Why does lookout stop communicating with a 1601?

[Control Phreak]

We have a setup where lookout is connected to fieldpoint modules (1 counter 500 and 3 relay 420 mods) through a hub and then to a 1601.  We have all the latest versions of software and firmware.  We are running XP.  Our process will be running in lookout and the fieldpoint modules will be working fine and then all of a sudden the outputs of the 420 will stay latched on even though lookout is telling them to turn off.  The inputs of the counter module can still be read in lookout.  We can go into server explorer and write values to the outputs and they respond correctly.  If we stop the process and exit lookout while the modules are locked up and then start lookout and the process again, the modules turn off and we can control them again until the next time they lock up.  The link LED is steady and the activity LED blinks occasionally while it is connected.  Also, while the mods are locked up we can disconnect the ethernet cable for the 1601 and we get and error in lookout saying the connection has been lost.  .  We have changed power supplies and installed a regulated bench supply for the fieldpoint bank but it made no difference.  Prior to this we had a FP1000 serial module connected to these same modules and everything worked fine.  The problems only started once we changed it to a 1601.  Is there some configuration that needs to be done to the 1601?  Any help would be appreciated.

Kevin

[Khalid]

Hi Kevin,

Since the Counter values can be read, it implies the communication itself is alright (may not be 100%, though).  Also, since you can turn-off the Relay outputs via Server Explorer that implies the RLY module itself is good, too. 

Here's what I would try:  there are 4 digita outs on the CTR module (channels 12-15).  Setup some switches in your Lookout process to toggle them On/Off.  And when this problem occurs next, try operating this switch.  How will this help?  I guess we will know if there's an issue with discrete operations (which is waht RLY are too).  If these work too, but not the RLY, then I am not sure.. we may have to dig deeper. 

Regards,

-Khalid

[Control Phreak]

We have already placed a discreet button on the panel that is connected to one of the unused relay outputs.  When the modules lock up, pressing the button has no effect on the output.  We can try a button connected to the outputs on the counter module and see what happens.  Would re-installing the firmware of the 1601 possibly help?  I don't suspect a hardware problem with the relay mods, we have 3 in the bank and all 3 lock up and they worked fine before the 1601.  The 100Mbs led is on on the 1601, is it possible that is too fast?  Can we change a setting and force 10Mbs or would this make a difference.   We have the firewall settings disabled in Windows, are there any other settings pertaining to the network that we can try?  Exiting lookout and then starting it again usually re-establishes connection, is there some way to put a button on the panel and connect it to the command to reconnect or poll (if there is such a thing)?  We are at a loss!  So much for plug and play! 

Kevin

[Khalid]

I am almost certain that going into the properties for the FieldPoint Object and clicking OK (don't have to change anything) will fix this as well.  This essentially resets the FieldPoint Object.  If this works, then reloading the Lookout process which has this FieldPoint Object would have the same effect. 

If this works, and is an acceptable workaround in the interim for you, then we could make the process reload programmatically. 

But, again, we should really get to the bottom of this -- with NI's help.  Since you're using OPC, there are some diagnostic tools that you can use on and log these transactions.  I don't think network speed would affect this. 

Regards,

-Khalid 

[Control Phreak]

Are you talking about the fieldpoint object while we are in lookout? Could you be a little more specific with regards to that please.  As far as OPC we are using OPCFieldpoint if that helps.  Where do I find the OPC diagnostic tools so I can start trying somethings?  Thanks for your help so far!

Kevin

[Khalid]

Kevin,

Yes, I meant the OPCFieldPoint Object.  See if "resetting" this works. 

As for the OPC diagnostic tools, there's an OPC "sniffer" available from Matrikon.  This can capture the messages between Lookout (the OPC Client in our case) and FieldPoint (OPC Server).  We could compare the messages when Lookout is able to write to the RLY outputs against when it is not able to.  We may not be able to tell unless it's something obvious.  In which case a developer from NI will have to analyse it and figure out the issue.  So, you will want to start a Service Request with them. 

http://www.matrikonopc.com/downloads/179/software/index.aspx

Regards,

-Khalid

[Control Phreak]

The relay modules locked up this afternoon and while the process was still running we tested going into the OPCFieldpoint object and just clicking "ok" and it reset the modules and the program was able to control them again without having to exit Lookout.  We started a service request on this whole issue almost 2 weeks ago but as of yet they don't know why it is doing it.  They said there might be a way around it using data sockets but I would rather find out what the problem is and fix it!  I will check into the OPC Sniffer and see what I can find.

Kevin