Hello Ignition Members,
Disclaimer - All of our senior designers/programmers are qualified for their jobs where I work. These problems are described as I see them, they may not be exactly what happened. Therefor they are to be used for troubleshooting the issue only. Thank you.
We are in contact with some ignition developers and are desperately trying to fix this problem. This is a GLOBAL problem therefore it won’t be affecting just us. It may be affecting anyone who is using ignition well. Time for the community to pull together to fix this. Any probable solutions will be tested and greatly appreciated. This problem has become a HAZARD and someone in our plant broke their finger yesterday because a RUD came down on his finger due to the condition of a bit sticking in the PLC after the HMI was interacted with. It could become a lot worse than just a broken finger.
Temporary/Unreliable solution - Go to your Ignition Developer and change your Project>Properties>Client>General>Update Mode to NOTIFY rather than PUSH. This will make life a little more difficult because you will have to go to the HMI to update it. But it could save a life, so do it.
How this temporarily fixes the problem - People will no longer be holding down buttons while the project is updated.
Today our team experienced a problem with the state of a bit in a portion of our Roll Up Door (RUD) logic. The bit was sticking to one state in the PLC after the HMI button was pressed and released
With problem number #1 we thought we figured out the cause. We came to the conclusion that because the HMI was being updated, a MouseReleased script was not being run (when you update the HMI by Push rather than Notify, when an operator has their finger on the button and it updates, no release of the button is registered to the PLC from the HMI script). Therefore the bit in the PLC remains ON until manually turned off, or until the HMI button is pressed again.
List of problems (growing unfortunately, stick around for updates).
1 - We’ve noticed if you have a momentary push button with Mouse/Press and Release scripts, if the button is being held down while a live update occurs. The MouseRelease script will not play and the state of the bit in the PLC program will not change until it is either manually reset in the PLC or if the button on the HMI is pressed again after the update.
2 - (Nightmare Problem) After a lot of trouble shooting and thinking that the Button-sticking situation was related to the OPC-path being cut. We found out that buttons/indicators were sticking to a single state even if the HMI was not updated. We have buttons that send big, metal clamps from HOME to WORK positions and vise-versa. We had an operator working/adjusting some tooling, he tried to send a clamp to WORK position, and as soon as he released the WORK button the clamp flew back to HOME position. Concluding that the HOME_PB bit in the PLC was sticking even if the OPC-path wasn’t updated. (Communication, unfortunately, is poor in our plant. We are not entirely sure yet if the projects weren’t being updated when this particular problem came up). With this problem we did notice one thing significantly different, there are no mouse pressed/released scripts for the clamp buttons.
This really pushed us to think that the problem revolves around the stability of the network itself.
3 - A possibility we’ve noticed that if you exceed the MEMORY on the projects server (Project Website/SYSTEMS/Performance), tags will begin to fault out on the HMI’s. We believe this is because the OPC-server resets itself to allow new connections to be made or to free-up room in the memory (educated-guesstimation). I personally think this causes the same problem as a project update. The OPC Path is cut momentarily so the PLC doesn’t know what to do with the condition of the bit.
Frequently Updated Conclusion.
As of 6/22/2018 @1:47PM problem still not fully understood - no fix
As of 6/22/2018 @2:58PM we believe the problem to be the server hop from HMI to PLC. There needs to be a way to create fluidity between HMI->SERVER->PLC and vise-versa.
As of 6/25/2018 @9:37AM - Thank you for all of your responses. Let me make myself clear, I am not ‘blaming’ ignition. This problem does not have to do with the ignition application itself. There are no issues with dirt sticking on the screens etc. This problem revolves simply around the connectivity and fluidity between the server hop between the HMI and PLC.
No updates from Developers - we will keep you guys posted
If anyone can make heads or tails of this problem it will be everyone’s favor. This is a problem that has been persistent through out multiple plants we’re in contact with and could begin crippling the face and reliability of ignition. ANY help is greatly appreciated.
I would be thankful if an ignition forum moderator could PM me the conditions for bumping a post to the top of the list (how many times I can do it a day, etc). I would like this pinned but I know thats a lot to ask for. Thank you.
Thank you Ignition forums and Best Regards,