-----Original Message-----
From: Lilly, Jr., Henry
Sent: Friday, July 21, 2000 8:11 AM
To: Klobuchar, Bob; Rodriguez, Jr. ,Angel
Subject: FW: Foxboro Service Notification Regarding CP30B, CP40B, and
CP60
-----Original Message-----
From: [EMAIL PROTECTED] [mailto:[EMAIL PROTECTED]]
Sent: Thursday, July 20, 2000 3:59 PM
To: [EMAIL PROTECTED]
Subject: Foxboro Service Notification Regarding CP30B, CP40B, and CP60
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
-----Original Message-----
From: John Miller [mailto:[EMAIL PROTECTED]]
Sent: Friday, July 28, 2000 2:15 PM
To: 'Foxboro DCS Mail List'
Subject: RE: Foxboro DCS Mail List Photos at the I/A User Meeting
Nope, we haven't gotten anything either.
-----Original Message-----
From: Lowell, Tim: [mailto:[EMAIL PROTECTED]]
Sent: Friday, July 28, 2000 12:10 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
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postings from this list are the work of list subscribers and no warranty
is made or implied as to the accuracy of any information disseminated
through this medium. By subscribing to this list you agree to hold the
list sponsor(s) blameless for any and all mishaps which might occur due to
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