Covering the case packer this week while the regular lad is off, so this is not my usual corner. 1769 L33ER with six modules in the local bank. I put a small edit in the palletiser handshake, downloaded it, and now slot 4 comes back with a yellow triangle and stays there. The other five are green and running.
Slot 4 is an input card, the IQ16 feeding the infeed photo eyes, and with it faulted the packer won't index. I pulled it and reseated it twice, then pulled it out and dropped it in slot 6 with the tree changed to match, and it faults in slot 6 as well. Put the old spare from the crib in slot 4 instead and that faults too.
Two different cards faulting the same way in two different slots has me thinking the backplane, but the rack's only eighteen months old. Is that where you'd look next?
Open Module Properties on slot 4, Connection tab, and give us the fault text and the code that comes with it, all of it, not just the number. If I remember right it spells the reason out in words underneath the number, and that text is the whole answer most of the time.
What version of Studio 5000 are you on, and what catalog number does the tree say is in slot 4?
v33 here. Tree says 1769-IQ16, Series A, and the Connection tab says Module Fault, 16#0114, something about an electronic keying mismatch and a product code.
I read that as the card not answering properly, which is why I went at the hardware, though I'm not sure what a keying mismatch means in practice. Both cards were pulled with power off, and the rack has not been touched otherwise.
We chased this on a 1769 bank at the old plant for most of a day. Count the modules and add up the backplane current, because the L33ER only carries so much on the 5V rail and you go over it the moment somebody adds a card. Ours went over on the seventh and the symptom moved around the rack.
Is the end cap on properly as well? An ECR that's half seated gives all sorts.
Six modules and no change to the count for two years, so I don't think we're over anything. Pulled the ECR off and refitted it anyway, no difference. Same 16#0114 on slot 4.
Maybe worth saying the infeed card was changed by nights about ten days ago, before I came on to this machine. Nothing faulted then, the packer ran all week. It only went wrong after my download. Getting a bit stuck.
There it is. Stop pulling hardware and go read the label.
16#0114 is the controller saying the product code of the card in the slot isn't the product code in the project. Not a dead module, not the backplane, not the end cap. The connection gets refused before it opens. Nights fitted something that is not a 1769-IQ16, and the controller only rechecks keying when the connection is rebuilt, which is what your download did.
Go and read the catalogue number off the side of the card in slot 4 and the one in the crib, and compare both against the tree. Nine times in ten it's a suffix. Fault codes and what they mean, there's a decent write up here: https://plctr.com/allen-bradley-plc-i-o-faults-causes-solutions/
OG
Card in slot 4 is a 1769-IQ16F. The crib spare is an IQ16F as well, so both of the cards I tried were the fast version and the project has plain IQ16 in it. Nights grabbed the last two off the shelf and nobody wrote it down.
Changed the module in the tree to 1769-IQ16F, kept keying on Compatible Module, downloaded, green in about a second. The F is just a faster input filter and the photo eyes don't care, so we've left it in. What I still can't explain is why the packer ran nine days on a keying mismatch without a murmur, unless the connection really does sit there untouched until something forces it open. Cheers rsdave, louk and billr.
The crib shelf is where half of these start. Label the bin.