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DeltaV MD+ controller all LED glows Stable

Hello All, we have DeltaV 10.3 version system. Recently Right-hand side controller ,all LES's are glowing stable (no blinking) I suspect It's backplane is faulty. How to replace the backplane. Also can I test the controller by removing the active controller (by shutting down the plant) . By powering off the system do I need to set IP address of active controller to secondary Controller while testing in said way. Pl. Help

• controller
• DeltaV #DCS

ghatevinod

• 12 Jan 2022 1:57 PM
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4 Replies

• Andre Dicaire

  

  • 12 Jan 2022 11:28 PM

  The Backplane is likely the last thing I would suspect. Hard to imagine how.
  
  First is check diagnostics to confirm that the standby controller is not available, not communicating. Assuming this is the case and it is dead in some unknown state, I would start with some basic actions first:
  
  If you have no spares, and you have no way of testing the hardware on a different back plane, then do nothing until you do. Taking a shutdown to trouble shoot something you cannot repair is not a good action to take. Make arrangements with local service provider to get spare controller, power supply and backplane. Likely the issue is with Power supply or Controller and you will not need to shutdown as these can be replaced on line.
  
  If you do have spares, try the following:
  
  1. Cycle Power on this controller. Observe controller LED's cycle through the initialization. Does this change anything? LED's go through expected initialization sequence? or they just light up as before?
  
  2. Replace the Power Supply on this two wide. It provides power to the controller and is most likely component to fail. Wait to see if controller goes commissioned. Normally it should. If same LED status, could be controller.
  
  3. Replace the controller. Again, wait for controller to go commissioned. It should.
  
  If this does not fix it, then Either the back plane is bad or the controller is BAD and it damaged the second Power supply, causing the same fault to be created in the second controller... Logically looks impossible.
  
  To replace the 2-wide, you will have to disconnect the left hand carrier and that will shutdown the controller. IO cards with injected power will send outputs to fail state value (hold last value or defined value in configuration). If you don't have the hardware on hand to repair, wait until you do.
  
  If there is room to the left of the existing two wide carriers to install a new third 2 wide, you can install this, remove the standby controller on the right hand carrier. Install power supply and controller to the left of the active. If the power supply and controller work on a new carrier but not the right hand one, then it must be the carrier.
  
  I'm betting its the Power Supply.

  Andre Dicaire

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• Stefan Muellner

  

  • 13 Jan 2022 7:34 AM

  In reply to Andre Dicaire:

  Good morning.
  
  What I hadn´t known is that it is possible to install a third 2-wide-carrier left-handed to the two existing carriers of a redundat controller pair? So if we imagine that in this case the right-hand carrier is defect and a shutdown wouldn´t be possible, could we leave this 3x 2-wide-carrier installation (power supply and controller only plugged onto the left and the middle carrier) for - lets say - the next 2 years without loosing redundancy features?
  
  
  just for information: 2021 we installed approx. 15 new redundant PK-Controllers and 2 of their controller carriers had damaged right slots - so unfortunately, for me, the unlikeliness of a carrier failure is not that low

  Stefan Müllner
  Senior Plant Engineer - Automation & Systems

  METADYNEA AUSTRIA GmbH
  

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• Andre Dicaire

  

  • 13 Jan 2022 4:47 PM

  In reply to Stefan Muellner:

  Stefan, Yes. As long as the two carriers with controllers are adjacent to each other, they will see each other via the redundancy link. The third Carrier passes through the IO selection and communications bus.
  
  Traditionally, users install VIMs on 2 wide carriers installed to the left of the controllers, so seeing a 2 wide carrier on the right of the controllers is not common. However, the VIM can be located on either side. In fact, with the PK controller released in v14, the controller carrier must be placed to the left of VIMs as the PK Carrier has no LocalBus connector on its left side.
  
  As for our carrier failure, I would distinguish between a damaged carrier that fails on initial startup versus a Carrier that fails under normal operation. Damage to connectors or violent shock in transport or handling could cause a failure on startup. The likelihood of failure of a passive component like a carrier is very unlikely. It is important to determine the root cause of the failure: Bad solder, damaged connector, physical damage, faulty assembly? In this case, the system had been running for years. That puts the carrier at the bottom of my list of likely causes.

  Andre Dicaire

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• LaurentB

  

  • 13 Jan 2022 5:05 PM

  In reply to Andre Dicaire:

  Bookonline section system installation will show you what André explained
  I also agree the André"s point a view regarding carrier failure
  I work with DeltaV sine 20years over thousand systems including DV in severe environnement and I only see 2 carriers failures on normal operation . These 2 failures causes was extrem corrosive atmospher which dammage printed circuit.
  Carriers have no active electronic components that the reason why the failure rate is extremely low. Of course pin connector can be dammage is carriers are installed whithout care

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