PP41 panel problem

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1

Hi All,

There is a 4P3040.00-K44 panel in our machine. The panel communicates with the ABB PLC and other equipment used in the machine via RS485 (7IF361.70-1). Unfortunately, although the panel seems to be fully functional, the Profibus communication does not work. We tried it with the 4P3040.00-K23 panel that works on another machine of the same type but a little older, but unfortunately it does not communicate either. I have a few questions about this problem:

  • Unfortunately, we do not have the project created with AS. However, we do have the instruction list prepared for PVITransfer, the necessary files and the PVITransfer used for this. As far as we understand from the PVITransfer features, the project was created with AS version 2.5.0.3017. Unfortunately, I could not find this version. Can someone who has it share it?

  • How can we understand what the problem is with the 4P3040.00-K44 panel? For example, is there a problem with the RS485 communication parameters? If so, how can we change these parameters?

  • Is it possible to upload the project on the 4P3040.00-K44 panel to the computer? If possible, how?

  • Can an AS project be created again with the files we have?

Thank you in advance for your help.

2

Hello,

I try to answer your questions:

  1. AS2.5 is obsolete since approx. 20 years and even if we send it to you it is no longer possible to licence this version
  2. I doubt that there is a problem with the communicaiton parameters. If this machine was running why should parameters suddenly no longer work ? I rather think there is a hardware issue with either the PP41 or the IF card (and both are obsolete but might be repairable depending on the issue)
  3. The project cannot be uploaded - only compiled BR modules can be uploaded but this is basically the same as you already have (the PIL list and the files you mentioned)
  4. No

Sorry for the hard answers but I think you should contact your responsible B&R subsidiary and ask for repair of the PP41 and IF card (assuming they worked before in this machine)
Nevertheless B&R cannot help with the project as also for B&R the compiled modules are not replaceable (or decompileable) to get the original project

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3

Dear Oliver,

First of all, thank you for your answer.

  • It seems that since the project was created with AS2.5, it is not possible to access this panel without the correct version, is that true? If so, how long can this version be used without licensing?

  • The IF card works. We know this because we tested it with other working IF cards on the same machine. Since I don’t have enough knowledge about B&R, this question may seem stupid, but I have to ask: The orange LED on the IF module is almost always ON, while the green LED flashes as if it is communicating. Does this mean that only the IF module is communicating? In this case, the panel communication is not actually working, but is the LED on the IF misleading us?

  • It is also confusing that the panel that works on the other machine does not work on this machine. Of course, I don’t think it should work 100%, because even if they are the same manufacturer and the same model machines, different parameters may have been used due to their production years. The versions of the files I upload from that panel are different. However, when I upload the files we want to work, the panel does not communicate.

  • Is there a way to change and/or test the RS485 parameters?

4

Hello @Nikolay_Nikolov

  • this is not 100% correct. Any AS version can access the PP41 (as long as the version supports a PP41 hardware). This means you can go online, watch variables, read the loggbook, etc…
    I suggest to use AS2.7 which does not need any licence any longer
    Automation Studio V2.7 | B&R Industrial Automation
    As you do not have the original project it is irrelevant which version you use (my opinion)

  • I do not find any LED documentation right now but as far as I remember the green LED indicates if communication between the PP41 and the IF card is taking place and the orange one if Profibus is active. Your LED status should mean: PP41 to IF = OK ; IF to Profibus = NOT OK (I think it should flicker)

  • I still think that there is an issue with the IF card or the attached Profibus devices. Have you checked wiring ? (probably this is only a damaged cable)

  • The IF361 is a Profibus card and for checking baudrate on Profibus you would need a Profibus analyzer. Using such a device would show if communication takes place and which Baudrate is used

5

Dear Oliver,

  • I really appreciate your help. I downloaded AS2.7 but I couldn’t connect to the panel. I didn’t try hard because I thought I couldn’t connect because I was using a different version, but apparently it is possible. Can you please tell me how I can connect to the panel that is working with the current project and check the variables?

  • I couldn’t find any information about the LED status either. I will look more carefully according to the information you provided.

  • All the other hardware works except the panel. I have tested and clarified this.

6

For going online to a PP41 you need a serial interface on your PC (USB adapters might or might not work sadly) and you also need to know the proper online settings of your PP41.
There is a nice thread how to go online on a so called “SG3” target:
Determine serial online connection parameters (SG3 legacy systems) - Share Info & Ideas - B&R Community

As mentioned your downloaded S2.7 will be perfectly fine to go online if…

  • the serial interface of your PP41 is enabled (within the applicaiton running on the PP41)
  • you know (or test out) the serial parameters (for this see the link I posted)

Both PP41 and IF361 are (roughly) 25 years old and back in this days the documentation was a bit vague sometimes

If all other hardware works I still doubt that this is a software issue.
Was this machine running for a long time ? If YES and it now no longer running then this is most likely a hardware issue (as software does not get bad over time)

7

As I mentioned before, I can connect to the panel with PLITransfer. In other words, the communication parameters are clear. However, I could not find how to connect with AS2.7. Since I do not have the project files that work on the panel, can you tell me if this is possible? If possible, how can I do it?

8

As you know the connection parameters its rather simple and you use the same parameters within Automation Studio
If you are able to connect with PVI transfer tool to the PP41 then AS2.7 will be able as well.
It is irrelevant which AS2.x version you use

I am sorry but I do not have any AS2.x version installed any longer (as I simply do not need them due to tha age of this versions)
Nevertheless you simply create a new online connection and use the same settings as the ones from PVI Tramsfer tool.