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Expert Troubleshooting Tips for Industrial Data Communication Solutions

Discover essential troubleshooting tips for resolving communication issues in PLC systems. Learn how to clarify symptoms, isolate communication problems, and optimize settings.

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Expert Troubleshooting Tips for Industrial Data Communication Solutions

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  1. The Leader in Industrial Data Communication Solutions Troubleshooting Tips

  2. Troubleshooting Tips • General • Clarify symptoms • Isolate comms from PLC network • Perform loopback or PING tests • Check diagnostic information • If communications are verified, consider PLC system: • Improper RSLinx configuration? • Latency causing timeouts? • Program problems?

  3. Larry’s Rockwell Tips • General Comments • Rockwell’s example PLC programs work very well • Noisy phone lines or less than ideal wireless links: • Greater retries (latency) • Do not exceed throughput capacity • Consolidate data to minimize number of MSGs • A few MSGs with larger amounts of data is faster

  4. Larry’s Rockwell Tips • SRM Wireless Ethernet Modem • Equipment attached to remote modems do not directly communicate • Use Ethernet switches, not hubs • IGMP snooping preferred

  5. Larry’s Rockwell Tips • DF1 Protocol • No limitations with Data-Linc modems • Prefer STD Polling Mode (multiple MSGs per scan) • DF1 master PLC will relay MSGs • “Missing Remote” Failure (not with Logix platforms)

  6. Larry’s Rockwell Tips • DF1 Protocol • “Missing Remote” Failure (not with Logix platforms) • On SLCs do this:

  7. Larry’s Rockwell Tips • NOT this: Reason: • With SLC or MicroLogix multiple enabled MSGs are queued in the transmit buffer. While queued their Timeout interval is timing. If a current MSG times out all others queued will timeout giving the appearance that multiple slaves have failed.

  8. Larry’s Rockwell Tips • Multi-drop Channel Pass-Through is a wonderful thing!

  9. Larry’s Rockwell Tips • Logix Platforms • These machines can REALLY move data and quickly overwhelm a radio network. As always, do not exceed the network’s throughput capability. • Be mindful of RPI. Ten 32 bit words with an RPI of 10 milliseconds is 32kbps without even considering protocol overhead!

  10. Larry’s Rockwell Tips • RSLinx • Red Xs can appear intermittently when using low baud rates (1200 baud) depending on communication quality and other communication traffic. This is normal. • DF1 Polling Master Driver. • The parameters Max Pkt Wait Time (Sec) and Max Retransmission Wait Time (Sec) and not well documented. • Values that have worked well: • Max Pkt Wait Time: 8 (default 150) • Max Retransmission Wait Time: 15 (default 600)

  11. Larry’s Rockwell Tips

  12. The Leader in Industrial Data Communication Solutions THANK YOU!

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