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Troubleshooting

Power and Startup Issues​

Device does not power on​

  • Verify power supply voltage is within range (+5V to +30V DC)
  • Check polarity of power connections
  • Ensure power supply can deliver sufficient current (minimum 1A at 12V)
  • Verify terminal block connections are secure

Pre-charge LED stays flashing​

  • Normal on first power-up; allow up to 2 minutes for supercapacitors to charge
  • If extended charging time, check power supply capacity

Flashing red LEDs on Ethernet ports​

Indicates a first-time boot failure. Attempt to reflash the firmware. If the problem persists, retrieve the log file /boot/.one-time-program.log and contact Brainboxes support.

Network Connectivity Issues​

Cannot connect to Wi-Fi access point​

  • Ensure the antenna is properly connected
  • Verify Wi-Fi Link LED is flashing (scanning for networks)
  • Access point mode is only active when no other network connectivity exists
  • SSID is "BB-400-XXXX" where XXXX is last 4 digits of MAC address

Cannot access web interface​

  • Verify correct IP address (check DHCP server or use 192.168.127.2 via Wi-Fi AP)
  • Use HTTPS on port 9090: https://[IP]:9090
  • Accept the self-signed certificate warning
  • Try accessing via hostname: https://bb400-XXXX:9090

I/O Issues​

Digital inputs not responding​

  • Verify NPN/PNP jumper configuration matches sensor type
  • Check input voltage levels are within specification
  • Ensure I/O line is configured as input in software

Digital outputs not switching​

  • Verify I/O line is configured as output in software
  • Outputs are open-drain; ensure load is connected to positive supply
  • Check total load current does not exceed 4A combined
  • Short-circuit protection may have triggered; cycle output state

Serial Port Issues​

No serial communication​

  • Verify jumper configuration matches selected protocol (RS-232/422/485)
  • Check software settings match connected device (baud rate, parity, etc.)
  • Verify wiring corresponds to selected protocol pinout
  • For RS-485, ensure termination is correct for network topology