MY ABB SM810 AND PM865 ARE IN FAULT CONDITION

[Abelky98]

Hello Linkinx64;

In one of our sites, we have two AC800M (PM865) controllers which are setup in redundant mode. These controllers are used in our Safety Shutdown System. My issue is that the Primary PM865 and its SM810 are in fault condition. The backup PM865 and SM810 are functioning well. I have tried all I could to clear the fault, but without success. I have even changed PM865 and SM810 to new ones using procedure in the user manual, but fault indicators are still there.
I used hyperterminal to capture the controller action when I reboot it and here is the text report:

Bootloader version 1.3.18.0
BOOTLOAD??
*** No CF card found ***
Program found 03008010 -- 031FC055 : 0D460677 - Ok

Shadow memory update: 00000000 - 01FFFFFC
.............................................................................
...................................................
Shadow memory update: 02000000 bytes of RAM updated!

RAM test: Test RAM 00000000 - 01FFFFFC
.............................................................................
...................................................
RAM test: 02000000 bytes of RAM tested OK!

Executable - boot
|----------------------------------------------------------------|
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Executable - ok
*FW Integrity Verification*
------------------------------------------------------------
############################################################

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
0
Stalltimer is enabled with time = 1984 us
This is Upper CPU running as Backup CPU .
Attaching interface lo0...done


VxWorks

Copyright 1984-1998 Wind River Systems, Inc.

CPU: ABB AC800M - PowerPC 860
VxWorks: 5.4.2
BSP version: 1.2/0
Creation date: May 2 2006
WDB: Ready.


Built: May 2 2006 13:40:40
Initialized. No time data available.
System time quality: BAD
CPU-core running at 96 Mc, bus /2, to=24.0 us
TCPIP CONFIG

Failed to generate the following system event:(INVALID_PARAM),possible message truncation
Source name suffix: _SWTargets
Message: ||CON_4023_B{1}Bkp_{2}_in_{3}\:\RCUMessHalt\AwaitDualTest
Limits : ^-----------------------------------------------------^
Severity: High
Timestamp: 1979-12-31:00:00:00:745678976
Failed to generate the following system event:(0001100b)
Source name suffix: _SWTargets
Message: ||CON_4023_B{1}Bkp_{2}_in_{3}\:\RCUMessHalt\AwaitDualTest
Severity: High
Timestamp: 1979-12-31:00:00:00:745678976
Failed to generate the following system event:(0001100b)
Source name suffix: _SWTargets
Message: ||CON_4024_B{1}Backup_CPU_halted\:
Severity: High
Timestamp: 1979-12-31:00:00:01:248130976
E 1979-12-31 00:00:01.749: ||CON_4023_B{1}Bkp_{2}_in_{3}\:\RCUMessHalt\AwaitDualTest
I 1979-12-31 00:00:01.749: Check Controller log for halt reason!
I 1979-12-31 00:00:01.750: This CPU will now voluntarily restart...
Bootloader version 1.3.18.0
Restarted due to stall
Program found 03008010 -- 031FC055 : 0D460677 - Ok

Shadow memory update: 00000000 - 01FFFFFC
.............................................................................
...................................................
Shadow memory update: 02000000 bytes of RAM updated!

RAM test: Test RAM 00000000 - 01FFFFFC
.............................................................................
...................................................
RAM test: 02000000 bytes of RAM tested OK!

Executable - boot
|----------------------------------------------------------------|
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Executable - ok
*FW Integrity Verification*
------------------------------------------------------------
############################################################

This PM has been intentionally stopped.
Reason:
- CPU stall timer has expired (Acknowledged)
- Manual shutdown was requested

Press init button or remove power to restart...

When I checked the Controller Hardware Status in the CB I saw "Controller in mode, no communication with primary controller, RCU connector is open ..." But I have checked physically and tightened all the connectors but fault indicatios are still there.

I know it is weekend, please, kindly give me advice on what to do to resolve this issue.

Best Wishes,

Abelky98

[Linkinx64]

Hello

Exchange primary and backup processor modules with their baseplates. I mean: make primary PM as backup, backup PM - as primary. Download program to PLC and report results. If the same issue now will happens with backup processor module - we will continue research other hardware, firmware and software.
Else, you know what to do.

P.S. Can you download and start failed PM in standalone (non-redundant) mode? Is it work at all?

[sania]

don`t dubble post!
closed