Automation APC 810: Error occurred after startup; even after reinstalling, the issue persists. How should I resolve this? Thank you

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1

Dear engineers, I’m having a major issue and would appreciate your help. Recently, after repairing a device, it has failed to start up.

As shown in the following picture, there is an error.

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21920×2560 1.14 MB

Subsequently, after I performed the reinstallation, although the software could connect normally (with the interface showing green), it still reported a network failure.

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31080×1440 249 KB

Then I attempted to restore the files in AR010. Although the network was stable, there were still other errors occurring.

The content of the AR010log.txt file:



Tue Mar 27 07:08:07 2012
RTOS-Driver COM1 : RTOS Serial port
RTOS-Driver COM2 : RTOS Serial port
Number of processors :1  active core(s):0x1
Cores in boot.ini : /numproc=1


Bernecker & Rainer 
IP shared Windows: 10.100.4.115
IP shared AR: 10.100.4.116
Timeout = 0[sec]
Retrycount = 30


Tue Mar 27 07:08:08 2012
Dongle for ARwin found!
Dongle for NC found!
BIOS-Version : 1.19
BIOS-Type : H
COMMAND_COLDSTART

Product:            VxWin V5.0.00 (5.0.0.39)
Base:               V5.0.0.39
RtosWin version:    5.0
Hosting OS:         Windows XP Embedded Service Pack 3.0 (32 bit) 


UploadRTOS.dll version:                                   7.18.18.0

RtosDrv - Realtime OS Driver
  Driver version                                          9.1.10.0
  Inf file version                                        1.2.4.0
  Installer version                                       0.0.0.1
  Required VMF version                                    1.27.11.0

RtosVnet - Realtime OS Virtual Network Adapter
  Driver version                                          7.7.0.0
  Inf file version                                        1.1.3.0
  Installer version                                       0.0.0.1
  Required VMF version                                    1.20.0.0

RteDevice - RTOS Serial port (COM1)
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - RTOS Serial port (COM2)
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.4.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #9
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #10
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #11
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #16
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #17
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #18
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #19
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - Realtime OS Virtual Network Adapter
  Driver version                                          ignored
  Inf file version                                        ignored
  Installer version                                       ignored
  Required VMF version                                    1.20.0.0

RteDevice - Realtime OS Driver
  Driver version                                          ignored
  Inf file version                                        ignored
  Installer version                                       ignored
  Required VMF version                                    1.27.11.0

RtosService version:                                      3.5.4.0

RtosControl version:                                      7.6.4.2

Virtual machine framework version:                        1.27.12.0
Virtual machine framework version required by Uploader:   1.27.11.0


Reservation active    : base 64Mb and size 200000Kb.


Loading VMF...Ok
Virtual machine framework version required by OS:         1.27.x.x


Start OS - Id:0... Ok
Waiting for Windows <--> Realtime OS communication subsystems...... ok
AR-version : P4.02
Unloading VMF...Ok

Product:            VxWin V5.0.00 (5.0.0.39)
Base:               V5.0.0.39
RtosWin version:    5.0
Hosting OS:         Windows XP Embedded Service Pack 3.0 (32 bit) 


UploadRTOS.dll version:                                   7.18.18.0

RtosDrv - Realtime OS Driver
  Driver version                                          9.1.10.0
  Inf file version                                        1.2.4.0
  Installer version                                       0.0.0.1
  Required VMF version                                    1.27.11.0

RtosVnet - Realtime OS Virtual Network Adapter
  Driver version                                          7.7.0.0
  Inf file version                                        1.1.3.0
  Installer version                                       0.0.0.1
  Required VMF version                                    1.20.0.0

RteDevice - RTOS Serial port (COM1)
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - RTOS Serial port (COM2)
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.4.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #9
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #10
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #11
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #16
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #17
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #18
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - B&R Interface Card for ARwin #19
  Driver version                                          5.3.3.0
  Inf file version                                        1.4.2.0
  Installer version                                       1.0.5.0
  Required VMF version                                    1.26.0.0

RteDevice - Realtime OS Virtual Network Adapter
  Driver version                                          ignored
  Inf file version                                        ignored
  Installer version                                       ignored
  Required VMF version                                    1.20.0.0

RteDevice - Realtime OS Driver
  Driver version                                          ignored
  Inf file version                                        ignored
  Installer version                                       ignored
  Required VMF version                                    1.27.11.0

RtosService version:                                      3.5.4.0

RtosControl version:                                      7.6.4.2

Virtual machine framework version:                        1.27.12.0
Virtual machine framework version required by Uploader:   1.27.11.0


Reservation active    : base 64Mb and size 200000Kb.


Loading VMF...Ok
Virtual machine framework version required by OS:         1.27.x.x


Start OS - Id:0... Ok
Waiting for Windows <--> Realtime OS communication subsystems...... ok
AR-version : P4.02

ARwin Startup Console Log:

2012-03-27 07:24:23 $arlogsys:ERROR 26456, lpBin=0x0a738a94, ARLOG_LEVEL_WARNING, "ROOT", "DP: '$root:TemperatureCPU'"
2012-03-27 07:24:23 $arlogsys:ERROR 26456, lpBin=0x0a738a94, ARLOG_LEVEL_WARNING, "ROOT", "DP: '$root:SystemTime'"
2012-03-27 07:24:23 $arlogsys:ERROR 28713, lpBin=0x0a7388e4, ARLOG_LEVEL_WARNING, "ROOT", "Platformclass not found"
2012-03-27 07:24:19 $arlogsys:ERROR 28724, lpBin=0x0a738a64, ARLOG_LEVEL_WARNING, "ROOT", "vcpf010"
2012-03-27 07:24:19 $arlogsys:ERROR 28729, lpBin=0x0a738a14, ARLOG_LEVEL_WARNING, "ROOT", "HW-Platform not supported"
2012-03-27 07:24:19 $arlogsys:ERROR 28729, lpBin=0x0a738a04, ARLOG_LEVEL_WARNING, "ROOT", "HW-Platform not supported"
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c16178e, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST16: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c161775, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST15: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c161775, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST14: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c1617a7, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST17: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c16178e, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST12: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c161775, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST11: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:49 $safety:ERROR 110403, lpBin=0x0c161775, ARLOG_LEVEL_INFO, "DdxxIoSafetyLogger", "SL2.IF2.ST2.IF1.ST13: Info0=0x0000, Info1=0x00000000 "
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1af844, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Master parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 34 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 33 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 28 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 27 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 26 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 25 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 24 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 23 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 22 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 21 parameter set"
2012-03-27 07:23:46 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 4 parameter set"
2012-03-27 07:23:44 $fieldbus:ERROR 0, lpBin=0x0c1b00bf, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "PROFIBUS Slave 3 parameter set"
2012-03-27 07:23:44 $fieldbus:ERROR 0, lpBin=0x00000000, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "Deleted static PROFIBUS configuration!"
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=12, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=16, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=15, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=14, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=11, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=10, Info1=0, Info2=0x0000 "
2012-03-27 07:23:36 $safety:ERROR 114825, lpBin=0x0c161162, ARLOG_LEVEL_WARNING, "DdxxIoSafetyLogger", "SL2.IF2.ST1: SafeMODULE ID=13, Info1=0, Info2=0x0000 "
2012-03-27 07:23:35 $fieldbus:ERROR 0, lpBin=0x00000000, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "Static PROFIBUS configuration found!"
2012-03-27 07:23:35 $fieldbus:ERROR 0, lpBin=0x00000000, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "Fieldbus interface: DPM     BRIE     - Version: V01.201 04.07.05 (Version V01.097 or higher is supported!)"
2012-03-27 07:23:35 $fieldbus:ERROR 0, lpBin=0x00000000, ARLOG_LEVEL_INFO, "DdxxIoProfiBus.SL1.IF2.ACC", "Startup PROFIBUS driver"
2012-03-27 07:23:34 $arlogsys:ERROR 28729, lpBin=0x0a7389d4, ARLOG_LEVEL_WARNING, "ROOT", "HW-Platform not supported"
2012-03-27 07:23:33 $arlogsys:ERROR 9212, lpBin=0x0a738ea4, ARLOG_LEVEL_WARNING, "ROOT", "Boot"
2012-03-27 07:23:32 $arlogsys:ERROR 30964, lpBin=0x0a738d24, ARLOG_LEVEL_FATAL, "ROOT", "ArConfig: CPU mismatch"
2012-03-27 07:23:31 $arlogsys:ERROR 0, lpBin=0x0a738cb4, ARLOG_LEVEL_WARNING, "ROOT", "missing descr. in HWD <0xa3ed>"

I hope everyone can help figure out the solution. Thank you very much.

2

Then I attempted to restore the files in AR010. Although the network was stable, there were still other errors occurring.

6
61117×1581 218 KB

8
8595×811 119 KB

3

Hi,

as you write it happened after repair of the device: what exactly was repaired? And was the repair done by the machine manufacturer, or by B&R? I’m asking because it looks like that the hardware does not match (anymore) to the software project.

From the logger data you posted (the data from $arlogsys) it looks like that the installed project does not match to the processor type → the first entry says “CPU mismatch”. This normally happens if for example the processor board does not match to the one used in the project (which then leads to many more hardware errors in the logger) → so is this software really the right one for this hardware, is the hardware really exactly the same then before?

The picture of the batch file where the software was reinstalled is unknown to me, doesn’t look like some software of B&R → I assume it’s something that was prepared from the machlne manufacturer?

Unfortunately that’s all what I can see out of the pictures.
I think this issue is too machine specific to be solved by the community.
I would recommend to reach out the machine manufacturer, who could get assistance from local B&R support if needed.

Best regards!

4

(post deleted by author)

5

IMG_20260822_234540
IMG_20260822_2345401916×476 217 KB

We are very grateful for your help over the weekend. We did not repair any hardware, we simply disconnected the power supply once. After ARwin failed to run the first time, we reinstalled ARwin (the CPU fault disappeared). ARwin can now run without error reports, but it cannot connect to the x20, and the operation failure shown in the picture below occurs. We do not know where the problem is and hope to get your help. Thank you.