Technical Forum

SIMATIC S7-1200

CPU changes from RUN to DEFECTIVE mode

Thread Starter: delafrique   Started: 6/24/2013 9:40 PM   Replies: 9

« Previous thread Next thread »
Page 1 of 1 (10 items)
  6/24/2013, 9:40 PM
Joined 6/26/2008
Last visit: 7/3/2014
Posts: 15
Rating:
Rated: Excellent [5 out of 5 / rated 1 time(s)]. (1) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
Hi,

A CPU1214 that has been running for smoothly for over a year suddenly stopped working today.
The status of the CPU changed from RUN to DEFECTIVE.
There were no suspicious diagnostic events before or after the incident.

Diagnostics reported:

CPU info: Serious hardware inconsistency
(not relevant for user, system code: 16#00644A4E)

The help suggested to switch the PLC off and on.
That did indeed clear the fault and the PLC is running again.

However my client wants to know the root cause of the problem and the likelihood of it happening again. Any ideas?  
Top
  6/24/2013, 10:39 PM
Joined 7/7/2010
Last visit: 7/25/2014
Posts: 2960
Rating:
Rated: Excellent [4.01 out of 5 / rated 335 time(s)]. (335) 
Users with special expertise supervising conferences
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
delafrique wrote:
Hi,

A CPU1214 that has been running for smoothly for over a year suddenly stopped working today.
The status of the CPU changed from RUN to DEFECTIVE.
There were no suspicious diagnostic events before or after the incident.

Diagnostics reported:

CPU info: Serious hardware inconsistency
(not relevant for user, system code: 16#00644A4E)

The help suggested to switch the PLC off and on.
That did indeed clear the fault and the PLC is running again.

However my client wants to know the root cause of the problem and the likelihood of it happening again. Any ideas?  

I have this same thing happen to me randomly, especially when downloading to a PLC that has a high communication load (modbus/tcp, profinet, profibus, plus being online and downloading).

I chalk it up to buggy firmware.

Helpful? Rate it.
Solved? Post it.
Top
  6/25/2013, 5:34 AM
Joined 2/27/2012
Last visit: 7/29/2013
Posts: 5
Rating:
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
Dear All!
I have a same problem with PLC s7-1200 CPU 1214c AC/DC/RLY but The status of the CPU changed from RUN to STOP.

Where i install PLC, nobody have computer or laptop have TIA Portal but i know to change status of the CPU S7-1200, you must you TIA Portal

WTF???????????????????????

I don't know what happen with my PLC, i must moved 700 km only to connect plc and changed status of the CPU from STOP to RUN

I want to know what happened and how to fix it
Top
  6/25/2013, 7:41 AM
Joined 4/17/2012
Last visit: 7/1/2014
Posts: 465
Rating:
Rated: Outstanding [3.44 out of 5 / rated 9 time(s)]. (9) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
delafrique wrote:
Hi,

A CPU1214 that has been running for smoothly for over a year suddenly stopped working today.
The status of the CPU changed from RUN to DEFECTIVE.
There were no suspicious diagnostic events before or after the incident.

Diagnostics reported:

CPU info: Serious hardware inconsistency
(not relevant for user, system code: 16#00644A4E)

The help suggested to switch the PLC off and on.
That did indeed clear the fault and the PLC is running again.

However my client wants to know the root cause of the problem and the likelihood of it happening again. Any ideas?  

Hi,

This may be some option given by SIEMENS itself to restart the CPU after some predetermined continuous working hours for maintanance????

i think May be there is a option to avoid this by using error OB and startup OB 
Top
  6/25/2013, 8:56 AM
Joined 9/7/2007
Last visit: 7/20/2014
Posts: 448
Rating:
Rated: Outstanding [3.67 out of 5 / rated 43 time(s)]. (43) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
delafrique wrote:
Hi,

A CPU1214 that has been running for smoothly for over a year suddenly stopped working today.
The status of the CPU changed from RUN to DEFECTIVE.
There were no suspicious diagnostic events before or after the incident.

Diagnostics reported:

CPU info: Serious hardware inconsistency
(not relevant for user, system code: 16#00644A4E)

The help suggested to switch the PLC off and on.
That did indeed clear the fault and the PLC is running again.

However my client wants to know the root cause of the problem and the likelihood of it happening again. Any ideas?  


Sometime when you have electrical fluctuations this may make troubles to the CPU. This is somewhat strange but happened to me before. The recommendation is to feed the Automation Station from a separate UPS power feeder.




Best Regards
Top
  6/25/2013, 3:25 PM
Joined 7/7/2010
Last visit: 7/25/2014
Posts: 2960
Rating:
Rated: Excellent [4.01 out of 5 / rated 335 time(s)]. (335) 
Users with special expertise supervising conferences
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
If you are developing your application for a client who is not taking full ownership of the process with the s7-1200 plc (meaning you provide the project and they can download and service the plc as needed), you may want to consider this:

Use a memory card for your program storage.  Add every possible OB to handle software, and hardware errors, set the plc to warm restart on power cycle.  Then set the memory card as read-only.

Then if it goes into stop mode, brief instructions on the hmi or whatever system you use to describe how to effectively cycle power to just the plc so it starts back up.

Or, you could request all your customers to establish the ability for remote connectivity for you to access the plc and restart when required.  This could be an added service, but from personal experience it is great to have the option but terrible to have an emergency need to use it.

Helpful? Rate it.
Solved? Post it.
Top
  7/25/2013, 10:52 AM
Joined 9/9/2008
Last visit: 7/23/2014
Posts: 60
Rating:
Rated: Outstanding [3.67 out of 5 / rated 12 time(s)]. (12) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
I have just encountered the same error with a S7-1215C after months of usage.

Part of my diagnostic buffer (see attached file for complete buffer): 
1 of 50; Event ID: 16# 02:401A
CPU info: Serious firmware exception 
(not relevant for user, system code: 16#00644A4E 16#10000034 16#080D0000) 
 |> CPU changes from RUN to DEFECTIVE mode 
 |> HW_ID=    52 - Operating mode control

I have tried to power cycle the CPU, but the problem reappears as soon as I try to download a hardware configuration. I have just tried with a totally fresh and empty project as well. And with and without the memory card inserted. 

I wonder if the error is related to this:
-I did try to upgrade the firmware about a week ago from the CPU web page, but it kept on failing after a few minutes of uploading: 
Error:The firmware update file failed to be written. Please try again.
I wonder if a 8 MB SMC card is necessary, as the firmware file is on 5 MB, and I only have a 2MB SMC (the black Siemens Memory Cards 954 series). Do I need a memory card to upgrade the firmware? It doesn't say on the firmware pages.

Attachment: FirmwareException.zip  (9 Downloads)

Anders Jorsal
Project Engineer, Automation
Automatic Syd A/S
Smedevænget 4, DK-6310 Broager, Denmark
Tel: +45 74 44 91 91 • www.automatic-syd.dk
PLCSQL Link - SQL database client in a Siemens S7 PLC - www.plcsql.com

Top
  7/25/2013, 11:17 AM
Joined 9/9/2008
Last visit: 7/23/2014
Posts: 60
Rating:
Rated: Outstanding [3.67 out of 5 / rated 12 time(s)]. (12) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
Here is the Diagnostic Buffer from my firmware upgrade attempts from the web page.

Attachment: DiagnosticsFWupdate.zip  (14 Downloads)

Anders Jorsal
Project Engineer, Automation
Automatic Syd A/S
Smedevænget 4, DK-6310 Broager, Denmark
Tel: +45 74 44 91 91 • www.automatic-syd.dk
PLCSQL Link - SQL database client in a Siemens S7 PLC - www.plcsql.com

Top
  7/25/2013, 4:06 PM
Joined 9/19/2011
Last visit: 7/22/2014
Posts: 53
Rating:
Rated: Outstanding [3.33 out of 5 / rated 6 time(s)]. (6) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
Jorsal wrote:
I have just encountered the same error with a S7-1215C after months of usage.

Part of my diagnostic buffer (see attached file for complete buffer): 
1 of 50; Event ID: 16# 02:401A
CPU info: Serious firmware exception 
(not relevant for user, system code: 16#00644A4E 16#10000034 16#080D0000) 
 |> CPU changes from RUN to DEFECTIVE mode 
 |> HW_ID=    52 - Operating mode control

I have tried to power cycle the CPU, but the problem reappears as soon as I try to download a hardware configuration. I have just tried with a totally fresh and empty project as well. And with and without the memory card inserted. 

I wonder if the error is related to this:
-I did try to upgrade the firmware about a week ago from the CPU web page, but it kept on failing after a few minutes of uploading: 
Error:The firmware update file failed to be written. Please try again.
I wonder if a 8 MB SMC card is necessary, as the firmware file is on 5 MB, and I only have a 2MB SMC (the black Siemens Memory Cards 954 series). Do I need a memory card to upgrade the firmware? It doesn't say on the firmware pages.


You need an 8 MB Memory card to upgrade the firmware.
Top
  7/26/2013, 12:56 PM
Joined 9/9/2008
Last visit: 7/23/2014
Posts: 60
Rating:
Rated: Outstanding [3.67 out of 5 / rated 12 time(s)]. (12) 
Rated: no ratings [0 out of 5 / rated 0 time(s)]. (0) 
I just succeeded upgrading the firmware to V3.0.2 using a 24 MB SMC card, and it seems like the problem is gone.

Anders Jorsal
Project Engineer, Automation
Automatic Syd A/S
Smedevænget 4, DK-6310 Broager, Denmark
Tel: +45 74 44 91 91 • www.automatic-syd.dk
PLCSQL Link - SQL database client in a Siemens S7 PLC - www.plcsql.com
Top
Page 1 of 1 (10 items)
Actions