Thanks to all for all of your helpful suggestions.
Thanks to Alex for offering to examine my control database. Unfortunately,
his prognosis ("It's fried!") was not what I wanted to hear.
Thanks to Bo for his suggestion of using check_db_sync. I didn't get around
to using it, but I'll have to make a note of checking into it before the
next disaster drill. (And despite Bo's misgiving about automating the
SaveAll job, I'll continue running this weekly job. I just have to do a
better job of raising awareness among our group as to all the things I'm
doing behind the scene. And to just say no!)
Here's how we fix our problem:
I'm fortunate to have the old hard drive for the host AW still sitting
around since the last upgrade. Even though it was at v6.1, it's good enough
for our purpose. I booted it up in an off-line node along with the CP in
question (20CP02). I then did a LoadAll using a good SaveAll from two weeks
back. Then it's just grunt work of comparing the list of blocks in the
compounds between the off-line CP versus the real-life CP. We had to delete
a compound and add a block to another compound to make the off-line CP match
the on-line one.
At that point, I copied all of the files in /opt/fox/ciocfg/20CP02 (workfile
and all the .O files) from the off-line AW to the real-life system, did an
upload and shrink. Then I verified that we now could do a SaveAll. I
further verified that that SaveAll is good by loading it back to the
off-line CP. Everything is hunky-dory without having to initialize and
reboot the CP.
Hope this may be of help to somebody who may end up in the same dire strait
some day.
Regards,
Duc
--
Duc M. Do
Process Control Systems
Dow Corning, Carrollton Plant
Carrollton, KY, US
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