Kyle,
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Thanks for the info. I think I mentioned this in an earlier email but the main reason we switched to the Cosy was because we thought the connection issues we were having were related to the built-in switch in the Cisco VPN router. The Cisco had a 4-port switch and sometimes the HMI would lose connection to the PLC and the guys at the location could get everything back communicating by power cycling the router. Sometimes moving the Ethernet cables to different ports would achieve the same thing.
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Okay, so all weekend all I have occasionally tried to connect to the HMI web interface and it has connected every time and I was able to see data in the HMI indicating that it is communicating to the PLC. However this morning after changing the ProxyMaxSocks to [100] I rebooted the Cosy and now my HMI has lost connection to the PLC. It’s strange because I can still access the HMI web interface and I can even make changes to the HMI configuration and download to it but the data connection between the HMI and the PLC is broken. This same thing happened last Friday but after 2 or 3 hours the connection was restored. Maybe that is what you are seeing in the logs.
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To answer your questions, as I related in item 2 we have had issues with the data connection between the HMI and PLC. Not sure how to answer about the Modbus TCP because to my knowledge there is nothing in the HMI or PLC that is using Modbus. The PLC and HMI are both connected to the Cosy LAN switch. The PLC we are using is an Allen-Bradley Micrologix 1400, Model 1766-L32AWA. The HMI is a RedLion G3, Model G306A000.
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I was wanting to mention another issue which I believe I have a solution for but wanted to get your take anyway. The control panel where all this hardware is located is in a mobile water system. So being a mobile system the power is not on constantly and thus when the trailer is moved to a customer site the power is reconnected and operational checks are done to verify everything is working properly. One of the things I noticed about the Cosy is that if it is powered up at the same time as the cellular modem it does not connect to Talk2M and will not unless it is power cycled after the modem is connected to the cell service. So what I plan to do is connect the power to the Cosy through an output on the PLC and delay it powering up for a minute or two to allow time for the cellular service to be fully operational.
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I have attached a current backup. It may look similar to the last one I sent due to the broken data connection between the PLC and HMI. If I see that the connection becomes reestablished I will do another backup and sent it to you.
Randy
MOVED TO STAFF NOTE (175 KB)