Recently upgraded Firmware of MFP02 & NVRAM, completed off-line download, RESTORE blks not in module

Hello,
I recently upgraded redundant MFP02 modules with newer firmware G5 and replaced NVRAM chips, completed off-line download, after a verification the RESTORE FC 140 blocks are not in the module. Has anyone else come across this?

Thanks,
Linda

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linda.j.lloyd Rank: 626

Asked 1 month ago

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Hi,
Very odd. Just to clarify, you compile and download the configuration to the controller, the controller works but the FC-140s that are in the CLDs are missing from the controller when you subsequently do a verify between the CLDs and the controller?

If you do a verify between the CLDs and the CFG file are the FC-140s present?
Revision G5 reportedly has some issues with saving and loading configurations that include Batch. Are you using Batch in this controller? If yes, did you download the controller from the NBS file or BDM? Try using BDM only.
Did the controller firmware change by a major revision. I.E. F? to G5. If yes, it might pay to update the controller properties to reflect the new firmware revision and recompile.
Are there any messages during the process of downloading and putting the controller to execute that are not normal?
Does the module status report show any abnormal status bits being active or any messages?
Did you do the special operations via SW4 to initialise the module? Maybe retry using Special Operation 2 (Initialise and format), 4 (Enable Infinet-Assuming you have an Infinet system) and 6 (Module timestamping-If needed for your site). After performing the Special Operations and the module is in execute, drop a fc89 (Last block, its an executive block already in the controller at block address 9999) onto a CLD and look at the block output. It's output should correlate to the the special operations carried out.
When doing the offline download do you initialize the controller as part of the download dialog. An offline download would normally be yes to initialize the function code configuration memory space. Not initializing overlays the program over the existing memory contents. Not sure why this would cause the symptoms you observe.

Finally as an fyi, revision G5 specifically has issues with

RIO02 firmware compatibility. The IMRIO02 firmware must be at E0 or greater.
FC4 (PULPOS). Tuning a FC4 can cause a controller to redlight.

Good luck,

Alan

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by linda.j.lloyd Rank: 626 on 4/20/2020 4:31:36 AM | Like (0) | Report

GM Alan,
Thanks for the reply. You understand correctly, I compiled and did an offline download, everything is working in the controller except the FC-140's RESTORE blocks they are missing. I went from rev F to G5. This controller does not have a BATCH program. The module properties were updated and reflect G5 firmware. There were no abnormal messages downloading and going to execute. I am not really sure how to read all the status bytes but I don't think there is anything unusual. We brought an ABB rep to site to do the upgrade, I wasn't out in the field with him as he radioed to me when to start the off-line download. I am assuming he did the special operation but I will confirm with him. I checked another couple of modules we upgraded and they have the same problem the RESTORE are not being recognized in the module after the off-line download with module firmware and NVRAM chips updated.
Thanks,
Linda

by Alan Rank: 23 on 4/20/2020 6:09:16 AM | Like (0) | Report

Hi Linda,
Most mysterious..
I don't have much experience with G5 and that was 20 years ago. I remember installing G5 on a couple of jobs and had problems with the PULPOS FC and remote IO so had to uninstall it and wait for a later version, G8.

The FC140 is an unusual function code in that all it does is collect block outputs and write them to non-volatile memory, and on controller startup the FC140 populate their associate function codes with the data stored previously. This is why I was focusing on things to do with memory in the initial post. I don't have any suggestion as to why only FC140s are affected but I have seen odd behaviours from controllers that were not set up correctly after firmware upgrades.

The fact that the problem is common to all modules that were upgraded is also interesting.
• What version of Composer / S+E are you using?
• Does the CFG file that is downloaded to the controller contain the FC-140s. A verify between the CLDs and the CFG file should be clean. This would also confirm that the FC-140s are part of the CFG file being downloaded.

Sometimes module firmware revisions close the gate on configuration practices that were not as intended but tolerated in earlier revisions.
• Are the restore blocks configured correctly as per function code reference manual?
• Are the restore block numbers greater than the block referenced by S1 of the restore block?

Can you test in the workshop? Perhaps build a configuration with 1 block and 1 restore block and see what happens.
Best of luck,
Alan

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Alan Rank: 23

Answered 1 month ago

Source: E96-202 - Multi-Function Processor Module (IMMFP02)

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Recently upgraded Firmware of MFP02 & NVRAM, completed off-line download, RESTORE blks not in module

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