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Analog Input module stuck

Created by: Sergey R at: 10/16/2008 11:23 AM (7 Replies)

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10/16/2008 11:23 AM	Rate (0)
Sergey R Advanced Member Joined: 10/13/2008 Last visit: 5/25/2023 Posts: 9 Rating: (0)	I have meet very unusual issues with analog input modules (6ES7 331-7NF10-0AB0): 2 channels jumped to 25%, when a real value from field device was 0%, and card stucked in this state till turn off. After turning on all meassures become in normal state. Another case: 6 channels simultaneously alarmed "wire break". This module wasn't connect to any measurement device, and all point were connected to 10K resistors. Trying to simulate real wire break by disconnecting resistor from any point didn't resulted to any changes. After reset all points become to normal. Both cases happend in different parts of the site and in different time. What can be reason for such issues?

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10/16/2008 7:58 PM	Rate (0)
jklm Platinum Member Joined: 12/22/2006 Last visit: 1/25/2022 Posts: 1742 Rating: (303)	Hello, I would first check if all mounting rules are correctly followed (earthing, schielding, deactivate unused channels, short-cut unsed channels when indicated in the manual, connection of MANA, ...).
	Best regards jklm Suggestion was helpful? Feel free to rate it.
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1/25/2009 9:14 AM	Rate (0)
Sergey R Advanced Member Joined: 10/13/2008 Last visit: 5/25/2023 Posts: 9 Rating: (0)	Hello edr We performed any believable and unbelievable checks. All looks OK. Grounding and noises are also OK. But problem countinue to appear. Last time we had same AI(6ES7331-7NF10-0AB0) module, simultaneously alarmed CH02-CH07 wire break. In diagnostic buffer of the specific card are next messages: "External error Faulty Module There is a channel error." Voltage on input is 24.5V Current 4.8 mA Inputs are shorted with resistors of 5.0 kOhms. Any ideas?

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4/8/2009 10:50 PM	Rate (0)
Frederik Posts: 23 Rating: (1)	We have a customer who is having the exact same problem, all 8 readings on the module freezes and the sf light goes on. It happened 3 times in the last few months. They have some spare parts and assumed that the module was faulty and replaced it. But today I was there when it happened and I noticed that simply switching on/off made the module work again. I tried all 3 other modules previously replaced in the last months and they all worked. Modules are 6ES7-331-7PF00-0AB0 with PT100 reading. System was installed approximately in 2004 and this never happened before recently. Right now I have a test rig with 4 of those that were removed and supposedly defect, there is nothing connected except for power, maybe this is the reason why I have the same diagnostic (I dont have any resistors or PT100 connected): External error Faulty Module There is a channel error Any ideas? I will program something to avoid damage to material in the process in case those readings stalls again, but I would like to know the cause to this as well. I have read entry 6568425 and also 5296808 about a defective component that could cause "inconsistent values" but it says it is solved from version 6 and mine appear to all be version 7. Thanks and best regards, Frederik
Frederik Posts: 23 Rating: (1)
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6/4/2009 4:34 PM	Rate (0)
Sergey R Advanced Member Joined: 10/13/2008 Last visit: 5/25/2023 Posts: 9 Rating: (0)	Dear Ferderik, Let's cooperate on reosolving this problem, and try to find the reason for such kind of problems. When I applyed to local resepresentive of Siemens i didn't received any objective answer. We performed very wide checks of power supply system on site like harmonics checks, spike checks, and of course voltage and current. And we didh't saw nothing unusual. I think that the problem can be in firmware, on our site we have following configuration: Redundand CPU 417-4 H, 2 redundant loops of remote IO panels ET-200M in total aproximately 70 panels, all panels have the same configuration (16DI:16DI;16DO:16DO;32DO;32DO;8AI;8AI), following are firmware versions: CPU 417-4 H 6ES7 417-4HL04-0AB0 firmware:V 4.0.8 IM153-2 6ES7 153-2BA01-0XB0 firmware:V 4.0.7 CP 443-5 Ext 6GK7 443-5DX04-0XE0 firmware:V 6.1.7 AI8x16Bit 6ES7 331-7NF10-0AB0 E-Stand 5 Which HW configuration and versions of firmwares you have on your customer's site?

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1/4/2011 4:57 PM	Rate (0)
Frederik Posts: 23 Rating: (1)	Sorry for taking that long to reply, for some reason I don't receive any notifications of replies, we did not find an explanation and Iforgot about this thread. We have different sites that are experiencing the same problem, but for us it is always with the 6ES7-331-7PF00-0AB0cards used with PT100. After the readings are stuck, resetting power usually restores normal behavior, but the problem returns shortly after (like 1 day) and the card eventually fails completely, reading open circuit (max reading). There is another type of recurring failure where the card simply goes to max reading and never returns and needs to be replaced. We had 2 of those "freeze"failures in the last 2 weeks, at 2 different sites, and at both sites the card had to be replaced. We are using WinAC Slot PLC PCI CPU cards (for instance CPU 416-2 PCI) in standard computers, with ET200M Profibus drops. Here are 2 examples: Site A: CPU 412-2 PCI 6ES7 612-2QH00-0AB0 v3.1 IM 153-1 6ES7 153-1AA03-0XB0 AI8xRTD 6ES7 331-7PF00-0AB0 v 8 There are 2 of those Profibus remote IO racks. The main rack is CPU only because the CPU card sits in a computer PCI slot. Site B: pretty much the same CPU 412-2 PCI 6ES7 612-2QH00-0AB4 v3.0 IM 153-1 6ES7 153-1AA03-0XB0 AI8xRTD 6ES7 331-7PF00-0AB0 v 8 There are 2 of those Profibus remote IO racks. Site C: CPU 416-2 PCI 6ES7 616-2QL00-0AB4 v3.0 IM 153-2 6ES7 153-2AA02-0XB0 AI8xRTD 6ES7 331-7PF00-0AB0 v 7 or above (not sure) There are5 IM 153-2 remote IOs, and one IM 153-1 . There is also another similar site which have had the max reading problem multiple times (not frozen, just max reading, had to replace card). What are your typical cable lenght between the PT100 and your RTD modules having the problem ? The card failures seems to be dependent on the time since the system was installed. The older sites have the problem first. The time appears to be approximately5-6 years. Let me know if you have any similarity or if you had new information on your problems. Given the fact we have this a multiple sites there must be others having the same failures ? Note: in our case, all 8 channels are always used on all cards. Frederik
Frederik Posts: 23 Rating: (1)
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1/19/2012 9:56 AM	Rate (0)
jereby Posts: 1 Rating: (0)	Hello! I have same problem here. I'm using "6ES7-331-7PF01-0AB0" module for measuring resistance in 4 point mode. When I do the measurements i get correct value a few times then suddenly i get some strange value. I already checked everything and I cannot solve the problem. After reseting CPU, module works for a while and then same problem appears again. Any ideas from you guys, Siemens support did not give me a relavant answer... Kind regards, Primoz!
jereby Posts: 1 Rating: (0)	Last edited by: jereby at: 1/19/2012 9:57 AM
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1/19/2012 3:06 PM	Rate (0)
Rated X Posts: 1547 Rating: (129)	It seems you are not discussing same modules? For Sergey there may be an idea in http://support.automation.siemens.com/WW/view/de/12370217 Sergey writes he uses 5 kOhm resistors. Does the problem also occur with 2 kOhm?
Rated X Posts: 1547 Rating: (129)	Last edited by: Rated X at: 1/19/2012 3:07 PM
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