Re: [foxboro] CP-60 Fieldbus Communication Errors
- From: Troy L Brazell <tlbrazell@xxxxxxxxxxxxxxx>
- To: foxboro@xxxxxxxxxxxxx
- Date: Tue, 22 Mar 2005 08:27:52 -0600
Tom,
I too would be interested in the solution to this problem. The first site
that Foxboro did "turn key" for us experiences the exact same problem.
However, these problems occur with CP40B's.
In order to help the problem I had to set the MPOLL to a 5, this created
another problem as it increased the loading by about 15%. Foxboro has had
this problem in there lap for 3 years and have not been able to solve it. I
refuse to allow them to clear the CAR.
I am convinced that at this site Foxboro put the fiber bus in wrong! The
field bus for this site was installed in a ring instead of a star
configuration. Unless I have misread the documentation it should be
connected as a star not a ring.
We have since installed I/A at two other sites with CP60s using a star bus
configuration and have had no problems.
Troy L. Brazell
Duke Energy Field Services
Sr. Process Control Analyst
ISA CCST
Phone (405) 263 4810 ext. 24
Cell (806) 898 4340
Okarche C&M
Route 4 P.O. Box 40
Okarche, OK. 73762
*****************************
MS Windoze the cure for Insomnia
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tom.vandewater@dow
corning.com To: foxboro@xxxxxxxxxxxxx
Sent by: cc:
foxboro-bounce@fre Subject: [foxboro] CP-60
Fieldbus Communication Errors
elists.org
03/22/2005 08:08
AM
Please respond to
foxboro
All knowing list,
I have a CAR in the que regarding intermittent fieldbus
communication errors associated with CP-60 fieldbus devices. We have had
continual problems with this since we started using CP-60's at Ver 6.2.1.
We have been through a host of EEPROM updates for the FCM/FBI/DCM's, (1.07,
1.09, 1.11, 1.12, and 1.13). The current recommendation to fix the problem
is that we upgrade our workstation software to Ver. 6.3.2 and our CP-60
software to 6.3.2 or 6.5.1 and then move our FCM/FBI/DCM, (iom82), EEPROM
level back to 1.11. Our plant is a 24-7-365 operation and we have been
running at capacity so we have not been able to reboot the CP's since the
recommendation was made at the end of 2003.
As a result, I am asking all of you if anyone else has
experienced
this problem? If so, how has the problem been resolved? Since I've
already
been on many wild goose chases regarding this issue, you might imagine that
I am a bit skeptical when another fix is proposed that tells me I need to
install more software and go back to a previous EEPROM rev for the
FCM/FBI/DCM's. Is there anyone out there running Ver. 6.3.2, (or later),
workstation software and 6.3.2 or 6.5.1 CP-60 image, and are still
experiencing intermittent fieldbus communication errors on CP-60's? Your
help would be greatly appreciated.
Below is a description of our problem:
Since Foxboro has been unable to identify and fix the problem
we
find ourselves deeply involved in committing OUR resources to nail down as
many of the symptoms as we can. Not being privy to the communication
structures and error detection and reporting strategies that only Foxboro
knows, we are much like the blind man trying to describe an elephant by
touching it. However, we have touched this elephant enough to develop some
theories.
Here are some of our findings:
Once all FCM's, FBI10E's, and DCM's were EEPROMed at rev 1.13,
these
are the symptoms:
* Continue to have large numbers of PIO Bus Access Errors if PIO bus
switching is enabled. (10 to 100/hour). We have ZERO errors when running
"A or B Disable" except for the complete but temporary failure experienced
when running "A Disable" at EEPROM 1.11 on the new DCM's.
* The errors are spread out across CP's using all three types of fieldbus
communication modules, FCM10EF, FBI10E, and DCM10E's and EF's.
* The "majority" of the errors occur on CP's communicating through DCM's
* Most of the legacy FBM's are at EEPROM rev. 61.1 with a few at 40.1 (As
far as repetitive errors are concerned we see no difference between the two
EEPROM rev's.)
* The majority of the errors occur repetitively on the same, relatively
few,
FBM's
* The majority of those errors are associated with legacy, discrete, FBM's.
(Our discrete FBM's run PLB ladders)
* Replacing the repeat offender FBM's with newer or different FBM's of the
same type does not stop that FBM from reporting errors.
* Moving the repeat offender to a different Y-Adapter does not stop that
FBM
from reporting errors.
* Changing the CP's Primary ECB .MPOLL parameter from 7 to 0 had no impact
on the frequency of the errors, but it also looked like my change from 7 to
0 had no impact on the Fieldbus Scan Loading as viewed in the CP's Station
Block. It should have made a big difference and I wonder if CP-60's only
use .MPOLL=7?
* The CP's involved are not experiencing any Control Loading or OM Scanner
loading overruns as displayed by the CP Station Block.
We have a few FBM's that are experiencing repetitive errors that we can
replace/reboot/move/EEPROM, with no adverse effect on the process and we
invite Foxboro to observe/troubleshoot using those. We also have all
System
Alarm logs over the past year that can be reviewed/analyzed. It is our
conclusion that there are serious errors in the CP-60 fieldbus
communication
and bus-switching strategies that will only be fixed when Foxboro decides
to
put some concerted effort into solving them. Our time is now, better spent
communicating with other users to heighten the awareness so they can submit
CAR's on these problems.
These issues have plagued us for over 4 years and we want to see them
fixed.
Below is a typical System Alarm log that shows one hour before PIO bus
switching is disabled. There are 12 PIO Bus Access Errors during that
timeframe. The CP's then ran for over 7 hours with no PIO Bus Access
Errors. After PIO Bus Switching is re-enabled there are 16 PIO Bus Access
Errors in a one-hour period.
11-25-03 07:00:20 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00057 Currently using PIO bus B
11-25-03 07:00:20 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:01:00 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 07:05:28 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00057 Currently using PIO bus B
11-25-03 07:05:29 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:05:29 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 07:13:30 0 SYSMON = SYS09A 09CP03 Equip = 09CP03
SYSMON -00057 Currently using PIO bus B
11-25-03 07:13:33 0 SYSMON = SYS09A 09CP03 Equip = 090803
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:14:07 0 SYSMON = SYS09A 09CP03 Equip = 090803
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 07:34:57 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00056 Currently using PIO bus A
11-25-03 07:34:57 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 07:35:13 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 07:37:29 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00057 Currently using PIO bus B
11-25-03 07:37:29 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:37:59 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 07:39:30 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00056 Currently using PIO bus A
11-25-03 07:39:32 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 07:39:36 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 07:44:54 0 SYSMON = SYS06A 06CP09 Equip = 06CP09
SYSMON -00056 Currently using PIO bus A
11-25-03 07:44:56 0 SYSMON = SYS06A 06CP09 Equip = 060710
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 07:45:00 0 SYSMON = SYS06A 06CP09 Equip = 060710
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 07:50:10 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00057 Currently using PIO bus B
11-25-03 07:50:10 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:50:26 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 07:50:30 0 SYSMON = SYS09A 09CP03 Equip = 09CP03
SYSMON -00056 Currently using PIO bus A
11-25-03 07:55:45 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00056 Currently using PIO bus A
11-25-03 07:55:45 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 07:55:45 0 SYSMON = SYS06A 06CP09 Equip = 06CP09
SYSMON -00057 Currently using PIO bus B
11-25-03 07:55:45 0 SYSMON = SYS06A 06CP09 Equip = 060301
SYSMON -00068 Single PIO Bus Access Error on A
11-25-03 07:55:53 0 SYSMON = SYS08A 08CP02 Equip = 080609
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 07:56:17 0 SYSMON = SYS06A 06CP09 Equip = 060301
SYSMON -00070 Single PIO Bus Access Recovery on A
11-25-03 08:05:39 0 SYSMON = SYS06A 06CP09 Equip = 06CP09
SYSMON -00056 Currently using PIO bus A
11-25-03 08:05:41 0 SYSMON = SYS06A 06CP09 Equip = 060301
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 08:06:03 0 SYSMON = SYS06A 06CP09 Equip = 060301
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 08:06:28 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00056 Currently using PIO bus A
11-25-03 08:06:28 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00069 Single PIO Bus Access Error on B
11-25-03 08:06:42 0 SYSMON = SYS13A 13CP07 Equip = 130506
SYSMON -00071 Single PIO Bus Access Recovery on B
11-25-03 08:09:29 0 SYSMON = SYS06A 06CP09 Equip = 06CP09
SYSMON -00059 PIO bus switching disabled
11-25-03 08:10:08 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00059 PIO bus switching disabled
11-25-03 08:10:55 0 SYSMON = SYS09A 09CP03 Equip = 09CP03
SYSMON -00059 PIO bus switching disabled
11-25-03 08:11:08 0 SYSMON = SYS09A 10CP05 Equip = 10CP05
SYSMON -00059 PIO bus switching disabled
11-25-03 08:11:44 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00059 PIO bus switching disabled
11-25-03 08:12:00 0 SYSMON = SYS13A 13CP08 Equip = 13CP08
SYSMON -00059 PIO bus switching disabled
11-25-03 08:12:37 0 SYSMON = SYS21A 21CP05 Equip = 21CP05
SYSMON -00059 PIO bus switching disabled
11-25-03 08:49:03 0 SYSMON = SYS18A 18CP01 Equip = 18CP01
SYSMON -00059 PIO bus switching disabled
11-25-03 15:43:04 0 SYSMON = SYS18A 18CP01 Equip = 18CP01
SYSMON -00058 PIO bus switching enabled
11-25-03 15:43:27 0 SYSMON = SYS06A 06CP09 Equip = 06CP09
SYSMON -00058 PIO bus switching enabled
11-25-03 15:43:50 0 SYSMON = SYS08A 08CP02 Equip = 08CP02
SYSMON -00058 PIO bus switching enabled
11-25-03 15:44:13 0 SYSMON = SYS09A 09CP03 Equip = 09CP03
SYSMON -00058 PIO bus switching enabled
11-25-03 15:44:25 0 SYSMON = SYS09A 10CP05 Equip = 10CP05
SYSMON -00058 PIO bus switching enabled
11-25-03 15:44:55 0 SYSMON = SYS13A 13CP07 Equip = 13CP07
SYSMON -00058 PIO bus switching enabled
11-25-03 15:45:05 0 SYSMON = SYS13A 13CP08 Equip = 13CP08
SYSMON -00058 PIO bus switching enabled
11-25-03 15:47:36 0 SYSMON = SYS21A 21CP05 Equip = 21CP05
SYSMON -00058 PIO bus switching enabled
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This mailing list is neither sponsored nor endorsed by Invensys Process
Systems (formerly The Foxboro Company). Use the info you obtain here at
your own risks. Read http://www.thecassandraproject.org/disclaimer.html
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to subscribe: mailto:foxboro-request@xxxxxxxxxxxxx?subject=join
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