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I'll try all of that today. Thanks for getting back to us.

((Sorry meant the X66 port as the KLI port! We aren't plugging anything into EtherCAT at the moment.))

Hi Johannes,

We thought we had the eCat error fixed once we successfully jumped the X55 connector. The message away and were able to run automatic programs for a few days. It was working great.

The problem returned when I started configuring the controllers for Roboteam. I did two things on both controllers. Not sure what caused the error, but now they both have it again:

1.)   I renamed both controllers from the pendant Start-Up wizard to KUKA1 and KUKA2. Previously, they were named after the controller serial number. We are eventually going to have students working and I wanted to make the machine ID more clear.
2.)   I connected the controllers to an ethernet switch via CAT5 on the X65 (KLI) connection.

As prompted, I saved the changes to the RDC and then performed a controller restart with the file refresh / update option checked. After reboot, the SYS-X44 error came up. Once again, we can't run programs in AUT.

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I tried the following to attempt to fix the issue. None of these worked:

1.)   Checked the X55 connections; both seated correctly. Same error with them plugged in or not. (hardware likely not the cause as it affected both systems after the software change)
2.)   I unplugged the X65 connections and renamed the controllers back to their original names and reset, etc. (tried to return it to the earlier state)
3.)   I changed the X44 restart value in KRC\Roboter\Config\User\Common\ECAT_SYS_X44.xml from "manual" to "auto", restarted etc.
4.)   I opened the current project in WorkVisual, removed the X44 interface and re-added it. eCat came attached to it by default. I deployed the project and restarted the controller.

I'm not certain whether I need to fix something else in WorkVisual, like you said. Perhaps we aren't properly running the shutdown sequence to recompile / deploy the files?

Do you have any ideas for things we could try?

Thanks!
Nick