Symptom Procedures
Problem – Unable to Browse to the PL1000E Home Page – Network Connection
Probable Cause
- Using Cat ET, confirm the Internet Protocol configuration. Confirm these settings with the network administrator.
- Confirm the PL1000E Communication ECM is properly connected to power, ground, and key switch inputs in the system.
- If the ECM Internet Protocol configurations are configured properly, try using a DOS shell window to “ping” the ECM.
At the command prompt, type the following command and press the enter key. Where “xxx.yyy.zzz.aaa” is the IP address or domain name of the module.
- Ping “xxx.yyy.zzz.aaa”.
If the ping command indicates successful communications to the ECM and are still unable to connect to the device using the browser, then check the browser settings. Confirm the ability to connect to other sites on the network. Contact the network administrator for help concerning the appropriate settings in order to connect a personal computer to the ECM that is on the network.
- Confirm the network cable is not a “Cross-Over” cable. The cable used to connect the ECM to a network should be a standard “pass-through” or “patch” cable.
Problem – Unable to Browse to the PL1000E Home Page Direct – Cross Over Connection
Probable Cause
- Use Cat ET in order to confirm the Internet Protocol configuration. Confirm that the IP settings are set appropriately for direct cross over connections. Refer to the System Operation Troubleshooting Testing and Adjusting, RENR8091, “Internet Protocol Configuration” section in order to help determine the appropriate settings.
- Confirm that the cable being used is a cross over cable.
- Confirm the PC settings. Refer to the “Configuring a Non-networked Windows-based PC to Access the PL1000E Communication Module” section. Any deviation from the required settings may prevent browser access to the PL1000E Communication ECM embedded web pages.
- At the command prompt, type the following command and press the “enter” key. Where “xxx.yyy.zzz.aaa” is the IP address or domain name of the module.
- Ping “xxx.yyy.zzz.aaa”
If the ping command indicates successful communications to the ECM and are still unable to connect to the device using the browser, review the PC settings and contact the network administrator. Certain settings are sometimes controlled by automatic logon scripts for certain networks. These will need to be temporarily disabled for direct cross over connections.
Problem – Unable to Establish FTP Connection with the PL1000E Communication ECM
Probable Cause
- Confirm the ability to browse the embedded web pages using a browser. If unable to browse the embedded web pages, refer to the “LAN Network Ethernet Connection” or the “Loading the PCL file Using FTP or DOS” sections of this manual.
- Confirm proper log on to the FTP server. Refer to the “Loading the PCL file Using FTP or DOS” section of this manual to review the procedure to log in to FTP server.
- Attempt to establish an FTP connection to the ECM using the DOS shell FTP feature that is covered in the, “DOS FTP Session with the PL1000E Communication ECM using a command Prompt” section of this manual. Some browsers and graphical FTP programs manage FTP connections differently. Some browsers and graphical FTP programs may not be compatible with the PL1000E. FTP using DOS will always be compatible with the PL1000E.
Problem – PCL file not moved from “New” folder to “Current” folder
Probable Cause
- Using a standard web browser, connect to the PL1000E Communication ECM and browse to the ECM mapping page. On the ECM Mapping web page will be displayed any known errors or issues with the PCL file. There are several things that can prevent proper processing of the PCL file. The table below shows the potential errors that can be displayed there as well as the remedy to repair the problem.
Log_Status.txt errors and the associated remedies
| Error | Probable Cause | Remedy |
| Status: Reset Configuration Parameters to Default | Module is in reset due to invalid configuration parameter. ex: invalid network mask caused a rolling reset | Review log_config.txt file in “Error” directory. An invalid configuration parameter value has been entered and should be corrected. |
| Status: Rolling Reset counter reset | The PCL file is of an incompatible format or there is an invalid configuration parameter causing the reset condition. | Use the “Parameter Transltion Editor” to re-create the PCL file and review the configuration parameters for any invalid data. |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 2 on RS-232-1 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 2. | Select a different port for one of the conflicting modbus configurations |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 3 on RS-232-1 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 2 with Modbus CFG 3 on RS-232-1 | Modbus Configuration 2 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 2 on RS-232-2 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 2. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 3 on RS-232-2 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 2 with Modbus CFG 3 on RS-232-2 | Modbus Configuration 2 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 2 on RS-422/RS-485 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 2. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 2 with Modbus CFG 3 on RS-422/RS-485 | Modbus Configuration 1 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| ERROR: Port conflict MODBUS CFG 1 with Modbus CFG 3 on RS-422/RS-485 | Modbus Configuration 2 is configured for the same port as Modbus Configuration 3. | Select a different port for one of the conflicting modbus Configurations |
| Error | Probable Cause | Remedy |
| Error: Rolling Reset 315-0627 Communication Software Group and earlier software |
The PCL file is of an incompatible format or there is an invalid configuration parameter causing the reset condition. | Use the “Parameter Transltion Editor” to re-create the PCL file and review the configuration parameters for any invalid data |
| Application Started | Indicates that the application software initialized properly. | No Remedy, since this is just an informational message. |
| Error: Creating File : log_config.txt | Unable to create the log_config.txt file indicating the module is out of available RAM space for file storage. | Delete older files from Archive folder. |
| Error initializing TCP socket | Unable to create socket at port 502 or PCL file is of an invalid format. | Use the “Parameter Transltion Editor” to re-create the PCL file and review the configuration parameters for any invalid data. If problem persists, contact the product support representative and be prepared to provide a copy of the PCL file and any log status messages to the product support representative for analysis. |
| Error initializing PX language | Potential Operating System error | Contact the product support representative. Be prepared to provide a copy of the PCL file and any messages from the log status files to the product support representative. |
| Error validating file | PCL file formatted incorrectly | Obtain latest copy of service tool and re-create the *.pcl file from scratch. There may be a version issue between the service tool and PL1000E software. |
| Error reading file | Unable to open and process *.pcl file | Indicates no *.pcl file found in the “New” or “Current” directory. Load the *.pcl file into the “New” directory. |
| Error | Probable Cause | Remedy |
| Error initializing Modbus stack | The PCL file was created containing Bodbus communications defined for both RS-422 and RS-485. The PL1000E cannot support these communications simultaneously, as they occupy the same physical serial port. | Open and modify the PCL file to change the RS-422 or RS-485 connection definitions so that there is only one or the other defined. |
| Error initializing software | Indicates some low level initialization failed during application software startup sequence. | Power down the unit for approximately 10 seconds and attempt to start it up again. If the problem persists, flash the module with undated application software. |
| Status: Valid – .pcl file loaded successfully | PCL file was validated and processed successfully | No remedy, since this is just an informational message. |
| Unable to create Current directory | During initializing, the software was unable to successfully create the Current directory. | Power down the unit for approximately 10 seconds and attempt to start it up again. If the problem persists, flash the module with undated application software. |
| Unable to create New directory | During initializing, the software was unable to successfully create the New directory. | Power down the unit for approximately 10 seconds and attempt to start it up again. If the problem persists, flash the module with undated application software. |
| Unable to create Archive directory | During initializing, the software was unable to successfully create the Archive directory. | Power down the unit for approximately 10 seconds and attempt to start it up again. If the problem persists, flash the module with undated application software. |
| Unable to create Error directory | During initializing, the software was unable to successfully create the Error directory. | Power down the unit for approximately 10 seconds and attempt to start it up again. If the problem persists, flash the module with undated application software. |
| Error | Probable Cause | Remedy |
| Error: Multiple .pcl files found in the Current directory. Multiple .pcl files found in the New directory. |
Indicates that multiple *.pcl files were found in the New or Current directory during initialization and the software did not know which one to process. | Delete the directory before resetting the PL1000E. Browsers sometimes cache the names of the files in the New and Current directories. Go to “Menu”, “View”, and click “Refresh” in order to force the browser to display the most recent list. |
| Error: Unable to move the .pcl from the Current directory to the Error directory. | Unable to move the PCL file indication the module is out of available RAM space for file storage. | Delete the older files from the archive folder |
| Status: Moved the .pcl from the Current directory to the Error directory. | PCL file was successfilly moved from the Current to the Error directory. | When a file is moved to the error directory, it indicates an error in the file content or format. The latest service tool should be used in order to create a new file. |
| Error: pcl file not found in the Current directory. | No PCL file exists in the Current directory. | The module first determines if a PCL file is loaded into the New directory, and if not, then searches for a PCL file in the Current directory. Lod a new PCL file into the New directory and power cycle the unit. |
| Error: Unable to set the RW permission on the Current directory. | Potential operating system error | Contact the Technical Communicator (TC) and be prepared to provide a copy of the PCL file and any messages from the log status files. |
| Error: Unable to move the .pcl from the Current directory to the Archive directory. | This error indicates the module is out of available file space for storage. | Delete older files from the Archive folder. |
| Error: .pcl file name truncated to 33 characters. | The maximum length for PCL file names is 33 characters. | No action is necessary unless a different file name is desired. If a different file name is desired, then load the newly named file in the New directory observing the maximum character limitation of 33 characters. |
| Error | Probable Cause | Remedy |
| Unable to move the .pcl file from the New directory to the Current directory. | Unable to move the .pcl file indicates the module is out of available file space for storage. | Delete the older files from the Archive folder. |
| Unable to set the RW permission on the Current directory. | Potential operating system error | Contact the Technical Communicator (TC) and be prepared to provide a copy of the PCL file and any messages from the log status files. |
| Invalid .pcl file in the New directory. | Invalid PCL file format. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Status: Invalid .pcl file in the Current directory. | Invalid PCL file format | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Status: Unable to read the .pcl file into the memory. | This is a general status message that indicates there was and error parsing the .PCL file into the PL1000E memory. The specific error should also be logged. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| On-board file header | Invalid PCL file format | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| On-board file header ID !=0xB100 | ||
| On-board file header Version !0x0002 | ||
| On-board file header File Contents Type !=0xC480 | ||
| Config Data Record block | ||
| On-board file header Recblock !=0xC480 | ||
| Config Data Record ID !=1 | ||
| Software Config Data | ||
| Software Config Data BlockID !=0xC490 | ||
| .pcl file Base Config | ||
| .pcl file Revision | ||
| Invalid size | ||
| Checksum position | ||
| Checksum not found | ||
| File seeking “pk_OnboardFileHeader_t” | ||
| ????? File seeking “pk_CfgDataRecBlock_t” | ||
| File seeking | ||
| File seeking “pk_PX_Baseconfig_t” | ||
| File seeking “builderBaseBlobSize” | ||
| Allocating memory for the tables |
| Error | Probable Cause | Remedy |
| Error reading the configuration tables into memeory | This is a general error message that indicates there was and error parsing the .PCL file into the PL1000E memory. The specific error should also be logged. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Error reading data link table | Specific error message for “reading the configuration tables into memeory”. | |
| Error reading ECM table | Specific error message for “reading the configuration tables into memeory”. | |
| Modbus port not configured | The PCL file specifies that a serial port for Modbus communications that has not been properly configured on the PL1000E configuration screen in ET | Use the service tool in order to configure the appropriate Modbus communications serial port to match that is defined in the PCL file. |
| Illegal Modbus address | The PL1000E will not accept a Modbus slave address of zero. | Modifiy the Modbus slave address to a value between 1 and 254. |
| Modbus slave address conflict RS-232 port 1 | The slave address that is defined in the PCL file for RS-232 port 1 is the same as the Modbus slave address that is defined in the service tool configuration. These two slave addresses must be different. The Modbus slave address that is defined in the PCL file is used to access data that is defined in the PCL file. The Modbus slave address that is defined in the service tool configuration screen is used to access communication statistics and ECM information from the PL1000E. | Use the service tool in order to change the slave address for the configuration that is associated to the RS-232 port 1. |
| Modbus slave address conflict RS-232 port 2 | The slave address that is defined in the PCL file for RS-232 port 2 is the same as the Modbus slave address that is defined in the service tool configuration. These two slave addresses must be different. The Modbus slave address that is defined in the PCL file is used to access data that is defined in the PCL file. The Modbus slave address that is defined in the service tool configuration screen is used to access communication statistics and ECM information from the PL1000E. | Use the service tool in order to change the slave address for the configuration that is associated to the RS-232 port 2. |
| Modbus slave address conflict RS-422/485 | The slave address that is defined in the PCL file for RS-422/485 is the same as the Modbus slave address that is defined in the service tool configuration. These two slave addresses must be different. The Modbus slave address that is defined in the PCL file is used to access data that is defined in the PCL file. The Modbus slave address that is defined in the service tool configuration screen is used to access communication statistics and ECM information from the PL1000E. | Use the service tool in order to change the slave address for the configuration that is associated to the RS-422/485. |
| Modbus slave address conflict TCP | The slave address that is defined in the PCL file for the Modbus TCP port is the same as the Modbus slave address that is defined in the service tool configuration. These two slave addresses must be different. The Modbus slave address that is defined in the PCL file is used to access data that is defined in the PCL file. The Modbus slave address that is defined in the service tool configuration screen is used to access communication statistics and ECM information from the PL1000E. | Use the service tool in order to change the slave address for the configuration that is associated to the TCP port. |
| Error | Probable Cause | Remedy |
| Error reading the tag table | Specific error message for “Error reading the configuration tables into memeory”. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Error reading the DSWrite table | ||
| Error reading the DSRead table | ||
| Error reading the Enum lookup table | ||
| Error reading the Unit Conversion table | ||
| Error reading the language table | ||
| Error reading the string index table |
| Error | Probable Cause | Remedy |
| Error reading string blob | Specific error message for “Error reading the configuration tables into memeory”. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Error validating Base Config | ||
| Error validating Data Link Types | ||
| Error validating ECM table | ||
| Error validating Tag table | ||
| Error validating DSWrite table | ||
| Error validating DSRead table |
| Error | Probable Cause | Remedy |
| Error validating Enum table | Specific error message for “Error reading the configuration tables into memeory”. | Obtain the latest copy of the service tool. Recreate the *.pcl file from scratch. There may be a version issue between the service tool and the PL1000E software. |
| Error validating | ||
| Error validating | ||
| lfp | ||
| Error fread !=readSize | ||
| Invalid source path/file name | ||
| Invalid destination path/file name | ||
| Error writing to destination file |
Problem – No response to data requests from Modbus Master
Probable Cause
- The PL1000E Communication ECM provides communication statistics for received and transmitted Modbus protocol messages as well as the physical layer statistics for received and transmitted bytes. If the “Physical Layer Bytes Received” is not incrementing, analyze and repair the harness. If the “Physical Layer Bytes Received” is incrementing but the “Protocol Layer Modbus Messages Received” are not incrementing, analyze and correct the Modbus message format. The ECM will not respond to an improperly formatted Modbus message. Refer to the Troubleshooting, RENR8091, “Diagnostic Capabilities” for the “Messaging Statistics Quick Reference Troubleshooting Guide“.