AB RIO Adapter faulting

This Remote Rack 13 and 14 have been installed for 5 months with no issues. In the last 3 days the RIO Adapter in Rack 13 has faulted 3 times. No sure what fault lights were on except the electrician said the "blinking". Two times the line was down for a maintenance downturn and one time while operating. The reset buttton on the adapter would not clear fault so power was cycled. Fault was cleared however output module 5 (8 module rack) would not output(no lights on module)while PLC had logic picked. Swaped output modules, no luck, swap back. Replaced 1794-TB3 terminal block and it was ok for over 24 hours then problem returned. This last time the electrician cleared the fault by cycling power and again had not output on module 5 so swap the module 5 output with another and it cleared and then he powered it down and swap back to orginal output modules. Any ideas on what is going on or where to check for problems?

Not saying that that this is it, but I have found that when problems seem to be in the PLC and replacing cards does not work, check the field devices on the offending card(s). A wire that has rubbed and is shorting to ground will fault a rack. Good luck.

Robert

OK I will. What is on the 8 channel output module are 3 PB relays and 5 indicator lights

Try installing a new card, but don't swing the wire connector thingy up. In other words, does the rack fault if the I/O has nothing connected to it?

Robert

"The reset buttton on the adapter would not clear fault so power was cycled."

Found the Dip Switch setting on the RIO Adapter was set to reset through PLC not manual reset. Can anyone tell me how to reset it through the PLC and how to look up fault details in the PLC if this fault happens again? It is a AB PLC5, unfortuately where I have worked in the past used several differnet brands of PLC's other than AB.

Rack Faults When Using a Flex 1794-ASB Series D or E RIO Adapter with a Classic PLC-5 Processor

The 1794-ASB Series D and Series E RIO adapters are NOT compatible with the Classic PLC-5 Processors. Rack faults will result when using this combination of hardware.​

The 1794-ASBLT Flex RIO Adapter was developed to provide a version of the RIO adapter that can be used with Classic PLC 5/15 (1785-LT) and 5/25 (1785-LT2) processors. Note: The 5/10 (1785-LT4) and 5/12 (1785-LT3) Classic PLC-5 Processors do not have Remote I/O capability.​

Use the 1794-ASBLT Series D adapter when communicating with Classic PLC-5/15 or PLC-5/25 processors via Remote I/O.​

The 1794-ASBLT Series D adapter is a replacement for the 1794-ASB Series D adapter ONLY when communicating with PLC-5/15 or PLC-5/25.​

Reference Publication No. 1794-IN110A-EN-P​

Click to expand...

This would apply if you are using a Classic PLC5. Find out if your is Classic or Enhanced based on the part number. These are part numbers for the Enhanced processors:

1785-L11B, -L20B, -L30B, -L40B,
-L40L, -L60B, -L60L, -L80B, -L20E,
-L40E, -L80E, -L26B, -L46B, -L86B

Thanks Paul.
I will research the areas you suggested. You guys on this Forum are a great resource for those of us that are looking for a directions on problems.

Flex

I would also check the Voltage at the ASB Card. We found older supplies would fault the rack due I think to poor regulation. We Have good luck with Phoenix and Omron. Phoenixcon.com has the product info. Also the Communication cable can give trouble. Is it terminated correctly? If this is the end of the drop it needs to have a termination rersistor. I would swap out the ASB card if everything else is OK.

I had a problem like you first described and it was cured by removing all modules, and disconnecting, then reconnecting the plugs between all the TB3 modules, and ASB, during this process I found 2 of the plugs had not been fully home, although they appeared to be, as the modules fitted.