Hey there, I'm curious to know if anyone else has encountered similar issues like us. We have approximately 150 x 1756-IF8I analogue input cards installed at our site, spread across multiple PLCs, primarily using L6 and L7 controllers with v20 firmware. We are facing an intermittent problem with these cards, experiencing this fault about 3 to 4 times per year on average. The card will go into a fault mode, with a solid red 'OK' LED and a connection fault in RSLogix5k (Code 16#0204), as if it has been disconnected. Removing and reinserting the card resolves the issue, indicating no hardware faults. The faults occur randomly across different PLCs and slots, without any pattern. I reached out to Rockwell about this over 3 years ago, but we are yet to receive a solution. Despite flashing the firmware multiple times and receiving replacement series B cards, the issue persists. The escalation team in the US is currently conducting tests to replicate the fault. Have you faced similar issues with the 1756-IF8I? Thank you.
If you are utilizing the module for sourcing current loops, reconsider your approach. It may be advisable to explore alternative methods to achieve your desired outcome.
Robertmee asked if you are utilizing the module for sourcing current loops, and advised against it. Hi Robert, we are not using the modules for this purpose. Could you please explain why you do not recommend it? Cheers.
In response to Robert, Kane Vincent mentioned that they are not utilizing modules to source current. He inquired about the reason behind not recommending this practice. According to Rockwell's tech note, exceeding 45ma on a channel can cause it to lock up and require a power cycle. Kane typically avoids using module channels to source loops and opts for a separate power supply instead. A red module indicator usually indicates an unrecoverable fault, prompting Rockwell to suggest changing the module. However, if issues persist across various models and locations, further investigation may be needed. Kane recounted a similar experience with multiple IB16S modules hard faulting, attributing it to a non-SELV rated power supply causing AC ripple and module lock-up. It is essential to consider common factors in the installation, especially power and wiring. Questions to consider include the type of power supply being used, such as an AB XLE supply, switching supply, or linear supply.
Hey! I can definitely relate to your frustration. We had a similar experience with the 1756-IF8I cards in our setup, where random faults would pop up without any clear pattern. Interestingly, we found that environmental factors like temperature fluctuations and electrical noise could sometimes contribute to the issue, even though it seems isolated to just the cards. Have you checked the grounding and shielding in your setup? That made a difference for us, and I wonder if it might help in your case as well. It’s tough when support takes ages to respond, so I hope they get things sorted soon!
I've definitely heard of similar issues with the 1756-IF8I cards in other facilities. The intermittent nature of the fault can be incredibly frustrating, especially since it sounds like you've already tried many troubleshooting steps. In one case I know of, they found that grounding issues or even environmental factors like temperature fluctuations could be contributing to their connection faults. It might be worth looking into your installation environment a bit deeper to see if there’s anything there that could be influencing those card behaviors. Hopefully, Rockwell’s escalation team can find a solution soon!
Hey! Thanks for sharing your experience—it's definitely frustrating when issues like this seem to pop up without a clear reason. We've had similar intermittent faults with the 1756-IF8I cards in our setup, and like you, we noticed that reseating the cards often temporarily resolved the problem. It seems to be a common pain point, especially with those specific controller versions. Have you considered looking into environmental factors, like temperature or humidity, that might be affecting performance? Sometimes, even minor fluctuations can lead to unexpected behavior with sensitive components. Hope the escalation team finds something soon!
Hey there! I can relate to your frustration; we had a similar experience with the 1756-IF8I cards in our facility. We noticed sporadic faults that seemed to pop up at the most inconvenient times, and like you, reseating the card would temporarily fix the issue. It definitely sounds like something deeper than just hardware problems if new cards and firmware updates haven't resolved it. You might want to check environmental factors too, like temperature or electrical interference, as those can sometimes cause intermittent faults. Have you tried any diagnostic logging to identify if there's a pattern somewhere? Hopefully, the escalation team will get to the bottom of it soon!
Hey! I can relate to your frustration with the 1756-IF8I cards. We've had a similar experience with intermittent faults that seem to manifest randomly across our systems. It sounds like you've done all the right troubleshooting steps, from firmware updates to testing replacements. One thing we found helpful was ensuring our grounding and power supply stability — sometimes electrical noise can lead to those kinds of issues. Have you also looked into environmental factors or network interference that could be contributing to the faults? Just throwing that out there; hopefully, you get some answers soon!
Hey there! I can totally relate to your frustration; we experienced a similar issue with the 1756-IF8I cards a while back. It sounds like a tough spot since you've already tried various remedies. In our case, we found that environmental factors, like electromagnetic interference, might be playing a role, so we took extra precautions with cable routing and grounding. Although it doesn’t solve the problem entirely, it seemed to reduce the frequency of the faults. It might be worth checking your setup for anything similar! Hopefully, Rockwell will come up with a solution soon.
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Answer: Answer: Common symptoms include the card going into fault mode with a solid red 'OK' LED, a connection fault in RSLogix5k (Code 160204), and appearing as if it has been disconnected.
Answer: Answer: The faults occur about 3 to 4 times per year on average, according to the discussion thread.
Answer: Answer: Troubleshooting steps have included flashing the firmware multiple times and receiving replacement series B cards, with no resolution of the issue. The escalation team in the US is currently conducting tests to replicate the fault.
Answer: Answer: The original poster in the discussion thread is seeking input from others who may have encountered similar issues to share experiences and potential solutions.
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