Re: [foxboro] FBM 233 to Controllogix question

With the earlier version of the driver, we 
found that misconfigured points (which were 
deleted) still were actively polled by the 
FBM. We could only clear it be rebooting 
the FBM and doing downloads of the driver. 
Ultimately, Foxboro published the info below.

Customer Advisory
FDSI FBM Safety Issue 
March 10, 2008

Invensys is committed to ensuring that our customers and employees are
kept current on issues that might affect or improve system operation. We
are dedicated to focusing on product, application and service
availability and reliability. 

Customer Advisories are intended to inform you of the possibility of a
situation occurring at system installations, and the identified
resolution. Invensys recommends that our customers consider taking
action to help prevent occurrence of the identified situation during
your production process. 

Potential Safety Issue: 
Invensys has reviewed the issue described in this Customer Advisory and
determined that, if no action is taken, there is potential risk of harm
to people, property or environment. This review has taken into account
standard industry practices such as failsafe system configurations.
Because the described problem may be unrevealed during system operation
it could result in an unknown and potentially unsafe condition.
Customers should make a determination regarding the impact of this issue
to assess whether any action should be taken to ensure the safe
operation of their system.

This advisory applies to the FDSI FBM230, 231, 232, and 233 with any
FDSI driver operating on the I/A Series V8.0 system and higher.  

Situation
When a user downloads an "invalid point" from the CP into the FDSI FBM
with an incorrect entry in the DCI block PNT_NO parameter, an "invalid
point address (W65) or Duplicate Connection (W66)" error appears in
FoxView as expected.   Then, when the user fixes the "invalid point",
FDSI may map the last modified point to one or several other points.
This results in several input points in the CP being mapped to a single
input point in the field or several output points in the CP being mapped
to a single output point in the field. 

Symptoms
A CP input block may not be updating from the correct field point or a
CP output block may not write to the correct field point. 

Actions or Resolutions
It is recommended to immediately apply the following workaround for this
problem, which will help avoid any potential safety issues with a
minimal disruption to the production process. 

The workaround : Invoke SMDH and issue the command sequence to take the
FDSI FBM "offline" and then bring the FDSI FBM "online".  This fixes the
issue of mapping the modified point to another input or output point.

Subsequently, when any changes to the I/O database result in an "invalid
point address (W65) or Duplicate Connection (W66)" error in FoxView, the
user should first fix the errors and then invoke the command sequence in
SMDH to take the FDSI FBM "offline" and then bring the FDSI FBM
"online".  

Invensys recommends installing Quick Fix 1009968 with IOM image 1.25
when it becomes available.  Quick Fix was released March 7, 2008. 


Supporting_Information
Download QF1009968



___________________________________
James J. H. Dykes
Tesoro Petroleum
Golden Eagle Refinery
Technical Services
Process Controls
150 Solano Way
Martinez Calif.
94553-1487

Phone:925.228.1220 Ext. 2930
E-mail:jdykes@xxxxxxxxxxx 

 


-----Original Message-----
From: foxboro-bounce@xxxxxxxxxxxxx [mailto:foxboro-bounce@xxxxxxxxxxxxx]
On Behalf Of Ron Schafer
Sent: Tuesday, August 12, 2008 1:09 PM
To: foxboro@xxxxxxxxxxxxx
Subject: Re: [foxboro] FBM 233 to Controllogix question


Ronald G. Schafer
Distributed Controls System Administrator White Birch Paper Company Bear
Island L.L.C. Division
10026 Old Ridge Road
Ashland VA, 23005
Phone 804-227-4034
Fax 804-227-4052
David,
        We to found that we initially had that problem. I have (3)
ZCP270/233 that I use as gateways. What I found was that it appears that
over time we would run out of memory. I believe it was due to invalid
point that didn't exist (yet). I could only prove that the memory was
reaching max(using John Dykes method) over a period of time. The theory
was that the invalid point(s) was getting logged into a file in the
cp/233 that grew until all memory was consumed. After some testing we
found that cleaning up the non-existing points seems to have cleared it
up. We also upgraded to the modbus driver to 1.1a as some other problems
were found to exist. The gateways have been operational for over 6
months now with no reboots.
        You can also use a Tap method to look at the Ethernet traffic
coming/going from the 233. Here is how. You will need a Hub (not a
switch) and plug both 233's into the hub. Plug the network into the hub.
Using a PC install ethereal protocol analyzer (freeware) and record and
analyze the traffic to see what Modbus TCP/IP problems exist. This is
pretty cool as you can watch every bit of traffic as well as the timing.

Ron Schafer

 
 
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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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