That sounds very strange. What fits the description with the hanging mode is when the station hangs in Cancel and the Cancel procedure is not completed. You could easily check this by looking at the step chain diagnostics (StepAnalysis Control in HMI) - there you should see immediately if an object or sequence is hanging in Cancel. But the fact that this state cannot be remedied by a Reset or Reset-Cold and that an Activate Configuration is necessary - I have never seen that before... Maybe it is a combination of different problems - the next time it happens, please check first if the station is still in Cancel and try to fix it. Then you might get a different error pattern and it will be clearer why it needs an Activate Configuration. Are you using any persistent variables that are still set and then always lead to this inconsistent state and are only deleted / reset by the Activate Configuration ? If yes - please try a Reset-Origin - this should reset the persistent variables... https://infosys.beckhoff.com/english.php?content=../content/1033/tc3_plc_intro/2528803467.html&id=
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