Dear Everyone,

I am facing one issue occurring every week. The system is with S71200 1215, where this error says that,

“Error: IO device failure - Connection abort by IO device

Potential inhibit/break reason for next startup:

- Unacceptable configuration difference (wrong or missing component)”.

With an

event id:16# 02:39CB

The system contains four Schmersal SFB-PN-IRT -8M12-IOP RIO modules and Eight Schmersal BDF200-FB-NHK-LM-LM-LT-G24-2875PB modules. In some moment one of 4 Schmersal SFB-PN-IRT -8M12-IOP RIO modules going in error state and in next 20 seconds all of them have same error: IO device failure - RPC application timeout.

The problem is that we cannot work with the machine until we solve the communication with the module. That's why we have to stop/start the PLC every time so that the network and communication with the module is stable.

For the troubleshooting even we have checked communication cables, power cables bur still remaining with the same issue. 

Hope you can give me some hint!

Thank you in advance!

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Split from 16# 0D:75E5 and 16# 0D:75D3 Safety F-DI8x24 VDC HF.

Hi 0_Einstein,

Thankyou for the suggestions. I have made the changes as you have suggested the PN device update time is updated from 2ms to 4ms also the communication percentage.

Also find the details you have asked for,

1. When you review each PN device's Profinet diagnostics, do any of them show something different compared to other PN devices in the project? - NO, its only showing "Module exits error. (snap attached)

 2. What is the current PLC scan time? - 15ms 

3.How many HMIs are connected?  How often is data being updated for your HMI tags?  Are they always updated, or only when needed (visible on a currently visible screen)? - No HMIs are connected, hence we are communicating the PLC with the server.

4.What is your communications % setting?  Default is 20%, with Max adjustable up to 50%. - It was setup with the default settings(20%). Increased to 40%.

5. How many interrupt OBs are present, like OB30? - No OB3n's were present in the program.

*The system is currently under observation after updating the settings.

I appreciate if you have any other suggestions.