7 1 Maintenance and Troubleshooting

7 1 Maintenance and Troubleshooting
Maintenance and
Troubleshooting
In This Chapter. . . .
— Isolating a Communication Problem
— Troubleshooting Chart
— ECOM Module Diagnostic LEDs
— Using NetEdit3 for Troubleshooting
— Replacing the ECOM Module
17
7--2
Maintenence & Troubleshooting
Maintenance and
Troubleshooting
Isolating a Communication Problem
If you are experiencing a problem communicating with an ECOM module, the
problem can usually be isolated to one of four components of the communication
link:
S the ECOM module itself (hardware or firmware)
S the communication program or the setup of the ECOM module
S the cabling and connections
S other external influences, such as electrical noise, heavy communication
traffic on the network or exceeding the PLC power budget
You can also use your PC’s DOS “Ping” command to verify communications with a
network server. The PC’s NIC must have the TCP/IP protocol enabled and the
server must have a valid IP address. Visit www.microsoft.com for information on the
“Ping” command.
Diagnostic Tools
and Techniques
Several available tools and techniques can help you isolate a communication
problem:
S The LEDs on the face of the module indicate the status of the link, the
module, and the network communications.
S NetEdit3 displays a list of the active modules on the network and their
protocol and configuration settings.
S Cable testing devices can pinpoint short or open circuits or diagnose
attenuation problems and other cabling problems.
Troubleshooting Chart
The following chart summarizes the different types of communication failures you
could experience. In each case the CPU PWR LED must be on, and you must be
attempting to communicate with the ECOM in question. You must be attempting to
send or receive RX/WX instructions or you must be attempting to link to the ECOM
using our KEPDirect for PLCs or other software driver.
The meaning of the diagnostic LEDs is explained begining on page 7-4.
Troubleshooting Chart
Legend:
Off
ECOM Module LEDs
ECOM(--F)
LINK/LINKGD
ACT
ERROR/ERR
ECOM(--F)
OR
ECOM100
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
LINK/LINKGD
ACT
ERROR/ERR
ECOM100
OR
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
On
Flash
Corrective Action
1. Cycle power to the PLC. This will clear
the error if it was due to a transient
condition.
2. Replace ECOM module
Maintenance and Troubleshooting
7--3
Troubleshooting Chart (Continued)
Legend:
Off
ECOM Module LEDs
ECOM100
LINK/LINKGD
ACT
ERROR/ERR
Flash
Corrective Action
1. Try another cable that you know works.
Check pinouts (see page 2-12).
2. Try another port on the hub or
another hub.
3. Replace ECOM module.
1. Are PLCs in RUN mode? Some communications require initiating and responding
PLCs to be in RUN mode.
ECOM100
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
ECOM(--F)
LINK/LINKGD
ACT
ERROR/ERR
2. Try another cable between PC and hub
or the other communicating ECOM and
hub.
3. Try another port on the hub or another
hub.
4. Make sure you have not exceeded the
recommended cable length for your
network cable. The link signal could
arrive with sufficient strength even
though the data transmission does not.
5. Could be related to Windows configuration. Consult Windows documentation.
Note: This is also the indication of proper
operation! Troubleshoot only if you are
failing to exchange data.
ECOM(--F)
LINK/LINKGD
ACT
ERROR/ERR
ECOM(--F)
OR
ECOM100
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
LINK/LINKGD
ACT
ERROR/ERR
ECOM100
OR
1. Try another cable between PC and hub
or other ECOM and hub.
2. Try another port on the hub or another
hub.
3. Confirm that ECOM module is in a usable
slot in the PLC base (see pages 2-7 to 2-9)
and that the CPU and CPU firmware support the ECOM module.
4. Look for errors in the setup of the ECOM
module or in the communication program.
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and
Troubleshooting
OK / STATUS
LINKGD/LINK
ACTIVE/ACT
ERROR/ERR
ECOM(--F)
On
7--4
Maintenence & Troubleshooting
ECOM Module Diagnostic LEDs
H0 Series
Indicators
The H0 series ECOM module has four status indicators. The table below explains
the status for each indicator.
Indicator
OK
(H0--ECOM only)
Maintenance and
Troubleshooting
LINK
ACT
ERR
100
(H0--ECOM100 only)
OK Indicator
LINK indicator
ACT Indicator
ERR Indicator
100MBIT
Indicator
Status
Description
ON -- GREEN
Module is powered up and functional
OFF
Module powerup failed
ON -- GREEN
Properly connected to network
OFF
Not connected to network or incorrect
configuration
ON or FLASHING RED
Active network data
OFF
Network idle
ON or FLASHING RED
A fatal error has occurred
OFF
No error present
ON --GREEN
Ethernet data is detected at 100MBit
OFF
(with ACT LED ON) -- Ethernet data is
detected at 10MBit
The green OK LED on the H0--ECOM module is on steady after a successful
powerup. If the LED fails to turn on, the module failed to powerup. It may not be
properly installed or it may be defective.
The green LINK (link good) LED is on steady when the ECOM module is correctly
connected to an active device on the network and is receiving 5VDC operating
voltage from the PLC power supply. The LINK LED verifies that the proper cables are
connected, and the ECOM module is functioning correctly. If a mismatch with the
10/100BaseT connections occurs this LED will not be illuminated.
The red ACT (activity) LED flashes to indicate that the module sees data travelling
on the network. If any network device is sending or receiving data, the ACT LED will
be illuminated. In idle mode (no network traffic) this LED is OFF. During heavy
communication loads this LED will be steady on.
If the ECOM module’s red ERROR indicator is flashing or steady on, a fatal error
has occurred. The error may be in the ECOM module itself, or a network problem
may be causing this symptom. The ERROR indication can be caused by a faulty
ground, an electrical spike or other types of electrical disturbances. Cycle power to
the system to attempt clearing the error.
The green 100 (100MB) LED is on steady when Ethernet data is detected at
100BaseT frequency. (H0--ECOM100 only)
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and Troubleshooting
H24--ECOM--(F)
Indicators
The table below describes the three status indicators on the H24--ECOM modules.
Indicator
LINKGD
ACT
ERROR
ACT Indicator
ERROR Indicator
Status
Description
ON -- GREEN
Properly connected to network
OFF
No connected to network or incorrect
configuration
FLASHES RED
Active network data
OFF
Network idle
ON or FLASHING RED
A fatal error has occurred
OFF
No error present
The green LINKGD (link good) LED is on steady when the H24--ECOM--(F) module
is correctly connected to an active device on the network and is receiving 5VDC
operating voltage from the PLC power supply. The LINKGD LED verifies that the
proper cables are connected, and the H24--ECOM--(F) module is functioning
correctly. If a mismatch with the 10BaseT or 10BaseFL connections occurs this LED
will not be illuminated.
The red ACT (activity) LED flashes to indicate that the module sees data travelling
on the network. If any network device is sending or receiving data, the ACT LED will
be illuminated. In idle mode (no network traffic) this LED is OFF. During heavy
communication loads this LED will be steady on.
If the H24--ECOM--(F) module’s red ERROR indicator is flashing or steady on, a
fatal error has occurred. The error may be in the H24--ECOM--(F) module itself, or a
network problem may be causing this symptom. The ERROR indication can be
caused by a faulty ground, an electrical spike or other types of electrical
disturbances. Cycle power to the system to attempt clearing the error.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and
Troubleshooting
LINKGD indicator
7--5
7--6
Maintenence & Troubleshooting
H2/H4--ECOM100
Indicators
The H2/H4--ECOM100 module has several status indicators. The table below
explains the status for each indicator.
Indicator
STATUS
(H2--ECOM100 only)
LINKGD
Maintenance and
Troubleshooting
ACTIVE
ERROR
100MBIT
STATUS Indicator
LINKGD indicator
ACTIVE Indicator
ERROR Indicator
100MBIT
Indicator
Status
Description
ON -- GREEN
Module is powered up and functional
OFF
Module powerup failed
ON -- GREEN
Properly connected to network
OFF
Not connected to network or incorrect
configuration
ON or FLASHING RED
Active network data
OFF
Network idle
ON or FLASHING RED
A fatal error has occurred
OFF
No error present
ON
Ethernet data is detected at 100MBit
OFF
(with Active LED ON) -- Ethernet data is
detected at 10MBit
The green OK LED on the H2--ECOM100 module is on steady after a successful
powerup. If the LED fails to turn on, the module failed to powerup. It may not be
properly installed or it may be defective.
The green LINK (link good) LED is on steady when the H2/H4--ECOM100 module
is correctly connected to an active device on the network and is receiving 5VDC
operating voltage from the PLC power supply. The LINK LED verifies that the proper
cables are connected, and the H2/H4--ECOM100 module is functioning correctly. If
a mismatch with the 10/100BaseT or 10BaseFL connections occurs this LED will not
be illuminated.
The red ACTIVE (activity) LED flashes to indicate that the module sees data
travelling on the network. If any network device is sending or receiving data, the ACT
LED will be illuminated. In idle mode (no network traffic) this LED is OFF. During
heavy communication loads this LED will be steady on.
If the H2/H4--ECOM100 module’s red ERROR indicator is flashing or steady on, a
fatal error has occurred. The error may be in the H2--ECOM100 module itself, or a
network problem may be causing this symptom. The ERROR indication can be
caused by a faulty ground, an electrical spike or other types of electrical
disturbances. Cycle power to the system to attempt clearing the error.
The green 100M (100MB) LED is on steady when Ethernet data is detected at
100BaseT frequency.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and Troubleshooting
7--7
Using NetEdit3 for Troubleshooting
NetEdit3 is a software utility which came with this manual. To review the procedures
for running and using NetEdit3, see pages 3--5 through 3--12. NetEdit3 allows you to:
S See active modules on the network.
S Examine and change the modules’ configuration settings.
S See the firmware revision number.
S Review statistical information about communication errors by type.
Select a Module
The Module box shows the Ethernet (MAC)
Addresses of all modules which are
currently linked to the NetEdit3 utility. If your
ECOM module is not on this list, try the
following:
S
Change Protocol selection and click on
Scan Network. See Change Protocol
on the next page.
S
Confirm that your PC has IPX or
TCP/IP protocol loaded.
Confirm that the ECOM module’s
LINKGD LED is on.
S
NOTE: The Ethernet (MAC) Address is permanently assigned at the factory, and it is
recorded on a label on the side of the ECOM module. See page 2-4 if you need help
locating the label.
Module Information The Module Information box gives the ECOM
module Type, firmware Version, Booter
firmware version and the address DIP switch
setting.
Verify
that
all
modules
of the same type have the same firmware
version.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and
Troubleshooting
If you can see the ECOM module on the list in the Module box (described below), you
are linking to the module from your PC. If you are linking to the module but failing to
communicate with the module, you can conclude that:
S The module is working.
S The cabling is satisfactory from the PC to the hub and from the hub to the
ECOM module.
S The hub is working.
S The problem is in one of the other components of the communication link.
7--8
Maintenence & Troubleshooting
Change Protocol
If you are experiencing a problem
communicating from your PC to a module
that does not appear on the list of active
modules, try changing the protocol and
clicking on Scan Network. You may be able
to link to your module with the other protocol.
Maintenance and
Troubleshooting
If you are not sure which protocol you have loaded on your PC, refer to pages 3--4
and 3--5, as well as your Windows documentation. This protocol selection is only for
PC-to-PLC communications and has no effect on PLC-to-PLC communications.
Ethernet Stats
If you are able to see the problem module on the list of modules currently active on
the network, you can select the module to see the Ethernet Stats for that module.
Select the module by clicking on the Ethernet (MAC) Address in the Module box.
To begin a new statistical record, click the Clear Stats button.
The diagnostic information available in the Ethernet Stats box is:
S
S
S
S
S
S
Missed Frames -- frames lost
due to unavailability of buffer
space.
TX Collisions -- detected when
RXD+ and RXD-- become active during a data transmission. Two
devices are trying to communicate at the same time.
Lost Packets -- packets that overflow the queue.
Bad Packets -- packets that fit the Ethernet standard but are not in the
right format for the ECOM module.
Unknown Type -- a foreign command was received and could not be
interpreted. This will probably happen only during software driver
development.
Send Errors -- the Ethernet standard number of retries were attempted
for a transmission.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and Troubleshooting
7--9
The RX/WX Settings box in this window provides a
place to make changes that affect PLC-to-PLC
communications only.
Change these settings only if:
S The LINK/LINKGD LED is on.
S The ACT LED is flashing.
S You have explored the module
configuration and RLL programming
for possible errors.
Record the
Module Settings
If you are replacing an existing module, record the existing network identifier settings in
the Configuration box. Set up the replacement module by linking to it with NetEdit3 and
inserting the same network identifiers in the Configuration box. Click on Update
Module to store the settings in the ECOM module’s flash memory.
Each module on the network must have a unique network identifier.
Maintenance and
Troubleshooting
RX/WX Settings
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
7--10
Maintenence & Troubleshooting
Maintenance and
Troubleshooting
Replacing the ECOM Module
If you are experiencing a communication problem, and you think the ECOM may be
defective, try replacing the ECOM module with a new one or one that you know is
working properly. If that corrects the problem, then the original module is probably
defective (assuming the replacement module was set up the same as the original
and no changes have been made to the communication program or other network
components). The diagnostic LEDs will help you determine which applies in this
case. If replacing the module does not correct the problem, then the problem is
probably not in the module.
If you are replacing an existing ECOM module with a new one, you need to set up the
new module with the same network identifiers as the module you are replacing. If
you used the DIP switch to set the Module ID, you will need to set the DIP switch on
the replacement module to the same Module ID. See pages 2-5 or 2-6 to review the
procedure for setting the Module ID using the DIP switch.
If you set up your original ECOM module using one of the software utilities, you will
need to refer to your record of the module’s network identifiers (see page 2-2) and
duplicate the settings in the new module using the same procedures. See page 3--5
through 3-12 to review the procedures for using the software utilities.
To replace the ECOM module, disconnect power from the PLC and remove the
original module. Insert the replacement ECOM module, connect the module to your
network and apply power to the PLC. Links to other network devices will
automatically be reestablished and communications between devices will resume.
WARNING: Your system can be damaged if you install or remove system
components before disconnecting the system power. To minimize the risk of
equipment damage, electrical shock, or personal injury, always disconnect
the system power before installing or removing any system component.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and Troubleshooting
7--11
Diagnosing Network Cable Problems
It is a good maintenance practice to test network cables periodically and maintain a
permanent record of cable characteristics. A number of cable test instruments are
available to test 10/100BaseT and 10BaseFL networks. These instruments will
check the electrical or optical characteristics of your cabling, including:
S Continuity -- This is a check to make sure the communication pairs are
wired correctly, and that the wires are continuous from end to end. In the
case of fiber optic network this is a test to be sure light is transmitted
from one end of the cable to the other.
S Attenuation -- This refers to the amount of signal loss over the cable
segment at the signal frequency of interest. The 10/100BaseT
specification allows for a maximum signal loss of 11.5 decibels (dB) for
the entire link at the signal frequency used by 10Mbps Ethernet. The
10BaseFL specification calls for the optical loss in link segment to be no
greater than 12.5 dB.
S Crosstalk -- Crosstalk occurs when a signal in one pair of wires is
electromagnetically coupled to an adjacent pair. This is critical
for10BaseT networks which are susceptible to noise interference.
10BaseFL networks are virtually immune to noise interference.
NOTE: Any significant difference between the cable characteristics of the
transmitter and receiver can cause communication errors.
Ethernet devices continually monitor the receive data path for activity as a means of
verifying their link is working correctly. When the network is idle, each network device
(including the ECOM module) sends a periodic link test signal to verify that the
network is working. If the link test signal or other network activity is not received
periodically, the LINK/LINKGD LED on the ECOM module is turned off.
Ethernet Communications Modules, 3rd Edition Rev. C, 06/11
Maintenance and
Troubleshooting
If you are experiencing communication problems, swapping cables is one of the
simplest diagnostic procedures you can perform. If the network operates correctly
with a different cable, you have isolated and cured the problem. If possible, use a
short run of cable to test the network because problems with longer cable runs can
be more difficult to diagnose and are more often intermittent.
If you are unable to swap cables, verify the proper operation of all other network
components. You probably have a cable problem if you have verified that your:
S ECOM module is working correctly.
S ECOM module configuration is correct.
S RLL program or PC program is correct.
S hubs are working correctly.
S Windows configuration is correct.
S network adapter card is the correct type, and it is working correctly.
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