Easily. And depending on how frequently a trigger event occurred, comm could be very unreliable, even before things fully broke.

How many BRX do you have in the system?
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #39 on: May 24, 2021, 09:29:04 PM »
I've currently got 6 BRX's running on my network.

jcb

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Re: ModbusTCPServer - Possibly Locked up
« Reply #40 on: May 25, 2021, 11:29:31 AM »
So I haven't had any issues with this for a while but also haven't made any changes to the HMI or PLC.

I had to update a report trigger to add a manual trigger function on the PLC. After I wrote the online change to the PLC I lost the ModbusTCPServer communications.

All Modbus and EIPMSG clients are working fine but I can't connect to the Modbus TCP Server from the HMI or my workstation. It shows no active sessions or transaction changes.

I also have an unused BX-P-ECOMEX in the POM slot. I was going to use it for dedicated Remote IO but didn't see any performance increase over a single network connection so I unplugged it but never pulled it.

DST411 is 0
DST51 is 0
OS: 2.8.2


They are running production on the line until the 11:30 PST lunch break at which time I am going to try in the following order

Reinitialize PLC I/O
Check for Comms restoration.
Firmware update
Check for Comms restoration.

Finally a Power Cycle if none of the above work.

Thanks
John.

jcb

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Re: ModbusTCPServer - Possibly Locked up
« Reply #41 on: May 25, 2021, 02:35:05 PM »
Reinitialize of PLC I/O didn't change anything.

Update to 2.8.5 and after firmware update power on reboot all comms are working.

I will post again if the problem persists.

BobO

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Re: ModbusTCPServer - Possibly Locked up
« Reply #42 on: May 25, 2021, 02:56:26 PM »
Reinitialize of PLC I/O didn't change anything.

Update to 2.8.5 and after firmware update power on reboot all comms are working.

I will post again if the problem persists.

We'll be dropping 2.8.6 shortly, probably tomorrow.
"It has recently come to our attention that users spend 95% of their time using 5% of the available features. That might be relevant." -BobO

Bolt

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Re: ModbusTCPServer - Possibly Locked up
« Reply #43 on: May 25, 2021, 05:06:32 PM »
We'll be dropping 2.8.6 shortly, probably tomorrow.

Just days after I finally got with the program and figured out I wasn't on 2.8.5!  :P

RBPLC

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Re: ModbusTCPServer - Possibly Locked up
« Reply #44 on: May 26, 2021, 08:04:53 AM »
Is there a way to deploy firmware updates to multiple controllers at the same time or is this an update each one individually type of thing?