SLC500 Fault

[AllenMPack]

We have an SLC500 that the fault light is flashing … if I look at the error in RSLOGIX it says “rack data error check slot 1” 

 

this happens almost as soon as the program tries to run 

[Mickey]

What is in slot one?

[AllenMPack]

10 hours ago, Mickey said:

What is in slot one?

16 Channel input card … slot 0 is the slc5 

[AllenMPack]

10 hours ago, Mickey said:

What is in slot one?

Also I tried another input card and seems to do the same thing … I believe the battery went dead and loaded from eeprom but ice loaded from eeprom before with no issues 

[Chris Elston]

To troubleshoot this, I would do a SAVE AS with your project. Then delete all the I/O for that input card and do your best to patch up the program. Then download the project back in and see what happens. To see if the program is some kind of execution or a hardware issue. I dunno that's what I would try if it was me.

[AllenMPack]

22 minutes ago, Chris Elston said:

To troubleshoot this, I would do a SAVE AS with your project. Then delete all the I/O for that input card and do your best to patch up the program. Then download the project back in and see what happens. To see if the program is some kind of execution or a hardware issue. I dunno that's what I would try if it was me.

So the bad news is I inheairted this plant … I do not have the original file .. I can download the program from the SLC but it doesn’t include any details … this plant was on and working and just shut down if that means anything? 

[IO_Rack]

6 hours ago, AllenMPack said:

I can download the program from the SLC but it doesn’t include any details

It should contain the I/O configuration. Does the configuration in RSLogix500 match what you see in the physical chassis?

8 hours ago, AllenMPack said:

Also I tried another input card and seems to do the same thing

I've seen bad chassis in the field. Especially in harsh environments. I've replaced one in a concrete mixing plant and another in a beverage plant.

[AllenMPack]

1 hour ago, IO_Rack said:

It should contain the I/O configuration. Does the configuration in RSLogix500 match what you see in the physical chassis?

I've seen bad chassis in the field. Especially in harsh environments. I've replaced one in a concrete mixing plant and another in a beverage plant.

 It’s been a while since I used an slc but I right click on “controller properties” I believe it is and looked at what card was assigned to which position and it appears to be correct … it’s in a very very clean cabinet but that doesn’t mean a chassis or card didn’t go bad it’s in a climate controlled building… I’ve had plenty go bad on a plc5 in a mining environment … is there a way to trouble shoot the card vs chassis? …. I feel like there’s just something I’m missing since it loaded from eeprom when that battery went dead however it might have been multiple things failed at once 

[IO_Rack]

11 hours ago, AllenMPack said:

it loaded from eeprom when that battery went dead

So it's possible this has never happened before and the EEPROM did not contain the current running program, or I/O configuration. I would re-seat the processor as well as the input card a few times to make sure the connections are clean. It wouldn't hurt to do the same with the power supply. I don't know I've seen this issue with a power supply but I have seen some strange things with them. 

The best you have right now is the project that was uploaded from the EEPROM. Save that, then do as Chris has suggested.

[AllenMPack]

5 hours ago, IO_Rack said:

So it's possible this has never happened before and the EEPROM did not contain the current running program, or I/O configuration. I would re-seat the processor as well as the input card a few times to make sure the connections are clean. It wouldn't hurt to do the same with the power supply. I don't know I've seen this issue with a power supply but I have seen some strange things with them. 

The best you have right now is the project that was uploaded from the EEPROM. Save that, then do as Chris has suggested.

Ok working on it now

thank You all so much 

[AllenMPack]

6 hours ago, IO_Rack said:

So it's possible this has never happened before and the EEPROM did not contain the current running program, or I/O configuration. I would re-seat the processor as well as the input card a few times to make sure the connections are clean. It wouldn't hurt to do the same with the power supply. I don't know I've seen this issue with a power supply but I have seen some strange things with them. 

The best you have right now is the project that was uploaded from the EEPROM. Save that, then do as Chris has suggested.

Ok I do believe I have found a saved copy of the program (latest) version it does exactly the same “rack data error check slot 1) … is it possible I could change everything that’s pointed at slot 1 to an empty slot? .. my psu only about 22v and not 24 is that enough to cause the issue?

 

do I need to go line by line to delete all the io as Chris suggested? Or is there an easy way to do this? 
 

is a 5/03 rack and power supply the same? If so I’ll go ahead and eBay one and get it headed this way just in case … I have no spare parts for slc only plc 

sorry it’s been a really long time for me 

[AllenMPack]

So I just stumbled on this … keep in mind this has ran for years so maybe my psu low voltage is the issue? 

[PaulKim1003]

Do you have any error ?

Edited December 30, 2024 by PaulKim1003

[AllenMPack]

8 minutes ago, PaulKim1003 said:

Do you have any error ?

Yes 

[PaulKim1003]

Hi Allen,

Do you have another identical digital input card in a different slot that is currently working? if you do, swap it with the problematic one and see if the error persists.

[AllenMPack]

2 minutes ago, PaulKim1003 said:

Hi Allen,

Do you have another identical digital input card in a different slot that is currently working? if you do, swap it with the problematic one and see if the error persists.

I have another identical … I wouldn’t think both went bad at the same time … I slid it in slot one same issue 

[AllenMPack]

So I’ve got this far … I pointed my program at slot 7 … transferred all the inputs .. now it faults with error and says slot 1 is detected as having an io card but the user program doesn’t require it … however there is no card at all in slot 1 but it thinks there is 

[IO_Rack]

9 minutes ago, AllenMPack said:

So I’ve got this far … I pointed my program at slot 7 … transferred all the inputs .. now it faults with error and says slot 1 is detected as having an io card but the user program doesn’t require it … however there is no card at all in slot 1 but it thinks there is 

I think that was a good exercise and I would have to believe the backplane (chassis) is bad. 

[AllenMPack]

Is there a way to bypass it searching for the card in slot 1? Or force run with the error of a card was in the slot when it’s really not? 

[IO_Rack]

I know of no method. I would believe that's in the firmware. 

What happens when you perform a Read I/O Config from the I/O Configuration dialog?

[AllenMPack]

27 minutes ago, IO_Rack said:

I know of no method. I would believe that's in the firmware. 

What happens when you perform a Read I/O Config from the I/O Configuration dialog?

Let me try it now 

[AllenMPack]

Also does anyone know where the test points are for the psu? 

[IO_Rack]

I don't believe it has any. That supply is for the internal circuitry of the modules. Not user accessible. At least to my knowledge. 

[AllenMPack]

2 hours ago, IO_Rack said:

I don't believe it has any. That supply is for the internal circuitry of the modules. Not user accessible. At least to my knowledge. 

Ok thank you I know the plc had them so I wants sure 

 

I hate to keep beating this dead horse but here’s what I’ve found out … the program seems to be fine BUT after I install about 4 input cards it always resorts back to slot one isn’t empty even tho it is … it’s fine until I got over 4 cards … after 4 cards it doesn’t matter what position they are in or if I mix and match cards … so I don’t think it’s a card because I can do 4 different cards same result … my question is does this seem like a power supply issue or backplane? … I think I have one of each coming just wanna make sure I’m on the right path 

[Joe E.]

I think you're on the right path. It looks more like an issue with the power supply than the chassis to me. It's good to have a spare of each on hand, though.