Oh Brotherrrrrr! What can I say. Probably the contacts are somewhere loose or dirty. Check for full operational voltage input and be careful with your grounds connections as well. Watch for any static charge spark during replacement operation hopefuly is not the case as static charges sometimes migth harm the board somehow, look out! Also try unplug for few minutes and plug it back again and try reboot it is neccesaraly after that. Check for any other sensor misalignment or dust covered reflector. Check if any microswitch are in the wrong (NC/NO) position as well just in case. That will do. Allset then, back on business!
You may need to do some programming on the new I/O card, or in the main controller, such as "telling" each what addresses to recognize. Or set some DIP switches. I apologize for the vagueness of this, but there are many combinations of controllers and I/O interfaces, of which I know few.
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Why did you change it? Is this the I/O card in the machine or in the computer/controller? Is the new one identical to the old one? Does it use the same cables/connections? What method of communication (RS232, RS485, Ethernet, Bluetooth, etc.) Have the settings been made identical to the original? etc...
We need LOTS more info.
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