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WinCC 6.0 - sudden project shutdown

Created by: laki78_pl at: 3/25/2009 9:00 AM (10 Replies)

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3/25/2009 9:00 AM	Rate (0)
laki78_pl Posts: 9 Rating: (0)	hello, I have redundant system based on WinCC 6.0.1.0 Hotfix 1. 2 servers, and the problem is only when 1 of this servers is the primary. After couple hours of working the project suddenly stops, messege screen appears: "An error has occurred. Please close all PCS 7 applications, if you cannot click on 'restart' " and the secound server becomes the primary. After restart the first server it works normally - but now as secoundary. In "CCRtsLoader.log" file I have messages like: //==================================================================== // WinCC reported exception with code: C0000005 ACCESS_VIOLATION // Date: 3.3.2009 - Time: 12.39.6 // Caused at logical address 6E0138A4 01:000228A4 //==================================================================== // WinCC reported exception with code: C0000005 ACCESS_VIOLATION // Date: 23.3.2009 - Time: 12.50.26 // Caused at logical address 6E0138A4 01:000228A4 //==================================================================== // WinCC reported exception with code: C0000005 ACCESS_VIOLATION // Date: 24.3.2009 - Time: 4.53.41 // Caused at logical address 6E0138A4 01:000228A4 //==================================================================== // WinCC reported exception with code: C0000005 ACCESS_VIOLATION // Date: 24.3.2009 - Time: 23.6.37 // Caused at logical address 6E0138A4 01:000228A4 //==================================================================== // FAULTING MODULE: c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb //==================================================================== // Registers: // ---------- // EAX:020F2FFC // EBX:0210EC88 // ECX:00000000 // EDX:0216266C // ESI:0210EC88 // EDI:00C70178 // CS:EIP:001B:6E0138A4 // SS:ESP:0023:0307FC94 EBP:0307FC98 // DS:0023 ES:0023 FS:0038 GS:0000 // Flags:00010206 // // Call stack: // ----------- // Address \| Frame \| // ---------+----------+---------------------------------------------- // 6E0138A4 \| 0307FC98 \| 0001:000228A4 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb // 6E00EEE8 \| 0307FCD8 \| 0001:0001DEE8 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb // 6DFF7DA9 \| 0307FD34 \| 0001:00006DA9 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb // 6DFF5177 \| 0307FD5C \| 0001:00004177 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb // 6E00CD5C \| 0307FD8C \| 0001:0001BD5C c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chb // 01F41CCC \| 0307FDB8 \| 0001:00000CCC c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chn // 01F42581 \| 0307FE08 \| 0001:00001581 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chn // 01F44929 \| 0307FE44 \| 0001:00003929 c:\SIEMENS\WINCC\bin\SIMATIC S5 ETHERNET LAYER 4.chn // 10087DC1 \| 0307FE70 \| 0001:00086DC1 c:\SIEMENS\WINCC\bin\CCDmRtServer.DLL // 1008936C \| 0307FE9C \| 0001:0008836C c:\SIEMENS\WINCC\bin\CCDmRtServer.DLL // 1008A933 \| 0307FEF8 \| 0001:00089933 c:\SIEMENS\WINCC\bin\CCDmRtServer.DLL // 100A5218 \| 0307FF14 \| 0001:000A4218 c:\SIEMENS\WINCC\bin\CCDmRtServer.DLL // 100A4F3A \| 0307FF7C \| 0001:000A3F3A c:\SIEMENS\WINCC\bin\CCDmRtServer.DLL // 780085BC \| 0307FFB4 \| endthreadex+BC // 7934987C \| 0307FFEC \| SetThreadExecutionState+227 //==================================================================== In Windows "Application event viewer" there is message from "RedundancyControl" source : Error WM_HEALTHCHECK : ReturnCode 80004005 call C2_HEALTHCHECK in CCRtsLoader110241140 causes failover Could you please help me solve this problem?? laki78_pl
laki78_pl Posts: 9 Rating: (0)
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3/25/2009 5:56 PM	Rate (0)
Phantom75 Posts: 2661 Rating: (279)	Was the system working properly before and the problem started suddenly? Are you communicating with S5 controllers?
Phantom75 Posts: 2661 Rating: (279)	Last edited by: Phantom75 at: 3/26/2009 8:03 PM
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3/26/2009 8:05 AM	Rate (0)
laki78_pl Posts: 9 Rating: (0)	The system has worked normally without any problem for 2-3 years, we could almost forget about it ;) The system communicates with 68 S5 controlers. But as you can see it the log file, the problem appeared for the first time on 3rd march.
laki78_pl Posts: 9 Rating: (0)	Last edited by: laki78_pl at: 3/26/2009 8:07 AM Last edited by: laki78_pl at: 3/26/2009 8:06 AM
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3/26/2009 8:09 PM	Rate (0)
Phantom75 Posts: 2661 Rating: (279)	Obviously there is a problem with your first server. Did somebody install/modify something? Are the network cards working properly? Normally in this kind of situation you should restore original image (or reinstall), but may be you can try the Siemens Support if they have a better idea... Regards PS: Was there a sudden powerloss?
Phantom75 Posts: 2661 Rating: (279)	Last edited by: Phantom75 at: 3/26/2009 8:10 PM Added PS
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3/27/2009 7:34 AM	Rate (0)
laki78_pl Posts: 9 Rating: (0)	There was no new application installation, no modyfications and no sudden power loss
laki78_pl Posts: 9 Rating: (0)
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3/27/2009 8:58 PM	Rate (0)
Phantom75 Posts: 2661 Rating: (279)	May be there is a problem with the memory (hard disk or RAM)? I would try to restore working image or perform a fresh reinstall...
Phantom75 Posts: 2661 Rating: (279)
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3/28/2009 6:13 PM	Rate (0)
laki78_pl Posts: 9 Rating: (0)	I tried to ping primary server from backup server for a longer time. There was 300.000 packets send by ping and 120 was lost. I wander if WinCC because of this packet lost can raise an error??
laki78_pl Posts: 9 Rating: (0)
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3/28/2009 8:44 PM	Rate (0)
Phantom75 Posts: 2661 Rating: (279)	Yes, this means there are problems in communication. Check the network adapters are functioning properly in DeviceManager(right-click MyComputer/Manage). Can you describe your network? That is, do you have Plant Bus and Terminal Bus or only a common network?
Phantom75 Posts: 2661 Rating: (279)
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3/30/2009 7:44 AM	Rate (0)
Nerli Posts: 21 Rating: (1)	it seems to be the common problem. here you can find good description what is it and how to catch. ...the operating system telling you that a program has malfunctioned and tried to reference to memory address not existed... it could be broken .CHB file. compare it with the other pc one. it could be some autoupdates of OS installed it could be antivirus when I get into such a "memory problem" I take my vacuum cleaner and clean the dust in PC memory & CPU slots. just as idea - if both pc are similar, you can change hdd and examine for error. then you will understand where the problem is - in HW or Sw. Tima
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This contribution was helpful to 1 thankful Users Phantom75

5/5/2009 9:07 AM	Rate (0)
laki78_pl Posts: 9 Rating: (0)	After 2 weeks of the first problem with WinCC my server reported me problems with RAID controler - baterry cache backup failed and cache wasn't functioning. After removing baterry to a new one I made this server primary and he have worked for 2 weeks without any problem. Now WinCC hangs, the secoundary server doesn't take the role of primary when he is hanged, client computers and backup server can see the hanged server as a primary and only suspicion information I have - is in the diagonos\simatic_s5_ethernet_layer log: Channel PES/API error - no more job numbers available. Max count of PES/API errors reached - logbook deactivated Anybody has an idea??
laki78_pl Posts: 9 Rating: (0)
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