Siemens S7-1200 CPU problem

RajeevCell · Mar 13, 2011

Dear Members,

I'm facing a strange problem with a micro-automation project done in Siemens S7-1200 PLC.

The small program I wrote compiles perfectly, and downloads successfully. But the CPU does not go into RUN mode. Diagnostics buffer shows "New startup inhibit information - Current CPU operating state: STOP". Also reports,
"Pending startup inhibit(s):
- HW configuration inconsistent (TIA portal activity)
- Manual warm start required."

I did the HW configuration alright, I know. Diagnostics status shows

"The loaded configuration and the offline project are not identical.
The online and offline module configuration data are different.
Order number: 6ES7 214-1AE30-0XB0
Configured order number: 6ES7 214-1AE30-0XB0"

The reported numbers are exactly same, I can't see why it's saying that the configurations are different. I tried to press the "RUN" button in online panel, I saw network activity in the CPU (Rx/Tx LEDs), RUN/STOP, Error, Maint LEDs blink. But the CPU does not start and repeats the above messages in diagnostics. I tried memory reset (MRES in online panel) also. Same result.

I also tried to download a new project. That also behaved in this way. Most importantly, I changed the CPU, and the new CPU also did this same thing, which surprised me very, very much.

Anyone experienced similar behavior? All helps are appreciated.

Regards
Rahul

krsh · Mar 14, 2011

Hello RajeevCell,
Write the same message here

http://www.automation.siemens.com/W...&SortOrder=Descending&ForumID=258&Language=en

this is the official Siemens support site, they have experienced specialists hired to answer this type of questions.
Hope this helps.

RajeevCell · Mar 14, 2011

Thanks much, krsh. I've posted the issue in the forum you indicated. Let's see what response I get.

I'll share the solution, if I get any. Regards.

krsh · Mar 14, 2011

You already received some answers on the forum.

RajeevCell · Mar 15, 2011

Yes, there are helpful members already posting replies in the Siemens forum. Thanks for pointing me out the link.

The problem has not been solved yet, unfortunately

jraef · Mar 15, 2011

We had a similar issue with a local client who bought his S7-200 PLCs from China, only to discover they were incompatible. Siemens sells the 200 for dirt cheap in China as part of their agreement to make them there, but ostensibly only for domestic use. So Siemens made them incompatible with 200s and other automation products used outside of China. However that doesn't seem to stop Chinese users from selling them and a lot of them end up on eBay for impossibly low prices, but then people discover they can't network them with anything else and when software gets updated, the new version won't work. They come crying to Siemens distributors for help and get asked for their original PO number, then discover their folly...

I've been told that program didn't happen with the 1200s, but neither did the extra low pricing. But that has sparked rumors they (the Chinese) have already come up with a counterfeit 1200 now. I don't know if that's true for absolute sure though, just a rumor, but that could possibly explain your situation as well.

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RajeevCell · Mar 15, 2011

Dear jraef, the CPUs I'm using were imported through proper channel, they are not Chinese counterfeits. I do not know if counterfeit PLCs exist at all!

We are a Siemens system house. I'm already talking to Siemens about the problem I'm having. It is not a known bug. I'm starting to think that the problem is with my own copy of TIA portal, not with the hardware.

krsh · Mar 15, 2011

I am 90% sure that the software is the problem, especially if u changed the CPU and the error persisted. TIA portal is still new as a software and may still have bugs unsolved.

RajeevCell · Mar 16, 2011

My problem has been solved. It was a helpful member on the Siemens forum that guided me to the solution.

My problem was I downloaded some corrupted hardware config into the CPU. Recompiling the hardware list, and re-downloading it should have solved it right away. But I misunderstood the procedure.

I was under the impression that, when I edit the hardware configuration of the project, TIA portal automatically downloads this new hardware config into the CPU. If not automatically, then atleast during the next software download. But, that's not the case. I had to do "Compile ALL" and "Download ALL" to remove the offending config from the CPU and system is running fine now.

Thanks everyone for helping me out here.

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