BRC100 replacement with BRC410 with analog signals problem
What firmware revision are you currently running on the BRC410 controllers? That could have something to do with it. Also, are you using remote I/O with this BRC and if so, what is the firmware revision on the analog cards as well as the RIO cards.
As is indicated on the ABB Support Web-site (My Control System, previously known as Solutions Bank), there may compatibility issues with these types of situations if you do not have compatible firmware on all of the pieces involved (i.e. controller, remote I/O modules and local and remote AI modules).
So, without this information, it may be difficult to know if this is a potential cause of your problems.