just a long shot GUESS - in case all else fails ...
this is just a GUESS – based on what you've told/shown us so far ...
notice that the output bit addresses on the wire labels are numbered in OCTAL – but the bit addresses on the module are numbered in DECIMAL ...
I'm just GUESSING that the system was originally controlled by a PLC-5 system (which uses octal addressing for its I/O signals) ...
considering your statement:
There is a huge amount of contractor work happening right now
maybe (just MAYBE) the contractors are "swapping over" your system from PLC-5 control – to ControlLogix/CompactLogix instead ??? ...
if so – then it's not uncommon for the difference between OCTAL and DECIMAL addressing modes to cause confusion ... think: the I/O bit addresses above "7" can end up being "off by two" – if the contractors/programmers/etc. aren't taking the various addressing modes into consideration ...
as I said this is all GUESSWORK – and personally I wouldn't bet more than pocket-change that this is even related to your problem ... but ... I have had to help a couple of customers troubleshoot this same problem over the years ... I offer this as a straw at which to grasp ...
here's another thing to check (which is even less likely) ... sometimes when converting from PLC-5 systems to ControlLogix/CompactLogix systems – the programmer will set up the I/O transfers by using the ControlLogix/CompactLogix default data-type setting of DINT (32-bit data) ... if the remote I/O is expecting to see INT (16-bit data) instead, then the transfers can get pretty wobbly with "overlaps" and "communication errors" etc. ...
TIP: the more you tell us about the DETAILS of your problem – then the more details we can put into our answers ...
good luck with your project ...
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