Re: [foxboro] CP60 Failure Error

Kabir Ahmed,

 

The message below "Error Escalation Threshold has been exceeded" is printed 
just before the CPFT pair break and one of the two modules goes RED only led on 
the front. This means that the pair made more than 7 (limit may have changed 
over the years)  attempts to re-marry in less than one minute. So rather than 
spend all its time on trying to stay FT, it breaks and one module continues to 
run the plant in the single CP mode.

 

There could be many reasons for this, usually site related. As Kevin has 
stated, you may want to start looking at 251550, but it could be electrical 
noise on your field bus (one or both) and 251550 just happened to be the module 
that was communicating to the CP60 when some time out occurred.

 

Although Foxboro allowed copper field bus (co-ax cable) outside the enclosures 
almost all other industrial ethernet literature recommends only fibre be used 
outside the enclosure. I think the comments on this web site fully support that 
copper fieldbus on CP60 is almost never working well. Dirk has suggested you 
contact your Foxboro field service rep due to the large number of changes in 
hardware and eeprom in both the CP60's, the FCM's and the cell buss. If you get 
all the latest updates and still have trouble, then you need for follow the 
co-ax shield grounding very carefully to ensure that every shield connection is 
grounded where it is supposed to be grounded. Test everything - make no 
assumptions. Any peripheral converters, etc. need to be checked. If you are not 
using fibre, you may actually need to start - which is no small matter.

 

Failsafe communication from the CP to the FBM is defined in the CP and ECB 
configuration. As Kevin has stated, if you use HART or other protocols between 
the FBM and the transmitter, you need to check there for "failsafe" 
communication.

 

On the CP to FBM, the default is to fail HOLD. The default timeout (FSDLAY) is 
10 seconds but you need to verify FSDLAY in your ECB for each FBM.

 

Then you configure the FSENAB parameter. The EDOC is slightly confusing on this 
because of the note that is added.

 

"FSENAB Failsafe Timer Enable is a configured boolean input. When true, it 
enables
the FSDLAY timer to detect a communications failure and place the FBM
in the Failsafe state. If communications fail with FSENAB false, there is
no failsafe activity.
0 = Disable FSDLAY timer
1 = Enable FSDLAY timer
NOTE
FSENAB does not affect the Failsafe configuration. Setting FSENAB false does 
prevent
the FBM from going to the Failsafe state because of a CP-to-FBM communications
failure, but it cannot prevent the FBM from going to Failsafe for any other
reason."

 

 

The "any other reason" is the tricky part.

 

If the FBM does not get a communication from the CP for 10 seconds, it will 
force the FBM to failsfe mode and place outputs to their configured failsafe 
value. Default is usually open contact for discretes and 4 mA for current 
signals, but you need to check each FBM configuration especially the HART or 
FoxComm FBM's.

 

On the block side of the CP, there are lots of configurable options for the BAD 
or other errors but I believe that the default is to hold the AIN value if the 
ECB has a hardware problem and any downstream controller goes to the HOLD mode. 
The CP blocks are extremely powerful and flexible here so you really need to 
know what has been configured.

 

Terry


 15-07-09 16:49:51    0    SYSMON = SYSMN2  03CP02 Process = PMAINT03CP02
PIOMAI   000002 hardware Fault 251550(Valve) FAILSAFE TIMOUT
  
 15-07-09 17:52:25    0    SYSMON = SYSMN2  03CP02 Process = PMAINT03CP02 
 PIOMAI   000002 hardware Fault 251550(Valve) FAILSAFE TIMOUT
  
 15-07-09 18:01:00    0    SYSMON = SYSMN2  03CP02 Fault Tolerant Exec
  SM_MSG  -00047 Fault Tolerant Prim Module Now single. ROM Addr 00006C170EB0
  
 15-07-09 18:01:02    0    SYSMON = SYSMN2  03CP02 Error Protocol
  FTXSS   000081 Error Escalation Threshold has been exceeded 00006C173E08
  
 15-07-09 18:01:02    0    SYSMON = SYSMN2  03CP02 Error Protocol 
  FTXSS   000081 Error Escalation Threshold has been exceeded 00006C173E08   
 
 Kindly Suggest possibile causes for such failure and How could we configure 
our CP in FAILSAFE mode so that it retain the last good value in case pf any 
such failure.



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