ASM EX160-SDN1A 0160B24F2 Service-Ready Spare Part

ASM EX160-SDN1A 0160B24F2 Service-Ready Spare Part for Industrial Maintenance

The ASM EX160-SDN1A (cross-reference: 0160B24F2, 02-324555D01, 0190-13031, 0270-76008) is a DeviceNet-compatible distributed I/O communication module widely deployed in automotive assembly lines, material handling systems, and process automation cells. As a service-ready spare part, it is pre-tested and available for immediate dispatch to support planned maintenance schedules, emergency breakdowns, and annual overhaul programs. NINERMAS maintains verified stock of this module to ensure continuity of supply for maintenance engineers and procurement teams managing aging automation infrastructure.

The EX160-SDN series was designed for high-density I/O expansion over DeviceNet fieldbus, enabling compact cabinet installations with deterministic scan-cycle performance. When this module reaches end-of-life or fails in the field, sourcing a verified replacement quickly is critical to avoiding extended production downtime. NINERMAS supplies this unit with full pre-shipment functional testing and a 12-month warranty covering manufacturing defects and operational failures under normal industrial use conditions.

Spare Maintenance Table

Maintenance Planning for Continuous Operation

Effective maintenance planning for systems using the ASM EX160-SDN1A requires a holistic view of the entire DeviceNet segment and the control cabinet in which it operates. When scheduling a replacement of this module, maintenance engineers should simultaneously inspect the 24 VDC power supply unit feeding the I/O bus — a degraded power supply is a common root cause of intermittent DeviceNet communication faults that are often misdiagnosed as module failure.

The DeviceNet trunk cable and drop cable assemblies, including the DeviceNet micro-style connectors and termination resistors at both ends of the network segment, should be verified for continuity and insulation integrity. A faulty termination resistor (typically 121Ω) can cause network-wide communication errors that mimic module failure. Alongside the EX160-SDN1A, engineers should check the DeviceNet master scanner card — such as an Allen-Bradley 1756-DNB ControlLogix scanner or an Omron CJ1W-DRM21 — to confirm the master is correctly configured for the node address assigned to this module.

In cabinets where the EX160-SDN1A is installed alongside other distributed I/O nodes, it is advisable to audit the I/O terminal blocks and field wiring connections at the module’s input and output terminals. Loose or corroded terminal connections are a leading cause of sporadic I/O faults in high-vibration environments. If the system includes signal isolators between field sensors and the module inputs, these should be tested for correct output voltage levels and response time.

For systems that also use EX160-SDN2A or EX160-SDN4A expansion nodes on the same DeviceNet segment, a full segment scan using a DeviceNet diagnostic tool (such as a Rockwell RSNetWorx for DeviceNet session) is recommended before and after the replacement to confirm all nodes are online and responding correctly. The DeviceNet power tap and network power supply (typically a separate 24 VDC, 4A or 8A DeviceNet power supply) should also be load-tested to ensure it can support the full node count after the replacement.

Where the EX160-SDN1A interfaces with a PLC backplane or remote I/O rack, confirm that the rack’s power budget accommodates the module’s current draw. In older installations, the rack power supply — such as a 1746-P4 or equivalent — may be operating near its rated capacity, and adding a replacement module with slightly different inrush characteristics can trigger nuisance trips. A 24 VDC relay output module in the same cabinet should also be inspected if the EX160-SDN1A controls relay-driven loads, as relay contact wear is a common co-failure mode in high-cycle applications.

Finally, if the system includes an HMI panel (such as a Siemens TP700 Comfort or Allen-Bradley PanelView 800) that displays I/O status from the DeviceNet segment, verify that the HMI communication link to the PLC remains stable after the module swap. Some HMI configurations cache I/O tag addresses that may require a forced refresh after a DeviceNet node replacement.

Site Replacement Workflow

Step 1 — Pre-Replacement Verification: Before removing the faulty EX160-SDN1A, document the current node address setting (typically set via rotary switches on the module face) and record the DeviceNet MAC ID. Download a backup of the PLC program and DeviceNet scanner configuration using the appropriate programming software (e.g., Rockwell Studio 5000 or RSLogix 5000 for Allen-Bradley masters). This ensures the replacement module can be configured identically without requiring a full network re-commissioning.

Step 2 — Power Isolation: De-energize the DeviceNet segment power supply and the 24 VDC I/O bus before disconnecting the module. Verify zero voltage at the module’s power terminals using a calibrated multimeter. Do not rely solely on the PLC’s software-controlled power-off — always confirm with a physical measurement.

Step 3 — Module Swap: Disconnect the DeviceNet drop cable and field wiring connectors. Remove the module from the DIN rail or panel mount. Install the replacement ASM EX160-SDN1A, set the node address rotary switches to match the documented MAC ID, and reconnect all wiring in the original configuration. Torque terminal screws to the manufacturer’s specified value to prevent loose connections.

Step 4 — Network Re-commissioning: Re-energize the DeviceNet segment and observe the module’s status LEDs. A solid green MS (Module Status) LED and solid green NS (Network Status) LED confirm successful network connection. If the NS LED flashes red, check for node address conflicts or termination resistor issues. Use RSNetWorx for DeviceNet or equivalent to verify the module is online and I/O data is exchanging correctly with the master scanner.

Step 5 — Functional Test: Exercise all I/O points mapped to the EX160-SDN1A from the PLC program or HMI to confirm correct operation. Document the replacement in the site maintenance log, including the date, replaced part number, new module serial number, and technician name. This record supports warranty claims and future maintenance planning.

Spare Parts Support FAQ

Q1: Is the ASM EX160-SDN1A (0160B24F2) a direct replacement for 02-324555D01 and 0270-76008?
Yes. The part numbers 02-324555D01, 0190-13031, and 0270-76008 are cross-reference identifiers for the same EX160-SDN1A module or functionally equivalent variants within the EX160-SDN series. NINERMAS verifies cross-reference compatibility before shipment. If you have any uncertainty about your specific application, contact our technical team with your system configuration details.

Q2: How does NINERMAS verify the module before shipment?
Every ASM EX160-SDN1A unit undergoes a pre-shipment functional test that includes power-on verification, DeviceNet node address configuration check, and I/O scan cycle validation. Units that do not pass all test criteria are not shipped. A test report is available upon request for quality-critical procurement processes.

Q3: What is the warranty coverage and how do I make a claim?
All units are covered by a 12-month warranty from the date of shipment. The warranty covers manufacturing defects and operational failures under normal industrial use conditions. To initiate a warranty claim, contact NINERMAS at sale@ninermas.com with your order number, module serial number, and a description of the fault. Replacement or repair will be arranged promptly to minimize your downtime.

Q4: Can NINERMAS support long-term supply for ongoing maintenance programs?
Yes. NINERMAS specializes in long-term supply of service-ready spare parts for discontinued and hard-to-source industrial automation components. We can arrange reserved inventory agreements, scheduled delivery programs, and multi-unit procurement contracts for maintenance teams managing large fleets of EX160-SDN series nodes. Contact our procurement team to discuss your annual spare parts requirements.