luanke
Member
Hello all, and thank you in advance for any assistance you may be able to provide! This is my first post, so if I need to reformat or change anything, please let me know and I will do so.
Quick Synopsis:
We unintentionally flashed a CompactLogix 1769-L24ER-QB1B Series B controller with firmware 30.011, which is unsupported by the Series B. Now it is seemingly stuck in a boot loop with no USB or ethernet connectivity available, and I get no response from attempting to reset the controller via faceplate reset button hold.
Longer Explanation:
My company used CompactLogix 1769-L24ER-QB1B (series A) controllers in a particular machine line that we produced for many years (and still support). However, now that the same controller in series A is no longer widely available, we must provide Series B controllers if a replacement PLC is needed in an existing machine. The most recent program used in the Series A controllers was made using RSLogix 5000 version 30, with controllers using firmware 30.011. We recently (~3 months ago) replaced a customer's Series A controller with a Series B for the first time, upgrading the firmware to 30.016 in the process (the lowest v30 firmware supported by the Series B), and they were back up and running with no issues.
Last week, I provided files to this customer to reload the program in their PLC via the SD Card. However, the SD Card backup files we sent them were created on a Series A controller running firmware 30.011. When I spoke to our local distributor and explained the situation (including the firmwares in use and the Series A vs B controllers), I was told this should be no problem and should cause no issues.
In preparing the SD card backup files for use, I verified that the XML config file within the "CurrentApp" folder dictated the following options for restoring the backup:
<ProgramLoadOption>
<ProgramLoadMode>ALWAYS_ENET_RESTORE</ProgramLoadMode>
and
<FirmwareSupervisor>
<UpdateMode>IN_ACTIVE</UpdateMode>
I also made the unfortunate choice to alter the "Load.xml" in the "Logix" folder from saying <MaximumRevision>2 to <MaximumRevision>3 to allow the controller to load the backup.
I see in hindsight that it is likely that the firmware "UpdateMode" was ignored and the firmware on SD Card flashed anyway since the program and controller revisions did not match.
The controller then went through the process of loading the SD Card backup files, and promptly defecated in its sleeping quarters. It now appears to be stuck in a boot loop, wherein upon power up the OK light is solid red for about 20 seconds before each of the other lights light up in sequence, but then it goes directly back to the OK light being solid red for another 20 seconds, followed by the same light sequence, followed by the OK light solid red for 20 seconds, etc. I have no ethernet or USB connectivity, and I have tried resetting using the faceplate button to no avail. I have also tried flashing a program and firmware via known-good SD Card backup which has a supported firmware (tried 30.016 and 32.015) and program on it from another controller with no effect.
I am pretty sure that the controller needs to have its firmware re-flashed at this point by someone who has the equipment necessary to connect directly to the board, but before we purchase a Rockwell support subscription (we do not use AB equipment often enough any more to justify the ongoing expense) or talk to a repair shop, does anyone happen to have any thoughts or ideas?
Any help is greatly appreciated.
Quick Synopsis:
We unintentionally flashed a CompactLogix 1769-L24ER-QB1B Series B controller with firmware 30.011, which is unsupported by the Series B. Now it is seemingly stuck in a boot loop with no USB or ethernet connectivity available, and I get no response from attempting to reset the controller via faceplate reset button hold.
Longer Explanation:
My company used CompactLogix 1769-L24ER-QB1B (series A) controllers in a particular machine line that we produced for many years (and still support). However, now that the same controller in series A is no longer widely available, we must provide Series B controllers if a replacement PLC is needed in an existing machine. The most recent program used in the Series A controllers was made using RSLogix 5000 version 30, with controllers using firmware 30.011. We recently (~3 months ago) replaced a customer's Series A controller with a Series B for the first time, upgrading the firmware to 30.016 in the process (the lowest v30 firmware supported by the Series B), and they were back up and running with no issues.
Last week, I provided files to this customer to reload the program in their PLC via the SD Card. However, the SD Card backup files we sent them were created on a Series A controller running firmware 30.011. When I spoke to our local distributor and explained the situation (including the firmwares in use and the Series A vs B controllers), I was told this should be no problem and should cause no issues.
In preparing the SD card backup files for use, I verified that the XML config file within the "CurrentApp" folder dictated the following options for restoring the backup:
<ProgramLoadOption>
<ProgramLoadMode>ALWAYS_ENET_RESTORE</ProgramLoadMode>
and
<FirmwareSupervisor>
<UpdateMode>IN_ACTIVE</UpdateMode>
I also made the unfortunate choice to alter the "Load.xml" in the "Logix" folder from saying <MaximumRevision>2 to <MaximumRevision>3 to allow the controller to load the backup.
I see in hindsight that it is likely that the firmware "UpdateMode" was ignored and the firmware on SD Card flashed anyway since the program and controller revisions did not match.
The controller then went through the process of loading the SD Card backup files, and promptly defecated in its sleeping quarters. It now appears to be stuck in a boot loop, wherein upon power up the OK light is solid red for about 20 seconds before each of the other lights light up in sequence, but then it goes directly back to the OK light being solid red for another 20 seconds, followed by the same light sequence, followed by the OK light solid red for 20 seconds, etc. I have no ethernet or USB connectivity, and I have tried resetting using the faceplate button to no avail. I have also tried flashing a program and firmware via known-good SD Card backup which has a supported firmware (tried 30.016 and 32.015) and program on it from another controller with no effect.
I am pretty sure that the controller needs to have its firmware re-flashed at this point by someone who has the equipment necessary to connect directly to the board, but before we purchase a Rockwell support subscription (we do not use AB equipment often enough any more to justify the ongoing expense) or talk to a repair shop, does anyone happen to have any thoughts or ideas?
Any help is greatly appreciated.