Hello all. Transfer pump set at a water treatment works, CPU 1214C DC/DC/DC with three signal modules on it. I took the project off the works server, added an hours run counter for pump 3, compiled clean and downloaded.
Since that download the CPU ERROR LED flashes and slot 3 sits there faulted in the online view. Slots 2 and 4 are green and their channels are live, so it is one module and not the rack. Diagnostics says "The module is not configured as set", or near enough, I will get the exact line tomorrow.
Power cycled the CPU twice and loaded the hardware configuration again on its own, no change. Slot 3 is the DI DQ card that runs the two duty pumps, so nothing starts while it is out.
Is a flashing ERROR and one module down a sign the card has failed, or does a download do something to a module that a power cycle won't undo?
The module is defective. We have had three go the same way, always after a load, because the load is when the module is addressed again after sitting.
Fit the spare and load once more. If the spare is good, the card was the fault.
Spare went in this afternoon, straight out of the panel builder's box. Same flashing ERROR, same slot 3 faulted, and I loaded the hardware again after fitting it.
Then look at the bus connector. On a 1200 the modules clip together and the connector on the left neighbour carries slot 3. A half seated clip gives you a module that's there and not there. I've seen it twice.
Move the card to the end of the rack, load, and see whether the fault follows the card or stays at position three.
Moved it to the end and changed the position in the device view to match, then loaded. Fault follows the card, so it is not the clip and not that position on the rail.
Something I should maybe have said earlier. The works had a fourth pump put in during 2024 and the contractor who did it changed some of the hardware while he was there. Nobody can tell me what he changed, or whether the project I pulled off the server is the one he left behind. I'm not sure anyone here knows.
So what is TIA actually comparing when it loads, the program or the hardware?
Both, and they are separate loads. The hardware configuration is a description of what should sit in each position, order number included. At every startup and at every load the CPU compares that description against what answers in the position. If the order numbers differ it refuses that module and flashes ERROR, and the others are untouched because each one is judged on its own.
So the card is not defective, neither was the first one, and it was never the clip. Read the 6ES7 number off the side of the card in slot 3, then read the order number in the properties of the configured module. Two different numbers is your answer. The general point about the configured card and the fitted card, there is a write up here: https://plctr.com/understanding-the-basics-of-input-output-modules-in-automation/
You're right, they don't match. The card on the rail is 6ES7 223-1BL32-0XB0, DI16 DQ16, and the project on the server has 6ES7 223 1BH32 in slot 3, the DI8 DQ8. The 2024 contractor uprated the module when the fourth pump went in and the server copy is from 2023.
Fixed it in the project, not the hardware. Device view, right click slot 3, Change device, picked the DI16 DQ16 version, put the addresses back where the program expects them, compiled and loaded. ERROR LED out, three modules green, pump 3 counter running.
What I should have done first is go online and upload what was actually in the CPU. Still no idea how many other projects on that server are two years behind. Thanks gunther, dieter_k and pnina.
Upload first on any site you did not commission yourself.