AC800M Controller fault
Our customer have PM2 claiming AC03 had a fault and machine stopped at around 4:06 AM.
They could not clear the fault so they cycled power to the cabinet and pressed the INIT button on the controller (unintentionally long enough so the application was erased). Then they downloaded the application again and started the machine.
At first, we thought it was a battery issue because of the errors in HW tree (RPA/RPB/Battery Low). But we checked 24V connections from/to battery and AC03, and 110 VAC power to cabinet. We also made sure the internal battery cable was plugged in.
Then I went through the logs and I found that there was a IAC connection down log (related to AC03 I guess) in other controllers which match the event logs in 800xA for Watchdog fault:
In AC03 logs I found a “Soft Error Upset detected by the FPGA” error which caused the controller to stop:
There is also a Post Mortem info but I am not able to understand it:
Attached please find all controllers logs and some screenshots (info, events, unit status before clearing latch).
Could it be CPU load is high? Any suggestion will be appreciated.
Thanks in advance.
CPU load is at 61% which is a feasible range and can go upto 70-75%.
Temporary Solution will be Redundancy Configuration to existing stand alone controller along with Battery to avoid any kind of Power failure issues in future.
Please raise the support case at your Local ABB support to find a permanent solution for this issue.