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IO Module errors with ET200S

Created by: tomearp at: 4/27/2009 8:20 PM (17 Replies)

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4/27/2009 8:20 PM	Rate (0)
tomearp Posts: 51 Rating: (3)	not sure if this is the right place to post, but couldn't find anywhere specifically for ET200S.... i have approx. 10 control panels built with IM151-8 PN/DP CPUs on the same site (6ES7 151-8AB00-0AB0) most of them are running fine, but some of them keep reorting the same error in the diagnostic buffer and entering stop mode... it reports as "STOP caused by IO Management" the help file refers to it as "Event 4x48" with possible causes of 'the cpu has detected a modification in the actual I/O configuration' and goes on to give examples of inserting/removing modules while in run mode (which is not happening) or powering down/disconnecting expansion racks while in run mode (which is also not happening) or 'bad electrical contact' i have removed all the modules and checked all the pins for dirt/corrosion/etc and they're all clean and all the modules are inserted correctly. or 'module defective' i have replaced the modules several times with spares and it makes no difference sometimes they'll run for 20 minutes before it re-occurs, sometimes a week or more. only thing i can think of it possibly being is the power supply into the site. it's in the sticks a bit, so voltage fluctuations do occur, however the power supplies i'm using are fairly tolerant and have reasonable hold-up times. any help much appreciated, getting pretty bored of call-outs justto go and flick the switch down and up again....
tomearp Posts: 51 Rating: (3)
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4/28/2009 6:33 AM	Rate (0)
DeepakD Bronze Member Joined: 11/30/2006 Last visit: 3/16/2021 Posts: 118 Rating: (11)	The possible cause of the error is due to some reason the I/O's are loosing . I am not sure wheather you have expansion racks with ET200S, if you have any then check the expansion cables (parallel cables ) if possible replace them with spare ones. If the expansion cables are faulty there is possiblity of loosing I/O's causing PLC to stop. I hope it helps you to resolve the issue.

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4/28/2009 5:53 PM	Rate (0)
tomearp Posts: 51 Rating: (3)	there are no expansion racks, all the IO modules are directly connected to the cpu. the devices are not subject to any shocks or vibration which could make something work loose
tomearp Posts: 51 Rating: (3)
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5/2/2009 1:14 AM	Rate (0)
H-H Platinum Member Joined: 7/2/2008 Last visit: 3/14/2023 Posts: 928 Rating: (303)	The next time you go there try to investigate your hardware configuration in online view and see what's exactly wrong with I/O modules. The strange thing is that the CPU goes in STOP. Why don't you download synchronous and asynchronous error OBs and analyze the local data of error OBs so you can know exactly what's wrong. Please check this FAQ. I believe diagnostic buffer should include more data than what you have told so please upload diagnostic buffer of the CPU.

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5/2/2009 1:48 PM	Rate (0)
tomearp Posts: 51 Rating: (3)	cheers for that, i'll try and gather some more information next time it happens
tomearp Posts: 51 Rating: (3)
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5/2/2009 2:29 PM	Rate (0)
H-H Platinum Member Joined: 7/2/2008 Last visit: 3/14/2023 Posts: 928 Rating: (303)	Hello Tomearp, It seems the error OBs will not help. Siemens saysI/O administration error can't be intercepted by an error OB. I've just found this FAQ and I think it's similar to what you are facing. The FAQ is quite old but I can't find a newer one talking about I/O administration /management error. So, according to above FAQ you were right from the begining. It might be power supplies and voltage dips. Best regards. H-H

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5/6/2009 3:15 PM	Rate (0)
tomearp Posts: 51 Rating: (3)	one of the controllers fell over again the other day....i've attached the diagnostic buffer the first 2 events can be ignored, some network switchgear on the site was taken offline to relocate some UPS units which is what caused the network interruption. i've still not really got any further in figuring out what's causing it. one thing i am going to try is earth referencing the power supplies in the control panel. at the moment the 0V rails of the various supplies in the panel are linked (so that analogue inputs/outputs are working from the same reference) but floating relative to earth. i wouldn't have thought it would make any particular difference but i'm running out of things to try! Attachment Diagnose.pdf (460 Downloads)
tomearp Posts: 51 Rating: (3)
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5/9/2009 1:45 AM	Rate (0)
H-H Platinum Member Joined: 7/2/2008 Last visit: 3/14/2023 Posts: 928 Rating: (303)	Hello Tomearp, I've checked your diagnostic text file. Isn't it strange that you are having output module (Address 14) frequently inserted and removed?!! I think you got something wrong in this module. What kind of power supplies are you using? Are you using the same power supply for CPU, Power modules andI/O modules? If this is the case, I'd recommend to use separate power supply for power modules and I/O connections. I also recommend to check the suspected module (Address 14) and its terminal module. Also check the wiring and make sure that load is suitable for output transistor.

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5/11/2009 9:44 AM	Rate (0)
tomearp Posts: 51 Rating: (3)	in this particular panel, i have a Puls CS10.243 (24Vdc) and a Puls ML30.102(10Vdc). The CPU and the load power supply are both fed from the same 24Vdc supply using seperate cables. The 10Vdc supply is used to supply some analog field devices; the 0V rails are tied together to maintain the same analog reference between the cpu and the field devices. i have used a clamp meter to measure the load and even with outputs switching there's nothing in excess of 500mA so it's well inside the rating. (the supply is capable of 10A+ continuous) i have tried replacing the module, but not the terminal module so that is something i can try. if it was a loose connection somewhere i would expect to be able to reproduce the error in real-time by monitoring the diagnostic buffer and subjecting the module/terminal module to movement by hand. however all attempts to do this have so far failed. the load being switched is a 240Vac coil solenoid valve. i have attached the manual for the particular digital output module i'm using. on page 7 it states the module is suitable for use with solenoid valves. i was careful to observe the note about not mixing SELV/PELV loads with non-SELV/PELV loads on a single module. (the other channel on this particular module is spare and not connected to anything) Attachment ET200S DO Module.pdf (288 Downloads)
tomearp Posts: 51 Rating: (3)
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5/13/2009 12:43 AM	Rate (0)
H-H Platinum Member Joined: 7/2/2008 Last visit: 3/14/2023 Posts: 928 Rating: (303)	Hello Tomearp, I'm running out of thoughts. The switched mode power supplies you are using look good. I've quickly revised the data sheet and found nothing wrong. I can expect that your total current consumption is less than 10 A (Not on the edge). Correct me if I'm wrong. I would say,leave the power supply youalready have for power modules and use a separate smaller new one for the CPU (Backplane bus). Try to reallocate this module in hardware configuration. I mean use it in a different slot and see if the error moves with module or stays at previous slot (With any different module). I wish if I have any experience with this type of faults. I wish Icould help you in a better manner.

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