Recently a change was made to a PAIC pack to eliminate a persistent diagnostic alarm for a transmitter that has been removed. The change was downloaded to the controller, and after the download completed a slew of alarms and bad readings came in related to a different I/O pack. Upon investigation it seems a PSCA pack isn't communicating to either IONet. We are unsure if during the download to the PAIC, the wizard detected a difference to the PSCA and automatically checked those boxes for download but it seems likely given the results after the download. It was attempted to undo the changes and redownload, but that did not help. We then downloaded to the PSCA pack Baseload, Firmware and Parameters but that also did not help. We rebooted the pack (power off then on) and the controllers but that did not help. We have not made any changes to the application code and therefore that was not downloaded.
The errors we are getting is that we have no signals (all Modbus) from that Pack/Module. We are getting diagnostics on that pack (PSCA) for loss of communication to controller and "unhealthy IONet - Minor Signature mismatch". We are also getting status errors for the pack stating under health "BAD_SIG_MAJOR". Lastly when doing a compare we are seeing difference for the PSCA pack under the category "IONet Exchange Versions -> GeCss Config IO Distributed.IoNetExchangeVersion -> SigMajor" with the Toolbox version showing a "5" and the Controller version showing a "4".
Any help would be greatly appreciated. Thanks in advance.
Sounds like some sort of unintended change occurred to the PSCA configuration, and the controller and pack no longer match. It might not have even been an actual change, but some action that bumped the signature for the I/O pack's EGD exchange without changing anything. When this happens, you need to rebuild and download the controller as well as the I/O pack--it is probably the Controller's view of the EGD exchange that is out of date.
Worst case, you could do a Compress Distributed I/O (from the Device->Compress menu) and rebuild and download everything. If that doesn't fix it, I'd submit a PAC case to GE.
Hope that helps!