CI853 Device Failure
We have several PLCs with CI853 module in service, in different systems. From time to time, we get reports that the module stops serial communication (Modbus, and IEC 60870-5-101).
When we get the controller log, we found the following error:
E 0-00-00 00:00:00.000 On Unit= 1.2.0 HWError PLC_Master_1_2 0000 See HWTree Error 16#00000400 16#00000000
We have checked this error code in the ErrorCodeExtract2_22.214.171.124.exe app, and this indicates for CI853 "device failure".
After we reset the controller, this problem is solved, and it continues working without any problem for long time (several months).
We have seen the same behaviour in version 5.0.2/0 and version 5.1.0/1.
If anyone has seen this problem, and arrive to any conclusion, please give us some advice, or suggestion.
I attach two Controller logs, from different controllers that presented this problem.
Thank you and best regards,
Just a few assumptions:
1. Check if the firmware version, loaded for CI853 is the latest one from CBM Tools->Maintenance-> Remote System
2. Look the LED's status of CI853 when it go down. Are there any F(ault) indication, what is R(un) LED status
3. Try to create a software reset of communication from the application by temporary ON->OFF->ON off En_C parameter for the corresponding MBConnect blocks when the error is detected
We also have several CI853 in different controllers with ver. 5.1.0 and didn't observe such breakages.
If after reset of the controller the module is working well for a few months, most probably there is no HW problem.
We have had this problem also, were the CI853 just stopped, fail led was on, with than again working for multiple months.
We tried several things, both software and hardware. In our case, we used a redundant controller, the problem was the base plate of one of the BC810 modules. Before we found this we already exchanged the CI853, redundancy cable between CPU's and BC810, BC810. And of course, between each exchange wait for a new error, which could take multiple weeks/months.
Some things that might help you:
Check timings, retries etc. Collisions on the serial channel (especially when using multidrop RS-485) could cause these problems.
Check hardware connections, cables, start replacing hardware.
Good luck on your quest.