Recently in our plant some new signals were added in the I/O and are working well in the toolbox and in the sequence.

But In order to configure the same in the cimplicity the new signals were added in the EGD data as described in the manuals.

When downloaded the above after validating and building, the toolbox which was on ONline went to OFF line with the following error messages "error D59 - SYSERR, Sys loader (59) : invalid configuration recieved: Pcode major revision diff.
Error 59 (0X3b) Invalid Pcode file".


Here the toolbox cersion in use is V.09, can any one tell me what could be the reason for the above error messages.

Is there any other way to get the new signals configured in the cimplicity pages. Any information would of great help.

Thanks,

Thomas

 

Were you thinking that if you did exactly what was described in the GE manuals that you would obtain exactly the results you desired?

I would suggest that you use the 'Help' function in Toolbox as opposed to any procedure in any manual. The procedures can change with Toolbox revisions and the manuals are usually the last thing to be updated, if ever. And the version used to refer to when writing the manual is almost never listed anywhere in the manual, so it's difficult to tell what version the instructions are referring to.

I hope you have a back-up of a working .m6b file to go back to.

 

My experience is with Toolbox Versions 10.x and 11.x. However, I assume that the main features in Ver. 9 are the same.

It seems that there is a major difference between the project file and the controller. This can happen if you modified the data assigned to the EGD Exchange. The result is that the download will be off-line. It means the panel will have to be re-started after the download. (Don't be confused between the terms online/offline and "online download"/ "offline download".)

After the signal is assigned to an Exchange:

validate
Do "Put Diagnostic Symbols"
Do "Put into Database"
Build and download the panel.
Save the project.
Call up SDB Browser, verify that the signals are shown in two places - under the panel and under the EGD interface.

From Toolbox, open the HMI Device (*.hmb) configured for the Cimplicity project.
Perform the following operations:

Put into database
Get from database
Validate
Build
Save

Note that these operations can be performed interactively one at a time or by a batch file (*.bld)

The new points should be in Cimplicity Master Database. Do "Configuration Update", start Cimplicity project. Point data should be available on Point Control Panel.

 

Hmm, it looks like you're doing an online download and the major revision in the tool does not match the major revision running in the controller. I'm surprised that Toolbox even attempted the online download, but I suppose it could be that V9 didn't check the major versions before downloading.

The major version difference could be because you started from an M6B that isn't exactly what is running in the controller, or you've made a change that cannot be downloaded online (and I suspect adding a variable to EGD falls into that category on a Mark VI, but I can't remember for sure)

You will have to do an offline download (ie reboot the Mark VI) to make a major change. There is a section titled Offline Download in GEH-6421 Chapter 5.

 

First of all thanks to everyone in the control.com for their replies.

Sorry for the delay in this reply as only yesterday I could try to do something as you have mentioned in your reply.

I did everything according to what is there in your message but I couldn't complete the step 'build and download' when I tried to download the application code I got the same error message, but I went ahead with the other steps and got the new signals configured in the work bench for the cimplicity project under the points.

I stopped and restarted the project after doing a configuration update but when opened the cimplicity pages it was all black in the signal areas. Now can you tell me what could be the reason to face this problem? Do I need to reeboot the MKVI panel to get back the normal screens.

Under the 'download' there are also some other files which can be downloaded like 'Runtime' etc is it necessary to download also the other files along with 'application code'

Seeking your opinion on this matter.


Thanks,

Thomas.

 

You shouldn't have to download the runtime or anything else non-default.

Basically, the error you are getting is after the download is complete and the Mark VI is attempting to load the downloaded application code. The loader notices that the new code has a major difference from the currently running code, and cancels the online load; the controller reverts to the application that was already running until the Mark VI is rebooted.

So, yes, you need to reboot the Mark VI panel, at which point the new app code will be running. Obviously, you have to be sure the Mark VI is not controlling at the time, or that you follow the offline download procedure, or you could trip--that is why I referred you to the manual, as I don't want to give bad advice here!

 

It's helpful to remember that the CIMPLICITY portion of the "Mark VI" is just a graphical "viewer" that can be used to issue commands as well as observe operation. The signals in CIMPLICITY Workbench are referenced to addresses in the .m6b application code. The two can be different, but when they are, it usually results in the black display elements you see, because they aren't supposed to be different. They must be the same.

So, the process is typically to get an error-free build, download it to the Mark VI control processors, verify that it's all working correctly (the TMR test), then configure Workbench and the CIMPLICITY project to use the working memory addresses.

Memory addressing in the Mark VI is dynamic, meaning that signals can shift memory addresses from one .m6b build to the next. Memory addresses must match between the CIMPLICITY project and the .m6b file, and what it appears you have done is to create a CIMPLICITY project that is looking for data at addresses which haven't been downloaded to the Mark VI and incorporated into the running application code of the Mark VI.

When such a shift takes place, it results in a Major Difference. A Major Difference means that the application code in the .m6b file must be downloaded to the Mark VI processors (all of them), and then they must be re-booted. This *MUST* be done with the unit 'offline', that is, not running.

According to the information in the Mark VI System Guide 'Installation and Configuration' section, once the download is complete, a TMR test must be performed to make sure the same application code has been successfully downloaded to and "implemented" (copied to RAM and being executed by the control processor) in all three control processors.

I think you were very lucky with your I/O assignment and configuration and sequencing modifications in that they probably only resulted in a Minor Difference, and so downloading didn't require a re-boot of the processors.

This may have lead you to believe that you could add signals to the EGD and perform a similar process for the Mark VI part of the system, but, it has likely resulted in a Major Difference, and that means the processors have to be re-booted. I suspect there are more problems in the Status pane of the Toolbox application window that aren't being addressed, problems with the configuration of the EGD signals. And that the TMR test has to be run.

Once that portion of the process has been completed, and the new memory locations are present in the Mark VI control processors, then you can get the CIMPLICITY portion of the process to work.

But, at this point I hope you have other HMIs to run the turbine with and that you have back-up .m6b files and CIMPLICITY project files that you can use to get all HMIs and the Mark VI back to a known working configuration until such time as you can determine exactly what problems are occurring.

But, I would really suggest you get someone to site to help with this issue. You could consider it to be "training", because this isn't really documented anywhwere, and while you have on-site assistance you should be writing down every step and making sure you understand each and every step before the individual leaves the site.

You shouldn't need to download runtime code, just application code.

 

Does anyone know if Toobox version 11.05.05 uses SDB Utilities to grab the new EGD points from the Mark VI to Cimplicity?

I'm working with Toolbox version 11 and our site manuals direct us to use SDB Utility after modifying the EGD echanges

Here are the steps we performed:

1. Added points to the EGD exchange for our DCS.
2. PUT SIGNALS INTO DATABASE from Toolbox.
3. Validate, Build, Download (to permanent storage) R, S, T.
4. Rebooted R, S, T.
5. The .m6b file shows EQUAL and matches.

Now we are trying to see the points with Cimplicity.