ABB 800XA 6.0.1 CONTROLLER HANG DURING LOADING OF MODBUS PROGRAMME.
We have PM866 Controller in ABB 800 XA 6.0.1
Presently Total System load is 92%
Total Cyclic Load: 70%
Today when i download 2 Nos.Conzerve meter then during downloading Both Controllers & Communication module becomes in Fault Mode & All plant trip and Complete DCS hanged.
Please suggest root cause of such situation.
Snaps attached for reference.
Voted best answer
From the session log, I see that you were still in the preparation to download (click few Continue buttons). The download process wasn't actually started yet. Please confirm.
So controller crashed due to other reasons. You need to find out before crashed, was it unit A or unit B running as primary, so you can look at the correct log file because it may be different controller that acts as primary before crashed and now.
In back up CPU:
E 2019-10-04 13:13:27.410 ErrorHandler PM: Protocol handler did not respond (1,2) This PM has been automatically restarted. Reason: - CEX_RESET, Reset signal from CEX slave interface
In Primary CPU:
PowerFails: 0 No memory dump due to missing compact flash card Initiating log upload... Log uploaded The controller has been shutdown due to an unrecoverable fatal state!! Press init button or remove power to restart... This PM has been automatically restarted. Reason: - restarted from an unrecoverable fatal state
Anyway, the best is still communicating with your local ABB support for this.
I'd suggest you to carefully read the AC 800M Configuration Manual (3BSE035980-...)
"The cyclic load is the percentage of controller CPU power used for program
execution of application code. If the cyclic load exceeds 70% in the controller,
so-called load balancing is initiated automatically. The interval time for all tasks,
except the time-critical task, is then generally increased, to limit the cyclic load to
70%. Load balancing is not available in High Integrity controllers."
You are running a severe system load and it is critical to address this issue before applying changes.
This in combination with risk assessment has to be done to avoid these kind of system and production disruptions.