Controller is not going online in 5.1 RevA System
We are facing a problem at one of our site, couldnot able to go online for one controller error is "Error in communication link"
But we are able to ping the controller from both connectivity serversbut while pinging there is some losses.
In OPC Server panel the respective Controller smiley status switching from red to yellow few times observed
Currently is in red.
but data access is happening on both connectivity servers,all dynamics are updating.
We restarted secondary connectivity server then data access is not happening from the secondary server presently plant is in operation dynamics are updating from Primary Connectivity server.
We couldnot able to take controller logs as it controller is not communicating.
We checked the system diagnostics faceplates,We attching the snaps of the same.
first of all you should verify if the controller itself is overloaded.
Go to the connectivity server.
By rightclicking the "R"- RNRP notification icon TWO TIMES quickly then you get th RNRP Fault Tracer. Select item 5 - Test rnrp response time from one node.
Enter the IP-address of your controller.
If you have several controllers, test each of them.
If you have response times > 100 ms (not a dot) then you should optimize your controller code.
If not, verify the network.
I have to agree with Ronny.
In one of the pictures I noticed 70% cyclic load which is too much.
1. The AC800 controller firmware will "slow down" your programs when 70% cyclic load is reached to prevent it to exceed 70%. This is no good since you can not trust that your code executes on the interval(s) you have chosen. When the load is "capped" certain events are output to the controller log (Interval time in ordinary tasks inc/dec...).
2. 99% memory used both now & download is another bad thing. Your are close (or beyond) to having to resort to cold download only since new version of program can not fit in parallel with existing version which is required for warm download.
3. Events To Send > 0 indicate that the controller is unable to send alarm & events to the OPC server. I suspect this may have to do with the CPU and memory usage above.
I recommend that you seek assistance from the regional ABB support team.
Yesterday we done controller cold restart, after that we are able go online/download the project.
But We have oberversed that
The memory which was showing 99% before cold restart,after cold restart and application download memory usage is only 17 %.
but the Cyclic load reamin the same(70%).
what could be the reasons of increase in memory usage to 99% ??
The increase in cyclic load was because someone has changed the task interval time to 50ms instead of 500ms.
After reverting the scan interval time to 500ms the cyclic load has come down to 25% .
Thanks for the support.
The problem is resolved, it was a known issue , the product bulletin also issued reagrding this issue, i am attaching the same for refrence.
The problems was primary and secondary control network got connected to same switch.
Thanks & Regards