16#0203 error code

I can not figure out how to get rid of this error

I have a L63 with a ethernet card in slot 1

slots 3-16 are as follows:

Slot 3 IB32
slot 4 OW16
Slots 5-11 IA16
Slots 12-16 OA16

This is some kind of communications time out error that will shut down the project and intermittently restart and shut back down.

I have read all i can find - no answer that helps

any a/ all thoughts appreciated

post the project

can not attach project file

everything was stripped from this project

it still fails to run

all output cards have geen flashing OK

This site will not let me upload the file

Sure it will.

Use the advanced reply method and there is an attach files feature lower on the reply page.

View attachment orderpick.zip

Had to zip it

Welcome to the forum, Len.

#0203 is a fairly ordinary connection error, so more info is needed to solve the problem.

Is this a new project with new hardware, or an existing machine that has developed a problem?

Let's focus on the blinking I/O module lights.

Are the failures really "intermittent", or are they regular and repeating ? In other words, does the system ever go into run mode and stay there for more than a few seconds ?

starting point is the hardware. Customner purchased hardware and controls from existing surplussed operation.
L63 controller, with three cabinets of control logix.

I have reconfigured their cabinets to match their operations and added IA16 and OA16 modules into their racks.

System ran for a few hours with limited program - simple motor run sequence and scanner reads.

Approx 2 hrs into run, system shut down and the output cards started flashing green OK on the face.

The error code did not cause a system fault as the cards were not configured to create an error on the controller.

Currently there is a 10 min auto restart that causes the system to start and trip

I previously unplugged all and reinstalled everything, the hardware remained stable for 3 days with out motor run circuits installed - all was hardwired while i tested and looked for answers.

I reinstalled the motor run circuits and all was fine. I started further programming and the system failed again.

i can discover the following cards with out issue
slot 1 - Ethernet
Slot 3 - IB32
Slot 4 - OW16
Slots 5-11 IA16
When I attempt to discover any of the output cards in slots 12-15 the system states the card is faulted 16#0203

this appeared to stabilize with an extended RPI of 100ms, this was an incorrect observation

I can not add an OA16 output card to this system. The OW16 configures correctly.

Can anyone please help me?

Exactly what do you mean by "discovering" a module: do you mean browsing with RSLinx, or creating a module in the RSLogix 5000 I/O tree, or something else ?

There's no reason a particular type of discrete output module wouldn't make a connection.

The unknown age and provenance of the hardware makes me a little uneasy. Have you audited the modules for the "Atmel 64" issue from a few years ago?

Your description suggests that the controller is not faulting or clearing the user program, but rather losing the I/O connection across the backplane to the I/O modules.

ControlLogix backplane connections are generally very stable, so intermittent failures suggest bent pins, a defective CPU, or a defective backplane.

Have you audited the modules for the "Atmel 64" issue from a few years ago?

Click to expand...

I looked it up.

http://www.plctalk.net/qanda/showpost.php?p=447124&postcount=2

Have you upgraded the firmware lately? If so maybe go back to an older version that worked.

in control logix5000
I/O tree project configuration of all modules

I can attempt to put the 1756-OA16 any point in the rack and it will have a 16#0203 fault.

All other cards in slots and "discovered" by the system run and the I/O indicator is "OK"

"create" a 1756-OA16 slot in the rack and the I/O indicator shows "I/O not responding" and the card properties indicate a 16"0203 comm fault

just inspected the L63 - mfg date is 11/05
New battery installed
the chip is "ARM" not Atmel

OK, I pulled the CPU removed the battery, let it sit overnight, reinstalled the battery, downloaded the same program, all OA16 cards are being seen and I/O is "OK" with no green flashing "OK" indicators on the 1756-OA16 card face plates

can anyone explain why the comms fail?