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

jun · August 21, 2026, 1:56pm

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.

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

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.

jun · August 21, 2026, 2:00pm

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

alexander.hefner · August 22, 2026, 2:56pm

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!

jun · August 22, 2026, 3:51pm

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.

alexander.hefner · August 22, 2026, 5:42pm

Hi,

these 3 messages are the only ones?
Then I assume that there’s no project downloaded into the AR until now… this logger looks like a fresh installed runtime, for example like a initial installation of a PLC without machine specific software loaded.
The ArWin is just the PLC Operating System itself and does not contain any machine specific configuration (like the hardware setup of the system) or application code - these parts are programmed and configured by the machine manufacturer, and you need the machine project or some similar software package from the machine builder.

Best regards!

jun · August 22, 2026, 6:45pm

Yes, I reinstalled ARwin. I have backups of the RPSHD and RPSHDS folders on my computer. I would like to ask, if I simply copy and replace the contents of the old backup RPSHD and RPSHDS folders to the new ARwin installation directory, will it be able to link properly? The meaning is that the ARwin status shows green, but the main problem at present is that the security module cannot be powered, and the auxiliary circuit cannot start.

alexander.hefner · August 22, 2026, 8:34pm

Hi,

As you have a copy, yes it’s worth a try copying RPSHD and RPSHDS. Normally these folders contain some subfolders which contain the executables for the PLC.
Please ensure that ArWin is completely shut down before copying the folders.

Best regards!

jun · August 23, 2026, 1:43am

Okay, I’ll test this method on Monday to see if it’s feasible. If there are error logs, I will consult with you again.

valerio.manenti · August 23, 2026, 12:32pm

Hi @jun ,
Out of curiosity, as Alex asked: Do you have the original project (.prj) and the instructions on how to configure the machine (such as homing, loading the machine configuration, or loading a recipe) developed by the machine builder?

If ArWin is running with no errors, and you have AS along with the AS project, you can transfer the project and load all the data needed to run the machine properly again.

Ciao
Valerio

jun · August 23, 2026, 12:44pm

As far as I know, we only have the file in the picture, not (. prj). Can this be fixed? We have replaced the motherboard hardware of the same model as apc810 and hope for guidance on the repair. Thank you.

valerio.manenti · August 23, 2026, 12:54pm

Hi @jun ,
In most cases, OEMs deliver the machine with a basic image of Windows, ArWin, and the project already installed. They might send a few upgrades later, which the end user installs using a USB drive, for example. From what I understand, you don’t have these, so follow the instructions provided by Alex and cross your fingers.

Ciao
Valerio

jun · August 23, 2026, 12:58pm

At present, we have only replaced the motherboard. Can we reinstall ARwin and only copy the contents of the RPSHD and RPSHDS folders? Can this be successful? Will the hardware information configuration ARwin automatically generate when reinstalled? Can this method be passed?

alexander.hefner · August 23, 2026, 5:12pm

Hi,

The folder structure from your screenshot (including the RPSHD and RPSHDS directories, but also everything else) contains the binaries of the project, the Automation Runtime used inside ArWin and also probably other stuff like webserver data, user files and so on (that depends on if it was used or not inside the project).
But everything is just in binary format, the project sources aren’t included.

When the motherboard was exchanged, it’s crucial that it was replaced with exactly the same type of hardware. If it isn’t the same, unfortunately it won’t work (the project sources also define which hardware is used, and these binaries can only be used with that type of hardware).
“Exact same type of hardware” in detail means for example:
The APC810/PPC810 system family has had several different processor boards (containing processor and chipset), different system units (the unit where additional PCI cards can be plugged in), and so on available.
The used APC/PPC configuration was defined in the project sources, and then compiled for exactly that hardware, and these binary modules can just be used on the same configuration when hardware is replaced.

Let’s make an example:
If the original system configuration had used a processor board with order code “5PC800.B945-01”, then the ArWin configuration using that executables can only be used on that processor board - if it’s excanged with another one (let’s for example say “5PC800.B945-02”), most probably WIndows XP will still work, but the compiled ArWin project does not fit to the hardware and therefore won’t start - in such a case, you’ll get in the logger error messages in direction of “CPU mismatch” and more.

→ so you should check if the replacement parts (“mainboard”, but maybe also other components) are really the exactly same than the origin one; if not, then it definitely won’t work with AR010.
Normally, inside the APC there should be some stickers containing a barcode and the textual information about the B&R order codes.

To get a running project with changed hardware, you definitiely need to have the Automation Studio project sources, the right Automation Studio version to make changes in this project, and all upgrades needed for the software (for example the right upgrade for the Automation Runtime Version).
This project sources can just be provided by the machine manufacturer (B&R does not have project sources from machine manufacturers, besige the hardware itself B&R just provide the “common stuff” like operationg systems, system libraries, and the IDE).

I’m not sure if you have this Automation Studio project, but unfortunately I don’t think so - at least the folders screenshots you provided don’t contain any source project data.

Best regards!

jun · August 24, 2026, 7:33am

Thank you very much for your kind reply. You are a person worthy of respect. We are considering whether the old motherboard can be repaired. If not, we have already planned to communicate with the equipment supplier in Italy for assistance. Thank you again for your help. Wish you all the best in your work and life.

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

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