PM866/CI854 with CI801, not all S800 modules are active
Hi... I have a PM866 / redundant CI854 communicating to 11 CI801 stations. These 11 stations are geographically located in 5 places, and we have 5 Phoenix Profibus fiber optic converters set up in a ring topology. (Please see attached screenshot). I have two issues I can't seem to resolve:
1. Station 10 (1 DI810 and five DO820) initially tested fine (green status, no yellow W), but when powered back up after initial testing, all five DO820 have green status but also yellow W, and I can no longer force the DO820 outputs (red triangle on channels in CBM). The DI810 works fine. The DO820 is relay outputs, no power is landed on termination. Manual states that the card will show yellow if supervision power for relays coming through modulebus is suspect.
2. Station 7 - the digital modules (DI810, DO810 and DO820) all come up with green status, but the AI830 all come up red. To try and pinpoint the problem source, we removed all digital cards (and redefined the station for only the AI830), we tried using a different Profibus address, we tried swapping CI801 for a known good unit. We even tried removing all AI830, adding one AI810... still, all digital cards come up green, anything analog comes up with red fault status. The common theme during troubleshooting seems to be that analog cards are never recognized, digital cards are. Note that station 7, along with 3,4,6 and 6 all connect via copper Profibus to the same fiber optic converter, passive terminators are on at the converter and station 3 (ends of copper chain).
Appreciate any suggestions.
Installation problems cause all sorts of WEIRD comms issues. Beg, buy, borrow or steal a comms analyzer ....
Basically, if you've configured the correct S800 IO module types and station numbers, then thats pretty much all there is to do in Control Builder. Go through the cable installation and check that everything is installed PROPERLY with attention to good quality workmanship, cable routing, splicing and terminations ( and no, not just the 50 ohm resistors ). You cannot take shortcuts with any field bus system - the cables need to be installed with care.
Please provide Online Unit Status for the modules in order to see the reason for fault indication.
If assume that Profibus connection to the modules is OK (some other modules in the same station are working well), then most probably it is power supply issue or wrong setting of parameters in CBM:
1. For DO820 - in settings, there is a Power Supervision parameter, by default true. Try if you set that to false. Check also if the module is locked to the termination.
From the help for the module:
The relay supply voltage supervision, derived from the 24 V distributed on the ModuleBus, gives an error signal if the voltage disappears, and the Warning LED turns on. The error signal can be read via the ModuleBus. This supervision can be enabled/disabled with a parameter
2. For AI830 - check in parameter tab if the channels are set to Active. Also check if the module is locked to the termination
From the help for the module:
The FAULT LED indicates that the module is in Init state, Error state or Not configured state
Yes, we had tried setting the Power Supervision parameter off on the DO820; the yellow light went away, but we were still unable to force the output on (red triangle on channel when trying to force in CBM). We also confirmed the modules were locked into the termination. We are able to force the outputs on DO820 in other Profibus stations, it's just one of the stations that we can't get them to work. I assume the 24v from the ModuleBus is coming through the 24vdc connection on the CI801, which itself seems to be working fine?
I'll be at the system later to look at fault status. Thanks.
If you think DO820 module is working on other position, then check the termination unit MTU. It could be broken too. Try to place DO820 at position 1 for station 10, and disconnect the other MTU's.
See below the block diagram for the module. Look Kamil's advise too regarding MTU's modulebus connectors on left and right side of the MTU.
As it turns out, Kamil's answer was correct - we discovered it before seeing Kamil's answer as we were troubleshooting a cluster of IO by taking it apart and reconnecting modules. We took a cluster apart, got the cards working one at a time but when we added a fourth, the CI801 went bad, we found a bent pin that was shorted out against another in the last card we added. We have a couple of non-functioning CI801 cards as a result.
thanks for all the answers!
It is good to know you found the problem. About not working CI801 - look inside for 1.5A fuse for Modulebus and 2A fast acting fuse for input.
In technical specification of CI801 is written, that:
"Besides +5 V CI801 also distribute a fused 24 V for the ModuleBus".
Fuse type: Subminiature fuse 3.15 A
- LT-5 Fast-Acting 622 series according to Littel fuse
- TR5-F Fuse-link No. 370 according to Wickmann
- MSF 250 according to Schurter
I think you could try to check / replace the fuse(s) and see if CI801 will become working - look it's block diagram below: