PM866 Non Redundant Controller Lost Communication with 800xA System
Using 800xA5.1 FP4 REV E standalone laptop with PM866 controller (Non Redundant) in use for process control. Usually after download the program, the laptop will be disconnected from the controller and the process is controlled through Modbus communication and it works normally for 1 or 2 months, After some times, some of the process becomes uncontrollable (ex : some valves cannot operate). To check this, connected back the laptop, it’s possible to ping controller from laptop but unable perform go online / download and go online even though there is no change in the control builder software. After Reset (Press Init Button) the program can be downloaded to the controller and it works normal for few months then the same problem repeats again. The total system load during normal operation was 23%.
FYI, When we reported this problem in December 2015, the Supportline informed us to upgrade the firmware from 5.1.1110.3 (Firmware dated 3/4/2013) to 5.1.1300.11 (Firmware dated 07/10/2015).
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I assume the recommendation to upgrade that you received from the support center was based on some findings made by them. Have you upgraded the firmware and the problem remains, or are you still running an older version than recommended? A "standalone" PLC like this should be very easy to upgrade.
I recommend extracting the controller log, or to use the AC800M Fingerprint tool (its located on the SV6 media and is backward compatible with 5.1) to extract additional information. This could bring more details about what goes wrong.
Did you check the total system load after download the program only or many times along this 1 or 2 months? I imagine there is something increasing the load and after reaching critical levels communications are lost. Communicactions have lower priority under controller overload...
Is it possible to leave the laptop connected to the controller in order to monitor periodically the status?