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All Delta V I/O cards error led blinking

Hi All 

we have a problem in our Delta V system of M5 series, after a power cutoff on UPS system all I/O cared  error led start blinking and the cards are not visible at Delta v explorer with question mark indicator we tried the following to solve the problem and unfortunately it's still exist

1-  download the program and   I/O configuration

2- auto sense for I/O cards

3- power reset for the controller

4- power supply circuit was checked and it's healthy for all cards

after figuring the problem in DeltaV diagnostics all the cards show Bad , and communication problems as in the attached photo , please help me I only have two weeks experience with DeltaV system 

• I/O cards
• DeltaV

Mohammad_alquzaa

• 16 Jul 2017 6:03 PM
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11 Replies

• Tinh Phan

  

  • 16 Jul 2017 8:09 PM

  Hello Mohammad,

  I have ran into this issues twice over the years.  Due to the power surge, it damaged the 2-wide railbus communication to the 8-wide.  Try replacing your 2-wide

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• Mohammad_alquzaa

  

  • 16 Jul 2017 8:16 PM

  In reply to Tinh Phan:

  Hi Tinh , thanks for the fast response
  could you please explain to me what does the 2 wide and the 8 wide are because I am totally new to DeltaV system

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• Mohammad_alquzaa

  

  • 16 Jul 2017 9:08 PM

  In reply to Tinh Phan:

  before downloading there a upload error regarding the cold restar memory does this has any thing related to our problem ?

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• Tinh Phan

  

  • 16 Jul 2017 9:14 PM

  In reply to Mohammad_alquzaa:

  Read this link: it should help explain your question:
  www2.emersonprocess.com/.../PDS_M-series_Horizontal_Carriers.pdf

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• Tinh Phan

  

  • 16 Jul 2017 9:23 PM

  In reply to Mohammad_alquzaa:

  You might want to call your Emerson Local Business Partner or Emerson Global Service Center (GSC) to diagnose this error code. It could be related since the communication is being related.

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• semova2

  

  • 17 Jul 2017 4:50 AM

  Dear Mohammad,
  i have this problem like you. but whenever this fault has appeared (on LED), i opened the i/o cards (MQ Series) from the 8-wide and then closed it again. after 10sec, the card works properly.
  but i agree with Tinh, it is because of 8-wide error and unfortunately i don't know how we can fix it!

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• Rein

  

  • 17 Jul 2017 8:35 AM

  The problem is that the cards are not communicating with the controller and could be resolved by any of the following:
  1. Re-seating the cards from the 8-wide carrier.
  2. Recycling the power.
  3. Re-commission and downloading the controller and/or cards.
  4. Setting the cold-restart mem to maximum or 30 days.
  5. By elimination method: Start from the downstream component (ie. IO cards), then 8-wide carrier, then 2-wide carrier, then controller (which is less likely to happen).

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• Andre Dicaire

  

  • 17 Jul 2017 4:39 PM

  In reply to Rein:

  Mohammed, If this is of a critical nature, i.e. the plant is down, you need to log a call with GSC to get dedicated resource to work this issue with you. There are several different reasons why a card or cards are not communicating. We don't know what the problem is, just that the symptom is that all cards are "Configured but Not Present". Please log the call.
  
  The DeltaV IO cards get their power from the same System Power supplies that power the controllers. These supplies provide 12 VDC for the IO bus, and a separate 5v for the controller. The cards will power up without the controller present, and will indicate the Red LED because they remain decommissioned without the controller. Since this is an M5 controller, the IO are likely Series-1. This might be important to know as these connect to the LocalBus differently than current series-2 cards.
  
  Loss of communication to all IO Cards involves a common component. Obviously, the controller is at the heart of the system. Next is the LocalBus that all cards and the controller are plugged into. The 2 wide controller that connects to the first 8 wide carrier is a common physical component, but as a strictly passive circuit board, it is unlikely to suddenly fail due to a power outage or surge.
  
  We know that the controller is communicating with the console, but is unable to communicate with the IO cards, thus the "Not Present" state in diagnostics. The Red LED indicates the cards are decommissioned and not communicating with the controller. So the first thing to identify, before suggesting random actions, are possible causes.
  1. Controller IO communication mechanism is failed somehow, and controller cannot talk to IO. (solution replace the controller)
  2. A Bad IO card that is chattering or otherwise corrupting all traffic on the communication line. (Solution, remove/replace the bad IO Card(s))
  3. A short circuit of the communication line preventing any communication from any card. (this could be anywhere along the bus) (replace the chorted cable or extender)
  4. Physical damage or disconnected bus between controller and all IO cards (i.e. 2 wide, or first 8-wide are preventing any communication) (replace the carrier)
  
  The Diagnostics from the controller and the LED on each IO card are consistent in indicating a loss of communication between these components. The GSC have access to their database of issues to cross references similar cases and confirm likelihood of these possible causes, and any others. Based in what we know, steps 2, 3 and 4 from Rein would not be expected to help. I'd go with step 5, proceeding in a structured fashion.
  
  Start with the most likely suspect and move methodically to the solution. Reseating one card will likely have no impact and still leave you with 40 "not Present" cards. Actions should be more definitive to get to the root cause the quickest. I would suggest the following:
  1. Test the controller to ensure this is not the problem
  - Install this controller in a test system with IO to see if it works there. This confirms the issue is not the controller.
  2. minimize your IO subsystem by disconnecting the first extender cable.
  - this reduces the issue to a smaller IO subset. If the problem goes away, it is in the disconnected IO. If you still cannot communicate, the issue is in the remaining IO and carriers.
  3. Remove all the IO and reduce the system to a single carrier. (you have 40 cards to deal with. pulling them one at a time will take time and if two or more cards are bad...)
  - As you remove IO, if the system starts communicating, you've found the bad IO card.
  - If you get to the last card, remove it and re-install another. The last card could be the bad one.
  4. If you get here, and you know the controller is good, and you have tested one of the removed cards to know that it is good, the issue must be in the remaining carriers.
  - Replace the 2 wide and first 8-wide carriers and get it working with a single IO card. reconnect carriers one at a time to observe if the issue returns.
  
  I strongly suggest you log a call to have a GSC engineer assist you. There may be another reason that explains this symptom, and this post may waste more of your time....

  Andre Dicaire

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• Mohammad_alquzaa

  

  • 17 Jul 2017 8:53 PM

  In reply to Andre Dicaire:

  Currently we are contact with local service and they will come soon , I have time to go through all these step because we are in commissioning phase , I really want to thanks you for your time writing this post , tomorrow I will start troubleshooting based on your input and I will inform you all.

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• Mohammad_alquzaa

  

  • 22 Jul 2017 8:41 PM

  In reply to Mohammad_alquzaa:

  thanks you all after deep investigation using the elimination technique we founded the faulty card interrupting the bus and we replaced it :)

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• semova2

  

  • 23 Jul 2017 4:41 AM

  In reply to Mohammad_alquzaa:

  Dear Mohammad,
  is this the Emerson solution for your card fault?
  could you explain more?

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