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We can all accept this is possible, but extremely rare or it would cause a lot more issues. So why go for the rarest, most unlikely event to troubleshoot a problem? Occam's Razor, the most likely problem is the most likely reason.

Hmmmmm...

Would help to know the brand and model of PLC, and if it is networked too. Is there a switch involved, possibly a managed one? That way you can do some checking of logs etc. In addition to above comments.

Yeah I know. We have a global RA TS account at work and I have made them give me older versions of some stuff when required (like RS Linx Enterprise 5.8) as when it comes to software it's often a pain to upgrade stuff as it breaks other stuff.

Use FC105 and FC106 premade function blocks to scale or unscale.

If you change the projects controller to v36 then that requires a firmware update to the controller using controlflash software. This wipes the project and it then has to be downloaded to the controller again. Check on RA KB site which bugs were resolved from v23 controller firmware and which...

It's not the programmers you need to consider, it's the maintenance techs who have to troubleshoot it at 3am when production is down! Not necessarily troubleshooting the code, but figuring out why the machine won't run, or is making junk instead of good product. Manufacturing runs on schedule...

Complexity for the sake of style, or complexity for the sake of complexity itself, are both a huge waste of time and resources as well as a massive pain to debug or maintain as said above. I'd use either subroutines for each piece, called as required by the main code or use a simpler ladder...

I've never met an IT team or network people who actually grasped industrial comms or protocols. If you are reliant on IT people helping you solve this, you'll wait a long time in my experience. You need to connect to the axiom with Telnet or Putty, have a poke around and see what's going on. It...

I had a similar issue with tension measurement modules, which were networked and were being queried for data by a prosoft Modbus TCP gateway. They were having TCP connections made each time they were being sent the setpoints data, which were never dropped again so each device began to rack up...

You can get hand held meters called process calibrators or loop calibrators, makes include chauvin-arnoux or Druck (personal favourite) and they can read and decode, or produce and impersonate, a 0-20ma, 4-20ma or 0-10v control loop. But they aren't "controlled by a logic input". However, very...

An update for anyone who was following this or has similar issues. The Prosoft MVI56E-MNETC card can read from, or write to, any configured modbus device / client but the write mode has three selections possible, enabled, disabled and conditional. We had the default which is "enabled" but...

Also some manufacturers list the modbus addresses from 1 to nnn but registers start at 0, it's not the first time I've had to knock one off the register address they quoted to read the data. You may also have to swap the word order or the byte order or both depending on whether the device and...

I wanted to say, thank you to all who contributed on the thread, helping me to get to an understanding of what was going on. I am truly grateful for your insight and time. Thank you all.

We now have a full wireshark capture of all the transactions before and after the "crash" totalling over 300mb. The slave is not recycling abandoned sockets. It leaves them open indefinitely. The prosoft should not be creating additional sockets, all transactions would go through the same...

I initially thought it was a speed issue and set polling to once per second. That made no difference but I can see how it might have. We have other slaves which hate being polled faster than that.

ProSoft say it "writes zero" every second when no value is sent from the PLC. I say "null" because if it actually wrote zero, it would overwrite my previous setpoint, which it doesn't, it just creates 7 TCP connections trying, and the Maxcess slave can't cope with that many. I expect it creates...

Ok so the issue appears to be solved. After spending some time in a video call with a senior engineer from ProSoft, we finally got to the bottom of the issue. It's a bit of interesting info for anyone using a ProSoft MVI56E-MNETC card to write to a slave. If you have the write function turned...

Thank you, I didn't realise that. I have some Stratix 5700s I can use.

It's a new TPLink desktop switch but unmanaged, I assumed like an old hub they would send all packets to all ports, is that not the case? Does it build an arp table and manage the ports that way, and if so how does that arp table ever get cleared - with no management interface nor dedicated IPs...