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1. 12 Redundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual 3 User Commanded Role Swap The user commanded role swap feature of the Redundant I O system allows an orderly transition of the active unit to standby status The original standby unit then assumes the active role This feature is accessed via a task code formatted as follows TC 43FE LAR 0310 RCC RBC where LAR two hex digits FO for role swaps on bases on channels 0 and 1 F 2 for role swaps on bases on channels 2 and 3 F 4 for role swaps on bases on channels 4 and 5 F6 for role swaps on bases on channels 6 and 7 RCC single hex digit corresponding to channel number 0 7 RBC single hex digit corresponding to base number 0 F This task code may be transmitted either directly to the Redundant 1 0 system as formatted above or as the body of a native primitive 01 toa SIMATIC TIWAY Host Adapter For example to command base 0 on channel 1 to do a role swap send either the task code 43F EF 0031010 or the TI WAY command 0143F E F 0031010 To command base 15 on channel 7 to conduct a role swap send either the task code 43F EF 603107F or the TIWAY command 0143F EF 603107F SIMATIC TI560 TI565 Redundant I O System User Manual Redundant I O System 13 Customer Registration We would like to know what you think about our user manuals so that we can serve you better How would you rate the guality of our manuals Excellent Good Fair P2. 0003 LISTOF EFFECTIVE PAGES Pages Description Copyright Third Edition History Effective Pages Third Edition 1 13 Third Edition Registration Third Edition Pages Description Redundant I O System 1 Overview Communication between Units 6 cc cece eee ene Planning Redundant I O Installation Determining Signal Losses 2 Hardware Components eee raa a a n n n n Software Requirements Status WOTUS cede Ree ias Hed FCR Gators CURE FOROR ROGER racc Remote Base Controller LED Display rm een poke cie EE ak ie gs Setting the RBC Number PowerSupply eicere neta reci a ttc ide Fa ai Parts I O Base and 15 RBC and Power Supply Installation and Removal User Supplied Materials Con oo ITuoITuo 2 3 User Commanded Role Swap nnn 13 Es S rte re ea rez en fa List of Figures Redundant I O System Diagram ieas adena nnn Dual Tap Splitter Arrangement foreach I O Channel Remote Base Controller ccc ccc cece mmm Dimensions for PPX 500 9940 Adapter Chassis Power Connections List of Tables 1 Dual Tap Loses dB usssssseseeeee Hs 2 Status iss dida ec nao eee chine eie debo Fea dede Pul ae d 3 LEDMessages SIMATIC TI560 TI565 Redundant I O System User Manual Redundant I O System 1 O
3. the presence of Redundant I O components Status Words 168 175 indicate whether or not dual RBCs are present status words 176 183 indicate the presence of dual power supplies Table 2 lists the status words and shows the channel and base indicated by each word If a 1 appears in a bit showing the status of a base containing dual RBCs check the corresponding bit for that base in status words 2 9 to determine if the other RBC is still functioning SIMATIC TI560 TIb 5 Redundant I O System User Manual Redundant I O System 5 Hardware Components continued Table 2 Status Words Status Words Indicating Dual RBCs Status Words Indicating Dual Power Supplies Word Channel i Channel 1 15 1 15 173 16 6 181 16 6 1 15 1 15 174 16 0 7 182 16 7 Bit 0 Dual RBCs present and good Bit 1 Error condition or single RBC Bit 20 Dual power supply present and good Bit 1 Error condition or single power supply MSB TI560 TI565 BIT ORDER LSB 123456728 910 11 12 13 14 15 16 Remote Base Controller Each RBC Figure 3 in the Redundant I O system is an intelligent interface between an RCC and a remote base containing either 8 or 16 1 0 slots The dual RBCs are installed in an adapter chassis connected to the 1 0 base which can be located up to 15 000 feet from the PLC If both RBCs are installed and operational at power up the RBC on the right assumes the active role 6 Re
4. PX 500 9940 Adapter Chassis Redundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual RBC and Power Supply Installation and Removal N WARNING NWARNING NWARNING Toinstall the Redundant 1 components When you install Redundant I O components or when you need to replace a unit ensure that the installation location is non hazardous i e before you insert or remove an RBC or power supply be certain that flammable gases are not present In order to prevent disruption of the I O channel disconnect the coaxial cable before removing or installing an RBC 1 Plugan RBC into each of the two connectors at the right side of the adapter chassis and tighten the top and bottom screws on each unit The RBC in the right slot assumes the active role when the base is powered up 2 Connect a coaxial cable to the top of each RBC Before removing or installing a power supply disconnect the AC power to the slot for that power supply 3 Plug the power supplies into the two slots on the left side of the adapter chassis Be certain the module is fully seated and that the tabs at the top and bottom have snapped into place 4 After the power supply is inserted attach the AC and ground wires as shown in Figure 5 To reduce the probability of failure power to each module should come from different sources with the commons at the same potential Use the voltage selector on the PPX 500 2151A to set the input power for e
5. SIEMENS SIMATIC TI560 TI565 Redundant I O System User Manual Order Number PPX 560 565 8 108 3 Manual Assembly Number 2597773 0030 Third Edition Copyright 1993 by Siemens Industrial Automation Inc All Rights Reserved Printed in USA Reproduction transmission or use of this document or contents is not permitted without express consent of Siemens Industrial Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Industrial Automation Inc does not possess full access to data concerning all of the uses and applications of customer s products we do not assume responsibility either for customer product design or for any infringements of patents or rights of others which may result from our assistance Technical data is subject to change We check the contents of every manual for accuracy at the time it is approved for printing however there may be undetected errors Any errors found will be corrected in subsequent editions Any suggestions for improvement are welcomed MANUAL PUBLICATION HISTORY SIMATIC 1560 1565 Redundant I O System User Manual OrderManual Number PPX 560 565 8108 3 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 09 88 Original Issue 2601358 0001 Second Issue 02 89 Second Edition 2601358 0002 Third Issue 1 94 Third Edition 2601358
6. delete it from PLC memory the LED display does not change LED display 7 until a restart or power cycle is performed Toreset an RBC with a 1 displayed move the base address thumbwheel switch to another address for 0 5 seconds then return the switch tothe correct address The RBC will attempt to come on line Thetop thumbwheel switch on the face of each RBC allows you to select the number 0 15 on the channel numbers must not be duplicated on another base however the active and standby RBCs on the redundant base must have the same number Redundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual Power Supply I O Base and Adapter Chassis The Redundant I O system uses two PPX 500 2151A 110 220 VAC power supplies that are installed in the adapter chassis along with the RBCs During normal operation both power supplies are active These units convert user supplied power either 110 or 220 VAC to DC power Each power supply module is protected from internal short circuits by a3 A 250 VAC slow blow fuse The internal circuitry maintains two DC voltages at 5 V and 5 V On each module the indicator labeled DC GOOD is on when the moduleis producing the correct DC power The indicator is off when overvoltage undervoltage or overcurrent faults are detected NOTE To allow replacement of a unit without taking down the entire base AC power to each power supply must come from separate source
7. dundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual 500 9912 STATUS REMOTE BASE CONTROLLER RBC GOOD SELF DIAG FAILURE MODULE MISMATCH 1 0 COMM TIME OUT RAM PARITY ERROR STDBY NO CONF ADDR MISMATCH COMM OK NO CONF WATCHDOG TIMEOUT STANDBY CONF WARNING INSURE INSTALLATION LOCATION IS NON HAZARDOUS PRIOR TO INSERTION WITHDRAWAL OF THIS DEVICE AVERTISSEMENT AVANT D INSERER OU DE RETIRER CE DISPOSITIF S ASSURER QUE L EMPLACEMENT DANS LEQUEL LE MATERIEL EST INSTALLE EST NON DANGEREUX WARNING DISCONNECT RF COAXIAL CABLE PRIOR TO INSERTION WITHDRAWAL OF THIS DEVICE Figure 3 Remote Base Contoller SIMATIC TI560 TIb 5 Redundant I O System User Manual Redundant I O System 7 Hardware Components continued LED Display Setting the RBC Number TheLED at the top of each RBC displays a number to indicate RBC status or errors The messages conveyed by the numbers are shown in Table 3 Table LED Messages Number 7 Meaning 0 RBC good configuration match 1 Self diagnostics failure Module mismatch Communications time out RAM parity error Standby unit not configured Standby good wrong address Communications good but no I O configured Watchdog time out om L Standby unit configured NOTE If an is configured in the PLC LED display 0 and you
8. ither 110 or 220 VAC See the PPX 500 2151 and PPX 500 2151A 110 220 VAC Power Supply Installation Manual for details on setting input voltage SIMATIC TI560 TI565 Redundant I O System User Manual Redundant I O System 11 Hardware Components continued AC Hot AC Hot Chassis GND Chassis GND AC Common AC Common oooolool 000000 W O Base Power Supply Power Supply um M Figure 5 Power Connections User Supplied To install the Redundant I O system you need the following additional Materials materials e grounding blocks or bulkhead coaxial connectors to install at each RCC and RBC to shunt noise on the coaxial cable shield to ground e Semi rigid coaxial cable two sizes to use for trunk line s and for drop lines e CATV tapstoinsert in the trunk distribution cable to provide drops from the active and standby PLCs tothe RBCs e Taps and splitters to distribute the signal from the active RCC to the standby RCC Trunk A and Trunk B e Taps and splitters to distribute the signal from the active RBC either Trunk A or B tothe standby RCC and the active RCC e Semi rigid coaxial cable fittings to connect trunk distribution cable to tap housing e F typeconnectors to connect drop cable to tap housing e Terminators to install on all unused terminals on a multi drop tap
9. ns detailed instructions for installing remote I O and for developing power budget The SIMATIC TI560 565 Hot Backup Installation Manual PPX 560 565 8103 x provides details about the additional signal losses with the Hot Backup Unit Consult these manuals for installing the overall O system The installation of the Redundant I O system requires dual cables and a dual tap splitter arrangement as shown in Figure 2 In developing the power budget you must include the dual tap and splitter losses Table 1 lists typical losses obtained when using taps and splitters with the values shown SIMATIC TI560 TI565 Redundant I O System User Manual Redundant I O System 3 Overview continued To To active Standby 560 565 560 565 gt SL SL gt gt IL Insertion Loss Y Y TL Tap Loss Trunk A Trunk B L Splitter L 3 pier Lass Recommended tap values 7 0 dB insertion loss of 2 7 dB Figure 2 Dual Tap Splitter Avangement foreach I O Channel Table 1 Dual Tap Losses dB Active to standby 14 0 dB Active to trunk A 6 2 dB Active to trunk B 10 5 dB Standby totrunk A 10 5 dB Standby totrunk B 6 2 dB These losses are based on the following assumed values Tap loss 7 0 dB Tap insertion loss 2 7 dB Splitter loss 35 dB Thetap losses shown in Table 1 were obtained in the following manne
10. oor Accuracy Organization Clarity Completeness Overall design Size Index Would you be interested in giving us more detailed comments about our manuals Yes Please send me a guestionnaire No Thanks anyway Your Name Title Telephone Number Company Name Company Address Manual Name SIMATIC TI560 TI565 Redundant I O System User Manual Edition Third Manual Assembly Number 2597773 0030 Date 1 94 Order Number PPX 560 565 8108 3 FOLD NO POSIAGE NEC ESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST C LASS PERMITNO 3 JOHNSON CMY TN POSIAGE WILL BE PAID BY ADDRESSEE ATTN Technical Communications M S 3519 SIEMENS INDUSTRIAL AUTOMATION INC 3000 BILL GARLAND RD P O BOX 1255 JOHNSON CITY TN 37605 1255 FOLD SIMATIC is a trademark of Siemens AG TIWAY is a trademark of Siemens Industrial Automation Inc T1560 TI565 TI560T TI565T and TI500 are trademarks of Texas Instruments Incorporated
11. r See Figure 2 for location of the different losses For example loss for Active to Standby is the sum of the two tap losses 7 0 7 0 214 0 Active to Trunk A loss is the sum of the insertion loss and the splitter loss 2 7 3 5 6 2 Active to Trunk B loss is the sum of the tap loss and the splitter loss 7 0 3 5 10 5 4 Redundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual 2 Hardware Components NWARNING Software Requirements Status Words The remote I O for the Redundant I O system consists of a Hot Backup installation plus the following components for each redundant I O base Do not use either the PPX 500 2151 power supply or non dual RBCs with a PPX 500 9940 adapter chassis in a redundant I O configuration To do so may cause improper operation of your system e TwoPPX 500 9912 Remote Base Controllers RBCs e TwoPPX 500 2151A 110 220 VAC Power Supplies e PPX 500 5864 8 Slot Base or PP X 500 5828 16 Slot Base e 500 9940 Redundant Controller Adapter Chassis e User supplied cables grounding materials and taps The CPU SFCPU software must be Rel 2 1 or greater With earlier software releases a redundant I O base with dual RBCs causes the RCC tofail that base Either the dual RBC or dual Power Supply may be used in single mode operation with any RCC software releases Non dual RBCs may be used with any RCC Rel 2 1 includes additional status words to indicate
12. s with the commons at the same potential and you must provide a means of disconnecting AC power from each power supply To install the dual RBCs and power supplies use either the PPX 500 5864 8 Slot Base or the PPX 500 5828 16 Slot Base with the PPX 500 9940 Redundant Controller Adapter Chassis The adapter chassis attaches to the right side of the I O base and provides slots for the two power supplies and the two RBCs In planning the installation of the 1 bases for the Redundant I O system follow the guidelines in the manual that comes with the bases To mount the PPX 500 9940 Adapter Chassis see Figure 4 for template dimensions and follow these steps 1 When preparing the mounting panel be certain the base and adapter are positioned for proper contact of the connectors 2 Partially insert the two top screws in the panel 3 Fit the screws into the holes in the adapter base see Figure 4 Slide the assembly down and to the left until the screws support the adapter chassis and the base connectors are fully seated 4 Attach the lower portion of the assembly to the panel with two 10 Screws 5 Tighten all screws SIMATIC TI560 TI565 Redundant I O System User Manual Redundant I O System 9 Hardware Components continued 10 lt 800N 20 34 CM 3 29 IN 8 37 CM 2PL 1 85 IN 244CM 14 20 IN 86 00 CM Figure 4 Dimensions for the P
13. transmits the dual tap and splitter arrangement splits the signal three ways to the standby RCC to Trunk A and to Trunk B When the active RBC transmits the dual tap and splitter arrangement splits the transmitted signal from either Trunk A or Trunk B two ways tothe standby RCC and tothe active RCC Each redundant RCC RBC or power supply can detect internal operating faults During normal operation the RCC detects trunk faults and recognizes the appearance or disappearance of redundant RBCs and power supplies When a fault is detected in the unit designated as active the corresponding backup unit automatically assumes control with minimal process interruption and without operator intervention All input output and SF message transactions occur between the active RCC and the active RBC The active RCC directs configuration messages to both the active and standby RBCs and the addressed RBC is responsible for acknowledging the message A status request command goes to the active RBC to determine dual power supply status and to the standby RBC to determine the condition of the standby transmitters If the standby does not respond to this request the RCC directs the active RBC to command the standby to assume a failed state When communication problems develop between the RCC and the active RBC the RCC directs a role swap command to the standby RBC The SIMATIC TI560T TI565T System Manual PPX 560 565 8109 contai
14. verview Redundant I O provide for an enhanced Hot Backup Unit HBU configuration that extends the redundant hardware capabilities The Redundant I O system illustrated in Figure 1 consists of the following elements e TwoSIMATIC TI560 v TI 5657 controllers in an configuration e Onetoeight channels of SIMATIC TI500W remote I O e Dual remote base controllers RBCs e Dual cables e Dual base power supplies The Redundant 1 0 system uses the TI 560 T1 565 controller hardware unchanged and provides the same major functions as the standard system It supports memory configuration I O configuration TI 500 operational modes I O cycles Relay Ladder Logic execution SF communication and operator interfaces TI560 TI565 TI560 TI565 R R C Channel 1 C Channel 1 C Channel2 C Channel2 Dual Tap and Splitter Trunk A Trunk B To other taps 2 To other taps Tap Tap Power Supply Figure 1 Redundant I O System Diagram Redundant I O System SIMATIC TI560 TI565 Redundant I O System User Manual Communication between Units Planning Redundant I O Installation Determining Signal Losses Standard CATV taps and splitters combine I O channels from the remote channel controllers RCCs to form two separate trunks redundant I O Each trunk leads to one of two RBCs located in an adapter chassis that also houses two power supplies When the active RCC
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