DIO module – Sudden issues with output – red powe led on Out LED – needs help for debugging

[mtrisic]

Hi everyone,

While building prototype of a new system I have encountered issues with DIO module.
After some time using, LED for Output power on DIO module got RED and output pins stopped working. (you may find full kern.log attached)
Everything was well-connected and was working. Output pins stopped responding during the test of a system.

Can someone please help me trace root cause of this issue? I can’t get it to work again. Tutorial page states that red status of LED indicates “No power supply to the outputs on the plug X2 or overloading.”.
Are there any fuses (including timer fuses or software fuses) on output pins that might be affected in some way? I'm starting to doubt that a part my DIO module got defected or surged in some way...

Input pins still work normally - I can read status of switches on my panel.
I probed voltage and connections, everything is still connected.

I'm using latest software, BUT i'm also unable to update firmware on DIO module:

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pi@RevPi21463:~ $ cat /etc/revpi/image-release
2019-03-14-revpi-stretch.img
pi@RevPi21463:~ $

Error on firmare update:

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pi@RevPi21463:~ $ piTest -f
update firmware fail
pi@RevPi21463:~ $

Any ideas on where to look next? Any feedback is welcome



Additional info about my setup:

DIO module on the left of Core3+ module.

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pi@RevPi21463:~ $ piTest -d
Found 2 devices:

Address: 0 module type: 95 (0x5f) RevPi Core V1.2
Module is present
     input offset: 113 length: 6
    output offset: 119 length: 5

Address: 31 module type: 96 (0x60) RevPi DIO V1.4
Module is present
     input offset: 0 length: 70
    output offset: 70 length: 18

I’m using MDR-60-24 to power DIO and Core3+ modules. Power supply on the left is for DIO and Core modules only. Power supply on the right side is connected to relays and 24v power socket in the middle, but those are not in use and are fully isolated from DIO/Core system.

3 output pins are connected to 24v control lights, 3 inputs are connected to switches, same power rail as +v on core module. You may ignore rest on the photo...

Here’s a photo of a system.

20200213_185738-resize.jpg (686.54 KiB) Viewed 12177 times

[dirk]

Hi mtrisic, thank you for your detailled description of the failure. The idea of doing a firmware update is good. There are two issues here:
Plese install the package "revpi-firmware" as we have seen there is an error in the kern.log "Feb 14 00:32:04 RevPi21463 kernel: [ 1612.231660] piControl: error: cannot open file /lib/firmware/revpi/fw_00095_001.fwu".

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sudo apt update
sudo apt install revpi-firmware

The firmware update requires the DIO to be on the right side. To be honest maybe this information may be outdated and we will check this. But anyway try it with your setup and in case you run into errors you have to switch the position of the DIO to the right.

[mtrisic]

Hey @dirk,

thanks on reply. I have already tried moving DIO on the right side.

Thanks on pointing out that file was missing. I have just noticed that file is not present at all! (revpi-firmware package was installed). Log states piTest is missing /lib/firmware/revpi/fw_00095_001.fwu but there is no such file in folder. Plase take a look:

apt-get info:

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pi@RevPi21463:~ $ sudo apt install revpi-firmware
Reading package lists... Done
Building dependency tree
Reading state information... Done
revpi-firmware is already the newest version (20180323-1).
The following packages were automatically installed and are no longer required:
  galculator leafpad libbluetooth3 libmicrodns0 libpng-tools libprotobuf-lite10 libproxy-tools libqt5x11extras5 libva-wayland1 libxcb-xv0 lxappearance lxappearance-obconf
  lxhotkey-core lxhotkey-gtk xarchiver zlib1g-dev
Use 'sudo apt autoremove' to remove them.
0 upgraded, 0 newly installed, 0 to remove and 0 not upgraded.
pi@RevPi21463:~ $ 

listing of firmware files:

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pi@RevPi21463:/lib/firmware/revpi $
pi@RevPi21463:/lib/firmware/revpi $ pwd
/lib/firmware/revpi
pi@RevPi21463:/lib/firmware/revpi $ ls
fw_00096_001.fwu  fw_00097_001.fwu  fw_00098_001.fwu  fw_00103_001.fwu
pi@RevPi21463:/lib/firmware/revpi $

dmesg output:

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....
[ 3322.016068] piControl: piIoComm_gotoGateProtocol returned 0
[ 3322.086082] piControl: error: cannot open file /lib/firmware/revpi/fw_00095_001.fwu
[ 3322.086091] piControl: update 0 addr 0 ret -2
[ 3322.086144] piControl: firmware file length: 29844
[ 3322.086195] piControl: firmware is up to date: 1.4 >= 1.4
[ 3322.086206] piControl: update firmware fail
[ 3322.086210] piControl: update 1 addr 31 ret 0
[ 3322.206041] piControl: start data exchange
[ 3322.448349] piControl: piDIOComm_Init(31) done 0
[ 3422.750200] piControl: stop data exchange
[ 3422.750226] piControl: piIoComm_gotoGateProtocol returned 0
[ 3422.820234] piControl: error: cannot open file /lib/firmware/revpi/fw_00095_001.fwu
[ 3422.820243] piControl: update 0 addr 0 ret -2
[ 3422.820276] piControl: firmware file length: 29844
[ 3422.820321] piControl: firmware is up to date: 1.4 >= 1.4
[ 3422.820330] piControl: update firmware fail
[ 3422.820334] piControl: update 1 addr 31 ret 0
[ 3422.940191] piControl: start data exchange
[ 3423.182484] piControl: piDIOComm_Init(31) done 0
[ 3438.262160] piControl: stop data exchange
[ 3438.262186] piControl: piIoComm_gotoGateProtocol returned 0
[ 3438.332213] piControl: error: cannot open file /lib/firmware/revpi/fw_00095_001.fwu
[ 3438.332221] piControl: update 0 addr 0 ret -2
[ 3438.332254] piControl: firmware file length: 29844
[ 3438.332296] piControl: firmware is up to date: 1.4 >= 1.4
[ 3438.332306] piControl: update firmware fail
[ 3438.332310] piControl: update 1 addr 31 ret 0
[ 3438.452159] piControl: start data exchange
[ 3438.694533] piControl: piDIOComm_Init(31) done 0

I tried re-installing package using 'sudo apt remove revpi-firmware' , 'autoremove' and then 'install' flags.
After re-installing package folder is empty and contains no firmware update files!

Any ideas on next steps? Repo /.deb is missing files or... ?

[dirk]

Hi mtrisic, after re-install of the firmware package you to change the directory or do a reboot to see the installed files. Please try to reboot and verify if the firmware update files have been installed.
But to sum it up maybe we have to analyze the device. So you wrote that the system worked until you performed some thests. What happend during the tests? Maybe the devices have received some electrical damage? I just want to avoid an unneccesary RMA so should I send you a RMA form via E-Mail?

[mtrisic]

Hey Dirk,
I agree, let’s first try fixing this remotely and make it a win-win
Additionally, somebody else might benefit from info we get and publish on this forum.
I personally don’t care much about warranty as much as I wanna’ figure out what happened. I’ll probably order a new pair of Core/DIO modules and we can do RMA after I receive a spare ones...


______
I have tried re-installing revpi-firmware package and re-booting multiple times. What I get is either empty folder or same list of files as listed in previous post, always missing a fw_00095_001.fwu file.

Next step I did was flashing my Rev3+ core from scratch, and that was not helpful neither
I downloaded img file from Kunbus store, backed up my original image and restored a fresh one. After re-setting my serial and MAC address, I have reconnected DIO module and re-configured it. First thing I tried after poweiring it back on was checking /lib/firmware/revpi folder:

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pi@RevPi21463:/lib/firmware/revpi $ ls -l
total 160
-rw-r--r-- 1 root root 29844 Mar 23  2018 fw_00096_001.fwu
-rw-r--r-- 1 root root 29844 Mar 23  2018 fw_00097_001.fwu
-rw-r--r-- 1 root root 29844 Mar 23  2018 fw_00098_001.fwu
-rw-r--r-- 1 root root 61576 Mar 23  2018 fw_00103_001.fwu
pi@RevPi21463:/lib/firmware/revpi $

As you can see, I’m still missing required update file, even on the fresh system.


DIO module still had middle(oug) LED set on RED. Everything was still well-connected to a working power supply.

Then I tried opening DIO module for a quick inspection for electrical surges.
There is no clear visual damage at all. I probed connections starting from a X2 connector to caps and P04P4 mosfet, all looks good. Haven’t tested those power switchers in the middle since I don’t have a scope at the moment, but at least I didn’t noticed any shorts. Haven’t spent a lot of time inspecting since I only had a basic digital multimeter with me, but hardware looks good for now...

Anything else you thing I might try before RMA?

Pic of my DIO board:

20200225_032157.jpg (1014.68 KiB) Viewed 12023 times

[dirk]

Hi mtrisic, I send you a RMA form via EMail.

[Ricarda]

Hey there,

I have a similar problem with mi DIO Module. The output LED suddenly turned red. Before, I added (when the Pi was off) an output wire to a relay and I cannot fix it. The voltage is just fine, the wiring is correct as well. I tried to update the DIO Module (module right-sided to the Core), but I got a "update firmware fail", probably because the version is just the right one?

Anyway, I really do not have a clou, why the module does not work anymore. I did not get your previous discussion completely, so I hope, you could give me a bit more detailed hint, what to do (I'm sorry, I just got started).

The best,

Ricarda

[mtrisic]

Hey Dirk,

Sorry on late reply (pandemic and stuff )

People from Umbra Software were very kind to borrow me their DIO module to test on my setup.
I can now confirm that issues I had were only due to something with DIO module, not the revPi or configuration.
My setup works flawlessly with a new module, so I'll order a new one.

I would like to send this DIO module back to you via Umbra (i originally purchased all hardware from this reseller) so you migh try figuring out what might be cause of issues.
Sounds good? Should I fill RMA form? If so, can you please send me a new RMA form link, the old one expired.

Thanks,
Mladen