Fatal error! Controller must be reset: Files from last download is missing
Hello everyone.
At the end of commissioning job on the plant I downloaded the project to compact flash and insertet in into the slot. After that I tried to go online without download, but unsuccesfully. Message appeared “Fatal error! Controller must be reset: Files from last download is missing” , I have attached the screen shot of error message also for better clarity .
BUT controller is running and everything is OK , it is not an error of controller. Cold restart did not help. I had no possibility to make controller reset. Where did I make any mistake ?
What must I do now for going online ?
Advance thanks for helping me in this.
Voted best answer
Hello,
First check whats Ronny said in his post. Correct firmware versions it's a must.
I had a similar issue. At that time I posted a question here too. In my case, I had no compact flash. The controller was running OK but at the time that we tried to do a download I got the same message.
I tried several things, but no one worked.
Everytime that you do a download, a file it's created in the Control Builder folder. That file should be up to date and syncronized in nodes, I did not try copying or modifying that files because the solution could be worse than the problem (and I wasn´t sure that it would work to take the risk). Sometimes little network issues in the wrong time could cause this "un-syncronization". Several thing could cause this message to appear. Unfortunately once you get that message the easiest way it's doing a reset. I have seen that message a couple of times and in both cases we have ending up reseting the controller.
The controller works OK because it has the application running OK but if you want to make changes and download them you will not be able.... if is not urgent to make changes you can wait until a plant maintenance stop or something similar.
I hope this information helps something.
Best Regards,
Valeria
Answers
Hello,
sometimes the problem is the compact flash itself, maybe you have another compact flash to use ?
The firmware, is the firmware actual from the software you are using or is it older ?
Please give us the versions of the ABB softwares you are using.
/Ronny
Hello There
We had that problems few month ago, we don't use compact flash, but the solutions was to make a Little change in the application (for instance create a dummy global variable) and download the controller
As i understand your problem, you have downloaded to the Controller directly, after that downloaded to the Compact Flash card.
Now the Controller is running with an "old" version and Control Builder "thinks" you have the new Version (as downloaded on Compact Flash) running.
Therefore going online is not possible, you need to reset the Controller in this Situation, and start from Compact Flash or re-download a (new) version online.
Other Workaround: Load a Backup of the Control Project from just before you made the CompactFlash download...!
by JClouseau Rank: 145 on 6/16/2015 10:47:54 AM | Like (0) | Report
I am having a similar issue during functional testing using soft controllers. Certain nodes will not go online if the project is downloaded from another node. We are having this problem with multiple nodes an multiple projects.
What is the name of the file that is created during download? How is the node synchronization toggled?
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