HI Redundant Controller goes in fault on download?
I am working on a 800xA System redundant HI controller (PM-865A) and I am facing the issue that sometimes that I download(mostly cold start) on the controller; the controller goes in fault. The controller and SM811 module of both the units goes in fault. This occurs when the controller is "Sending Domanins" for our application?
Any advise on the probable reason for this would be greatly appreciated since even though we are in engineering status at the moment, we cannot proceed until we iron out this problem?
Most (all?) controller halts are logged in the controller log (CBM->Tools->Remote System->Show controller log).
Interpreting a controller log is not trivial. You may have to ask your regional ABB support center for help with the translation. If you post the halt message on AKS you may get a hint or two.
Please find attached the controller logs; the file Controller 172.16.80.202 2015-08-29-17.59.01.322 CPU seems to be showing some issue while the system was being downloaded.
Any support on the subject would be greatly appreicated.
Looking at the following errors on the controller log, the ErrorHandler is called (see, 1,3, ERS). So I doubt it is a controller crash, did you receive any controller dump on flash card or SD card (if inserted on the controller)? That would be really helpful in further investigation. CRC32 fail is reported, which I predict there is a mismatch in CRC of PM and SM execution. So, please make sure you are not executing any SIL restricted modules in SIL3 application through MMS or IAC. for example, Sending Alarm Cond State or acknowledgement status. As already pointed out earlier, if you dont get it rectified, send your controller log and crash dump file to respective support team. Otherwise, it is really hard to predict the crash.
E 2015-08-29 17:50:12.814 Unit= _SWTargets Contro~D_FnG_1 4007 P:Switchover to Lower CPU performed
E 2015-08-29 17:50:12.848 ErrorHandler PM: 4180 MBM1 SM vs PM CRC32 fail ad 0x45 (1,3,ERS)
E 2015-08-29 17:50:12.848 Error message PM: 4180 MBM1 SM vs PM CRC32 fail ad 0x45
E 2015-08-29 17:50:12.850 FATAL ERROR in ..\..\source\BASICS~1/ErrorHandler/errorhandler/errorhandlerimp.cpp: 872939520 (0x34080000)
I 2015-08-29 17:50:13.511 Flushing modulebus frame discrepancy buffer:
E 2015-08-29 17:50:13.588 Modulebus frame discrepancy
As per log its controller crash(Stack pointer at crash moment: 0x802760)
Please look at the network configuration:
E 1979-12-31 00:00:05.900 RNRP Config error: Same path no. used twice in area 20
Are you using BC810? if so please then check they have properly mounted since its showing unknwon in your log file
The log tell us that the PM and SM have computed different results on channel 12 and 13 on the DO880 on position 405:
Adress AccessType Ch16 (bin) Ch1 Unused To Fr Mi Ma Ci
PM: 405 WriteDigital 0001111111111111 00000000 45 00 00 0A 1C
SM: 405 WriteDigital 0000011111111111 00000000 45 00 00 0A 1C
You need to check the application code that writes to these channels. Most likely the code contains a string operation or SIL restricted function that does not exist on the SM side.
E.g. comparing two identical strings will return TRUE in the PM, but FALSE in the SM.
I faced a similar problem while downloading from different stations, shutdown happened with PM865. We discovered that problem was a different packages installed at 800xA at aspect server and enginnering station. If you are using 800xA (in fact you must use 800xA. Compact doesn´t work with safety) and shutdown happens when you download from different stations check your 800xA installlation. You can use 800xA Collect Tool to do it.