ci840 are not getting powered up
I have following configuration for my PLC panel:
AC800M-PM861 (REDUNDANT) : two controllers have been put up.
THREE NODES installed on PROFIBUS CONNECTIONS, using CI840.
PROFIBUS connections have been done in the following manner:
a) From IN input of Profibus connector of Main Controller, to IN input of Second Controller ( OUT output of that Profibus Connector on First PM861 has been put empty). [ termination resistance at First Main PM861: ON] [at second PM861: 0FF]
b) From OUT output of Profibus Connector at Second PM861, one cable is inserted at IN input ( A LINE) of the Profibus Connector at the CI840 module. [ termination resistance at First CI840: OFF]
c) Similarly, this OUT to IN pattern continued to THREE nodes. Termination Resistance at Last Profibus Connector ( A LINE) has been made ON.
SIMILARLY FOR B-LINE, HAS BEEN DONE FROM STARTING PM861-2, TO PM861-1, TO B- LINE OF CI840-1, .........at LAST & FIRST PROFIBUS CONNECTOR(B-LINE), TERM. RESISTANCE: MADE ON.
I then follow the procedure for Configuring CONTROLLERS:
Keeping all connections maintained, ( RCU & CEX CONNECTED, AND REMOVING ALL TYPE OF BATTERIES), I started with Powering OFF the Second Controller, and Serial Firmaware Upgrade & then assigning IP by IPCONFIG. Then as suggested by one ABB contact person, that after all this make Power ON of Second Controller, it will Sync automatically in the Configuration, (i.e. we dont need to assign the IP for Second Controller).
But it didnt worked in my case, so I attempted to make that Procedure for Second Controller also. After successfull Firmware Upgrade, when assigning IP, it detected System Reset, but Get Stopped showing: "CONTROLLER ATTEMPTED TO ASSIGN IP, PLEASE CONNECT PRIMARY CONTROLLER".
I thus assigned IP for Both Controllers separately. I luckily got both Controllers in Redundant Mode( dont know it was right/wrong). DUAL LED of both Controllers are showing well. But "R(run)" of only Second Controller is showing.
BOTH CI854 ARE SHOWING that they are in Redundant mode, one is Primary, etc, Rx and TX.
At this stage,all was well.
But still NODES didnt get powered up :(
I checked the voltage at D.O.R. unit, at Power Distribution TB, at main CI840 unit also, it is giving correct 24 V , at L+ terminal.
Sir, Can you suggest me, where I was wrong ??? And what is the possible reason why it is not getting Powered ON ?
I have attached FILES for my panel arrangement.
Are all profibus cables at least 1 meter long? if not make them at least 1 meter.
Also are dipswitches on the ci840 correct with you control builder project
trouble shooting tip, make the system simpler get rid of the redundant profibus cable, maybe get rid of all the redundancy. create a test project in control builder non redundant get that working and go from there.
Also looks like you don't have a connection on your pm861 from L+ to SA and SB these are redundant power aupply supervision signals if you don't connect them you will always have warning in your hardware tree.
Here is the Configuration.
Like I have provided CI840 Hardware Modules Addresses , as 4, 5 and 6 respective;y for all three nodes. So, Please also guide me for two things:
1) Do i need to Insert CI840 hardware as Redundant/ not, as Two modules are there on my every node .....??? Because accordingly, 4 or 4(68) etc address will be assigned??
So, have I provided addresses to my DI, DO,AI modules correctly????? Or they should be 401, 402........and 501, 502.......etc ?? (which I have provided 1,2,3....under my CI840 module
2) After controller firmware upgrade, I have done some CI854 upgrade also, by going in REMOTE SYSTEM in my Control Builder.
Its hard to see from the third photograph but it look like you may have connected the battery backups backwards.
Anyway, the CI840 cards ( and any other cards on the CEX bus) will not power up until you have a valid configuration in the controller. And you will need to correct the IP address configurations to be able to connect to the controller and load the configuration.
Use IPConfig to configure the IP adresses in the primary controller, allways use advanced mode and make sure you check the menu options to set the backup address as well. Read the manuals or the on line help in IPConfig carefully, its easy to make a mistake.
Before coming to CI840 Powerup:You said in 4th para as you have the set the IP address for both but since 800M controller acting as a redundant controller(1:1) means any controller you to set the IP address generally cable with name"UPPER" will come as primary when boot for the first time so set the IP address for that controller & ensure other controller is "powerd OFF" before setting IP address please upgrade firmware using serial cable(TK212) & then configure IP using IP config tool start-programs-ABBindustrialIT800xA-Engineering-utilities-Ipconfig tool but ensure CN1 cable is connected to Primary Controlnetwork switch & CN2 to secondary control network switch & always while setting IP address once controller is conncted press "factory default settings" & then goto-file-advanced(select) & then set the IP address with proper subnet mask & then for backup controller you have to select the drop down box as ETHERNET1 & set IP address using "deafult rule"in optin box & press apply & do the same for ETHERNET2 & set IP address using "deafult rule"in optin box & press apply & you press store IP. & then reset the controller by pressing init for Run led blinks for 3 times.
this completes the Primary IP setting of the controller & set the Secondary Ip address in CBM & make the "secondary ethernet-enabled=true" & then download & then you reset the controller once to make secondary cable detect in the RNRP/starts pinging
Now PowerOFF the primary controller & powerON the secondary controller to upgrade the firmware ensure no CN1 & CN2 cable connected while upgrading(else it won't sync with primary controller so) once firmware is upgraded turn off the secondary controller again & powerON the primary controller with CN1 & CN2 cable connected but no Tk212 cable connected to COM4 this time.
Now you turn on the secondary controller(ensure the RCU cable is connected & battery is removed) & once controller becomes "DUAL" down load the hardware configuration.
2.For CI840:As per your configuration your CI840 position is 2 so in physically you have to set the address to 2 using rotory key (1x2 & 0x10) since 2 rotory keys & then reset the CI840 by removing the power using TB & powerON.
Please refer the manual page no82 onwords
Thanks for the valuable suggestions.
I have tried my program to be run on Single separate controller(without redundancy),keeping the second completely Off. Further I used CI840A in redundant modes on all three nodes. It worked well. And also I was able to Power up my nodes. :)
My main fault is :- I have not tightened the Screws on CI840 units . Thats the mere pity issue.
But, before when I was trying the same(i.e. Separate this all procedure)on Ist previous controller ,I upgraded the firmware ,and then assigned an IP.
But when I proceeded for download the program, it perform some successful steps (like "Download for the first time", etc) Later but it aborted the operation showing me a message. :- "ANOTHER CONTROLLER IS TRYING TO DOWNLOAD THE PROGRAM".
What the reason can be ?? Pls suggest !!