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How do you recover from problems accessing configuration or project files?

Configuration files are stored in the controller's flash disk in the folder /flash/config and project files are stored in folders under /flash/projects.

If your controller begins to display errors loading configuration data at startup, or if previously working projects display errors during loading and compilation, it is possible that the controller’s flash disk has become corrupted. The most likely cause of flash disk corruption is powering-down your controller while data is being written to the flash.

The flash disk is written whenever you: issue "Save all to flash" from the web interface; save programs to flash from GDE; or execute GPL programs that write data to the flash. After any write to the flash, you must wait at least 10 seconds before powering down the controller. Otherwise the write operation maybe only partially completed.

If the flash disk is corrupted, simply restoring your files from a backup is not sufficient. You must first reformat the flash disk, which erases all user data. GPL system software and FPGA firmware are not affected by this formatting operation.

To reformat the flash disk, do the following:

1. Backup any data on the user flash disk by copying it to a PC using FTP. If the flash disk is too badly corrupted, this may not work and you need to rely on previous backups.
2. Start up a Telnet client and connect to your PreciseFlex™ controller. On most Windows-based PCs you can invoke Telnet as follows:
   • Click on Start and select Run.
   • In the Run popup window, enter "telnet" and click "OK". You should get a command window with the prompt: "Telnet>"
   • At the prompt, type "open nnn.nnn.nnn.nnn," where nnn.nnn.nnn.nnn is the IP address of your PreciseFlex™ Controller, for example 192.168.0.1.
3. You should see the message "Welcome to the GPL Console," followed by a prompt to enter a password. If you receive an error, use the web browser interface to verify that DataID 411 "Network console enable" is not zero.
4. Enter the password for your GPL controller. The password will not be displayed. The default password is "Help." DataID 410 "Network password" contains the password for your system.
5. You should see the command prompt "GPL:"
6. Enter the command "format". You will see a warning message and a prompt to type "ERASE".
7. Enter the keyword "ERASE".
8. The format operation will take several minutes and is followed by the message "Success".
9. Close the Telnet window to exit.
10. Use FTP to restore your config and project files.
11. Wait at least 10 seconds, then reboot your controller.

The complete dialog is shown below:

Telnet> open 192.168.0.1
Welcome to the GPL console
Password: Help
GPL: format
WARNING: This command will erase the user flash disk area.
Type ERASE to continue: ERASE
Success
GPL: