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CIOC carrier MAINT alarms

Good afternoon.

First time poster with a new installation of Delta V Live 14.

Forgive the inexperience, but I have a few questions on our Charms based system.

I am on my 5th CIOC that has thrown a MAINT alarm that has multiple or all of  the following errors:

ACTIVE SECONDARY COMMISSIONING MODULE ERROR

ACTIVE PRIMARY COMMISSIONING MODULE ERROR

STANDBY PRIMARY COMMISSIONING MODULE ERROR

STANDBUPRIMARY I/O PORT ERROR

STANDBY PRIMARY CASCADE PORT ERROR

ACTIVE PRIMARY I/O PORT ERROR

ACTIVE PRIMARY COASCADE PORT ERROR

STANDBY SECONDARY I/O PORT ERROR

STANDBY SECONDARY CASCADE PORT ERROR

ACTIVE SECONDARY I/O PORT ERROR

These points may change slightly, but never less than 9 of them.  I have lifted the copper IOPS, I have forced a switchover and all to no avail. The only thing that I have found to correct this issue is changing the CIOC base.

Is there something else that my be a solution that i can do without waiting on a mill shutdown since I cannot do this during normal operations, and currently have 3 different CIOC bases with this issue.

Mark Spears

• 19 Jan 2025 8:07 PM
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3 Replies

• Andre Dicaire

  

  • 21 Jan 2025 4:46 PM

  Mark, although familiar with the CIOC, I don't know the root cause of these particular errors. The CIOC Carrier internally connects the IO Ports to the CIOC. The IO Ports also contain the CIOC commissioning information (Node Name, IP address assigned to these particular hardware cards based on their MAC address) All these messages relate to the connectivity of the CIOC to the IO ports. Obviously, the CIOC was communicating enough to be able to provide this information.
  
  When you swapped out the carrier, did the new carrier have new IOP's or did you move the CIOC cards and IOPs to the new carrier. If only the carrier was swapped, then it would seem that is the source of the issue. If you also swapped out the IOP's, it could be an IOP issue, or whether the IOP was fully seated.
  
  Your best bet is to open a call with the GSC. They may have more insight especially if there is a known issue with any hardware runs which they would identify based on serial numbers of affected parts. Can you reproduce the issue? i.e. try the same carrier again and swap out the IO ports and CIOC cards. If the issue is always with the carrier, and it is new, it should be replaced under warranty, but that will require a GSC call and arrangement for material return, especially if the root cause needs further investigation.
  
  I've not personally seen these messages, but obviously, the software is triggered by specific conditions. The GSC would be able to explain what underlying issues these conditions are reporting.

  Andre Dicaire

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• Mark Spears

  

  • 22 Jan 2025 2:21 PM

  In reply to Andre Dicaire:

  Andre,
  Thanks for the reply. I lifted/reseated both IOPs as instructed in the past on alarms that occured after patches and subsequent switchovers. Obviously, that didn't work in this case. I then replaced each IOP as instructed and the the only thing that ended up working was changing the carrier. I am going to start a card with GSC, I just wanted to throw this out here hoping someone may have seen this.

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• Jesse Delanoy

  

  • 3 Jun 2025 2:34 PM

  In reply to Mark Spears:

  Mark,
  
  What was the result of your call with GSC? Any advice you can provide related to this error?
  
  I noticed this morning that one of our CIOC's has an active alarm that is cycling through the same list of alarm messages you provided in your original post. Looking in diagnostics I do not see any issue with the CIOC, however the alarm is still active. Our operations team is going to give me a window to power cycle the CIOC to see if that resolves the issue. Hopefully it is not a carrier issue as we do not currently have a spare.
  
  Jesse

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