1.) When you ping the IP address of the Click plc do you get a reply? If yes, disconnect cable and ping again to see if you get reply? This will verify no duplicate IP addressing.

2.) What is the IP address of the Click and your PC?

3.) Is the PLC in run mode?

4.) Are the other PLC's on the same subnet as your Click PLC?

5.) Question 5 what does WT stand for?

6.) Can you provide a topology of your network and all devices on it?

7.) Do you have the correct Network Adapter selected when trying to connect?

Hello,

1. When I ping the PLC from a direct PC to PLC it does not ping. I can Ping the Click 3.21 and it works fine along with the Direct soft 6. The Click 3.30 is not working. I was told that my magic box is to old and will work with the 3.21 not 3.30.
2. The address are
   1. PC 169.254.121.101
   2. PLCs are 169.254.121.125 and 169.254.121.253
3. Yes the PLC is in run mode and the programs are running correctly
4. I have about 10 PLCs that I can communicate with. The only ones I can not talk to are the Click 3.30 programed ones.
5. WT was for Waste Treament and is currently a Click 3.21 program. I have not done anything to it until i can figure out what is going on with the 3.30 Clicks.

***Also all Ethernet cables have been verified with a tester to make sure they are working correctly***

Update

1. I had IT update my Windows 10 last night and now the new magic box is being properly identified by the programing laptop. So that means the drivers are working now.
2. The new magic box still will not establish a connection with the PLC

What in gods name happened between 3.21 and 3.30!? I have never had any issues with the Clicks in the last year. Now I can not even get the magic box to work anymore!

Update

Click Issue

C-More 6.72

Click 3.30

Will not produce ethernet comms out of the PLC

1. Replaced all ethernet cables and checked them with got green lights

2. Hooked laptop cable directly into PLC and still could not communicate

3. Readdressed the PLC to an address that is defiantly not used

4. Stair Stepped the Poll time

5. Can access Water Tower 3.21 Click PLC from office

6. Can control program from small micro screen with serial port

7. Computer will talk to all Direct Logic 6 PLCs and Click 3.21 PLCs

8. When pinging the PLC directly plugged into the PLC it still would not ping.

Will Not

1. Communicate through ethernet cable to any of the PLCs except Version 3.21

2. Can not ping the Clicks on 3.30 version

New Issue

1. Can not connect to new PLCs with magic box cable

               A. But can connect with special cable as long as bringing up program and connecting.

2. New Magic Box

               B. Will not upload the drivers for the new magic box

3. Had to call IT Department. The programing laptop had many updates that had to be done. After this was done the new magic box finally loaded the drivers.

4. Still will not connect to the Click PLC through new magic box with windows 10 updates and drivers for magic box working.

Success!!!!!

How did the problem get solved

1. The Blue magic box was out of date with the 3.30 revision

2. The Windows 10 software had many updates that were not done because it is not allowed on the internet.

3. The firewalls were turned off but IT had to allow the Automation Direct programs through the anti-virus when the updates were done.

4. The ethernet cable for Heat Zone 3 to the network was damaged by being pinched and pulled behind a metal wall.

5. The ethernet port on Heat Zone 3 was bad

6. The C2-14AR card that was being used in the test station was bad.

What it looks like is the computer is seeing the PLC but not the laptop.

We talked it over and he says that he doesn’t want to say it’s a hardware issue. But we covered everything that you can do to rule out. He was very adamant that he did not want to say it was a hardware issue because its almost always not. I would agree to this.

I did have this exact same ping reading on

169.254.121.125 (Mez PLC)

169.254.121.123 (Water Tower PLC)

The antivirus should not be an issue since it is reading two Click PLS that are version 3.21 and 3.30

My current working theory is

1. Using a 3.21 magic box on the 3.30 software messed up the brain and it is not thinking right.

2. There was a power surge (our plant gets them sometimes) and messed up the brain. This PLC is protected by a fuse. But it was designed before I was here. So, is it over fused and does not protect the PLC?

3. The ethernet cable for Heat Zone 3 was smashed and very well could have shorted out the wires. Could this have caused the Ethernet Cable to short circuit and damage the ethernet port on the PLC?

***FedEx is scheduled to deliver three new CPUs today. I will take and install a new one with the old Heat Zone 3 CPU. To make sure the test lab does not possibly corrupt the CPU. The only thing left on the lab station is the incoming 120V (Reading is at 119V) is dirty somehow. But this seems like a far fetch since all the power supplies were changed out with three different ones and the voltage is reading 120V***

Success On Heat Zone 3!

The new CPU came in and swapped out with the old one. I made sure to use the magic box 3.30 with software 3.30 (looks like the CPU that I received was a 3.00 version). I did the updates and loaded the exact same program with no changes. It took off and I was able to communicate with the serial cable and the ethernet cable with no issues. Currently it is communicating with my main panel touch screen!

Success Ethernet port was bad on Heat Zone 3 CPU!

07MAY22

Lab Test

I received a new CPU and installed it into the lab test station and still getting the slow green blink. I plugged into two different 120 outlets but still getting the slow blink. However, both circuits were coming from the same panel. I did try all the recepts also.

Took the slow blinking PLC and swapped it with the working Heat Zone 3 CPU and it was still slow blinking. I took and put the Heat Zone 3 CPU and it was a solid green light and started to work properly. 

08MAY22

Replay To Matt The Technician

Good Morning Matt,

1. I have talked to four separate AD techs over the month. I will attach the notes I have been taking.

2. Yes, I tried two different CLICK power supplies with the same results. I then got a separate 24VDC power supply you guys sell and made sure that the voltage was in-between 24VDC and 26VDC. Also, yesterday I put CPU in a working system with a known working power supply and still got the slow green blink without plugging in ethernet or magic box. I then put the known working CPU back in and took right off.

3. I am getting 119V on the test lab. Which should be more than enough to fall within the specs of the CPU. I tried a couple different outlets. However, they were all going back to the same panel. So, I walked across the factory to a completely separate panel and got the same slow green blink with nothing plugged in.

4. See note 2.

5. I have it set up 14AR, input sim, input sim, thermo, analog input, analog output, 120 output. When I run it through the CPU power usage I am well in specs of the power usage.

6. They were all connected and as soon as I turned on the power it starts slow green blinking.  

I have one unopened CPU. I’m worried that there is something damaging it. But I don’t know what it could be. There is absolutely nothing connected to the I/O cards. Because I am trying to isolate the issue.

08MAY22

I took one of the new CPUs straight from the box and installed it in the Heat Zone 3 project. The CPU green light stayed solid green and even had the little blue light show up also once I applied power. I did not see it flash green.

I also made sure to verify the wiring of the 120V plug in and it was correct. I verified good connections on the 120V system to include the neutral at all connection points. And everything looks good.

I changed out the Power supply to the Click system with a new click power supply. I disconnected everything in the panel and directly wired up the Click PLC to the 120 plug going through a breaker and switch only. This time the Green light stayed solid and looked good. I tried to connect to the CPU with the magic box and the click would not communicate. Which then went to a Red Error light with solid green light.

I took the CPU and put it back into Heat Zone 3 Project and got the blinking green light again.

I put the CPU back into the test station and now I have

Solid Green Light

Solid Red Light

RX is solid Green when magic box is plugged in

***Once you try to connect through the magic box the RX light will not illuminate anymore. Once you close the connect box a few seconds later the RX will be solid Green again.

I am using Version 3.21 with corresponding magic box

When I plugged the magic box 3.21 in the RX light would stay solid green. When I tried with the 3.30 box the RX light would not illuminate at all.

09MAY22

I asked the companies Master Electrician to come over and take a look at what is going on. We thought it was the capacitor bank and it is not. The bank has been locked out for many years and I was using the clicks in the shop a few months ago.

They are leaning towards noise on the 120V side and causing an issue. They want me to use a surge protector and try it first. Their next step will be to call in a contractor to measure the noise on the system.

Loaded the touch screens back up and they are working. However the mez touch screen does not want to talk to the Heat Zone 3 touch screen still. All the touch screens are the same program but different addresses. I think the Heat Zone is just to far away. But it is reading the main loader panel and the mez PLC. I just erased the Heat Zone off the Mez PLC so the communication error will no longer show up.

10MAY22

Success! The blinking green light corresponded with the C2-14AR card.

I proved this out multiple times with a suspect CPU and a new out of the box CPU. When ever I installed the marked card I would lose communication and the green power light would start blinking. I tested this on a 120 recept across the plant and on the suspect test station. Every time I would install the card the green light would start slow blinking.

I can now communicated to all CPUs through the blue magic box and the ethernet cable.

How did the problem get solved

1. The Blue magic box was out of date with the 3.30 revision

2. The Windows 10 software had many updates that were not done because it is not allowed on the internet.

3. The firewalls were turned off but IT had to allow the Automation Direct programs through the anti-virus when the updates were done.

4. The ethernet cable for Heat Zone 3 to the network was damaged by being pinched and pulled behind a metal wall.

5. The ethernet port on Heat Zone 3 was bad

6. The C2-14AR card that was being used in the test station was bad.