Hello everyone, I am currently facing an issue with the Modicon System that operates our Generator System, specifically the Dresser-Rand SFGLD 560. The problem lies with the analog Output Module BMXAMO0410, which unexpectedly malfunctions and causes the Generators to trip. One of the channels on this module is responsible for maintaining and controlling Voltage via AvR. When the issue occurs, all 4 channels in the module stop functioning and only 1 green status LED remains stable. We have to power recycle the rack to normalize the module, but the problem resurfaces almost every week. We tried replacing the Analog Output Module, which temporarily solved the problem. However, after 3 to 4 months, the same issue reappeared and we are at a loss. We also checked the debug option from Unity Pro for the module and it indicated External Fault - Power Supply Fault, Internal Fault - Module Unserviceable, and Other Fault - Application Fault. These faults reset after power recycling. If anyone has any insights on resolving this issue, please let me know.
To troubleshoot, start by inspecting the wiring. Check if the outputs are fused at the panel and if the fuses are the right size. Consider the distance between the control card and the final device. It appears there may be a short circuit or excessive load causing the entire card to fail.
Although I haven't utilized Modicon before, I have encountered similar faults in a few PLCs. These issues are often caused by loose or broken wiring within the outer coating, which can make a connection when moved. Poor contacts or dry joints on the backplane connectors are also common culprits. I recently fixed a similar issue with an SLC500 PLC by cleaning the backplane connectors and re-soldering all the connections. It may be beneficial to investigate these areas if you are experiencing a similar problem.
When troubleshooting an electrical issue, it is important to first check the wiring. Ensure that the outputs are properly fused before exiting the panel, and that the fuses are the correct size. Also, consider the distance between the control card and the final device to identify any potential short circuits or excessive loads that may be causing the card to fail. In this case, the wiring has been inspected and no fuses are installed between the panel and the final device. The distance is relatively short, about 50 to 60 meters. Isolation and loop testing have been conducted on the cable with no issues found. The cable has been thoroughly inspected and no damage to the wires has been detected.
Parky mentioned that, while they have not used Modicon PLCs, they have encountered similar faults in a few PLCs in the past. The most common causes of these faults were found to be issues with wiring, such as loose connections or broken wires within the insulation that could make contact when moved. They also noted that poor contacts on the backplane or dry joints could be contributing factors. In a previous experience with an SLC500 PLC, cleaning the backplane connectors and re-soldering all the connectors resolved the issue. I, too, am considering the possibility that the issue is related to the backplane. However, the programming software is also indicating a problem with the Power Supply. With this in mind, I decided to replace both the Power Supply and the Backplane today and put the machine back into operation. Hopefully, this will resolve the issue.
Troubleshooting Communication Issue between M340 PLC and PRA 0100 Greetings, I am currently facing a challenge with the communication link between an M340 PLC and a PRA 0100 device. While controlling a critical process, the process suddenly halts without any apparent faults in either the PLC or the PRA. Upon closer examination, it was noted that a specific input module intermittently flashes before the process comes to a stop, resembling a manual stop command being triggered – despite no such action being taken. I am inclined to suspect that the issue may stem from a potential backplane problem or a defective module.
From your description, it sounds like an underlying issue might be causing your Analog Output Module to fail repeatedly, especially since you've already replaced the module once and the problem reoccurred. One possibility you might want to look into is the power supply itself - it's worth checking if there's any fluctuation or instability that could cause the module to malfunction. Additionally, issues in the communication between the module and the AvR could also contribute to this problem. Just as a suggestion, you may want to analyze the system's operational behavior prior to the module's failure - it could provide valuable insight. Another solution might be to reach out to Schneider Electric's technical support for the Modicon System, as they might have more specialized advice.
From your description, it sounds like this could potentially be due to an issue with your power supply rather than the analog output module itself. Fluctuations or instability in the power supply could easily cause the module to dysfunction and generate the faults that you're seeing in Unity Pro. You may want to confirm whether the power supply is stable or not, and if there's any noise on the supply. You could also consider adding a UPS system or power conditioner to ensure clean power is being supplied. And if the problem repeats in a specific time frame, you might want to see if there any scheduled events happening concurrently. It's also worth checking that the firmware and software of your Modicon system are up-to-date as sometimes these issues can be fixed through updates.
It sounds like you’re dealing with a frustrating situation! Given the recurring nature of the faults and the need to power cycle the system frequently, it might be worthwhile to check the power supply stability and ensure there are no grounding issues or interference that could be influencing the BMXAMO0410. It might also help to review the overall load and ensure that the module isn't being overloaded. Additionally, consider reaching out to the manufacturer for any known issues or firmware updates that could resolve the problem. Sometimes, these specific modules can have quirks that documentation might not fully cover. Good luck!
It sounds like you're really facing a tough situation with that system! Given the recurring nature of the issue and the various faults cited, it might be worth checking the power supply and grounding conditions, as inconsistent power can often lead to such module failures. Additionally, if the module is overheating or there's interference from other equipment, that could also be the culprit. Have you considered monitoring the operating conditions when the failure occurs to see if there are any patterns? Sometimes tracking temperature or voltage spikes can reveal underlying problems.
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Answer: - The issue could be related to the External Fault - Power Supply Fault, Internal Fault - Module Unserviceable, and Other Fault - Application Fault detected by the debug option in Unity Pro. These faults reset after power recycling, indicating a recurring problem.
Answer: - Power recycling the rack temporarily normalizes the module, but the issue resurfaces almost every week. This suggests a persistent underlying problem that needs to be identified and addressed to prevent frequent failures.
Answer: - The user mentioned replacing the Analog Output Module, which initially solved the problem but recurred after a few months. Checking the debug option in Unity Pro provided insights into the faults detected, but a lasting solution is still needed.
Answer: - Regular maintenance checks, monitoring of error logs, and conducting thorough diagnostic tests on the analog Output Module could help identify any potential issues before they escalate into full-blown malfunctions causing the Generators to trip.
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