The ControlLogix CPU is linked to Flex I/O via ControlNet. The Flex I/O system comprises 5 modules: IB10XOB6, AIE8, BIE4XOE2, and BIR8IR8. The two BIR8IR8 modules tend to overheat, causing all inputs to max out, even when not connected to a field. The Module OK LED remains steady green, indicating normal functionality. When connected to the CPU through RSLogix, there are no reported issues in the IO tree. Replacing the faulty module resolves the issue temporarily. This is an older setup operating for several years, with two other Flex I/O drops configured similarly but not experiencing the same problem. Testing the faulty modules in a separate rack produces the same outcome. To address this recurring concern, identifying the root cause behind these malfunctions is essential.
When troubleshooting issues with your industrial control modules, there are a few key factors to consider. Firstly, ensure that the TB3 base wiring is accurately connected by referring to the manual1794-IR8 and cross-checking against the specifications outlined in chapter 2. Secondly, if you are experiencing "noise" on your 24V dc power supply, it could indicate issues with the modules. Additionally, it is important to check for any AC interference on your field wiring to the RTDs. Lastly, if the modules are consistently malfunctioning on both your test rig and field setup, there may be a possibility that they are faulty and in need of replacement. By addressing these potential issues, you can ensure optimal performance and reliability of your industrial control system.
When troubleshooting issues with TB3 base wiring, refer to the manual 1794-IR8 and cross-check against chapter 2 for accuracy. It's crucial to ensure there is no "noise" present in the 24V DC power supply to the modules, or even AC interference in the field wiring to the RTDs. If the modules continue to exhibit the same behavior on the test rig or are being damaged in the field setup, check the points mentioned above. Additionally, if the wiring remains unchanged from the old installation and issues persist intermittently after maintenance shutdowns, consider running a scope on the DC to detect any noise. With 8 faulty modules replaced within a short period, conducting temperature checks on the modules in the test rack revealed varying surface temperatures. The faulted module with no inputs reached 42 degrees C, while the faulty module with test resistors installed peaked at 72 degrees C. Contemplating a return to Rockwell for further analysis.
Kellian mentioned that a ControlLogix CPU is connected to Flex IO via ControlNet. The Flex IO setup includes 5 modules: IB10XOB6, AIE8, BIE4XOE2, and BIR8IR8. Two IR8 modules tend to overheat, causing all inputs to go to full scale regardless of field connections. Despite the solid green OK LED indicating normal function, the issue persists. Replacing the modules temporarily resolves the problem. This recurring issue in an older installation prompts the need to identify the root cause. Other Flex IO drops in similar configurations do not experience the same problem. Testing the faulty modules in a separate setup yields the same results. If you have found a solution to this issue, please share as I am facing a similar situation. Thank you - Mike Hanners, Procter & Gamble PCI&S.
Interesting predicament you've got there. It sounds like you've done a thorough job of diagnosing the issue on the system level. One thing I'm curious about, have you considered the environmental factors, such as operating temperature or electrical noise, that may be causing these issues with BIR8IR8 modules? Also, since it's an older system, it's worth mentioning that the components might have degraded over time and could be operating outside original specs, which can lead to overheating. For a longer-term solution, I'd recommend looking into preventative maintenance or even the possible upgrade of the system if the overheating continues to persist.
Given your description, it seems you've gone through comprehensive diagnostics to figure out this issue with your BIR8IR8 modules. One possible cause that comes to mind might be that the power supply units for these modules could be producing an excess voltage, leading the modules to overheat and max out. A simple voltage check might help you discern this. Meanwhile, considering the legacy status of your system, it might also be useful to check if these modules are still within their usable lifespan. Even though the Module OK LED is functioning normally and there are no reported issues in the IO tree, some inherent wear and tear, possibly due to age, might be leading to this overheating. Finally, reevaluate the thermal management of your Control Cabinet. After years of operation, sometimes, the cooling system may not be as efficient, leading to overheating.
Your BIR8IR8 overheating issue is intriguing, especially given that the Module OK LED remains green and no issues are reported in the IO tree within RSLogix. My immediate thought is considering environmental factors. If these modules are located in a hotter part of your facility or exposed to any unusual conditions that the other unaffected Flex I/O drops aren't, it could cause some trouble. Also, just as a long shot, have you tested for any kind of electromagnetic interference? Lastly, I'm not discounting the possibility of a product defect or aging causing this, seeing that replacing the faulty module resolves the issue temporarily. It's good practice to periodically replace hardware in critical applications.
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Answer: - The overheating issue with the BIR8IR8 modules could be due to various factors such as a malfunction in the module itself, environmental conditions, or potential issues in the wiring/connection.
Answer: - The inputs maxing out could be a symptom of the overheating issue in the BIR8IR8 modules, potentially causing a malfunction in the readings even when not connected to a field device.
Answer: - The temporary resolution after replacing the faulty module might indicate a deeper underlying problem within the system that needs to be addressed to prevent recurring malfunctions.
Answer: - To identify the root cause, thorough troubleshooting steps such as checking the wiring, analyzing environmental conditions, examining the configuration, and conducting further testing or diagnostics may be necessary.
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