BX-08AD-3 not detected by CPU

[Kristjan]

I have three BX-08AD-3 that are not detected by the CPU.

Create Do-More program with I/O config - Connect to PLC - Download program and I get an error because the CPU is seeing a different module setup than config says. We have tried this on different CPUs and get the same error. The CPU apparently doesn't detect the modules. If I connect to the PLC directly, DoMore Designer shows me all the modules in the rack except for BX-08AD-3.

The modules in question have IC number 03254C00083B / 03254C00083C / 03254C00083D and hardware revision 4C. We haven't had this problem before or since, most of the modules we have in stock are HW rev 4A.

Is there a known issue with HW rev 4C?

[BobO]

I have three BX-08AD-3 that are not detected by the CPU.

Create Do-More program with I/O config - Connect to PLC - Download program and I get an error because the CPU is seeing a different module setup than config says. We have tried this on different CPUs and get the same error. The CPU apparently doesn't detect the modules. If I connect to the PLC directly, DoMore Designer shows me all the modules in the rack except for BX-08AD-3.

The modules in question have IC number 03254C00083B / 03254C00083C / 03254C00083D and hardware revision 4C. We haven't had this problem before or since, most of the modules we have in stock are HW rev 4A.

Is there a known issue with HW rev 4C?

First I've heard of it, but I'll check.

[BobO]

Nothing specific to those modules. We have had some issues with the small discovery flashes, but most were the result of some bad parts we got during the supply chain crisis. We are happy to do a failure analysis and rework if required.

[Kristjan]

Now we are having issues with three BX-08DA-3 not being detected by the CPU. This seems to be the root cause of a previously discussed error on slot 255. The system was running fine for about 9 months and then this error.

I am testing the modules in my workshop with a simple setup: BX-DM1E-M-D (FW 2.11.2) + 3 pcs BX-08DA-3. The CPU doesn't detect the modules (attached screenshot with I/O System View). Removing one or two modules gives the same results, "...nothing installed in this slot".

The modules are HW Rev 2A. Serial numbers 10222A0001AE / 10222A0001B3 / 10222A0001CB.

Any clue what happened to the modules?

[franji1]

Click on slot 3 and show the error message for that slot, like the screen shot you did for slot 1 warning.  Its status is in red, so it is reporting an error (vs. yellow warning).

[Kristjan]

Attached is what I see when I click on slot 3, the same error message as for the yellow warnings.

I was on site last night to troubleshoot and did the following:
1. Changed slot 3 to BX-08DA-2B (because I thought that I might be offending a power limit). Then only the first two modules gave the same warning/fault.
2. Changed slot 2 for a fresh BX-08DA-3. Then fault is only on first module.
3. Changed slot 1 for a fresh BX-08DA-3. No faults, system back up and running.

[Kristjan]

Extra information for future reference:

The screenshots above are from my testbench. The actual IO rack on site is now BX-DMIO-M-D + 2 pcs BX-08DA-3 + 3 pcs BX-08DA-2B (changed it a little bit yesterday). Today the PLC stopped again, reporting a missing module in slot 2, similar as before. The DMIO/OK light was orange, I tried different configurations, removing one module at a time and it turned out that it was the second BX-08DA-2B that was faulty (DMIO/OK light green). DoMore Designer did not report the BX-08DA-2, maybe because the DMIO never started communicating (Ethernet I/O Monitor gave no activity on the slave) and therefore no update to the respective error message.

So now we have a running system again and fingers are still crossed, hoping that the BX-08DA-2B was the root cause and we don't need to rush out in the middle of the night 

[Kristjan]

Well, now we had a new fault on the IO modules. Thankfully I wasn't dispatched until early Saturday morning 

The DMIO in question has 2 pcs BX-08DA-3 and 3 pcs BX-08DA-2B. PLC firmware 2.11.2 / DMIO firmware 4.2.239

This time the PLC/DMIO reported no module found in slot 6 - there are only 5 modules installed. Clicking on slot 6 shows "BX-08DA-2B detected in slot 6 but no module detected" (see screenshot). After some rework the PLC told me there is no module found in slot 7 (!) - still only 5 modules installed.

I removed the DMIO and attached the 5 IO modules to a DM1E and it detects 8 modules (!) out of which the first two are unknown (see screenshot). Some more shuffling around and replacing the first two modules (BX-08DA-3) resolved the issue, it now detects the correct number and module types and the system is up and running again.

It seems like the BX-08DA-3 is somewhat sensitive/vulnerable. I am planning to replace these with BX-08DA-2B and hesitate to use BX-08DA-3 in upcoming projects.

Does this documentation give any clues as to what might be happening to the BX-08DA-3 modules? Or why the PLC/DMIO are detecting modules that aren't real?

[franji1]

Do you have Manual I/O Configuration enabled?  (Modules configured manually show up, but then get reported as missing if they are not actually there)

Are you re-mapping your discrete inputs?  I ask this because in your first screen shot (STAP_IO_view_onlocA_mod7.png) the X's for slot DMIO Remote Base 1, Slots 3 and 4 appear to have their X's out of order - this can only happen if you are re-mapping the I/O manually. There's nothing wrong with this, just making sure that you are wanting to do that on the X status bits, but you did not manually configure the I/O mapping for the analog output WY's themselves (they are IN order).

Just asking/noticing to help us understand better what is going on.

[BobO]

I know of no problems with the -3 analog. If you have failing hardware, I'd really love to test it.

[MikeS]

I put together a quick test system here with the same I/O modules in the same layout you have and tried doing hateful things to it do make it fail with no success. Any error condition I could generate was resolved when the cause of the error was removed.

If you have a specific I/O configuration that can readily reproduce the error you're seeing please let me know. If it takes a particular module to generate the error, I'd like to have that module back here to see what's going wrong. If the module is damaged, it will be repaired before being sent back.

[Kristjan]

Thank you for the feedback guys, we appreciate it 
I will be shipping the modules to Host and looking forward to the outcome.