Recently i faced sudden boot failure, which made controller stuck in a boot loop.
Though problem seem to be resolved somehow, i'd like to better understand what happened and how to prevent it in the future.
Robot is KR240-2
Controller:
KRC2 ed 05 (XP SP3)
KSS 5.6.9
4*256 Mb RAM
2700 hours online time
Safe Robot
Problem happened after booting from hibernation - after about 10 seconds online, everything got lagging and system freezed, HMI was "rescanning for disks" or something along the lines. Though no BSOD, system got totally unresponsive.
After rebooting it using manual switch on the controller, it started crashing on splash screen at 10% (at least 7 consecutive attempts).
What didn't help:
- reinstalling KSS
- booting with various combinations of RAM installed (one module, three, in different slots, etc)
- checking HDD for errors (chkdsk /f /r didn't show any errors)
- there were no VxWorks.freeze file
- Windows Event Log revealed no new errors on each attempted startup
What worked:
- removing "Start KCP" from Autostart
- manually going through "StartKRC.exe.config" sequence, with, large delays, between starting each program
When HMI first booted as above, there was additional error "Short-circuit braking requested RDC1".
Nothing was running before hibernation except Submit Interpreter where i was testing every 250 msec, CREAD and CWRITE on COM3 port, with Rx and Tx pins connected by wire.
32V 10A battery backup fuse seem to fail between hibernation and attempted boot up. Though replacing it didn't change a thing, same crash at 10%.
Now, after starting HMI once, controller works perfectly, no errors.
What could have caused such behavior?