AC500-PM573-ETH | ABB to communicate with honeywell EBI SCADA though MODBUS TCP. Communication not working
The above image is for a non working plc.
if i try to use modscan for a working plc below is the result.
Holding register values are changing at 40019 and at 40020 the value is fixed is 512.
We tried to upgrade the firmware version of the plc where the SCADA communication was not working. The firmware is not getting updated. below are the snaps for the status
A little more clarification here that we are able to complete the firmware upgrade by physically power cycling the PLC.
Another scenario is that we upgraded one of our working PLCs from version 2.2.0 to 2.8.5 and we also lost communication with that PLC after upgrade. see the snapshots attached.
As you can see from the attachments that Ethernet throttling statistics disappeared, at the same time we lost communication to this PLC from SCADA system but still we can ping it from the SCADA workstation.
All the other PLCs which are non-working, also do not have any information in the "Onboard Ethernet Throttling Statistics" Tab
For some reasons you have now upgraded your firmware's. I guess you have also upgraded your projects from the old programming software version to new one. Going from firmware 2.2.0 to 2.8.5 means that your original software was Control Builder Plus 2.2.0 and from your pictures your current version is Automation Builder 2.4. There are about 25 programming software versions between these versions. There are several issues on release notes about project not updating/upgrading properly to newer programming software.
Have you followed all the guides and proper methods while you have upgraded your project or did you just opened the project with a new version?
With such an old firmware's i recommend that you use SD card to make the firmware update to at least version 2.5.x before using this built in tool for firmware update.
I get that it's hard with a new system and ABB's documentation can also be a little bit confusing, but i think it's common for all systems. Here is some basic tips and some history, which might help you.
There are two options to just upgrade project with a newer version. Opening the project file with a newer version or creating a project archive with the old version and opening that with a new version.
However in this case neither options work. From the latest Automation Builder (AB) 2.4.1 release note you can find a line that from Control Builder Plus (CBP) (AB 0.x) software's to AB 2.x versions you should first upgrade the project to version AB 1.2.x. This has been mentioned on pretty much all the release notes from the version AB 1.2.x onward.
To overcome this issue there are two reasonable options. Start installing these old versions and upgrade the project until you end up to the latest version or create a new project, fill hardware structure manually and import/export Codesys 2.3 section to the new project.
On my opinion you should use the option number two here if your hardware structure is small.
From your descriptions your system is Scada as Modbus TCP client and AC500 PLC as Modbus TCP Server. If you create the hardware structure again remember to put at least one to "Server connections" parameter on AC500 (or as many as you have those connections). This will open 502 port.
If i remember correctly upgrade from CBP 2.2 to CBP 2.3 (eg. AB 1.0) had some changes on Ethernet behaviour. On my opinion this wasn't properly documented on the release notes and personally i had a few projects where Modbus TCP communication stopped after the upgrade. I newer saw any details of this modification but it affected the Ethernet ports socket behaviour.
To get the projects working i remember that the AC500 Modbus TCP setting "OMB time" needed to be changed. This can be checked from the "PLC Browser" with a command "coupler desc" or "coupler settings", can't remember which one. While you are online the command shows all the Ethernet sockets and their statuses. 502 port sockets are the ones, which you are now interested. Rapidly update the command manually for about one minute and if there are no connections from the client or connections which are only for few seconds then your issue is most likely "OMB time". This can also be checked from the Ethernet bus with a Wireshark (three way handshake work and then the connection is just dropped). I suggest to increase the OMB time by steps of 500 or 1000.
SD cards have an SDCARD.ini file, which during bootup tells the PLC what to do eg. update firmware or boot code. This file structure has changed a little bit. If i remember correctly this happened when firmware 2.5.x was released and AB 1.2.x. To make a safe bet i would first manually (Sdcard) update the PLC firmware to at least 2.4.x and then to 2.5.x. After that AB programming tool should be able to update it without issues.
AC500 PLC's have a hardware index number. It's a letter with number and written at the sticker right side of the module after the PLC type eg. PM573-Eth C0. PM573-Eth with index number B3 or higher can't be downgraded below firmware 2.5.x. There was some kind of memory chip change on the physical hardware.
Oh and AB 2.2 doesn't use firmware 2.2.0, versions don't go hand in hand