Cp3586 wont start

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1

My cp3586 occasionally will not start just hangs. R/E RDY/F S/E are all dark.

the eth plk cf and dc are green My 2 x20 if2792 and x20 if1072 are red just waiting for the cpu. Cf card has been replaced

2

Hi @Cameron_Howson ,
it’s clear that behavior is not normal, Have you seen error entries in the system logger?

Could you attach the SystemDump to your post?
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Question to AI: “How is it possible that B&R X20CP3586 occasionally will not start just hangs?“

Answer:
The B&R X20CP3586 typically “hangs” during startup because it has entered Service Mode due to a critical system error or a hardware mismatch.

Common Causes for Startup Hangs

  • CompactFlash (CF) Card Issues: The application on the CF card may be corrupted, or the card itself may be failing, especially if a non-industrial grade card is used.

  • Hardware Configuration Mismatch: If “Module Supervision” is enabled, the PLC will hang in Service Mode if a configured I/O module is missing, unpowered, or has a firmware mismatch.

  • Software Errors: Critical runtime errors such as cycle time violations (code taking too long), division by zero, or illegal memory access (page faults) will halt the startup process.

  • Power Supply Instability: A flickering or unstable 24V supply can corrupt the CF card during boot or cause the internal power supply to fail.

Troubleshooting Steps

  1. Check LED Indicators:

    • Steady Orange/Yellow: Generally indicates the PLC is in Service Mode.

    • Blinking Red (R/E): Often indicates a specific system error or license violation.

  2. Access the System Diagnostics Manager (SDM): Open a web browser on a connected PC and enter http://<PLC_IP_Address>/sdm. This provides a detailed error log explaining exactly why the PLC is not reaching “Run” mode.

  3. Check the Logger in Automation Studio: If you have the project file, use the Automation Studio Logger to view the backtrace, which points to the specific line of code or hardware module causing the hang.

  4. Try a Cold Restart: A standard reboot may clear temporary issues, but if the underlying cause (like a cycle time violation) remains, it will hang again.

  5. Force Boot Mode: To bypass application issues and establish communication, you can manually trigger BOOT mode by pressing the reset button, waiting for the LED to turn red, and then holding the button again within 2 seconds.

    If I face your issue and I’m in Canada I send an email (with SystemDump and a short video when you see the issue) to our Support in US.

    Thanks
    Ciao
    Valerio

3

Hi @Cameron_Howson , what is the final solution on your question, have you investigated it?

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We can consider this closed. An actuall diagnosis is still ongoing how ever im convinced it’s the cpu it’s self. Since this is not a constant problem and production demands my hands are tied as to when I can actually get in their and do some digging around. Thanks for your help.