error at power up

[PLCGuy]

Module configuration changed at power up - $InstIOChanged (ST134)
This is the message I get every time I power up my BRX system. I can not figure it out.

[BobO]

Module configuration changed at power up - $InstIOChanged (ST134)
This is the message I get every time I power up my BRX system. I can not figure it out.

Dead battery?

[PLCGuy]

This is a new unit. No battery alarm. I took out the battery to see if low battery was working and it is. I put the battery back in. Also i loose all v memory entries. Everything goes to zero.

I started with a new project and same thing. I removed all the rungs thinking something in the program causing it, but same.

There are no errors, just that info message at power up.
I do not know what to do at this point.

[BobO]

What are all of the part numbers in the system?

[PLCGuy]

BX-08AD-1
BX-08DA-2B
BX-12ND3
BX-12TD1
BX-DM1E-M
I did the module configs, checked voltages, cleared memory, started a new program. same result.

I am thinking of removing all the modules but not sure with no i/o do more will like it.

[BobO]

Wait...have you ever put the CPU on RUN mode?

[PLCGuy]

i believe so. the program runs fine, the run light is on the CPU. Turn off power then back on and the run light is off, power light is on. I have to go back into the program and put it in run mode or use the mode switch on CPU. All my memories are at zero after a power up. I loose all memory values.

I just removed all the modules up dated config, and just ran the CPU, no I/O. Same thing happens, same message, out of run mode.

No errors in log or lights. Just the blue info box and that message.

The CPU is all up to date according to the software.

[PLCGuy]

DO MORE 2.1.0
OS 2.1.0
BOOTER 1.0.2
FPGA 1.7
HARDWARE 6A 3A

[BobO]

Verify one more thing for me. What is the value of $BatteryLow (ST149)?

[PLCGuy]

It says OFF

[BobO]

It sounds like the CPU is defective; the retentive memory isn't retaining. You can also check the system log and see if it is basically empty and says the the retentive memory was initialized. If it keeps saying that after every power cycle, the battery isn't retaining data. I've never heard of that before, but it's certainly possible.

I'm sure our manufacturing group would want to do a failure analysis to determine why, and to see if there is room for improvement in the manufacturing tests.

[PLCGuy]

I will order a new one and send this one back. Do you want the CPU for testing? Or will AD tag this and send it to Host anyhow?

[BobO]

They do come back to us, but just as boxes of units. I want to make sure we know which unit it is. I will talk to the product management team at ADC and see if we can get special handling for this unit.

[ADC Product Engineer]

PLCGuy, Tag both the box and the unit with "Send to BRX Product Engineer for analysis" when you send it back.  That will get it to me and I will get it to HOST for analysis.

[PLCGuy]

thank you. I will also pass on that info when I get the RMA from AD.