Battling the Fanuc Datapanel

by scamorama

The following is true.  No names were changed, because no one is innocent.

The task appeared simple: replace a database on a GE Fanuc 1062 Datapanel using GE's proprietary WinCfg software running on a laptop.

Use "Communication Protocol 80: Modicon Host Slave" in the new database.

Save a copy of the existing database.

The Datapanel was in the Control Room, and would be used to replace a failed unit at a remote location.  No problem, right?

Monday

First off, there was the need for the software.

Was there a copy onsite?  Of course not.  Was it available from GE?  Sure, if one had a Customer Identification Number.  Did anyone have one?  Of course not.  Could I get one?  Sure, if I didn't mind waiting an hour.  But it was only an hour, and the software downloaded and installed easily.

I downloaded the user manual as well.  In order to transfer files, the Datapanel needed to be in "Host Transfer" mode.  To get into "Host Transfer" mode, one needed to be in "Off-Line" mode, which required a password.  Did anyone know the password?  Of course not.  Was there a default password?  Not that GE would say.  Was trial-and-error an option?  It was now.  The passwords are numeric, and the range is 000000-999999.  Got it at 111.  Was it all going to be this easy?  Of course not.

With the Datapanel in "Host Transfer" mode and the laptop connected, it was time to transfer the existing database for safekeeping.  I started the transfer and received the error message: "Cannot Initialize Port"

Pathetic poking and probing at port and program produced piffle.  Took a closer look at WinCfg (the name alone should have warned me) and saw "Windows 95, Windows 98, and Windows NT".  The customer's locked-down Windows XP Professional laptop was not going to allow it to communicate.  Was there a suitable laptop onsite?  Of course not.

Tuesday

Brought in my ThinkPad 600X (running Win98 SE) and installed WinCfg.

Connected it to the Datapanel.  Initiated the database transfer.  No error message!  Had I won?  Of course not.  No progress bar.  No transfer, either.

Rebooted the Datapanel and put it into DOS mode.  No database file on the C: volume.  Did anyone know where it was?  Of course not.  Did the manual give any clue?  Silly question.  Was there another volume?  You bet!  The database was on D: (I, rather stupidly, assumed that WinCfg was smart enough to know where the file was).  Copied the database file to C:, rebooted the Datapanel, put it in "Host Transfer" mode, and was elated to see the progress bar.  Was I out of the woods, had I figured this out?  Of course not.

Before I continue, a few words about the user manual.

This was obviously the product of a technical writer - someone who knew a lot about software, but little about English.  There were no screenshots of what one might expect to see, no examples of how to perform any task, and only the most minimal of glossaries.  It appeared to have been translated from the original Sanskrit by an Urdu-speaking Italian.  Consulting it for guidance on any topic was an exercise in masochism.  I tried to RTFM, but the FM was no F good.

With the original database safe on the 600X, it was now time to put the new one in its place.  I opened the transfer window, selected the new database, and checked the communication protocol to see that it matched.  Everything looked good.  But was it all good?  Of course not.  I started the transfer and got the error "Database Type Does Not Match Datapanel Type".

More digging was required.  It turned out there are two flavors of a 1062 Datapanel:

I had a Vanilla database and a Pecan Datapanel.  The manual said, "You can modify an existing database for a different Datapanel."  Did it tell me how?  You needn't ask?

Poking around in WinCfg revealed that, if the database was open, the "Save As" function provided the needed selection.  So, I opened the database, configured it to use "Communication Protocol 80: Modicon Host Slave" - as I was told - and saved it.  Started the transfer.  It worked!  Was I finished?  Of course not.  I couldn't connect and test the Datapanel until the following day.

Wednesday

Took the panel to its new home and hooked it up.

Turned the power on.  It looked good when it came up, but (you knew there was a "but" coming, didn't you?) nothing on it worked.  No output to the PLC.  Did I have my 600X with me?  Of course not.

I booted the Datapanel into DOS, renamed the new database file, and copied the old database file from the C: volume.  Restarted it and was surprised to see that the old database could communicate.  Good news: the old database had a page that duplicated the new database, bad news: the page had inputs only, no outputs.

While doing this, I made an interesting discovery.  Changing the extension on the database file on D: to something other than what was normally expected resulted in the Data-Panel booting directly into "Off-Line" mode.  DOS could be entered directly from the Data-Panel access screen.  So much for password security.

I installed WinCfg on the desktop I'd been using, and opened the database I had installed.  Poked and peeked in the selections to see if there was a way to generate a report on the database showing the input/output addresses.  Did I consult the manual?  Of course not.

After a few dead ends, I managed to come up with a way to get a report.  After a few more dead ends, I actually got a usable report, which showed that, yes, indeed, the database had the addresses it needed.  Was I surprised by this?  Of course not.

Thursday

Copied the database that I had checked the previous day to the 600X.  Connected it to the Datapanel.  Booted the Datapanel into DOS and deleted the now-suspect database.  Transferred the database that I knew was good and that had the requested protocol.  Restarted the Datapanel and got the same result as the day before.  Was I ready to give up?  Of course not.

I sat back and considered what was in front of me.  I had a good database, and I'd configured it with the Communication Protocol requested by the customer.  Is the customer always right?  Of course not.

I opened the Communication Configuration in WinCfg and looked at the available choices.

Found "Protocol 91: GE Fanuc Genius".  Seemed a logical starting point.  Configured the database with Protocol 91 and transferred it.  Rebooted the Datapanel.

It worked.
Return to $2600 Index