(777): Unable to connect using ‘MachineShop Phonebook entry?
Problem Description: Misconfiguration on the PowerStation system.
Solution: The Net Setup is for Com1, but the cable is on Com2. Toolbar is setup for a serial transfer, but Shell is configured to an Ethernet transfer. The RS232 with handshaking line cable is unplugged at either end?

(792): Unable to connect using ‘MachineShop Phonebook entry?
Problem Description: Misconfiguration on the PowerStation system.
Solution: The default settings on the P2 are: NET1: Serial Download NET2: Ethernet. Or you can change it to: NET1: Ethernet NET2: Serial Download Everything seemed to work fine for both methods of download.

Nodes are not communicating on network
Problem Description: A set of terminating resistors is needed at each end node of the Profibus network. This set of resistors may be included in a cable end that is switch-able. If this is the case, make sure all but the end two connections are turned off and the two nodes on the end are turned on.
Solution: Add a terminating resistor at the end of the network.

Network seems to be transmitting slow
Problem Description: Profibus requires time to service each node that is included in the node list. Even the nodes that are skipped require an update time. Placing the nodes numbers close to each other and modifying the highest node number will improve the network speed.
Solution: Make sure the node numbers are as low and consecutive as possible.

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Node is not communicating

• Problem Description: Although Profibus has auto-baud detect on the nodes, some devices cannot talk at the higher rates. Check the devices fastest talk time and compare it to the network speed.
  Solution:Check the baud rate on the node.

• Problem Description: Profibus has a maximum distance it can communicate with and without a repeater. If this distance is exceeded the node may not be able to communicate.
  Solution: Check the distance of the network cable.

• Problem Description: Many of the pieces of information required on the configuration tool must be extremely accurate in order for the node to work. A simple incorrect revision number could cause this error.
  Solution: Verify the data on the configuration tool.

The wrong binary file is sent to the PowerStation
Problem Description: You can check the binary file by looking in the directory at the dates of the files. They should match the date you last saved the project.
Solution: Make sure the directory that your placing the FILENAME.BSS or FILENAME.UCP is the project being worked on. These files should be placed in the PROJECTNAME directory under the CONFIG directory of the location MachineShop is pointing.

Control-Alt-Delete will not work
Problem Description: Setting in MACHLOG.INI is set to “DISABLED?
Solution: Change the setting in MACHLOG.INI in the MACHLOG directory. Use a text Editor to changed the setting from CtrlAltDel=DISABLED to CtrlAltDel=ENABLED. This must be all caps.

The cable may be broken
Problem Description: There are 5 stands going though the DeviceNet cable. One of these may be broken.
Solution: Check cable pin-outs. There should be 5 wires that run strait though the DeviceNet cable. Try a known good cable.

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The network does not have a terminating resistor
Problem Description: The DeviceNet requires a 121-ohm resistor at both ends of the network cable.
Solution: Place a terminating resister between pins 2 and 4 on the DeviceNet Cable end.

Power is not supplied to the network cable
Problem Description: The DeviceNet Network requires a 24-volt power supply to the network. Solution: A 24-volt power supply should be placed between pins 1 and 5 of the connector. If a tap is not used a 24 volt supply should be added. The +side of the 24 should be connected to Pin 1 and the ?side should be connected to Pin5.

The MACHLOG directory is empty
Problem Description: The project does not include MachineLogic. This will happen if the project was not properly restored. Using the toolbar Click on <View> then <Project Information>. The list of things in the project should include MachineLogic.
Solution: Restore the project in the proper manner.

1. Start MachineLogic by clicking on the gear of the toolbar.
2. Click On select .
3. Click on the files of type drop down menu.
4. Select <*.zwt files> from the drop down menu.
5. Select FILENAME.ZWT from the available files. –Keep in mind your file may be placed in another location other than C:\MACHSHOP\PTOJECTS\MACHLOG. If so use the brows button to locate the ZWT file to be restored.
6. Once the Restore process is finished save the file with the proper project name.
7. Close the toolbar and reopen it. It should now contain the MachineLogic that was in the project.

Control Project name: None
Problem Description: The retentive memory sizes don’t match.
Solution: Check the retentive memory size set on the development system and match it to the retentive memory size set in shell.

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MACHLOG.INI file has an improper setting
Problem Description: The last line of MACHLOG.INI located in MACHLOG directory should read “PowerOnOperation=ENABLED?
Solution: In MachineShop Shell go to Settings, General, Machinelogic and then select “yes?

DOS is wrong version
Problem Description: Incompatible compact flash.
Solution a: Run flashback on flash compact.

Error in CONFIG.SYS line7
Problem Description: As the PowerStation boots up look for the HIMEM.SYS file to flash on screen. If it states Bad or missing C:\DOS\HIMEM.SYS Error in CONFIG.SYS line 7 or something similar it is an indication that this file needs to be present.
Solution: Run flashback on flash compact.

Control Kernel not loaded
Problem Description: If the control card is missing this error will occur. If the board is blown (This may happen if it was mis-pinned.) this error message may also come up.
Solution: Replace the board.

File has the wrong name
Problem Description: The Binary file name does not match actual filename in the MACHLOG directory. For DeviceNet the binary file can be found in UCSDVNT.INI. Or for Profibus the binary file can be found in SSTPFBS.INI.
Solution: Check the filename in the appropriate INI file and rename the binary file to the name that follows the statement CfgFileName= –Recycle power. Note: The default is UCSDVNT.UCP for DeviceNet and PFBS.BSS for Profibus.

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Configuration file <FILENAME>not found
Problem Description: The binary file does not have the correct extension. For DeviceNet the binary file <FILENAME>can be found in UCSDVNT.INI. Or for Profibus the binary file <FILENAME>can be found in SSTPFBS.INI.
Solution: Use a text editor and add the proper extension (?UCP?for DeviceNet or ?BSS?for Profibus) to the filename that follows the statement CfgFileName=. –Recycle power.
Note: The default <FILENAME>is UCSDVNT.UCP for DeviceNet and PFBS.BSS for Profibus.

Memory error! Out of memory (dynamic memory)!
Problem Description: By selecting the ERROR button of the Resource dialog this error condition will appear in the PLC Error tab of the Message window.
Solution: Using the MachineShop toolbar select the “edit?menu then select “Memory and Ports? Using the spin box increase the “Total Memory Size?in an increment of 10K. Keep the “Program Memory?the same size.

Memory error! Not enough memory in PLC! Shrink project!
Problem Description: By selecting the ERROR button of the Resource dialog this error condition will appear in the PLC Error tab of the Message window.
Solution:

1. Decrease the size of your program logic.
2. Using the MachineShop toolbar select the “edit?menu then select “Memory and Ports? Increase “Program Memory?in an increment of 5K.
3. Using the MachineShop toolbar select the “edit?menu then select “Memory and Ports? Using the spin box increase the “Total Memory Size?in an increment of 10K. And increase the “Program Memory?by 10K.

Memory allocation error
Problem Description: During the boot of the PowerStation this error is encountered when loading MachineLogic. This error indicates that more convention memory was used than was available. Solution: Remove the REM remark in front of the appropriate EMM386 statement for the particular I/O driver used in your project.

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Memory Allocation Error. Cannot load COMMAND, system halted
Problem Description: During the loading of the MachineShop shell if you encounter the following error you have selected a Total Memory Size such that there is not enough conventional memory to load the shell. This error occurs after MachineLogic successfully loads.
Solution: Using the MachineShop toolbar select the “edit?menu then select “Memory and Ports? Decrease the “Total Memory Size?in an increment of 10K.

Error 32867
Solution: Look at problem Memory allocation error. Cannot load COMMAND, system halted.

Retained memory does not seem to work

• Problem Description: The MachineLogic card saves the retained data within a specified data range. This range is determined in the shell. This range is also pointed at in the data area settings within the resource settings.
  Solution: Make sure the address is called out with the proper address range.

• Problem Description: MachineLogic does not know that the value in the register should be retained just by the address. It must be established when the variable is called out. "VAR RETAIN".
  Solution: Make sure the address is called out with the retained heading.

System Error 435
Problem Description: The runtime system has detected an out of boundaries condition in the addressing of the I/O. Check the actual I/O range in the configuration settings of the MachineLogic to determine the boundaries.
Solution: Correct all addresses to be within the actual I/O range.

Error 182
Solution: Look at problem Memory error! Out of memory (dynamic memory)!

Error 468
Solution: Look at problem Control Project name: None.

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?? on Interact tools that were not there previously
Problem Description: In an older version of the tag editor in Interact if the tags were not properly sorted and saved the ??would appear all over the Interact screen. This was changed in a later version of Interact to auto sort save when the tag editor is closed.
Solution: Sort and save Tag file.

Interact will not load
Problem Description: Interact takes about 100K of space to run. It resides in conventional memory along with several other programs including Dos, RTXDOS and MACHLOG. There is not enough room in the conventional memory with all the drivers stored there. Enabling EMM386 will allow these drivers to be loaded high into upper memory clearing the memory for Interact.
Solution: Un-REM EMM386 in the CONFIG.SYS file.

The simulator may be selected
Problem Description: It may be that resources were checked and the simulator was used to try the program out. The simulator would need 'DUMMYIO' in order to work properly.
Solution:

1. Change the I/O configuration to read DUMMY for I/O type.
2. Change the simulator to the proper COM port.

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Internal Range exceeds 64K limit
Problem Description: A typo caused the range of this var to exceed the 64K limit.
Solution: The number should be edited to reflect the right number.

VAR RETAIN

PART9_BUFF4 AT %MW34167 : INT;
PART9_BUFF5 AT %MW3234169 : INT;
PART9_BUFF6 AT %MW34171 : INT;

END_VAR

VAR RETAIN

PART9_BUFF4 AT %MW34167 : INT;
PART9_BUFF5 AT %MW34169 : INT;
PART9_BUFF6 AT %MW34171 : INT;

END_VAR

Hitting Cntrl - F9 will not cause a recompile
Problem Description: Usually hitting the control key and the F9 key at the same time will cause a project to be recompiled. When you hit it this time nothing happens.
Solution: MachineLogic may be in Online Debug mode. Click on the Debug Icon to turn the use of online debug off.

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Debug is accessing the wrong POU
Problem Description: Three POUs are created: POU1, POU2 and MAIN
MAIN calls Function Block POU2 and Function Block POU1.
MAIN calls Function Block POU1.
MAIN -------- POU2 ------- POU1:instance1

|
+---- POU1:instance2

This will cause two instances of POU1. The first being called in POU2 and the second being called in MAIN.
Solution: Whichever POU is declared first in MAIN’s variable table will get called no matter which instance was intended. If the declaration in the variables for MAIN are:

VAR
POU1_Instance1 : POU1;
POU2_Instance1 : POU2;
END_VAR

And in POU2 are:

VAR
POU1_Instance2 : POU1;
END_VAR

The POU will call instance1 when calling POU1_Instance2 for debug. (It will use the proper POU for the logic).

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Cannot see all of the logic on the screen
Problem Description: You may have this problem if you try to use same program on a different computer. The MachineLogic setting may not be same on the computers. In order to see the entire program you may want to maximize these settings.
Solution: In MachineLogic select options, preferences, graphical editor and change worksheet height to 999 and worksheet width to 999.

Not enough room for my entire POU on this worksheet
Problem Description: POUs don’t care about the name within the POU. To enlarge the program within the POU just copy and paste the worksheet name. It will automatically change the name to be different than the original worksheet name. If the original name was MyProgram the copied worksheet name will be MyProgram_1.
Solution: Add an additional worksheet within the same POU.

Can’t tie an Interact push button to MachineLogic
Problem Description: In order for Interact to talk to MachineLogic it needs an address from MachineLogic once an address is added the tag editor will allow the dragging and dropping of the MachineLogic tag into Interact tags. The address does not need to be dragged and dropped in order to use it in Interact. If the same address is used in interact and MachineLogic the button will reference the proper coil/contact. I.e. MX0.0 in MachineLogic and MLD\MX0.0: BOOL in Interact.
Solution: MachineLogic must be given a coil reference for Interact to talk.

Project name does not show up

• Problem Description: The project was created by a more recent version of Toolbar. The removal of the project name will force the older version of toolbar to accept the project.
  Solution: Remove the .WMS file.

• Problem Description: Go to file and select Open Project or select a recently opened project.
  Solution: No project was selected.

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Wrong Data type
Problem Description: MachineLogic addresses its memory in the form of bytes. A WORD consists of two BYTES. If a word is not defined with two bytes between it and the next they may overwrite each other. If a Word were addressed at MW100 the next available WORD would be MW102. Doubles and Floats take up 4 bytes.
Solution: Check for address overlap.

Illegal small letter for keywords used
Problem Description: MachineLogic requires all keywords to be capitalized.
Solution: Type BOOL instead of bool.

The variable worksheet is set for a different type of variable than the one used
Solution: change to the proper variable type either in the function or the variable worksheet.

Illegal use of size prefix X
Solution: Try BOOL for data type.

Illegal use of size prefix B
Solution: Try BYTE, SINT for data type.

Illegal use of size prefix W
Solution: Try INT, UINT, WORD for data type.

Illegal use of size prefix D
Solution: Try TIME, DINT, DUINT, DWORD, FLOAT for data type.

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