This is the latest I've got on the problem
Regards
John
> -----Original Message-----
> From: Lowell, Tim: [SMTP:[EMAIL PROTECTED]]
> Sent: July 28, 2000 1:10 PM
> To: 'Foxboro DCS Mail List'
> Subject: RE: Foxboro DCS Mail List Photos at the I/A User Meeting
>
> Does anybody have a copy of the e-mail from Foxboro regarding the latest
> CP40BFT/CP30BFT reboot problem? Our service guy said we should have
> received it already (we didn't), and Foxboro said they can get it to us
> next
> week, but if one of you had it, that would speed things up a bit. Since I
> won't be in the refinery next week, it would be nice to know what is going
> on so that I can inform the people who will be here what the problem is.
>
> Thanks,
>
> Tim
> **************************************************************************
> ****
> Foxboro Service Notification
> =============================
>
> Regarding Sites Experiencing Problems with
> Control Processor 30 Style B
> Control Processor 40 Style B and
> Control Processor 60
>
> July 17, 2000
>
> ===============================
> This notification is to inform you of software problems that Foxboro has
> identified in Control Processor 30 Style B, Control Processor 40 Style B
> and Control Processor 60 stations and the proactive steps being taken to
> resolve the issues.
>
> It is crucial that our customers and field service organization be aware
> of the issues and support the resolution process by reporting any Control
> Processor problems in writing via the Customer Action Request (CAR)
> process.
> A CAR should be entered even if the issue sounds similar to one already
> reported. A completed Control Processor (CP) checklist and specific
> details
> relating to any problems experienced should accompany the CAR.
>
> Synopsis
> Problems have been reported from customer sites involving CP30B and CP40B
> fault
> tolerant pairs, all running Rev E+ hardware with software released as
> Version
> 4.2.4, 6.1.1 as well as QF990590B (6.1.2 control level). Please do not
> confuse
> this control level of 6.1.2 with the upcoming 6.1.2 Maintenance Release.**
>
> Similar issues are reported from sites involving CP60 Rev B+ fault
> tolerant pairs
> with software release V6.2 and also QF991554 (also known as 6.2b). The
> symptom
> experienced at all sites is described below.
>
>
> Fault Tolerant Control Module Reboot with no messages or dump files
> ==============================================
> Symptom: One or both control processors of a fault tolerant control
> station reboot
> without producing a dump file. If one module reboots, there is no
> interruption in
> control. However, in the case of both modules rebooting, an interruption
> in control
> results, with all configured failsafe safeguards remaining operational.
> The module
> LED(s) goes to a RED/GREEN state while rebooting. The module(s) then
> recover and the
> LEDs return to the green state following fault tolerant marriage with no
> manual
> intervention.
>
> The problem affects fault tolerant control stations only. An example of
> the only
> message generated after station recovery is:
>
> 07-13-00 08:30:04 0 SYSMON = SYSME1 CP6E03 Software Manager
> SYSMON -00003 Powerup reboot OK. ROM Addr = 00006C0F0102
>
>
> Stations affected: CP30B, CP40B, and CP60
>
> Control Version: CP30B, CP40B: 4.2.4, 6.1.1 and QF990590B (6.1.2
> control level)
> CP60: 6.2 and QF991554 (also known as 6.2b)
>
> Diagnosis: There are (3) failure scenarios that result in the single
> symptom described
> above:
> ===================================
> 1. On occasion, a problem is encountered during the database transfer
> between the
> primary and shadow stations in a fault tolerant pair. After a hot remarry
> of the
> stations occurs, diagnostics are executed. After completion, the database
> is
> transferred from the primary module to the shadow. The primary expects to
> receive
> interrupt notification during this process. The problem occurs when this
> interrupt
> is not received; the primary module waits for this interrupt and then
> trips the Watch
> Dog Timer (WDT) in both stations. The result is a reboot of both modules.
>
> The software has been changed to allow the primary module to continue
> operation in
> this scenario. Since the memory transfer has not completed to the shadow
> module,
> the shadow module will reboot and recover, thus downloading a complete
> database.
> No interruption in control is experienced.
>
> 2. A similar failure mode may occur at the beginning of the database
> transfer. During
> the state of preparing the modules for memory transfer, the pair may
> experience a WDT
> timeout. This may occur while trying to sync the primary module to the
> start of the
> OSTICK (10ms) clock. Because the WDT timeout occurs on the primary, the
> memory transfer
> does not take place, causing both modules to reboot simultaneously. This
> failure is the
> result of the microprocessor handling of the halt (HLT) instruction.
>
> The method of syncing with the OSTICK clock has been changed to eliminate
> the
> possibility of the pointer returning to the halt instruction at the wrong
> time.
> No interruption in control is experienced.
>
> 3. The third failure mode also involves database transfer. Following a hot
> remarry a
> fault-tolerant CP may experience a WDT timeout during preparation for
> data-transfer in
> DMA_MEMCP1 routine. This failure happens because of a WDT trip while
> waiting
> indefinitely for the OSTICK interrupt either in the poll-out code or on
> the Halt
> instruction. This causes the primary module to fail, preventing the
> shadow module from
> recovering because of the inability to complete the data transfer. The
> result is a
> reboot of both modules. This failure is due to a problem using the "Poll"
> command to
> detect an interrupt. A defect with the internal timing of the 8259 PIC
> chip could cause
> this interrupt to be missed.
>
> To correct this, a software change has been added to also poll the "Period
> Interrupt
> Flag" in the 8570 Timer chip. This polling eliminates the problems
> associated with the
> 8259 PIC chip.
>
> ==============================
> Workaround:
> The problems occur on fault-tolerant control stations only. Analysis
> indicates that this failure may be avoided by running fault-tolerant
> stations in single
> mode instead of fault-tolerant mode.
>
> ==============================
> Resolution:
> The corrections for the failure scenarios described above have been
> included
> in the 6.1.2 Maintenance Release for CP30B and CP40B. They are also
> included in the
> 6.2.1 Maintenance Release for CP60. These software corrections have been
> confirmed as
> resolved during field trials of 6.1.2 and 6.2.1 Maintenance Release
> software.
>
> The formal release of the Version 6.1.2 is planned for August 30, 2000,
> thus making this
> correction available for all CP30B and CP40B customers presently running
> 6.1.x. 6.1.2
> is a delta upgrade Maintenance Release and does not require a Day 0
> installation.
> QF 991747-C will also be available August 30, 2000 for sites that cannot
> upgrade all
> stations to 6.1.2.
>
> The formal release of Version 6.2.1 is planned for August 30, 2000, thus
> making this
> correction available for all CP30B, CP40B, and CP60 customers presently
> running 6.2.
> 6.2.1 is a delta upgrade Maintenance Release and does not require a Day 0
> installation.
> No Quick Fix will be generated for CP60. Sites must upgrade to the full
> 6.2.1
> Maintenance Release level.
>
> ================================
> ACTION:
>
> For 4.3 systems:
> ---------------
> CP30B and CP40B: Utilize the 6.1.2 station images for 4.3 systems via QF
> 991747-C.
> CP60: Not applicable.
>
> For 6.1 systems:
> ---------------
> CP30B and CP40B: Upgrade to the 6.1.2 Maintenance Release or utilize the
> 6.1.2 station
> images for 6.1 systems via QF 991747-C.
> CP60: Not applicable.
>
> For 6.1.1 systems:
> -----------------
> CP30B and CP40B: Upgrade to the 6.1.2 Maintenance Release or utilize the
> 6.1.2 station
> images for 6.1.1 systems via QF 991747-C.
> CP60: Not applicable.
>
> For systems with QF990590B:
> ----------------------
> CP30B and CP40B: Upgrade to the 6.1.2 Maintenance Release or utilize the
> 6.1.2 station
> images via QF 991747-C.
> CP60: Not applicable.
>
> For baseline 6.2 systems or systems with QF991554:
> ----------------------
> CP30B and CP40B: Utilize the 6.1.2 station images for 6.2 systems via QF
> 991747-C.
> CP60: Systems that utilize CP60 MUST be upgraded to 6.2.1 via Maintenance
> Release Update.
>
>
> Please ensure that this information is cascaded to applicable personnel to
> facilitate
> swift and thorough resolution to these issues. We are concentrating our
> efforts on
> these releases to provide a solid control processor baseline for our
> customers.
>
> If you have any questions regarding any Control Processor issue, please
> call the Foxboro
> Customer Satisfaction Center at 888-FOXBORO (International 508-549-2424)
> where a team of
> individuals has been assembled to assist you. For any questions related to
> CAR submittal
> please email [EMAIL PROTECTED]
>
>
>
> ** Control levels are cited to avoid confusion with what is displayed in
> the station
> block for CP30B and CP40B. QF990590B will display 6.1.2 in the station
> block display;
> this software should be upgraded. The 6.1.2 Maintenance Release and
> QF991747-C will
> display V2K_01 in the station block; this is the correct software level.
>
> Foxboro Confidential
> Distribution Restricted to Foxboro Personnel Only
> DO NOT REPRODUCE
>
> (c)The Foxboro Company, 2000
> All Rights Reserved
>
>
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