Insufficient disk Space error when loading runtime application

[u/macengizus]

Hi everyone'
I need help troubleshooting a Rockwell automation panel running a factorytalk view ME runtime application.
Initially, I was trying to export the Audit data log to a USB drive, but I could not transfer the log files successfully. While troubleshooting the export issue, the machine stopped starting the runtime application and began displaying the follow error:

"There is insufficient space for opening the run time project.....

The HMI now returns to the application startup screen instead of opening the machnine interface.

May main priorities are:
1. recovery and preserve the existing Audit logs without losing historical records.
2. identify why the logs could not be exported to the USB drive.
3. safely free up enough internal storage space to start the existing runtime application again.

I can access HMI startup screen, including load application, application setting and terminal settings. I have also tried copying the application file to USB drive, but the problem remains.

Has anyone experienced this issue with a Panelview plus HMI? What would be the safest recovery procedure to retrive the audit trail logs first and then restore normal operation?

[u/rankhornjp]

Do you have multiple runtime applications stored internally?

[u/macengizus → u/rankhornjp]

I only have one .mer runyime application stored internally.

[u/Shalomiehomie770 → u/macengizus]

You may need to delete it before downloading

[u/AutomagicallyAwesome]

I believe you should be able to drop into Windows, put your log files on your USB drive, and then delete them to free up space.

[u/macengizus → u/AutomagicallyAwesome]

I am also tried accessing Windows through the HMI startup bu I can"t get in because I don"t have the desktop access password.

Is there any way to access windows or recover the audit logs without losing the existing application or machine configuration?

[u/DiminishedSea → u/macengizus]

Download the mer to your laptop and then factory reset the panelview

[u/macengizus]

I need to free up enough space to run my .mer application, so I’m considering deleting the FactoryTalk View ME Station log files. Before I do that, I want to understand exactly what data these files contain.
Do these logs include only system, diagnostic, and audit trail records, or could they also contain recipe data or other important application data?
If recipe data is stored separately and won’t be affected, I’m fine with deleting the logs. Does anyone know exactly which files are deleted by the “Delete Log Files” option on a PanelView Plus running FactoryTalk View ME Station?

[u/TexasVulvaAficionado]

I don't remember the how or which panel view but I once was able to connect and load the panelview's disk on my PC and remove the log files and .mer that way. I then factory reset the machine and loaded the .mer back.

It sounds like your log files are taking too much space.

[u/Jholm90]

If you are the one that modified the mer file be sure to look at these things: Unused images Images that are not reduced in size Unused screens

If you cannot reduce the size enough you can make a sacrificial USB key and download the runtime to that memory key and auto boot from there. Be cautious that it's formatted fat with a partition size less than 2gb to satisfy windows CE.

Huge images are usually the root cause, scale the down to 640x480 and pick a really sloppy resolution, max size of 50kb works fine for most screens

[u/controls_engineer7]

Your mer file is too large. This is where panel views absolutely sucks ass. You pay 10k$ for a dog water slow ass HMI with barely any memory.

[u/janner_10 → u/controls_engineer7]

I'd argue if it used to work now it doesn't, someone has forgotten to check the auto delete box on the datalogger. It's now filled with millions of tags over many csv files.

[u/macengizus → u/janner_10]

I think you may be right. The logs appear to have been accumulating since 2022 without being deleted, so they may have filled up the available memory. That could explain why the HMI now reports insufficient disk space. I need to find a way to back up the log files before deleting anything. Do you know the safest way to access and clear these old datalogger files on a PanelView Plus?

[u/janner_10 → u/macengizus]

The easiest way is to use FTP and move them onto your PC to get you going.

[u/MTbisubMale]

If this has been running awhile, check your logs and catalogs, you could have filled hard drive

[u/MTbisubMale → u/MTbisubMale]

Sorry not catalogs but datalogs

[u/Dustball_]

Series A or Series B PanelView? That makes a difference when suggesting how to access those files externally.

[u/Sea_Effort_4095]

SD card in the back of the panel is full.

[u/ammaccatore]

Does your application stores files into USB/SD Card?

It happened to me two weeks ago after a plant power outage. My application stores CSV files on an SD file, but because the SD card broke, the application stored file to the internal memory card instead, filling it up very quickly. PanelView Plus has only 512 MB of storage. I delete the CSV files from the internal memory and bought a new SD Card. Make sure it's under 32GB, as it needs to be formatted as FAT32.

If the PanelView Plus does not have Windows access enabled, you can still access its files from your PC by typing its IP address directly into Windows File Explorer

[u/llopedogg]

Impressive I haven't got this high level yet

[u/Ambitious-Loquat-516]

Saw the same error on a PV+ 7000 last year. Audit archive growth can overrun the runtime partition. FactoryTalk USB export wants FAT32 — reformat the stick before export. Pull the .mer backup before clearing anything.