BX-DM1E-10ER3-D Onboard I/O Not Working After Power Cycle

[JeffS]

I have several new out of the box BX-DM1E-10ER3-D PLCs that seem to be forgetting they have onboard I/O.  I can program them and it seems like they work for one power up, but once they go through a power cycle the onboard I/O stops working.  I noticed that when I look at the I/O configuration it has changed to a PLC that doesn't have onboard I/O. 

Sometimes I can get it to revert back to the original PLC I/O layout after rewriting the firmware and booter then power cycling.  But again as soon as I cycle the power again it changes to a PLC I/O that doesn't have onboard I/O and those inputs/outputs stop registering. 

Any thoughts on what I can try?  So far I have tried and been able to repeat this on 5 BX-DM1E-10ER3-D PLCs we have here.

Edit:

Looks like this is the same issue as https://forum.hosteng.com/index.php?topic=3656.0

[Controls Guy]

I still have mine, still unreverted to 2.9.3.

I have HW Rev 8A 4B, same as you and also 0122 MFG VIN same as you (date/batch code?)

MAC 30.5f.8f (143), so 92 units later than yours, assuming all numbers are used.

I'm going to power it up and see what it does.   Last time, it was fine.    OK, mine's doing it on this cycle as well.   Host guys want me to send it back so you can check on the connectors, etc?

[BobO]

That sounds like some kind of manufacturing or part defect. :sigh:

Send to Host whatever you have that's misbehaving. We'll evaluate, fix, and return ASAP. Jeff, you should have Host contact info, right? Send to my attention and I will get it where it needs to go. Ditto for you Steve. If not, PM me.

Don't think the firmware version is relevant. Probably get the same result by power cycling or even re-initializing the I/O.

[BobO]

Emailing you both...

[JeffS]

Confirmed the firmware doesn't appear to be the issue.  Rolled back to the same firmware that has been working on a PLC that has been working in the field and got the same behavior.  I noticed that a longer power cycle (10-15 mins) DST53 would start registering as subtype 150 again rather than 128 on the first power up.  But again that would revert to 128 the next time a program/run cycle occurred.  And all this coincides with the I/O not working.

[JeffS]

Connectors on the 10 BX-DM1E-10ER3-D were showing pins similar to the attached picture.  Pushed the boards together and confirmed 5 of the PLCs that had previous not worked correctly are now working as they should, so I am assuming the other 5 will also work properly now.

Thanks for the help!

[Controls Guy]

Less than 24 hours from report to diagnosis & fix.   AB would still be looking in the database to make sore I'd paid my 'tech support' vig for the year, & I'd still be waiting on a call back from Siemens (probably exaggerating that one).