mylespetro
Member
Hey everyone, ran into something I've never seen before and was wondering if anyone had any idea of what's happening.
Currently in the middle of a phased upgrade from a PLC-5 to ControlLogix where we have a ControlLogix chassis with a DHRIO card and we replaced the PLC-5 processor with a 1771-ASB (Series B) RIO adapter and are continuing to use the PLC-5 I/O cards as Remote I/O to the CLX.
The existing PLC-5 rack was configured as 2-slot addressing with Complementary I/O, no RIO racks in the original install. So we have a Rack 0, with module groups 0 through 7, and module groups 0 through 5 each have a 1771-IAD (16 bit digital AC input) and 1771-OAD (16 bit digital AC output), group 4 being an exception in that it only has an input card in the left slot of the module group, no output card in the right slot of module group 4. I've attached a picture of the chassis for reference.
I bench tested this with an identical CLX chassis and an equivalent 16-slot PLC-5 chassis, replacing the PLC-5 processor with a 1771-ASB module, and was able to connect the PLC-5 chassis as Remote IO in the CLX program. I didn't have any of the 1771-IAD/OAD cards though, so I could not bench test the I/O configuration exactly as it is in the field.
When I went to swap the customer's PLC-5 in the field, I got the ASB module to connect, but the module would connect as expected for about 3-5 seconds (green "Active" light would be on and solid), and then simultaneously the ASB's "Active" light would flash and the "ACTIVE" indicators on only the 1771-OAD output cards would go out. Regardless of what state the ASB module "Active" light was in, I could see both the current inputs and outputs present on the cards, although I expect the outputs were being held due to the chassis DIP switch configuration (hold outputs in last state during comms fault). For example, Rack 0 Group 0 Input 15 was present on the PLC-5 I/O, which was mapped to R_0:I.Data[0].13/I_000_Bit15 in my ControlLogix program, which was being read as a 1. When I went to the Channel A Protocol Errors tab in the 1756-DHRIO card configuration, the only thing that was coming up was that the "Non-Octet Alignment Error" counter was counting up. On coming back to the office to try bench testing again, I have no issues and no errors counting up in the tab.
For further reference, my ASB module DIP switch settings were as follows (both for in the field and bench testing):
SW1
1 - ON (1&2 always on)
2 - ON (1&2 always on)
3 - ON (Primary chassis)
4 - ON (I/O rack number 0; 4/5/6 on for this rack number)
5 - ON (I/O rack number 0; 4/5/6 on for this rack number)
6 - ON (I/O rack number 0; 4/5/6 on for this rack number)
7 - ON (First I/O group number 0; 7/8 on for this group number)
8 - ON (First I/O group number 0; 7/8 on for this group number)
SW2
1 - ON (57.6k baud)
2 - OFF (Complementary chassis - just seeing this now, should this match DIP switch 3 of SW1?)
3 - OFF (3&4 always off)
4 - OFF (3&4 always off)
And my PLC-5 chassis DIP switches were as follows (both for in the field and bench testing):
1 - ON (Outputs in last state during comms fault)
2 - ON (Processor can restart I/O chassis after comms fault)
3 - OFF (3&4 always off)
4 - OFF (3&4 always off)
5 - OFF (2-slot addressing; 5/6 off for 2-slot)
6 - OFF (2-slot addressing; 5/6 off for 2-slot)
7 - OFF (7&8 always off)
8 - OFF (7&8 always off)
Sorry for the wall of text, just trying to give as much information as possible.
Thanks in advance!
EDIT: No idea why my picture attached upside down
Currently in the middle of a phased upgrade from a PLC-5 to ControlLogix where we have a ControlLogix chassis with a DHRIO card and we replaced the PLC-5 processor with a 1771-ASB (Series B) RIO adapter and are continuing to use the PLC-5 I/O cards as Remote I/O to the CLX.
The existing PLC-5 rack was configured as 2-slot addressing with Complementary I/O, no RIO racks in the original install. So we have a Rack 0, with module groups 0 through 7, and module groups 0 through 5 each have a 1771-IAD (16 bit digital AC input) and 1771-OAD (16 bit digital AC output), group 4 being an exception in that it only has an input card in the left slot of the module group, no output card in the right slot of module group 4. I've attached a picture of the chassis for reference.
I bench tested this with an identical CLX chassis and an equivalent 16-slot PLC-5 chassis, replacing the PLC-5 processor with a 1771-ASB module, and was able to connect the PLC-5 chassis as Remote IO in the CLX program. I didn't have any of the 1771-IAD/OAD cards though, so I could not bench test the I/O configuration exactly as it is in the field.
When I went to swap the customer's PLC-5 in the field, I got the ASB module to connect, but the module would connect as expected for about 3-5 seconds (green "Active" light would be on and solid), and then simultaneously the ASB's "Active" light would flash and the "ACTIVE" indicators on only the 1771-OAD output cards would go out. Regardless of what state the ASB module "Active" light was in, I could see both the current inputs and outputs present on the cards, although I expect the outputs were being held due to the chassis DIP switch configuration (hold outputs in last state during comms fault). For example, Rack 0 Group 0 Input 15 was present on the PLC-5 I/O, which was mapped to R_0:I.Data[0].13/I_000_Bit15 in my ControlLogix program, which was being read as a 1. When I went to the Channel A Protocol Errors tab in the 1756-DHRIO card configuration, the only thing that was coming up was that the "Non-Octet Alignment Error" counter was counting up. On coming back to the office to try bench testing again, I have no issues and no errors counting up in the tab.
For further reference, my ASB module DIP switch settings were as follows (both for in the field and bench testing):
SW1
1 - ON (1&2 always on)
2 - ON (1&2 always on)
3 - ON (Primary chassis)
4 - ON (I/O rack number 0; 4/5/6 on for this rack number)
5 - ON (I/O rack number 0; 4/5/6 on for this rack number)
6 - ON (I/O rack number 0; 4/5/6 on for this rack number)
7 - ON (First I/O group number 0; 7/8 on for this group number)
8 - ON (First I/O group number 0; 7/8 on for this group number)
SW2
1 - ON (57.6k baud)
2 - OFF (Complementary chassis - just seeing this now, should this match DIP switch 3 of SW1?)
3 - OFF (3&4 always off)
4 - OFF (3&4 always off)
And my PLC-5 chassis DIP switches were as follows (both for in the field and bench testing):
1 - ON (Outputs in last state during comms fault)
2 - ON (Processor can restart I/O chassis after comms fault)
3 - OFF (3&4 always off)
4 - OFF (3&4 always off)
5 - OFF (2-slot addressing; 5/6 off for 2-slot)
6 - OFF (2-slot addressing; 5/6 off for 2-slot)
7 - OFF (7&8 always off)
8 - OFF (7&8 always off)
Sorry for the wall of text, just trying to give as much information as possible.
Thanks in advance!
EDIT: No idea why my picture attached upside down