Hey Sherman, let's take a trip down memory lane! Is there anyone in the forum who has experience with a redundant GE Series Six system? A facility with a system installed back in 1986 has been encountering sporadic issues with the CPU dropping out of run mode. When the backup CPU takes over, the transition is smooth, but both CPUs are facing the same issue. They are able to reboot the PLC using the keyswitch. The system has been inactive for a few months, but the batteries still seem to be in good condition based on the battery LEDs. I have some ideas on which modules to replace first, but I'm curious if anyone else has dealt with these old systems before. Rootboy, I'm looking at you!
Verify the watchdog timers for each CPU. While I am not familiar with these systems, this is the initial consideration. Best of luck.
For detailed instructions on operating the Asix Plus system, you can access the user manual at http://www.cimtecautomation.com/doc...Six/Manuals/GEK-96602Asixplususer'smanual.pdf.
Check out the following link for more information on GE Series Six PLCs: https://www.nuovaelva.it/docs/Ge-Fa.../INFOLINK/MORE_PLCS/SERIES_SIX/GEK-25366C.PDF.
Hello TWS, thank you for providing all the necessary manuals. AKAHammer, it is possible that the CPUs are halting due to a watchdog timeout issue. Surprisingly, the programs have not been altered since they were functioning properly. The real concern here is identifying the reason for the increased time per program scan. If the delay is caused by the redundancy controller taking longer to transfer data between the primary and backup units, which specific module in the RPU should be swapped out? It would be helpful if any forum members have experience with common system failures and can offer insight on this matter.
Have you checked if the programmable logic controllers (PLCs) in the same panel are connected to an ethernet switch? It might be worth reseating the connections between the PLCs and the backplane, as well as the input/output (I/O) cards. Dirty connections have been known to cause issues with AB PLCs in the past. This simple troubleshooting step could potentially resolve the issue. Feel free to reach out if you need further assistance. Thank you, James.
Hey there! It sounds like you're dealing with a real dinosaur there. I worked with a GE Series Six system quite awhile ago. Seems like your CPUs might be the issue. Although it's interesting both are experiencing the same problem, so it could also be a network issue. Before going for a full replacement, I'd suggest trying to test the communication modules, these could be causing some instability as well. Given the system is so old, I'll admit locating replacement parts might be a challenge. But before diving into that, consider revisiting your fail-safe and redundancy strategy if this continues to be an issue. Good luck!
Ah, a GE Series Six! Now that's a blast from the past! Sounds like you're dealing with a typical sync/failover issue that's not uncommon with these systems as they age. In my experience, often the source of the problem could be a failing power supply module causing sporadic issues. You might want to look into that first. Also, don't discount the battery just yet; sometimes the battery LED's can mislead. Run a few more checks on them. It's definitely a tough puzzle, but a rewarding one once sorted out. Good luck, buddy!
Hey there, Sherman! While I haven't personally worked on a GE Series Six, your description of the issue reminded me of a similar one I encountered while working with another redundant system of the same era. The CPU dropout was actually caused by intermittent degradation of some onboard components due to age. You might want to think about checking not only key functional modules but also ancillary components that have not been replaced for a long time. Also, remember that failing batteries might still show good condition on the LEDs, so maybe consider testing the batteries under load or just replacing them to rule them out.
Hey there! I can relate to the challenges of working with older GE Series Six systems; they certainly have their quirks. When we had a similar issue, it turned out to be a combination of aging connectors and intermittent contact on the I/O modules. Even if the battery LEDs look good, it might be worth checking for corrosion or loose connections that could affect stability. Also, if you haven’t already, try running a diagnostic on the CPUs. Those old systems can sometimes benefit from a good cleaning and reseating of the components as well. Hope that helps!
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Answer: There could be various reasons for this issue, such as faulty modules, aging components, or power supply problems. It's essential to troubleshoot and identify the specific cause.
Answer: To ensure a smooth transition, it's crucial to have proper synchronization and redundancy setup in place. Additionally, monitoring the system performance and addressing any underlying issues promptly can help maintain a seamless transition.
Answer: Start by checking the modules, power supplies, and connections for any signs of wear or malfunction. It might also be helpful to review the system logs for any error messages or warnings that could provide insights into the root cause of the problem.
Answer: Even in inactive systems, maintaining the batteries is crucial as they can degrade over time. Checking the battery condition regularly and ensuring they are functioning correctly is essential to prevent unexpected failures or issues when the system is put back into operation.
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