PM 861 Backup Failure
We are facing an issue with the backup unit of a PM861 controller.
All the procedure about configuring the bakup unit has been done and on a lab enviroment it works. However when installing the controllers on site the redundant controller does not work. Fault led flashes quickly and stop flashes quickly and stop. This indicates firmware downlod or another error to check in the log. I checked the log and the errors that I could found are about redundancy and module bus. The last one makes sense because in the lab it works hoever on field where we have other modules it fails. How ever I cannot see what actually is wrong. I attached the only log that has information and a picture of the controllers. Cables and connection phisically checked and changed (just in case).
Any help will be grateful.
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The CPU will stop mainly if I/O's are not visible to it or both Eth lines are broken.
You have to check if the connection to I/O's is correct for BOTH CPU's, also if your HW configuration corresponds to what is installed, connected and wired in real.
Could you please check following:
W 2016-04-19 20:48:14.142 On Unit= 0.11.103 HWError C151CO823A 0000 See HWTree Error 16#00000030 16#00000000
W 2016-04-19 20:48:14.143 On Unit= 0.11.104 HWError C151CO823A 0000 See HWTree Error 16#00000030 16#00000000
From log file, I can't see the module 103 ?? Also there should be 101 and 102 ??
General message says:
51CO823A 4030 Stopped ModuleBus inaccessible Backup CPU
That for me means that the connection of I/O's to the backup CPU is wrong. You could try to start the Backup CPU as primary or single and check if it could read I/O correctly
The Controller crashes when it tries to start the CI853 Modbus master interface. There's a few things you could check ....
- The firmware in the CI853 looks to be very old ( dated 2002 ) Check for a later release.
- The Startup log indicates 2 * CI853 modules, the photograph only shows one
- You might need to check the rules about redundant CI853, IIRC there are some restrictions.
Theres also a message about the Modulebus IO being inaccessible from the backup CPU.
Thank you Rob, the system it is quite old, so the module firmware is the "newest" one that can be download to it.
The hardware configuration it is configured as 2 modules separated, not redundant, this configuration as far as I know it is allowed and we have the information that was working before, until the redundant controller failed.
I am working on this and I think that maybe (it is just an idea) the cex-bus or module bus fuse it is broken and maybe this is leading the issue. As soon as we have the chance to check this I will let you know.
Anyway any ideas are welcome :)
Thanks for your replies, answering your questions:
- The firmware version of the lower unit is the sam as the upper unit.
- The modulebus it is an optical module bus, the modules are not visible in the picture but are ok (it were working porperly until the backup cpu enter in failure mode)
- The backup configuration looks ok as per the messages shown in the logs.
I 1979-12-31 00:00:00.882 Network address is 172.16.84.157, 172.17.84.157.
I 2016-04-20 00:55:16.734: Ethernet port status(P-CN1 P-CN2 B-CN1 B-CN2)= OK OK OK OK
- Unfortunately I cannot do the test of just using the backup as a primary cpu because is a running plant.
- I still suspect that it's related to the fuses we haven´t had the chance to check that, as soon as I have some news I will let you know.
Best regards :)