The Controller Failed to parse the project

[Svenfabian]

Hi! I'm new in this forum and from Sweden. I hope it's fine that I'll take this in English. comment in what ever language you prefer.

I have had a IHC gen 1 since 2001 isch. It has worked really without any problems. Anyway, I decided to upgrade to latest version of controller before it is too late, hoping to get some more possibilities for integration to other system like HA etc.

After I have reprogrammed every configuration I today was ready to upload the config to the new controller. I updated to latest FW and configured IP, time and DNS. But when trying to upload it stop on the 4'th line with a red cross and then a error message pops up telling that "the controller failed to parse the project". Then it was impossible to upload anything. Controller was in fault state. I then needed to load the factory default FW and then after redoing the initial configuration I tried with a very simple config, with just a few devices added, and that works fine. But then I again tried with a more complete config and again it fails the same way.

Anyone have any tip why it fails and if there is some way to check the config before crashing the controller?

 

[Lars1]

If your controller is a Visual 3 controller, it has a reset button you can use to bring the controller out of fault mode. Beside that. A Visual 3 controller should ALWAYS run with firmware 03.03.44 or later. Otherwise you risk it entering boot loop, which you can't recover from.

Have you tried to upload the program using USB? Failing to upload a large program over network, is often caused by short network outages. If your controller is a Visual 3 controller there is a risk that you have one of the controllers with an unstable network interface. If you can reproduce the problem you can get the controller replaced by calling Schneider Electric.

[Svenfabian]

1 hour ago, Lars1 said:

If your controller is a Visual 3 controller, it has a reset button you can use to bring the controller out of fault mode. Beside that. A Visual 3 controller should ALWAYS run with firmware 03.03.44 or later. Otherwise you risk it entering boot loop, which you can't recover from.

Have you tried to upload the program using USB? Failing to upload a large program over network, is often caused by short network outages. If your controller is a Visual 3 controller there is a risk that you have one of the controllers with an unstable network interface. If you can reproduce the problem you can get the controller replaced by calling Schneider Electric.

Thanks Lars! Yes, it’s a new Visual 3 controller. I loaded the 03.03.44 before trying to upload. I will test with USB and a shorter Ethernet connection to see if that helps. Otherwise I’ll contact Schneider for replacement.

[Svenfabian]

On 1/14/2025 at 12:30 PM, Lars1 said:

If your controller is a Visual 3 controller, it has a reset button you can use to bring the controller out of fault mode. Beside that. A Visual 3 controller should ALWAYS run with firmware 03.03.44 or later. Otherwise you risk it entering boot loop, which you can't recover from.

Have you tried to upload the program using USB? Failing to upload a large program over network, is often caused by short network outages. If your controller is a Visual 3 controller there is a risk that you have one of the controllers with an unstable network interface. If you can reproduce the problem you can get the controller replaced by calling Schneider Electric.

Hi @Lars1.
I have now tested what you suggested. What I note is that the reset button doesn't make it come out of Fejltilstand!. I need to load the factory default FW for it to be okay again.
Then I tried with just a direct ethernet cable from laptop to controller. But it failed to load the config anyway, same as before. Then I tried with the USB cable but exactly the same behavior.

I then tried with a much smaller config, I did save it separate just after adding some inputs/outputs in the process of redoing all configuration from the old configuration, and that transfer works fine, but with the bigger one it still fail when sending project.

At that moment I also noticed that it was enough to send the "small" configuration to controller to make it come out of fejltilstand, without any reset or factory default fw.

So to me it looks like there is something wrong with my configuration, can that be detected in the middle of the file transfer? And aborted the transfer?
Does anyone have a "big" working configuration file to version 3 controller that is known working and could be shared with me just for testing?

[Svenfabian]

I found the issue now. It was a strange one, and I tested with deleting some config and save until the transfer were working.
It seems like it was a device that I had put in a location, a 3-key Push Button. For some reason that wasn't working and when I replaced that one with 3 separate 1-key Push Button it was working. I'm using IHC Visual version 03.04.69.03 (it's in english).
 

[Lars1]

Good that you found the issue. Have you created the products yourself? I don't think we have that many push button products in the DK version.

The products are defined in XML files in \Program Files (x86)\<Visual root>\IHC Visual\Products. You could try to compare the 3 push button file with the others to see if there are some notable errors. Changing anything is at your own risk and you might end up with the same error again.

[Svenfabian]

No, this is the default products in English version. I noticed that it was a complete different setup in the danish version, a bit strange.