PanelView Plus 6 troubleshooting: FAULT/COMM indicators, start-up codes, touch, battery and firmware restore

A PanelView Plus 6 terminal (2711P) that will not start properly tells you why in two places: the red FAULT and green COMM status indicators, and the state message and code on the start-up splash screen (2711P-UM006I-EN-P, pp. 161–165). A code shown with the state message "Fatal" is an error; the same code with "AutoTest", "Update" or "Restore" is only progress information. Fatal codes fall into four groups: firmware installation, power-on self-test, restore operations and the watchdog. Chapter 8, "Troubleshooting" (pp. 161–173), is the full reference. PanelView Plus 6 terminals are discontinued; most end-of-life pages, such as 2711P-T10C4D8, give the replacement Rockwell names, while for some, such as 2711P-T6C20D8, Rockwell names none.

Read the status indicators

At a normal start, FAULT and COMM flash on and off, then COMM flashes to show progress. When startup is complete, COMM stays on and is then driven by the communication driver or application; it typically flashes when communication is active (p. 162).

If both indicators stay off, the power supply or the logic module has failed. Check the supply first: out of range, replace the power supply; in range, replace the logic module or the terminal (p. 162). DC terminals take 24 V DC nominal, 18 to 30 V DC on the 400 and 600 and 18 to 32 V DC on the 700 to 1500 (p. 36); AC terminals take 100 to 240 V AC (p. 39).

If the terminal powers on and stops during startup (Table 78, p. 162):

Start-up messages and codes

The splash screen shows a state message, a status or error code, a progress bar and the revisions of the boot loader (BL), operating system (OS), Machine Edition (APP) and other firmware components (p. 164). Codes with AutoTest, Boot, Init, Update or Restore are for information only (pp. 164–165). The fatal codes (Table 80, p. 165):

By default a watchdog error (02) is shown at startup, halts the boot and opens the maintenance window, where you can continue booting; it is also written to the System Event Log (p. 99).

Battery, clock and temperatures

The lithium battery only runs the real-time clock; it is not used for backup or retention of the application (p. 128). In Hardware Monitor the battery reads Depleted below 2.0 V, Low from 2.0 to 2.74 V and Normal from 2.75 V; it is updated at power-up and then every hour (Table 51, p. 92). In Configuration mode, Terminal Settings>System Information>Terminal Information shows the voltage and a state of Good, Failing or Bad (pp. 74–75).

• A low, missing or dead battery gives a warning at each startup. The default shows it and continues; it can be set to halt startup until OK is pressed, or to never show (pp. 97–98).
• The terminal can run without a battery if accurate time and date are not needed (p. 97).
• Replace it with 2711P-RY2032 or an equivalent CR2032, with power removed and the area known to be nonhazardous (p. 128). On the 700 to 1500, the logic module comes off to reach the battery; it can be out for up to 15 seconds without losing clock and calendar data (p. 130).
• Afterwards check the date and time: Terminal Settings>Time/Date/Regional Settings (pp. 77, 97).

The CPU and logic board read High at 95 °C or more (Table 52, p. 92): check for obstructed airflow and the enclosure temperature (p. 163). On 700 to 1500 terminals with a CCFL backlight, the backlight is driven down to 40 % or less of full brightness above 60 °C internal temperature, and an error goes to the System Event Log (p. 65). A screen that dims in a hot cabinet may be this, not a failing display.

Display, touch and keypad

From Tables 81 to 84 (pp. 166–167):

• Touch inaccurate: calibrate under Terminal Settings>Input Devices>Touch Screen>Calibration. It takes five touches; a touch screen that never calibrates is not working: replace the display module (700 to 1500) or the terminal (400 and 600).
• No touch input at all: plug in a USB mouse. Mouse works but touch does not: the touch driver or touch screen. Neither works: the application.
• Dim or unreadable: Terminal Settings>Display>Display Intensity.
• Backlight goes off unexpectedly: the screen saver, Terminal Settings>Display>Screen Saver.
• Cursor missing: Terminal Settings>Display>Cursor.
• USB keyboard and mouse in one device: use a standalone keyboard or mouse instead.

Ethernet

The Ethernet connector has one indicator for the link, normally on, and one for data activity, normally flashing (p. 167). The IP settings are under Terminal Settings>Networks and Communications>Network Connections>Network Adapters. With DHCP enabled and no address received, the terminal assigns itself 169.254.nnn.nnn, which in general does not support a network connection. A bad connection or no valid IP address is typically reported as a Communication error with Winsock critical error 10065 - No route to host. Also check for duplicate IP addresses and duplicate device names (p. 167). Ping, ipconfig and tracert run from the desktop (pp. 167, 169). Shortcut and controller-path checks inside the application are covered in PanelView Plus 7 shows no data from the PLC.

Application does not run at startup

• Start-up option: Terminal Settings>Startup Options; "Run Current Application" runs the loaded .mer at startup, "Go to Configuration Mode" is the factory default (p. 49).
• Application itself: a start-up screen must be configured and the runtime file must be a compatible version. If it runs when started by hand, check the shortcuts in \Windows\StartUp. If components or DLLs are missing, remove and reload the application (p. 168).
• Integrity log: Terminal Settings>File Integrity Check, View Log (p. 72).
• Reloading the .mer: Load Application (F1, p. 44), choose Internal Storage, External Storage 1 (SD card) or External Storage 2 (USB). Answering Yes to replacing the terminal's communication configuration loses any changes made to device addresses or driver properties in the terminal's RSLinx communication settings (p. 48).
• No Goto Configuration Mode button: enter Safe mode from the maintenance menu, or enable "Detect Safe mode request at startup" (a white box in the lower left to touch, or F1). If the terminal is set to start in Configuration mode and does not, reload the firmware (pp. 98, 168).
• Event log: Terminal Settings>System Event Log (p. 74), or the Hardware Monitor, which can export SystemLog.csv to \Windows (p. 91). Crash dumps are in \Windows\DumpFiles (p. 169).

Stop the application before removing power, and do not pull a USB or SD card while it is being written: data logging, event logging and historical trending write to non-volatile memory (p. 169).

Maintenance menu and factory restore

The maintenance menu needs a USB keyboard. Press the Default switch on the back of the logic module with a thin non-conductive probe; from a fault state, press Reset, then press and hold Default until the menu appears (p. 171). Use the arrow keys to set "Special BOOT Action", go back up to "Continue booting with selected options" and press Enter (pp. 172–173). Work in this order (p. 170):

1. Safe mode: the application does not start; the terminal opens Configuration mode. The application runs again at the next reset.
2. Reset terminal: removes user applications, configuration changes and user data; the current firmware is kept.
3. Restore factory defaults: returns firmware, registry, file system and configuration to the out-of-box state; all user-installed firmware updates are removed. This is the recovery for a failed firmware upgrade, such as fatal code 0F (p. 172).

After step 2 or 3, the application has to be reloaded; after step 3, the firmware revision the plant used as well. Restarting the terminal brings operator controls back online: follow the plant's permit and lockout rules.

Re-installing firmware

The firmware package is downloaded from Rockwell as PVP6__6.x-yyyymmdd.exe; it installs the Firmware Upgrade Wizard (FUW, version 6.10 or later) and the .fup file (p. 154). The FUW either writes a firmware upgrade card (USB flash drive or SD card) or upgrades the terminal over Ethernet with RSLinx Enterprise 5.0 or later (pp. 154, 158). With a card, the upgrade starts when the card is inserted; press Upgrade or [F7] (p. 157). Do not remove the card or switch off the terminal during the upgrade, and avoid USB hubs (p. 157). The upgrade keeps the registry, the loaded application, network settings, display settings and touch calibration (p. 153). If it fails through a power loss or a removed card, restore factory defaults (p. 157).

Before calling for help

Record the catalog number, the revisions on the splash screen, the state message and code, the FAULT and COMM states, and export the System Event Log. Planning the move to a new terminal: PanelView Plus 6 to PanelView Plus 7 migration. For an engineer on site: breakdown support.