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Quantum Hot Standby - Guillevin Industrial Automation Group

1. INIT command HALT INITIALIZING E OFFLINE STOP RUN STOP transition lt gt ee OFFLINE Y STOP RUN transition RUN OFFLINE RUN Switchover RUN PRIMARY STANDBY NOTE e APLC that is in the Run Offline mode cannot go directly to Run Primary Mode e APLC that is in the Run Primary mode cannot go directly to Run Standby Mode 35010533 07 2011 125 Programming and Debugging Automatic Start in Run Option At a cold start with the Automatic Start in Run option configured a PLC restarts depending on the operating mode of the other PLC this PLC s operability and on whether identical applications are present on both PLCs If Then The other PLC is Primary the two The PLC restarts in Standby mode applications are identical and this PLC is operating normally The other PLC is Primary and the two The PLC restarts in Offline mode applications are not identical or this PLC is not operating normally There is no Primary and this PLC is operating The PLC restarts in Primary mode normally There is no Primary but this PLC is not The PLC restarts in Offline mode operating normally A local abnormal or inoperative operating state will be reported when e There is a loss of power to the CPU rack e An application program error that generates a HALT state for e
2. 0 00000 eee eee Operating Modes of the Safety PLC 00 0c eee eee Configuring and Maintaining a Quantum Hot Standby System 222 c eee Configuring with Unity Pro 00 eee eens Unity Pro Tabs and Dialogs 0 e eee eee ees Introducing Unity Pro 1 1 ee eee Using the Summary Tab 0 0 c eect eee Using the Overview Tab 00 cc eee tte Using the Configuration Tab 0 0 0 cece ee Using the Modbus Port Tab 0 c ee eee eee Using the Animation Tab and PLC Screen Dialogs 35010533 07 2011 2 2 2 3 Chapter 3 3 1 3 2 3 3 Chapter 4 41 4 2 4 3 Using the Hot Standby Tab 0 0 cece eee 78 Configuring the PCMCIA Cards 1 0 0 0 cee eee eee 80 Configuring the Modbus Plus Communication Type 81 Non Transfer Area and Reverse Transfer Words 82 Setting Up the Quantum Hot Standby System 05 83 Reading and Configuring Registers 00 eee eee eee 85 Hot Standby Command Register 0 0c cee eee eee 86 Hot Standby Status Register 0 0 0 c eee 90 Hot Standby Firmware Mismatch Register 20005 93 Using Initialized Data 2 ee 94 Synchronizing System Timers 2 0 0 0 cee eee 95 NOE Modules sbi a Sea ene ely Al Ae aie 96 Quantum Hot Standby and 140 NOE 771 1 Modules 97 NOE Operating Mo
3. NOTE The dialogs illustrated here are depicted in offline mode When Unity Pro is connected to a PLC the information displayed in these tabs changes Viewing the Task Tab Unity Pro Task tab dialog PLC Screen A tate Activate or Ee Disable all Number a Stop OY Start reStart Output Fallback Warm restart Applied Outputs Output Fallback Cold start NOTE Click to see the PLC screen in online mode and the corresponding description see Unity Pro Operating Modes 74 35010533 07 2011 Configuration Describing the Task Tab Description of the Task tab Thursday 25 September 2003 Update pI PC gt PLC Item Option Value Description Events State XXX Status information of events available Online Number XXX N A Activate or Disable all Click button Button to control the events Start reStart Warm Start Click button To initialize Warm Start Cold Start Click button To initialize Cold Start Output fallback Applied Outputs N A Not used in Modicon Output Fallback N A Quantum Hot Standby with Unity system Last Stop Read only e Day Indicates the day date e DD MM YY time and cause of the last e Time controller stop Viewing the Realtime Clock Tab Unity Pro Realtime clock tab dialog i PLCScreen Be Q Task Realtime clock information PLC Date and Time Use
4. 1 Operating System update in the Standby PLC is possible with the primary CPU PLC still running 0 2 After Operating System Update the Standby CPU PLC changes back to the ONLINE mode SWP_MB1 BOOL If a switchover has occurred for Modbus ports 1 1 There is no swapping of addresses 0 There is swapping of address SWP_MB2 BOOL Not used Reserved SWP_MB3 BOOL Not used Reserved 35010533 07 2011 143 Programming and Debugging HSBY_ST Function Description This EFB allows you to use the Hot Standby function It searches together with the other Hot Standby EFBs the configuration of the respective Quantum PLC for the required components These components refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed This EFB is used to read the IEC Hot Standby status register SSW61 see Unity Pro Program Languages and Structure Reference Manual Ifthere is no Hot Standby configuration present the HSByY output is set to O EN and ENO can be configured as additional parameters Representation in FBD Representation HSBY_ST_Instance HSBY_ST HSBY HSBY_ConfigurationFound THIS_OFF PLC_Offline THIS PRY Primary_PLC THIS SBY Standby_PLC REMT_OFF Remote_PLC_Offline REMT PRY PrimaryRemote_PLC REMT SBY StandbyRemote_PLC LOGIC_OK IdenticalProgra
5. 10 1 o RTU RS2s NOTE If you need the Modbus address of the controller go to the 140 CPU 671 60 module and find the address using the keypad see page 225 Configuring Modbus Plus MB Addresses When configuring the MB address for the first time e Default MB address 1 140 CPU 671 60 60S e Change MB address at first configuration on both controllers see page 62 A WARNING UNINTENDED EQUIPMENT OPERATION Do not change the Modbus Plus MB address after the first configuration Failure to follow these instructions can result in death serious injury or equipment damage 72 35010533 07 2011 Configuration Describing Modbus Port tab Item Option Value Description Modbus Port Baud 9600 Data must be specified for 50 19200 kBit s every Iink Data Bits 8 Stop Bits 1or2 Parity EVEN ODD NONE Delay ms 10 ms Address 1 247 For Modbus switchover 1 119 Primary CPU 129 247 Standby CPU Head Slot 0 Mode RTU ASCII Protocol RS232 RS485 35010533 07 2011 73 Configuration Using the Animation Tab and PLC Screen Dialogs Accessing the PLC Screen Dialogs To access the Task Realtime clock and Information tabs of the Unity Pro Animation tab Step Action 1 Select the Animation tab 2 The PLC screen tab appears automatically
6. Hot Standby Safety CPU Specifics Introduction The 140 CPU 671 60S Quantum Safety CPU module is certified for use in Hot Standby SIL3 solutions compliant with the 61508 IEC standard For more details about to the safety certifications see the Quantum Safety PLC see Modicon Quantum Quantum Safety PLC Safety Reference Manual In the Standalone Safety CPU the Ethernet port is used to communicate with other devices using a normal Ethernet cable In the Hot Standby Safety CPU the connection used to exchange data between the Primary CPU and the Standby CPU controller is a fiber optic link Because the fiber optic link is not part of the Safety loop the PFD and PFH values of the Hot Standby CPU are the same as those of the Standalone CPU Each Safety CPU can include a PCMCIA memory card see Modicon Quantum Quantum Safety PLC Safety Reference Manual but its use and presence is not mandatory NOTE This CPU cannot be used in a Quantum Ethernet I O Hot Standby system Description of a Safety Hot Standby Configuration The Hot Standby configuration contains two identical local racks and at least one remote I O drop because I Os cannot be placed in the local rack of a Safety Hot Standby configuration Besides a power supply module there must be at least one 140 CPS 124 20 each local rack must contain e 140 CPU 671 60S module e 140 CRP 932 00 module Besides a power supply I O modules including at least one 140 CPS 124 20
7. In EtherNet IP a device is considered the originator when it initiates a CIP connection for implicit or explicit messaging communications or when it initiates a message request for un connected explicit messaging 35010533 07 2011 249 Glossary OS Loader PLC port 502 port mirroring QoS Firmware upgrade tool for Quantum hardware P programmable logic controller The PLC is the brain of an industrial manufacturing process It automates a process as opposed to relay control systems PLCs are computers suited to survive the harsh conditions of the industrial environment Port 502 of the TCP IP stack is the well known port that is reserved for Modbus communications In this mode data traffic that is related to the source port on a network switch is copied to another destination port This allows a connected management tool to monitor and analyze the traffic NOTE In port mirroring mode the SERVICE port acts like a read only port That is you cannot access devices ping connection to Unity Pro etc through the SERVICE port on the 140 CRP 312 00 and 140 CRA 312 00 Q quality of service The practice of assigning different priorities to traffic types for the purpose of regulating data flow on the network In an industrial network QoS is used to provide a predictable level of network performance Quantum Ethernet I O device These devices in Quantum Ethernet I O systems provide automatic network recov
8. You should possess a working knowledge of the Unity Pro software It is helpful if you are familiar with Ethernet networks This document is valid from Unity Pro 6 0 35010533 07 2011 Related Documents Title of Documentation Reference Number Quantum Ethernet I O Ethernet Remote I O Modules Installation and Configuration Guide S1A48978 English S1A48981 French S1A48982 German 1A48983 Italian 1A48984 Spanish S1A48985 Chinese Quantum Ethernet I O Global System Planning Guide S1A48959 English 1A4896 French S1A48962 German 1A48964 Italian S1A48965 Spanish S1A48966 Chinese Modicon Quantum Change Configuration on the Fly User Guide S1A48967 English S1A48968 French S1A48969 German 1A48970 Italian 1A48972 Spanish S1A48976 Chinese Unity Pro Program Languages and Structure Reference Manual 35006144 English 35006145 French 35006146 German 35006147 Spanish 35013361 Italian 35013362 Chinese Unity Pro Operating Modes 33003101 English 33003102 French 33003103 German 33003104 Spanish 33003696 Italian 33003697 Chinese om ee eS 10 35010533 07 2011 Quantum with Unity Pro Hardware Reference Manual 35010529 English 35010530 French 35010531 German 35010532 Spanish 35013975 Italian 35012184 Chinese Unity Pro Installation Manual 35014792
9. The following figure shows the basic one bus architecture of an S908 Quantum Hot Standby system 10 4A 1A 2A 3A 4B 1B 2B 3B P S _CPU_ CRP P S _CPU_ CRP 12 P S CRA 1 0 VO VO 12 P S CRA I O I O 1 0 U 1A 2A CPU and Copro of Primary controller 1B 2B CPU and Copro of Standby controller 3A 3B Quantum RIO Head modules 4 OONO VWI 11 12 Primary and Standby power supplies Coaxial cable Self terminating F adapter Splitter Tap Tap withTrunk terminator CPU Sync firer optic link Unity Pro workstation 908 RIO Drops 35010533 07 2011 29 Quantum Hot Standby System The following is a two bus S908 system 908 RIO Network l i l The 140 CRP 93 00 RIO Head module is connected to the 140 CRA 93 00 RIO Drop modules through cables self terminating F adapters signal splitters and taps Dual cabling offers even more Hot Standby redundancy There may be up to 31 RIO drops connected to the two RIO Head modules The minimum Quantum Hot Standby does not require any RIO drops but it must include at least one pair of connected RIO Head modules 30 35010533 07 2011 Quantum Hot Standby System Parts List The parts list for a S908 single cabled Hot Standby system is as follows Name Reference Minimum Number of Firmware Units Version Quantum Standard Racks 140 XBP Oee 00 2 Qua
10. Using the Upload Information Management Feature Before doing any modifications and at the initial start up of your system do the following Step Action From the menu select Tools Option General tab Select Automatic in the Upload Information Management area Press OK to close the window Save the program a AJ wo mM Download the program to the PLC Handling Online Modifications to the Standby CPU For major modifications to the application program on the Standby CPU verify that the Standby CPU is in Offline mode Two benefits result from this action e Run process continues e Primary CPU does not perform a Switchover during modification of the Standby CPU NOTE If the Standby CPU is online during modifications there is a possibility of Switchover occurring If this occurs the Standby CPU becomes Primary CPU and the process may run with incomplete modifications 35010533 07 2011 193 Application Modifications Performing Application Program Transfer Avoid the possibility of having two different application programs running in the Primary CPU and Standby CPU by performing an application program transfer after completing online modifications with an application mismatch Resetting Command Register System Bit SW60 3 When resetting the Command Register system bit Sw60 3 to 0 you want to avoid the possibility of having two different application programs running
11. 2 Go to Communication menu 2 Go to Communication menu 3 Go to Serial Port submenu 3 Go to Serial Port submenu 4 Select address 4 Select address 5 Change address 5 Change address 6 Perform application program transfer 6 Perform Switchover 7 Verify Standby CPU Modbus address 7 Ensure Standby CPU switched to Primary is 128 CPU 8 Perform application program transfer 9 Verify Standby CPU Modbus address is 128 Using the Modbus Port Tab in Unity Pro Editor To change address download application program see page 189 Note If the Modbus address is changed in the Primary CPU using the front panel keypad ensure that application program transfer is made to enable the corresponding Modbus Switchover in the Standby CPU NOTE In a Quantum Hot Standby system only one port is available for Modbus By default there is an address swap at Switchover between the Primary CPU and Standby CPU Modbus ports This default condition can be changed using the following two methods e Using Hot Standby menu in the Unity Pro editor This choice requires the application program to be downloaded e Using the Command Register system bit sSw60 8 This choice must be performed online in the Primary CPU Selecting deselecting address swap at Switchover Using Hot Standby Menu in Editor Using the Command Register system bit sSw60 8 1 Open Hot Standby menu in Unity Pro 1 Connect to Primary CP
12. BOOL Not used Reserved SWP MB3 BOOL Not used Reserved Description of the output parameters Parameter Data type Meaning HSBY BOOL 1 Hot Standby configuration found 0 Hot Standby configuration not found 35010533 07 2011 149 Programming and Debugging REV_XFER Function Description This EFB allows you to use the Hot Standby function It searches together with the other Hot Standby EFBs the configuration of the respective Quantum PLCs for the required components These components refer to hardware that is actually connected REV_XFER provides the ability to transmit 2 registers SW62 63 from the Standby PLC to the Primary PLC The two registers EFB are used by the application program in the first section to register diagnostic information REV_XFER can only be used in the first executable section of the project The parameter addresses TO _REV1 and TO_REV2 have to be in the Non Transfer Area to prevent being overwritten by the Primary CPU As additional parameters EN and ENO are projected Appearance in FBD Appearance REV_XFER Instance REV_XFER Standby PLC FirstReg TO REV1 HSBY HSBY_ConfFlag Standby_PLC_SecondReg TO_REV2 PRY Primary_PLC_Flag SBY Standby PLC Flag FR_REV1 FirstRevTransReg FR_REV2 SecondRevTransReg 150 35010533 07 2011 Programming and Debug
13. If not perform the transfer with the keyboard NOTE Verify that the Modbus or Modbus Plus address is the same as the address indicated in Step 4 20 Put the Primary and Standby CPUs in the Run Primary and RUN Standby Modes 21 Perform a Switchover by stopping the Primary CPU with the keyboard NOTE Verify that the Standby CPU becomes Primary CPU check the LCD screen 22 Repeat Steps 4 through 21 on the new Standby CPU 23 Connect Unity Pro to the new Primary CPU through Modbus Modbus Plus or USB 24 Set Command Register system bit Sw60 4 to 0 25 Disconnect the PC and ensure Primary and Standby CPUs are in Run Primary and Run Standby Modes 200 35010533 07 2011 Firmware Compatibility Issues To upgrade a Quantum Hot Standby Operating System without shutting down the process the current application program must be executable by the new Operating System Observe this requirement when installing minor revisions targeted for bug fixes or minor enhancements When a major function enhancement needs to be made maintaining this compatibility may not be possible In this case to perform an Operating System upgrade requires a system shut down 35010533 07 2011 201 Firmware 202 35010533 07 2011 Appendices At a Glance The appendices for the Quantum Hot Standby system are included here What s in this Appendix The appendix
14. Modify the application program offline 2 Perform Build Project and save NOTE Do not use the Rebuild All Project option because this causes the Standby CPU to go offline when the application program is downloaded Verify that the Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Connect Unity Pro to the Primary CPU Set the Command Register system bit SWE60 3 to 1 Connect Unity Pro to the Standby CPU and open the modified program NIOJ amp Download the program and select RUN NOTE Check the controller state and ensure that it is in Run Standby mode Verify that the Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Perform a Switchover see page 190 NOTE Ensure that the Standby CPU switched to the Primary CPU 10 Perform an application transfer see page 192 to the Standby CPU 11 Set the Command Register system bit SW60 3 to 0 NOTE The Command Register system bit is then returned to 0 from 1 NOTE For more details refer to Application Mismatch see page 193 A WARNING Before tran process UNEXPECTED EQUIPMENT BEHAVIOR sferring a modified application to the Standby CPU e Examine carefully all the impacts of the modifications on the application e Check that the modified application does not have adverse effects on the Failure to follow these instructions can result in death serious injury
15. backlight turns on when one of the following occurs e akey is pressed e the key switch state is changed e an error message is displayed on the LCD The backlight stays on for error messages as long as the error message is displayed otherwise the backlight automatically turns off after five minutes Adjusting the Contrast The contrast is adjustable from the keypad when the default screen is displayed Step Action 1 Press the MOD key To adjust the contrast darker press To adjust the contrast lighter press MOD To confirm the setting press ENTER 35010533 07 2011 221 Controls and Displays Keypad The keypad 5 has five keys that are mapped to hardware addresses Each of the two arrow keys includes an LED O l em or 1 5keys 2 2LEDs Using the Keys Keypad functions Key Function To cancel an entry suspend or stop an action in progress ESC To display the preceding screens successively move up the menu tree p To confirm a selection or an entry ENTER To set a field on the display into the modify mode MOD LED on Key active e to scroll through menu options he e to scroll through modify mode field options LED flashing Key active The modify mode field can be scrolled LED off Key inactive No menu options and no field options LED on Key active e to move around in a scree
16. Executive Checksum User Logic Check Processor Run Time RAM RAM address Executive Checksum User Logic Check 210 35010533 07 2011 Additional Information 140 CPU 671 60S Specifications Module Specifications Processor Memory Reference Capacity Component Description Communication ports 1 Modbus RS 232 RS 485 1 Modbus Plus RS 485 1 USB 1 Ethernet used as a Hot Standby port Bus current required 2 5A Maximum number of NOE 771 11 modules 6 supported Key switch Yes Keypad Yes Feature Description Model Pentium Clock speed 266 MHz Coprocessor Yes Built in Ethernet Watchdog timer 250 ms software adjustable RAM 4 MByte IEC program memory and or application data and configuration 1024 kByte IEC program memory maximum with PCMCIA card 7168 kBytes Discrete bits 64 k any combination Registers words 64 k maximum 35010533 07 2011 211 Additional Information Remote I O Battery and Clock Diagnostic Maximum I O words drop 64 in 64 out MAXIMUM number of remote drops 31 This information can be a mix of discrete or register I O For each word of configured I O one of the I O words must be subtracted from the total available Battery type 3 V Lithium Service life 1 2 Ah Shelf life 10 years with 0 5 los
17. Hot Standby Order A or B FIRST Hot Standby Power Order Modifiable only SECOND NOTE To change the A B order the PLC if the key switch must be in the STOP mode is in the unlocked position Hot Standby Transfer Pressing the lt ENTER gt key confirms the This menu option is only enabled if the key Transfer The transfer initiates the request of switch is in the unlocked position a program update from the Primary PLC Pressing any other key cancels the Transfer initiation and returns to the Hot Standby Transfer menu option screen 228 35010533 07 2011 Controls and Displays Screen Field Option Description Hot Standby Diag The order of diagnostic screen varies with the operation Halt User task in halt mode RIO fails Detected error reported by RIO head HSBY fails Detected error reported by optical link Stop Stop command sent Off keypad Offline command entered on keypad Off SW60 Offline command set in command register Off appli Offline due to application mismatch Off vers Offline due to PLC or Copro OS mismatch Off RIO Offline due to Remote O error Take over Standby CPU switched to Primary CPU mode Run Run command sent Plug amp Run Sun link operational and Standby CPU is started Power up No message PLC has just started 35010533 07 2011 229 Controls and Displays Communications Menu Co
18. Refer to CPU Controls and Displays see page 220 and Using the CPU LCD Display Screens see page 224 Configuring in Unity Pro Using Unity Pro configure a network that is appropriate for the installed racks and the cabling Configure the Hot Standby Register for the Quantum Hot Standby CPU in Unity Pro as described in Configuring the Unity Pro Dialogs see Quantum with Unity Pro Hardware Reference Manual 35010533 07 2011 83 Configuration Transferring and Sending the Program from Primary CPU to Standby CPU Transfer the program from your PC to CPU using the Unity Pro command PLC gt Transfer program to PLC Refer to Application Program Transfer see page 160 Send your program from the Primary CPU to the Standby CPU using the Primary or Standby CPU keypad Select Quantum PLC Operations PLC Operations Hot Standby Hot Standby Transfer Press lt ENTER gt to confirm Transfer Refer to Using the HE CPU 67160 LCD Display Screens see page 220 NOTE A program always goes from the Primary CPU controller to the other CPU controller 84 35010533 07 2011 Configuration 2 2 Reading and Configuring Registers Purpose This section describes configuring the command register of a Quantum Hot Standby system by selecting options that affect the register You may want to use this method if your system has specific configuration needs This section also describes the read only status registers What
19. The first 16 WORDs contain the local CPU diagnostics The second 16 WORDs are used to exchange the local diagnostics between the 2 CPUs 79 Configuration Configuring the PCMCIA Cards Configuring with Unity Pro This is the procedure to allocate memory to the memory card Step Action If not opened open the Local Bus configuration editor 2 Go to the local bus in the Structural View of the Project Browser Open the local bus either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open Result A graphical representation of the local bus appears 4 Select either PC Card A 1 slot or PC Card B 2 slot 1 Memory configuration of the PCMCIA card 1 2 Memory configuration of the PCMCIA card 2 5 Double click or right click either PCMCIA card Results The New Replace Submodule dialog appears New Replace Submodule Part Number Description ESM Cancel TSX MCP C 002M_ SRAM FLASH PCMCIA Prog 2048kb Data 1024kb ane TSX MCP C 512K SRAM FLASH PCMCIA Prog 512kb Data 512kb Help TSX MFP P001M__ FLASH PCMCIA Prog 1024kb TSX MFP P 002M__ FLASH PCMCIA Prog 2048kb_ FLASH PCMCIA Prog 4096kb FLASH PCMCIA Prog 512kb SRAM TSX MRP C 001M SRAM PCMCIA Prog 1024kb Data 832kb TSX MRP C 002M SRAM PCMCIA Prog 2048kb Data 1856kb TSX MRP C 003M __ SRAM PCMCIA Prog 3072kb Data 2880kb TSX MRP C 007
20. control of the system and the Primary CPU goes to RUN Offline e if the Primary CPU is inoperative the Standby CPU takes control of the system There are 2 cases e lf the user application does not have the Link Redundancy Needed FB implemented An inoperative RIO network is detected by both Primary and Standby Quantum Ethernet I O Ethernet CRPs the Standby PLC goes Offline while the network repairs itself When the network works again this PLC goes back online as the Standby PLC again e Ifthe user application does have the Link Redundancy Needed FB implemented 35010533 07 2011 115 Maintaining Detecting High Speed Sync Link Interruptions Diagnostic Information Facts 1 High speed data link connects the two Copros 2 Using the high speed data link the Primary CPU controller communicates with the Standby CPU every 10 milliseconds 3 Primary CPU sends either e data message e health message NOTE If both the Primary CPU and Standby CPU do not hear from each other either station can detect a high speed data link interruption Standby CPU Detects an Error At first Step Action Result 1 Standby CPU does not hear 1 Standby CPU requests the Primary CPU to from the Primary CPU on the monitor the RIO link high speed data link 2 Primary CPU sends a request to the RIO Head When the RIO Head receives the request If Then RIO Head finds the 1 RIO Head assumes that
21. dual drops dual cabling dual sensors and actuators can be used with a Quantum Hot Standby configuration The Quantum Hot Standby system e increases the system availability of your treatment plants and remote stations allowing you to conduct many maintenance operations while the system is operational e is a single detected fault tolerant system that is the system can continue operating even though one component of the system is inoperative e provides control redundancy for Quantum Ethernet I O Ethernet or S908 Remote I O systems e requires no specialized modules or equipment other than the Hot Standby PLCs and Ethernet modules You can use standard Quantum racks power supplies and I O modules analog and discrete e offers a user friendly development environment compatible with IEC 6113 3 e allows creation of a redundant ready application program almost as easily as for a standalone PLC and requires few changes from your normal programming methods NOTE If not mentioned in the document all features of Standalone High End Quantum PLCs are available in Quantum Hot Standby PLCs 35010533 07 2011 19 Quantum Hot Standby System Overview Quantum Hot Standby The Quantum Hot Standby controller implements system redundancy using redundant hardware and by automatically switching over to the Standby backup hardware when certain defined system events are detected While your prior PLC experience is very important to
22. the remote drop s must include a 140 CRA 932 00 module A CAUTION UNINTENDED EQUIPMENT OPERATION Use only high availability RIO modules with dual cabling in a Safety Related System Failure to follow these instructions can result in injury or equipment damage 35010533 07 2011 53 Quantum Hot Standby System Description of the Operating Modes e Safety Mode This is the default mode It is a restricted mode in which modifications and maintenance activities are prohibited e Maintenance Mode This is a temporary mode for modifying the project debugging and maintaining the application program State Compatibility with Safe and Maintenance Modes A Quantum Hot Standby system has two states e Redundant 1 CPU is Primary 1 is Standby The Standby CPU controller mode follows the Primary CPU controller mode For example if you switch the Primary CPU controller from Safety to Maintenance mode the Standby CPU controller switches from Safety to Maintenance mode at the start of the next cycle e Non redundant at least 1 CPU Offline The two controllers are independent one can be in Safety mode and the other one in Maintenance mode For example the Run Primary controller can be in Safety mode while the Stop Offline controller is in the Maintenance mode Impact of the PLC Switchover on the Process Safety Time If the Primary CPU detects an internal or external problem it stops exchanging data with the Sta
23. 0 0 c cee eee eee 140 HSB RD Ee a cure ine Rice te saan ane eects oe ts arenes bras 141 HSB ST rarr a obs tet ged ead desk a gic et 144 HSBY WRisisns ep e eee ue Beer be celta ine Se kaa Aegean 147 REV XFER venien ae Sina ened ae ete atin tent 150 Equipment Restrictions onasan aaaea 153 Local and Distributed I O Restrictions 002 0 eee eee 154 Module Restrictions 2 0 0 cece eee 156 Application Restrictions 0 2 0 cee tee 157 35010533 07 2011 4 4 PLC Communications 0 0 0 0 c cee 158 Data Transfer sco sepa rano a EAE rack pases Se wens 159 Application Program Transfer 0 0 0 0 e eee eee 160 SCAN Times s rire taae ia aw tetera Saad E he ae 164 4 5 Developing A Hot Standby Application 0 0 cee eee 167 Adjusting MAST Task Properties 2 0 0 0 eee eee eee 168 How to Program a Quantum Hot Standby Application 172 Transferring Your Program to the Primary and Standby PLCs 174 4 6 Debugging a Hot Standby Application 0 02 cea eee 175 DeDUgGING 2 iranier ei irna ks evar atic ace acpi aei aiaa a A aE tana et ara sas 175 Part Ill Modifying and Upgrading 000e005 179 Chapter 5 Application Modifications 0 2000ees 181 Quantum Hot Standby Application Mismatches 4 182 Online or Offline Modifications and Application Mismatch 186 Standby CPU Online Application Modif
24. 00 59 The leading 0 is displayed it can be omitted during data entry DTM device type manager A device driver running on the host PC It provides a unified structure for accessing device parameters configuring and operating the devices and troubleshooting the network DTMs can range from a simple graphical user interface GUI for setting device parameters to a highly sophisticated application capable of performing complex real time calculations for diagnosis and maintenance purposes In the context of a DTM a device can be a communications module or a remote device on the network See FDT 35010533 07 2011 241 Glossary EDS EF EFB EN electronic data sheet Simple text files that describe the configuration capabilities of a device EDS files are generated and maintained by the manufacturer of the device elementary function A block used in a program to perform a predefined logical function A function does not have any information on the internal state Several calls to the same function using the same input parameters will return the same output values You will find information on the graphic form of the function call in the functional block instance Unlike a call to a function block function calls include only an output which is not named and whose name is identical to that of the function In FBD each call is indicated by a unique number via the graphic block This number is managed automatica
25. 312 00 1 0 2 Modules Quantum Hot Standby RIO Drop 140 CRA 312 00 1 0 As needed Modules Dual Ring Switch DRS TCSESM083F23F1 As needed TCSESM063F2CU1 TCSESM063F2CS1 NOTE The above hardware is always required in Hot Standby systems but it does not provide a useful redundant system because no redundantly managed I O modules are included 35010533 07 2011 35 Quantum Hot Standby System Additional Quantum Ethernet I O Redundancy The S908 and Quantum Ethernet I O Hot Standby systems offer redundancy by having 2 identical PLCs Primary and Standby to control the system I O A Quantum Ethernet I O Hot Standby system offers increased redundancy when its Remote I O is configured in a daisy chain ring In this configuration there are three links see page 34 between the Primary and Standby PLCs 1 directly between the two Copros over the Sync link see page 27 2 over the daisy chained Ethernet Remote I O Drops between the 2 CRPs 3 over the Ethernet direct link between the 2 CRPs This direct link cannot have Remote or Distributed I O Drops for example the following is not allowed P S I O VO d P S CRA VO x v 4 LT THAT Ty 35010533 07 2011 Quantum Hot Standby System Dual Ring Switch A dual ring switch DRS can be used to e insert a sub ring into the main daisy chain ring e connect
26. Modbus RS 232 1 Modbus Plus R 1 USB 1 Ethernet used a a Bus Current required Max number of NOM NOK GRP 811 and MMS modules supported any combination Key switch Processor 35010533 07 2011 65 Configuration Using the Configuration Tab Configuration Screen Change values using the Configuration tab of the editor Mii 1 2 140 CPU 671 60 P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB fal Overview Summary fS Configuration Modbus Port E Animation Hot Standby IER 1 0 Objects State RAM Mem usage 3 Automatic start in Run __ Automatic start in Run MWi Reset _ Cold Start Only Automatic start in Run A No memory card selected B No memory card selected Communication Maximum Unity Data exchanged by Plc Scan 4x256 i Potential impact on cycle time if gt 4x256 see documentation M MW 1 IW Viewer Configuration Online Modification Online modification in RUN Only simple modification Add delete discrete or analog modules or modification of parameters DIO bus S800 and Symax droops don t support this option Description Configuration tab Item Option Value Description Operating Mode On Automatic start in Run x Determines the operating condition Cold Start MWi Reset on cold start x d
27. OK e Flashing battery is low only for green PCMCIAs PV lt 04 With blue PCMCIAs version gt 04 when main battery is low there is no flash 226 35010533 07 2011 Controls and Displays PLC Operations Menu The structure of the PLC Operations menu and submenus are Unity HE CPU PLC Operations gt PLC Operations Press lt ENTER gt to Start PLC gt confirm Start gt PLC Operations Press lt ENTER gt to Stop PLC gt confirm Stop gt PLC Operations Press lt ENTER gt to Init PLC gt confirm Init gt PLC Operations Hot Standby Hot Standby gt State State Hot Standby Mode Mode Hot Standby Order A or B Hot Standby Press lt ENTER gt to Transfer gt confirm Transfer gt Hot Standby Hot Standby Diag gt diag halt Hot Standby diag rio fails Hot Standby diag hsby fails Hot Standby diag stop Hot Standby diag off keypad Hot Standby diag off sw60 Hot Standby diag off appli Hot Standby diag off vers Hot Standby diag off rio Hot Standby diag Take over Hot Standby diag Run Hot Standby diag Plug amp Run Hot Standby diag Power up 35010533 07 2011 227 Controls and Displays Submenu for PLC Operations Start Stop and
28. PLC in their local racks e When local or Distributed I O are used they have to be managed in the first section of the MAST task of the application by using located MW that are not transferred from the Primary CPU to the Standby CPU e Distributed I O are not compatible with the safety processor 140 CPU 671 60S Local I O Management Handling I O It is possible to manage outputs locally in both PLCs They may be written with different values at the same time that depends on application program processing For that the first section of the MAST task of the application must be used On the other hand only the located variables that are not transferred from the Primary to the Standby must be used for managing the different values applied on the output modules When outputs are managed locally in each PLC the output values must be evaluated in the first section of the MAST task at each PLC scan If this is not done the Standby output value is erased by the value coming from the Primary PLC CAUTION RISK OF EQUIPMENT DAMAGE Output values must be evaluated in the first section of the MAST task at each scan Failure to follow these instructions can result in equipment damage The Quantum Hot Standby system supports I O connected to a RIO drops and DIO connected using I O scanning Local I O can be configured and run but is not redundant in a Quantum Hot Standby system 154 35010533 07 2011 Programming and D
29. Sync fiber optic link 4A 4B Primary and Standby power supplies 5A 5B Primary and Standby RIO Head modules 6 Ethernet connection between RIO Head modules 7 Ethernet RIO Drops in a daisy chain configuration 8 Unity Pro workstation 34 35010533 07 2011 Quantum Hot Standby System Quantum Ethernet I O RIO Network The 140 CRP 312 00 RIO Head module is connected to the 140 CRA 312 00 RIO Drop modules through Ethernet cables and if necessary dual ring switches DRSs This network must use a daisy chain ring topology and the RSTP 2004 protocol There may be up to 30 RIO Drops connected to the 2 CRP modules on one side of the main ring If more than 30 CRA Drops are needed there can be additional Drops connected in one or more sub rings using dual ring switches DRSs The other side of the main ring must have the 2 CRP modules directly connected without RIO Drops between them There can be a maximum of two DRSs on this side of the ring The minimum Quantum Hot Standby does not require any RIO drops but it must include at least one pair of 140 CRP 312 00 Head modules Parts List The parts list for a Quantum Ethernet I O Hot Standby system is as follows Name Reference Minimum Number of Firmware Units Version Quantum Standard Racks 140 XBP Oee 00 Quantum Power Supplies 140 CPS eee 00 2 Quantum Hot Standby Controller 140 CPU 671 60 3 0 140 CPU 672 61 3 0 Quantum Hot Standby RIO Head 140 CRP
30. a Quantum Ethernet I O Ethernet system 30 ms and 350 ms A WARNING UNEXPECTED EQUIPMENT OPERATION The Drop hold up time must be set to at least 4 times the MAST task watchdog value Failure to follow these instructions can result in death serious injury or equipment damage 35010533 07 2011 157 Programming and Debugging 4 4 PLC Communications Overview This section describes data and application transfers and the scan time What s in this Section This section contains the following topics Topic Page Data Transfer 159 Application Program Transfer 160 Scan Time 164 158 35010533 07 2011 Programming and Debugging Data Transfer Hot Standby Transfer Diagram The following diagram illustrates the transfer of data from the Primary CPU to the Standby CPU Copro in a configuration using 140 CPU 67e processors t ns Hot Standby User Hot Standby gt S Input system TH Section 4 Output input Output input system function E WW Z x 0 2 DATA TRANSFER User data transferred or 128 kB located 1536 kB unlocated For 140 CPU 671 60S 9 x only 128 kB located S 2 DATA TRANSFER Ne unlocated a20 ne S J WW nn Hot Standby User logic Hot Standby g s system function Output input system function MAST task cycle n MAST task cycle n 1 35010533 07 2011 159 Programming and Debugging Ap
31. a firmware version lower than 2 00 118 35010533 07 2011 Maintaining Troubleshooting the Standby CPU This table gives the location of Standby PLC detected errors Controller RIO Head Status Detected Error Type Description Status Stop All LEDS off except Ready Controller A detected Interface error occurred on or Ready on and Com Act blinks once a second Offline Ready on and Com Act Fiber Optic connection between A detected communication error stops blinking both controllers occurred Stop Com Act displays detected RIO Head After replacing the module and cycled error pattern see page 215 power to ensure that the controllers have identical application programs perform an application program update Stop Ready on and Com Act RIO Cable becomes inoperative In a dual cable system the RIO Head blinks four times at Standby CPU end gives no indication if only one cable has become inoperative Offline Com Act on Either type of fiber link interruption e from Standby CPU Transmit to Primary CPU Receive e from Primary CPU Transmit to Standby CPU Receive 35010533 07 2011 119 Maintaining 120 35010533 07 2011 Programming and Debugging Overview This chapter describes what is necessary to know to program and debug applications for a Quantum Hot Standby system What s in this Chapter This chapter contains the following sections Se
32. address assignment at power up as follows If the Hot Standby state is Then the IP address assigned is unassigned IP address configured in Unity Pro Primary CPU IP address configured in Unity Pro Standby CPU IP address configured in Unity Pro 1 unassigned to offline transition See Offline Mode at Power up Sequence in the next table 35010533 07 2011 99 Configuration If two NOEs power up simultaneously a resolution algorithm e determines the Primary NOE e assigns the IP address configured in Unity Pro to that Primary NOE e assigns the IP address configured in Unity Pro 1 to the Standby NOE Sequence Offline Mode at Power up Result controller B Controller A powers up before e P address of controller A is the IP address configured in Unity Pro e P address of controller B is the IP address configured in Unity Pro 1 Both controller A and controller B power up at the same time The resolution algorithm assigns the configured IP address to controller A and it assigns the configured IP address 1 to controller B The NOE performs a duplicate IP test by issuing an ARP request to the IP address configured in Unity Pro If a response is received within 3 seconds the IP address remains at the default IP and the NOE blinks a diagnostic code If no IP configuration exists the NOE remains in the Standalone mode and the IP address must be obtained fr
33. delivered to only a specified subset of network destinations Implicit messaging typically uses multicast format for communications in an EtherNet IP network 248 35010533 07 2011 Glossary network NIM NTP O gt T operation network originator There are 2 meanings e Ina ladder diagram A set of interconnected graphic elements The scope of a network is local concerning the organizational unit section of the program containing the network e With expert communication modules A set of stations that intercommunicate The term network is also used to define a group interconnected graphic elements This group then makes up part of a program that may comprise a group of networks network interface module A NIM resides in the first position on an STB island leftmost on the physical setup The NIM provides the interface between the I O modules and the fieldbus master It is the only module on the island that is fieldbus dependent a different NIM is available for each fieldbus network time protocol Protocol for synchronizing computer system clocks The protocol uses a jitter buffer to resist the effects of variable latency O originator to target See originator and target An Ethernet based network containing operator tools SCADA client PC printers batch tools EMS etc PLCs are connected directly or through routing of the inter controller network This network is part of the control network
34. discrete output module during your initial start up Before performing a Switchover connect to the Primary CPU and force the output bits in the module Perform the Switchover and take note of the bumpless Switchover effect on the forced bits Switchover Test Using Front Panel Keypad To force a Switchover using the front panel keypad do the following Step Action 1 Access the front panel keypad of the Primary CPU controller 2 Go to PLC Operation Hot Standby Hot Standby Mode 3 Change Run to Offline NOTE Ensure that the Standby CPU switches to Primary CPU 4 Change Offline to Run NOTE Ensure that the LCD displays Run Standby CPU Switchover Test Using Command Register Follow these steps Step Action 1 Connect Unity Pro to the Primary CPU 2 Observe if the controller order on the Primary CPU is A or B using either of the following methods e Unity Pro status dialog Refer to the bottom of the Unity Pro window when connected online e Access the Command Register system bits e f the connected Primary CPU is A set SW60 1 to 0 e Ifthe connected Primary CPU is B set SW60 2 to 0 NOTE Ensure that the Standby CPU switched to Primary CPU If bits SW60 1 and SW60 2 are set to O simultaneously a switchover occurs e Primary PLC goes to RUN Offline e Standby PLC goes to RUN Primary 138 35010533 07 2011 Programming and Debugging Step Action
35. distributed I O devices to the system e connect Ethernet CPR Head modules and CPA Drop modules For connections e lt 100m use copper cable e gt 100 m fibre optic cable must be used Each DRS counts as 2 devices on a ring For more information about the available DRSs refer to the ConneXium Dual Ring Switch Dual Ring Switch Topology Examples The following example shows 2 possible uses of DRSs DIO Devices PIS CRA I O VO VO DIO Z Devices Actions of the DRSs 1 amp 2 These DRSs connect the 2 Ethernet CRP modules in the Hot Standby PLCs using fibre optic cable because the distance is gt 100 m 3 This DRS attaches Distributed I O devices to the main daisy chain ring 4 amp 5 These DRSs connect the CRA modules of 2 Remote I O Drops using fibre optic cable because the distance is gt 100 m 5 This DRS also attaches Distributed I O devices to the main daisy chain ring On this ring there are 2 CRP devices 2 CRA devices and 5 DRSs that count as 10 devices for a total 14 devices 32 14 18 additional devices can be added to this ring 35010533 07 2011 37 Quantum Hot Standby System A DRS can be used to connect a sub ring to the main ring VO VO VO P S CRA I O On the main ring there are 2 CRP device
36. e the seconds encoded in an 8 bit field NOTE The 8 least significant bits are not used The TOD type is entered as follows TOD lt Hour gt lt Minutes gt lt Seconds gt This table shows the upper lower limits of each field Field Limits Comment Hour 00 23 The leading 0 is displayed it can be omitted during data entry Minute 00 59 The leading 0 is displayed it can be omitted during data entry Second 00 59 The leading 0 is displayed it can be omitted during data entry Example TOD 23 59 45 TR transparent ready Web enabled power distribution equipment including medium and low voltage switch gear switchboards panel boards motor control centers and unit substations Transparent Ready equipment allows you to access metering and equipment status from any PC on the network using a standard web browser 254 35010533 07 2011 Glossary trap UDP variable An event directed by an SNMP agent that indicates one of the following e a change has occurred in the status of an agent e an unauthorized SNMP manager device has attempted to get data from or change data on an SNMP agent U user datagram protocol A transport layer protocol that supports connectionless communications Applications running on networked nodes can use UDP to send datagrams to one another UDP does not always deliver datagrams as reliable or ordered as those delivered by TCP However by avoiding the ove
37. further details 176 35010533 07 2011 Programming and Debugging Debugging the Redundancy Part Do not attempt to debug or otherwise verify the performance of an application intended for use in a Hot Standby system on a non Hot Standby PLC You must debug Hot Standby related applications on a Hot Standby PLC Do not use the debug and diagnostic operations normally available for Quantum PLCs on a redundant Hot Standby system The operations such as step by step and breakpoints halt program execution and eliminate the redundancy of the Hot Standby system NOTE A Switchover is not generated when the Primary application stops on a breakpoint The debugging that can be accomplished once your application program is loaded onto a redundant Hot Standby system offers the following debugging features e Static verification Check that e application restrictions see page 157 in this manual have been observed e MAST task characteristics have been configured properly e Dynamic verification After each PLC has been made live application already transferred check that the redundancy function is correctly performed in each PLC the Status register bit SW61 15 is equal to 1 and the bit SW61 6 is equal to 0 Once the Hot Standby PLCs have entered either the Primary or Standby operating modes confirm that e all application program sections of the MAST task are executed on the Primary PLC e only the first section of the MAST task is
38. in the Primary CPU and Standby CPU Step Action 1 Connect to Primary CPU 2 Access the Command Register system bit sSw60 3 3 Reset bit to 0 194 35010533 07 2011 Firmware Overview This chapter describes the Quantum Hot Standby system firmware and how to upgrade it in the Standby CPU while the process is controlled by the Primary CPU What s in this Chapter This chapter contains the following topics Topic Page Firmware Levels 196 Quantum Hot Standby Firmware Upgrade 198 Executing the Operating System Upgrade Procedure 199 35010533 07 2011 195 Firmware Firmware Levels Overview Hot Standby CPU Firmware Levels The firmware level selected in Unity Pro defines the functionality of the Hot Standby CPU processor There are major updates with new functions and minor releases with bug fixes If an application has a major firmware change in Unity Pro the application must be completely rebuilt Minor release changes do not require a rebuild The following table gives the Quantum CPU firmware levels that allow construction of a Hot Standby system Firmware Quantum CPUs Function Version 2 00 to 2 60 140 CPU 671 60 Hot Standby 2 70 140 CPU 671 60 Hot Standby CCOTF see Quantum Ethernet I O System Planning Guide 2 80 140 CPU 671 60 Hot Standby 140 CPU 672 61 CCOTF see Quantum Ethernet I O System Planni
39. instructions can result in injury or equipment damage NOTE The NOE modules must communicate with each other to swap IP addresses Schneider Electric recommends that you connect the Primary and Standby NOEs to the same switch because connecting two NOEs to the same switch minimizes the probability of a communication interruption 35010533 07 2011 97 Configuration A NOE waits for either a change in the controller s Hot Standby state or the swap of UDP messages If the NOE module Then Detects that the new Hot Standby state is The NOE changes the IP address either Primary CPU or Standby CPU Receives a swap UDP message The NOE transmits a swap UDP message and swaps the IP address All client server services I O scanning global data messaging FTP SNMP and HTTP continue to run after the switch from the old to the new Primary CPU NOE NOTE If an NOE module stops communicating this does not cause the Primary CPU to go Offline A WARNING UNINTENDED EQUIPMENT OPERATION Design your application so that un monitored modules support communication only to noncritical parts of the application Failure to follow these instructions can result in death serious injury or equipment damage Hot Standby and NOE Module Functionality The 140 NOE 771 family provides different Ethernet services for the Quantum Hot Standby system The following table identifies the servic
40. module 108 restriction 103 REV_XFER 150 run time confidence tests 110 S scan times 164 startup confidence tests 109 swapping addresses 132 Switchover 41 switchovers application mismatches 181 cold starts 94 swapping addresses 132 USB 43 sync link 27 system errors 107 system timer 95 T transfer times 161 164 transferring programs 160 U upgrading 195 upload information management 193 using Unity Pro 61 W wiring accessories fiber optic 27 258 35010533 07 2011
41. not avoided can result in equipment damage Electrical equipment should be installed operated serviced and maintained only by qualified personnel No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation and has received safety training to recognize and avoid the hazards involved 35010533 07 2011 About the Book A At a Glance Document Scope Validity Note This guide describes the Modicon Quantum Hot Standby S908 System and Quantum Ethernet I O Ethernet system consisting of e Unity Pro software e Modicon Quantum Hot Standby CPUs e 140 CPU 671 60 e 140 CPU 671 60S e 140 CPU 672 61 power supplies remote I O RIO network distributed I O DIO e RIO Head modules This guide describes how to build a Quantum Hot Standby system Users of Concept ProWORX Quantum Hot Standby systems please note that there are significant differences that exist between Unity Pro and legacy systems and where important this guide identifies those differences Who should use this document Anyone who uses a Hot Standby system or needs fault tolerant availability through redundancy in an automation system You should have knowledge of programmable logic controllers PLCs Familiarity with automation controls is expected
42. occurs the new Primary PLC takes the IP address of the old Primary PLC When the PLC that has stopped becomes operational again and rejoins the Hot Standby system it takes the IP address of the Standby PLC 35010533 07 2011 103 Configuration The new Primary NOE must have the same IP address as the former Primary NOE The IP address in the Secondary NOE is IP address 1 The NOEs integrated into the Quantum Hot Standby configuration coordinate this swapping of IP addresses with the management of Ethernet services used NOE IP Address Swap Time The following table details the 140 NOE 771 1module address swap time Typical Swap Time Maximum Swap Time 6ms 500 ms 104 35010533 07 2011 Configuration NOE Modules in Hot Standby System DIO Ethernet Topology A Quantum Hot Standby system can control distributed I O devices using NOE modules The example below contains no Ethernet RIO modules Legend 1a Primary CPU 2a Primary CRP module 3a Primary NOE module 1b Standby CPU 2b Standby CRP module 3b Standby NOE module 4 Ethernet switch 5 Distributed I O devices SNMP An SNMP service on the NOE module is always a
43. or equipment damage 35010533 07 2011 189 Application Modifications Switchover Methods with Application Mismatch Ovewview Switchover can be performed using one of two methods e Hot Standby submenu on the front panel keypad e Change Command Register system bit SW60 1 or SW60 2 NOTE If bits SW60 1 and SW60 2 are set to 0 simultaneously a Switchover occurs e Primary CPU controller goes RUN Offline and e Standby CPU controller now operates as RUN Primary CPU Switchover Using Front Panel Keypad To force a Switchover using the front panel keypad do the following Step Action Access the front panel keypad of the Primary CPU controller Go to PLC Operation menu Go to Hot Standby submenu Go to Hot Standby mode oa AJOJN Modify Run to Offline Note Verify that Standby CPU switched to Primary CPU 6 Modify offline to run Note Verify that the LCD displays Run Standby Command Register Switchover To perform the Switchover using Command Register system bit SW60 1 or SWEO 2 e save the application program twice under a different file names e file 1 Saved before modification e file 2 Saved after modification e verify the A B order of the controller using one of two methods e Hot Standby submenu on the front panel keypad PLC Operation Hot Standby Hot Standby Order e Unity Pro status dialog refer to the bottom of the Unity Pro window wh
44. s in this Section This section contains the following topics Topic Page Hot Standby Command Register 86 Hot Standby Status Register 90 Hot Standby Firmware Mismatch Register 93 Using Initialized Data 94 Synchronizing System Timers 95 35010533 07 2011 85 Configuration Hot Standby Command Register Setting the Bits in the Command Register The Command Register System Word Sw60 defines the operating parameters of a Hot Standby application for both the Primary CPU and Standby CPU At each scan the Command Register is replicated and transferred from the Primary CPU to the Standby CPU Transfer occurs only from Primary CPU to Standby CPU Any changes made to the Command Register on the Standby CPU has no effect because the values transferred from the Primary CPU overwrite the values in the Standby CPU The following illustration identifies the operating options provided by the Command Register CPU Keypad Enabled 0 CPU Keypad Disabled 1 Sets Controller A to OFFLINE mode 0 Sets Controller A to RUN mode 1 Sets Controller B to OFFLINE mode 0 Sets Controller B to RUN mode 1 Forces Standby offline if there is a logic mismatch 0 Does not force Standby offline if there is a logic mismatch 1 Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 vse as sa ia ia iifaofe s 7 e s s 2 Jo tse 0 No application program
45. segment the network and limit the likelinood of collisions Packets are filtered or forwarded based upon their source and destination addresses Switches are capable of full duplex operation and provide full network bandwidth to each port A switch can have different input output speeds for example 10 100 or 1000 Mb s Switches are considered OSI layer 2 data link layer devices T target to originator See target and originator In EtherNet IP a device that is the recipient of a connection request for implicit or explicit messaging communications or when itis the recipient of a message request for un connected explicit messaging 35010533 07 2011 253 Glossary TCP transmission control protocol A key protocol of the internet protocol suite that supports connection oriented communications by establishing the connection necessary to transmit an ordered sequence of data over the same communication path TCP IP Also known as internet protocol suite TCP IP is a collection of protocols used to conduct transactions on a network The suite takes its name from 2 commonly used protocols transmission control protocol and internet protocol TCP IP is a connection oriented protocol that is used by Modbus TCP and EtherNet IP for explicit messaging TOD time of day The TOD type encoded in BCD in a 32 bit format contains the following information e the hour encoded in an 8 bit field e the minutes encoded in an 8 bit field
46. the complete application program and data to the Standby CPU The following table shows the Application Program Transfer procedure Step Action 1 Ensure the Primary CPU Controller is in RUN PRIMARY CPU mode Result The LCD on the PLC displays the mode as RUN PRIMARY CPU 2 Check that both invalidate Keypad option is NOT selected e the key switch is unlocked 35010533 07 2011 161 Programming and Debugging Step Action 3 Go to the submenu Hot Standby Transfer 4 Push Enter to execute the application program transfer from the Primary CPU to the Standby CPU NOTE The Hot Standby Transfer command can be performed either in the Primary CPU or Standby CPU controller but only the Standby CPU controller is updated Transferring the Application Program Using Command Register System Bit SW60 5 To transfer use the command register in the Unity Pro software The Primary CPU copies the complete application program and data to the Standby CPU To transfer an application program logic program or project to either the Primary CPU or Standby CPU controller using Command Register system bit SW60 5 do the following Step Action 1 Connect to the Primary CPU or Standby CPU controller 2 Access Command Register system bit SW60 5 3 Set bit to 1 Note The process of setting the bit toggles the bit from 0 to 1 and back to 0 Automatic Applic
47. the same type array or with different types structure For a defined application and architecture the ability to predict that the delay between an event change of an input value and the corresponding change of an output state is a finite time t smaller than the time required for your process to run correctly An Ethernet based network within a remote I O network that contains both remote I O and distributed I O devices Devices connected on this network follow specific rules to allow remote I O determinism derived function block Function blocks that can be defined by the user in ST IL LD or FBD language Using these DFB types in an application makes it possible to simplify the design and entry of the program e make the program easier to read e make it easier to debug e reduce the amount of code generated dynamic host configuration protocol An extension of the BOOTP communications protocol that provides for the automatic assignment of IP addressing settings including IP address subnet mask gateway IP address and DNS server names DHCP does not require the maintenance of a table identifying each network device The client identifies itself to the DHCP server using either its MAC address or a uniquely assigned device identifier The DHCP service utilizes UDP ports 67 and 68 distributed I O cloud A group of distributed I O devices connected either to a non ring port on a DRS or to a distributed I O communications m
48. transfer 1 Application program transfer requested 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address on switchover System Bit SW60 0 Invalidate Keypad is an option that allows a controller to refuse commands from the Hot Standby submenu in the front panel keypad e ssw60 0 1 Invalidate Keypad enabled The Quantum Hot Standby system refuses all changes from the Hot Standby submenu in the front panel keypad e sSwWw60 0 0 Invalidate Keypad disabled The Quantum Hot Standby system accepts all changes from the Hot Standby submenu in the front panel keypad 86 35010533 07 2011 Configuration System Bit SW60 1 Controller A OFFLINE ONLINE mode e ssw60 1 1 Controller A goes to the ONLINE mode e sSsw60 1 0 Controller A goes to the OFFLINE mode System Bit SW60 2 Controller BOFFLINE ONLINE mode e sSwe0 2 1 Controller B goes to the ONLINE mode e SSW60 2 0 Controller B goes to the OFFLINE mode NOTE The Primary CPU controller goes to RUN OFFLINE only if the secondary CPU is RUN Standby At Startup of the Secondary PLC the secondary CPU goes to ONLINE mode RUN Standby only if both bits ssw60 1 and sw60 2 are set to 1 regardless of A B assignment If bits sSw60 1 and sSW60 2 are set to 0 simultaneously a switchover occurs e the Primary CPU controller goes to the RUN OFFLINE mode e the Standby CPU goes to the RUN Primary CPU mode To complete the switchover bit
49. using the keypad see page 222 on the front of the controller For detailed information about the menus and submenus see e PLC Operations Menus and Submenus see page 227 e Using the Communications Menus and Submenus see page 230 e Using the LCD Settings Menus and Submenus see page 232 e Using the System Info Menus and Submenus see page 233 Structure LCD display menus and submenus Mode State Bat L A w port PCM Quantum p Quantum pe Quantum p gt Quantum 2 PLC Operations gt Communications gt System Info gt LCD Settings gt L Default screen System menus Sub menus Sub screens AON 224 35010533 07 2011 Controls and Displays Accessing the Screens Default Screen Use the keys on the keypad to access the system menus and submenus Step Action 1 To access the screens ensure that the key switch is in the unlocked position a 2 To step down to a lower menu operate one of the following keys e 3 To return to the previous menu press ESC The default screen is read only and contains the following fields Mode State Bat L port PCM The default s
50. 1 means Standby CPU requests an application program transfer from Primary CPU e SwW60 5 0 is default and no transfer occurs NOTE 3Sw60 5 is a Monitor Bit SW60 5 monitors an action Once the action occurs SW60 5 returns to the default which is zero 0 NOTE In the case of ONLINE application mismatch selected the Hot Standby system needs 2 seconds to check the consistency of the application and the detection of an application mismatch SW61 4 Therefore the request for application transfer SW60 5 has to be done with a minimum delay of 2 seconds after any modification of the application A WARNING UNEXPECTED BEHAVIOR OF APPLICATION When the ONLINE application mismatch option is selected a request for application transfer Y SW60 5 has to be done with a minimum delay of 2 seconds after any modification of the application Failure to follow these instructions can result in death serious injury or equipment damage 88 35010533 07 2011 Configuration System Bit SW60 8 Swap Modbus on port 1 e SSw60 8 0 Address swap on Modbus port 1 when a switchover occurs e sSwe0 8 1 No address swap on Modbus port 1 when a switchover occurs System Bit SW60 9 Swap Modbus on port 2 e SSw60 9 0 Address swap on Modbus port 2 when a switchover occurs e sSw60 9 1 No address swap on Modbus port 2 when a switchover occurs System Bit SW60 10 Swap Modbus on port 3 e sSw60 10 0 Addre
51. 3 Connect Unity Pro to the new Primary CPU 4 Access the Command Register system bits as in Step 2 and set them ti 1 NOTE Ensure Standby CPU displays RUN Standby CPU NOTE Ensure the Primary CPU and Standby CPU controllers are in RUN Primary CPU and RUN Standby CPU mode Warm Start Restarting recommendation After a global power loss while the system is running the two CPUs synchronize each other at power up primary PLC selection To insure synchronization at power recovery two methods are proposed e The two PLCs must be powered at the same time within 500 ms NOTE In this case the CPU with lower MAC address starts as Primary e The two PLCs must be powered one after the other with a minimum delay of 2 seconds NOTE This second solution allows user to select which CPU becomes Primary the first that is powered up 35010533 07 2011 139 Programming and Debugging 4 2 EFBs for Quantum Hot Standby Overview This section describes the Quantum Hot Standby elementary function blocks EFBs HSBY_RD e HSBY_ST e HSBY_WR e REV_XFER What s in this Section This section contains the following topics Topic Page HSBY_RD 141 HSBY_ST 144 HSBY_WR 147 REV_XFER 150 140 35010533 07 2011 Programming and Debugging HSBY_RD Function Description This EFB allows you to use the Hot Standby function It searches together with the other Hot Standby
52. 35010533 08 Modicon Quantum Hot Standby System User Manual 07 2011 Schneider Electric www schneider electric com The information provided in this documentation contains general descriptions and or technical characteristics of the performance of the products contained herein This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications It is the duty of any such user or integrator to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use thereof Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein If you have any suggestions for improvements or amendments or have found errors in this publication please notify us No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Schneider Electric All pertinent state regional and local safety regulations must be observed when installing and using this product For reasons of safety and to help ensure compliance with documented system data only the manufacturer should perform repairs to components When devices are used for applications with technical safety requirements the relevant instruct
53. 4 Col8 BUILT 0 ovr caps 35010533 07 2011 57 Quantum Hot Standby System 58 35010533 07 2011 Configuring and Maintaining a Quantum Hot Standby System Overview What s in this Part This part describes three important processes in using a Modicon Quantum Hot Standby system e configuring a Quantum Hot Standby system using the Unity Pro software e installing and cabling a Quantum Hot Standby system e maintaining a Quantum Hot Standby system once installed This part contains the following chapters Chapter Chapter Name Page 2 Configuring with Unity Pro 61 3 Maintaining a Quantum Hot Standby System 107 4 Programming and Debugging 121 35010533 07 2011 59 Maintaining Quantum Hot Standby 60 35010533 07 2011 Configuring with Unity Pro Overview This chapter provides an overview of using Unity Pro to configure registers and program a Quantum Hot Standby system What s in this Chapter This chapter contains the following sections Section Topic Page 2 1 Unity Pro Tabs and Dialogs 62 2 2 Reading and Configuring Registers 85 2 3 NOE Modules 96 35010533 07 2011 61 Configuration 2 1 Unity Pro Tabs and Dialogs Purpose Use the Unity Pro editor dialog tabs to e Select options for configuring the Quantum Hot Standby 140 CPU ee 60 60S e Obtain system status information What s in
54. 6 986 35010533 07 2011 247 Glossary local rack local slave MAST MIB Modbus Modbus TCP multicast A Quantum rack containing the controller a power supply and an Ethernet remote I O head module A local rack consists of 1 or 2 racks the main rack containing the remote I O head module and an optional extended rack A Quantum Ethernet remote I O network requires 1 local rack on the main ring A functionality offered by Schneider Electric EtherNet IP communication modules that allows a scanner to take the role of an adapter The local slave enables the module to publish data via implicit messaging connections Local slave is typically used in peer to peer exchanges between PLCs A master processor task that is run through its programming software The MAST task has 2 sections e IN Inputs are copied to the IN section before execution of the MAST task e OUT Outputs are copied to the OUT section after execution of the MAST task management information base A virtual database used for managing the objects in a communications network See SNMP An application layer messaging protocol Modbus provides client and server communications between devices connected on different types of buses or networks Modbus offers many services specified by function codes Modbus over TCP protocol A Modbus variant used for communications over TCP IP networks A special form of broadcast where copies of the packet are
55. 6 indicates if the CPU sync link between the two PLCs is valid If SW61 6 0 the CPU sync link is operating properly and the contents of SSW61 5 is relevant If SW61 6 1 the CPU sync link is not operating properly and the contents of SW61 5 are not relevant because the comparison of the two MAC addresses cannot be performed 35010533 07 2011 91 Configuration System Bit SW61 7 SW61 7 indicates if the Operating Systems in the Primary and Standby PLCs are the same If SW61 7 0 the Operating System versions are the same in both the Primary and Standby e CPUs e Copros e Ethernet CRPs If 3SW61 7 1 the two PLCs have at least one Operating System version mismatch between the Primary and Standby e CPUs e Copros e Ethernet CRPs For details about the component mismatch s refer to the Firmware Mismatch Register see page 93 System Bit SW61 8 3SW61 8 indicates if the Operating Systems in the 2 Copros are If 3SW61 8 0 the two Copros have the same Operation System version If 3SW61 8 1 the two Copros have different Operation System versions System Bit SW61 12 and 13 lf sSwW61 12 1 the SW61 13 indicates the address of the NOE e If sSw61 13 1 the address is the configured IP address 1 e lf sSw61 13 0 the address is the configured IP address lf SSW61 12 0 3SW61 13 is not relevant System Bit SW61 15 SW61 15 indicates the Copro Hot Standby activity If SSW61 15 1 means th
56. AST tasks occur in sequence with no reference to the system clock without any delay between tasks other than a very brief period of system processing Almost immediately after one task completes another begins Therefore the actual duration of a MAST task in the cyclic mode can vary significantly depending on the size and activity of the application and the number of inputs and outputs to be controlled t T1 T2 T3 T4 Hot Standby User logic Hot Standby User logic system function Output Input system function Gestion 2 Section 3 Output MAST task cycle n MAST task cycle n 1 168 35010533 07 2011 Programming and Debugging e Periodic mode In the periodic execution mode MAST tasks are sequenced according to a countdown timer which is referenced to the system clock This countdown timer may be set for a period between 1 and 255 ms If the countdown expires before the end of the task the task completes normally If this occurs regularly the system will appear as if the cyclic MAST task execution mode had been selected However some applications such as process control do require regular cycle times If this is the case for your application confirm that the task period is of sufficient length to avoid cyclic like behavior T1 T2 T3 T4 I5 Hot Standby User logic Periodic Hot Standby User logic tee system function Output sae Input system function Output Sie A MAST task cycle n MAST task cycle n 1 E
57. BOCOD h e big endian x 0A x 1 0B x 2 0C x 3 0D e little endian x 0D x 1 0C x 2 0B x 3 0A It is perhaps easier to remember these by their uncorrupted forms which indicate that you first put the big end in big endian or little end in little endian error notification The output associated with the optional input EN If ENO is set to 0 either because EN 0 or if a runtime error is detected e The status of the function block outputs remains the same as it was during the previous scanning cycle that executed correctly e The output s of the function as well as the procedures are set to 0 A 10 Mb s 100 Mb s or 1 Gb s CSMA CD frame based LAN that can run over copper twisted pair or fiber optic cable or wireless The IEEE standard 802 3 defines the rules for configuring a wired Ethernet network the IEEE standard 802 11 defines the rules for configuring a wireless Ethernet network Common forms include 10BASE T 100BASE TX and 1000BASE T which can utilize category 5e copper twisted pair cables and RJ45 modular connectors A network communication protocol for industrial automation applications that combines the standard internet transmission protocols of TCP IP and UDP with the application layer common industrial protocol CIP to support both high speed data exchange and industrial control EtherNet IP employs electronic data sheets EDS to classify each network device and its functionalit
58. EFBs the configuration of the respective Quantum PLC for the required components These components refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed The HSBY_RD EFB checks System Word see Unity Pro Program Languages and Structure Reference Manual SW60 to see if a Hot Standby configuration exists e f a Hot Standby configuration is present the contents of the command register are returned and the HSBY_ConfigurationFound output parameter is set to 1 e If a Hot Standby configuration is not present the contents of the command register are returned and the HSBY_ ConfigurationFound output parameter is set to 0 EN and ENO can be configured as additional parameters Representation in FBD Representation HSBY_RD_ Instance HSBY_RD HSBY HSBY_ConfigurationFound INV_KEY InvalidateKeypad PCA _RUN PLC_A Running PCB RUN PLC_B Running SBY_OFF StandbyOff EXC_UPD ExecUpdate SWP_MB1 SwapAddressModbusPort1 SWP_MB2 SWP_MB3 35010533 07 2011 141 Programming and Debugging Representation in LD Representation HSBY_RD_Instance Representation in IL Representation HSBY_RD EN ENO HSBY_ConfigurationF ound HSBY C InvalidateKeypad INV_KEY D PLC_A Running PCA RUN C PLC B Running PCB_RUN p StandbyOff SBY_OFF D Expt EXC_UPD SwapAddressMod
59. French 35014793 English 35014794 German 35014795 Spanish 35014796 Italian 35012191 Chinese You can download these technical publications and other technical information from our website at www schneider electric com Product Related Information User Comments 4 WARNING UNINTENDED EQUIPMENT OPERATION program install alter and apply this product Follow all local and national safety codes and standards equipment damage The application of this product requires expertise in the design and programming of control systems Only persons with such expertise should be allowed to Failure to follow these instructions can result in death serious injury or We welcome your comments about this document You can reach us by e mail at techcomm schneider electric com 35010533 07 2011 11 12 35010533 07 2011 Introducing the Modicon Quantum Hot Standby System 35010533 07 2011 Introducing Modicon Quantum Hot Standby 35010533 07 2011 Modicon Quantum Hot Standby System 1 Overview This chapter briefly describes the Modicon Quantum Hot Standby system and some of the concepts needed to understand the system Also included is information about the Hot Standby Safety system only available with S908 RIO and compatible equipment What s in this Chapter This chapter contains the following sections Section Topic Page 1 1 Quantu
60. Init Start Stop Init Fields Available Description Screens Display Start PLC Press lt ENTER gt to confirm Start Pressing lt ENTER gt starts the controller Stop PLC Press lt ENTER gt to confirm Stop Pressing lt ENTER gt stops the controller Init PLC Press lt ENTER gt to confirm Init Pressing lt ENTER initializes the controller On safety processors this command is only available in the maintenance mode Submenu for PLC Operations Hot Standby CPU Screen Field Option Description Hot Standby State State PRIMARY CPU Controller serves as Primary unit read only STANDBY CPU Controller serves as Standby unit Offline Controller is neither Primary nor Standby unit Hot Standby Mode Mode RUN STS steady Controller is active and is either serving as modifiable only Primary PLC or able to take over the Primary if the key switch CPU role if needed is i JE STS Controller is transferring updating When the un og ed flashing transfer is done RUN stays on steady position OFFLINE STS steady Controller is taken out of service without stopping it or disconnecting it from power If the controller is the Primary PLC when the mode is changed to Offline control switches to the Standby PLC If the Standby PLC changes to Offline the Primary CPU continues to operate without a backup STS Controller is transferring updating When the flashing transfer is done OFFLINE stays on steady
61. M_ SRAM PCMCIA Prog 7168kb Data 6976kb TSX MRP C 01M7 SRAM PCMCIA Prog 1792kb Data 1600kb TSX MRP C 768K __ SRAM PCMCIA Prog 768kb Data 576kb SRAM Data storage TSX MRP F 004M SRAM PCMCIA Data or Files 4096kb TSX MRP F 008M SRAM PCMCIA Data or Files 8192kb 6 Add or replace the desired memory 80 35010533 07 2011 Configuration Configuring the Modbus Plus Communication Type Configuring with Unity Pro This procedure configures the Modbus Plus communication type Step Action 1 If not opened open the Local Bus configuration editor Go to the local bus in the Structural View of the Project Browser Open the Local Bus editor either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open Results A graphical representation of the local bus appears Point to the Modbus Plus port No 3 Double click or right click on the Modbus Plus port Results The Submodule dialog appears The General tab is the default wi 1 2 MBP l MBP ry Overview m General E VO objects Communication Type M DIO Bus M Peer Cop Please choose a link No Link v 4 Select one or both Communication Type e DIO bus Peer Cop 35010533 07 2011 81 Configuration Non Transfer Area and R
62. OE B or after the NOE A watchdog timer times out it stops all its Ethernet services e lf it has received a UDP request NOE B sends a UDP response to NOE A e f its watchdog timer has timed out NOE B does not send a UDP response NOE A then swaps its IP address and starts the Secondary services NOE B swaps IP addresses and starts Ethernet services as Primary NOE After NOE A senses that its local CPU changes from Offline to Standby it takes the Secondary IP address 9 NOE B now becomes the Primary NOE 10 NOE B opens all client connections listens for all server connections and reestablishes those connections 11 NOE A listens for all server connections and reestablishes those connections NOTE During the Hot Standby switchover there is a loss of communication during 500 ms between the PLC and the HMI and or Unity Pro 35010533 07 2011 101 Configuration Going to Offline When either the CPU stops or the Hot Standby CPU goes to Offline mode two events occur 1 NOE goes to the Offline mode 2 NOE uses the IP address of the present configuration The IP address assignment when going offline Hot Standby State IP Address Assigned Is Primary CPU to Offline Configured IP address if other controller does not go to Primary CPU mode Standby CPU to Offline Configured IP address 1 NOTE For more information refer to NOE IP Address Assi
63. OTE When a CPU is in the RUN mode its A B assignment cannot be changed It must be in the STOP mode to change its assignment 22 35010533 07 2011 Quantum Hot Standby System The two CPU cannot have the same A or B assignment e Ifa CPU starts with the same assignment as the other CPU this CPU goes to the STOP mode displays the Hot Standby menu and waits for an assignment from the keypad e If you replace one of the PLCs the identification of PLC A and PLC B may no longer align with the Primary and Standby operating modes The same thing is true for any physical labels you might apply to your PLCs to distinguish them in your system CRP Head modules IP addresses are based on the user configured IP address in Unity Pro and the A B assignment Establishing the Primary and Standby Controllers If the system is properly configured the first Hot Standby PLC to which power is applied assumes the role of the Primary controller Therefore you can determine controller roles by delaying the application of power to one PLC using a time lag relay or some related means When you apply power simultaneously to two properly configured Hot Standby PLCs the firmware automatically assigns the role of the Primary controller based on the A B assignment The PLC that is A becomes the Primary controller Identical RIO Head Modules Required In addition to requiring two identical controllers a Quantum Hot Standby system requires a minimum of
64. P mismatches unless allowed Local I Os are updated but not the Remote I Os For a Quantum Ethernet I O configuration the Standby PLC checks the RIO Drop connected Run Offline Depending on the setting of Behavior of the CPU in Run Offline mode see page 78 the PLC executes e all sections of the MAST task application program but the I O is not written e the first section of the MAST task of the application program but the I O is not written e none of the application program MAST task This state is either manually activated or by the CPU which detects the state by itself If there is no Primary PLC the CPU tries to change to the Run Primary CPU state If the Primary PLC exists the PLC checks each cycle to see if can go to the Run Standby CPU state There are several commands are available e Application transfer e Any online command e STOP command e HALT command Stop Offline The PLC neither executes the application program nor controls the process It is not part of the Hot Standby system Two commands are available e Application transfer e RUN command e Init The run offline and the stop offline state can occur in the Primary CPU and in the Standby CPU at the same time 35010533 07 2011 123 Programming and Debugging Table of States The following table shows the possible states of the 2 controllers of a Hot Standby configuration Controller A state Run Pri
65. S 5 F ox B aSr h AA n gS drivers functions drivers drivers functions drivers MAST task cycle N 1 MAST task cycle N In this case the execution time of the Hot Standby part T2 is increased with the time required to copy the data base from the CPU memory to the Hot Standby Copro shared memory The execution time of the last MAST cycle SW30 T1 T2 T3 T4 with T2 T2 time to copy the data base from the CPU memory to the Copro shared memory There is no need for a Wait state to be added to the Primary MAST task because the User Logic covers the Copro data transfers 2 The data transfer has an impact on the Primary MAST task duration p MAST task cycle N MAST task cycle N 1 gt T1 T3 T4 Bes Input Hot ae aan a a Output Wait If Input jot Standby system User Logic Output Wai gs drivers E EEA Cg drivers al drivers functions drivers al 2 x gs Data transfer g VYVYVYYVYYY S Data transfer ip z8 a x Input Hot Standby system f User Pee RA Input fot Standby system aks em 28 drivers functions eee drivers drivers functions MAST task cycle N 1 MAST task cycle N In this case the time to copy to the Copro shared memory increases T2 compared to T2 170 35010533 07 2011 Programming and Debugging Also because of the increased data the data transfer between the Primary and Standby Copros requires a Wait state in the Primary MAST task The execution time of
66. Standby yes yes Switchover yes yes EFB Swap no yes Keypad yes yes Application mismatch yes no OS Upgrade yes if Standby CPU is in Stop Offline no Application Transfer yes no 35010533 07 2011 55 Quantum Hot Standby System Operating Modes of the Safety PLC Introduction The default behavior of the Quantum Safety PLC is to perform Safety Functions to achieve and to maintain the Safe state of a process Nevertheless you must be able to debug and to maintain your project Use the Safety Mode to control your process and the Maintenance Mode for debugging and refining your project In Maintenance Mode the I O and CPU modules are still executing the diagnostics and establishing the Safe state if a fault is detected Only the application program and the application data which may be changed in Maintenance Mode are not checked NOTE To program a Safety PLC Unity Pro XLS is required Safety and Maintenance Mode Features The operating mode of the Quantum Safety PLC depends on events such as application exception power on off and so on The functions available in Unity Pro XLS depend on the operating mode Switching between the modes requires defined conditions and follows certain procedures For details see the chapter Switching Between Safety and Maintenance Mode see Unity Pro XLS Software Operating Mode Manual Safety PLC Specifics in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics You ca
67. There is only one root in the loop CRP B has a higher priority than CRP A but lower than the CRA RIO Drops and DRSs therefore it is the backup root If CRP A becomes inoperative CRP B becomes the root However after a Switchover if CRP A is still healthy the root does not change no loop re configuration If CRP B starts without CRP A in the loop CRP B becomes the root If CRP A starts while CRP B is the root the loop is re configured and CPR A becomes the root The root CRP reports the status of the Ethernet RIO loop This information is then transferred to the CPU B during the next scan 46 35010533 07 2011 Quantum Hot Standby System Hot Standby System without RIO The Quantum Hot Standby system can operate without any Remote I O installed but must have linked CRPs installed NOTE This type of S908 Hot Standby system is not compatible with CCOTF Drop Hold Up Time The Drop hold up time must be configured for each Drop module in the Hot Standby system e for a S908 system 1200 ms e fora Quantum Ethernet I O Remote I O Drop 4 times the MAST task watchdog e fora Modbus TCP Distributed I O Drop must be e must be larger than the connection timeout e 4 times the MAST task watchdog 1 second e fora Quantum Ethernet I O Distributed I O Drop 4 times the MAST task watchdog 1 second NOTE Schneider Electric devices can have different configurations of drop holdup time and connection timeout but th
68. U 2 Go to Swap Address at Switchover area 2 Access the Command Register 3 Deselect Modbus Port 1 System bit ssw60 8 4 Verify modifications 3 Set the bit to 1 5 Download application program to controller The default is 0 6 Perform Switchover 7 Ensure Standby CPU switch to Primary CPU 8 Perform application program transfer 35010533 07 2011 133 Programming and Debugging Using Hot Standby Menu in Editor Using the Command Register system bit sSw60 8 When a Switchover occurs e f you change the options the port addresses are not affected until Switchover occurs e If NOM modules are used in the configuration the offset of the Modbus address is 32 after the Modbus Plus address Switchover e Switchover with swapping Modbus addresses If controller A is the Primary CPU controller and its Modbus port has an address of 1 then the default addresses for the comparable port on controller B the Standby CPU is 129 which is 1 plus the offset of 128 If controller B becomes the Primary CPU controller as the result of a Switchover its Modbus port assumes the address of 1 and the comparable port on controller A assumes the address of 129 e Switchover without swapping Modbus addresses If controller A is the Primary CPU controller and its Modbus port 1 address is 1 then that port address remains at 1 after the switchover occurs Likewise if controller B becomes the Primary CPU contr
69. ailure to follow these instructions can result in death serious injury or equipment damage Upgrading Firmware without Stopping Under normal operating conditions both controllers in a redundant system must have the same versions of firmware There are checks by the controllers to detect if there is a mismatch in firmware Normally when a mismatch exists performing a Switchover is not be possible because the Standby CPU controller is not allowed to go to the RUN Primary mode However to allow a firmware upgrade without stopping the application set the Command Register system bit SW60 4 see page 88 to 1 NOTE Enabling the firmware upgrade without stopping the application overrides the process of checking whether the Primary CPU and Standby CPU are configured identically As soon as the firmware upgrade is finished set sSw60 4 to 0 for an upgrade without stopping NOTE An upgrade is only possible if the firmware used is compatible the target hardware 198 35010533 07 2011 Firmware Executing the Operating System Upgrade Procedure General Using Modbus Upgrade Procedure Perform an Operating System upgrade using the OSLoader tool Use one of two communication methods available in the OSLoader e Modbus RTU e Modbus Plus List of the useful material e PC with Unity Pro and OSLoader e cable 110 XCA 282 Oe and adaptor 110 XCA 203 00 All the references about the keyboard are detailed in the Quan
70. alPrograms HSBY ModuleSwitchA HSBY ModuleSwitchB Description of output parameters Parameter Datatype Meaning HSBY BOOL 1 Hot Standby configuration found 0 Hot Standby configuration not found THIS OFF BOOL 1 This PLC is offline 0 This PLC is not offline THIS PRY BOOL 1 This PLC is the Primary CPU PLC 0 This PLC is not the Primary CPU PLC THIS SBY BOOL 1 This PLC is the Standby CPU PLC 0 This PLC is not the Standby CPU PLC REMT OFF BOOL 1 The other remote PLC is OFFLINE 0 The other remote PLC is not OFFLINE REMT PRY BOOL 1 The other PLC is the Primary CPU PLC 0 The other PLC is not the Primary CPU PLC REMT SBY BOOL 1 The other PLC is the Standby CPU PLC 0 The other PLC is not the Standby CPU PLC LOGIC_OK BOOL 1 The programs for both PLCs are identical and application mismatch is active 0 The programs are not the identical THIS ISA BOOL 1 This PLC chose the CPU with the lower IP address between both Hot Standby CPUs This is the Hot Standby CPU A 0 This is not CPU A THIS ISB BOOL 1 This PLC chose the CPU with the higher IP address between both Hot Standby CPUs This is the Hot Standby CPU B 0 This is not CPU B 146 35010533 07 2011 Programming and Debugging HSBY_WR Function Description This EFB allows you to use the Hot Standby function It searches together with the other Hot Standb
71. andby configuration 35010533 07 2011 67 Configuration Automatic Start in RUN The enabling of this option automatically changes the PLC to Run mode see Unity Pro Program Languages and Structure Reference Manual on cold start Two types of start e inthe absence of a PCMCIA memory card the PLC starts on the contents of the internal RAM of the processor e inthe presence of a PCMCIA memory card it is its content which fixes the start A WARNING UNWANTED APPLICATION RUN ON PLC COLD START With the Automatic start in RUN option enabled the following events will trigger the run of the application on cold start e Inserting the PCMCIA card when the PLC is powered e Replacing the processor while powered e Unintentional or careless use of the reset button e Powering up a PLC with a defective battery after a power outage To prevent the run of the application on cold start e use the STOP input on Premium PLCs e use the switch on the front panel of the processor for Quantum PLCs Failure to follow these instructions can result in death serious injury or equipment damage MWi Reset On application download e if you check the box the MWi values will be re initialized or set to 0 e if you uncheck the box the MWi values will set to 0 On cold start or after inserting the PCMCIA memory card e if you check the box the MWi values will be re initialized or set to 0 e if you uncheck the bo
72. andby redundancy Only a subset of Unity Pro s debug features can be used during this stage NOTE See Debugging Your Hot Standby Application see page 175 for further details Primary Standby or Offline Execution In a Quantum Hot Standby system your application is executed differently depending on whether it is running on the Primary PLC or on the Standby PLC The full application program is executed on the Primary controller while the Standby only runs the first section of the MAST task According to the user configuration the Offline PLC can execute e full program e only the first section of the MAST tack e none of the MAST program task This is important because some system behaviors must be commanded in the first section of the MAST tack For example the Standby PLC s Reverse Transfer Registers SW62 SW65 can contain custom diagnostic information for use by the full program on the Primary PLC 35010533 07 2011 51 Quantum Hot Standby System 1 2 Hot Standby Safety CPUs Overview This section describes the use of the Quantum Safety CPU 140 CPU 671 60S ina Quantum Hot Standby system NOTE This CPU cannot be used in a Quantum Ethernet I O Hot Standby system What s in this Section This section contains the following topics Topic Page Hot Standby Safety CPU Specifics 53 Operating Modes of the Safety PLC 56 52 35010533 07 2011 Quantum Hot Standby System
73. at the Copro device is set up correctly and working If SSW61 15 0 means that the Copro device is not operating correctly 92 35010533 07 2011 Configuration Hot Standby Firmware Mismatch Register Bits in the Firmware Mismatch Register SW69 The Hot Standby Firmware Mismatch Register SW69 gives information about the firmware levels in the Primary and Standby main rack components e The firmware levels in the Primary and Standby CPUs Copros and Ethernet CRPs are compared e Ifa bit 0 the Primary and Standby components have the same firmware versions e Ifa bit 1 the Primary and Standby components have different firmware versions e Bits 0 to 15 correspond to rack positions 16 to 1 Slots 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 WWE bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 140 So Proc mismatch CoPro mismatch CRP mismatch 35010533 07 2011 93 Configuration Using Initialized Data Loading at Cold Start Time Updating Online The Quantum Hot Standby CPUs support initialized data Initialized data allows you to specify Cold Start initial values using Unity Pro for the data that are to be loaded at cold start time for more information refer to the Unity Pro Program Languages and Structure Reference Manual see Unity Pro Program Languages and Structure Reference Manual You can also update the initial values online but e Amismatch situation occu
74. ation Program Transfer As soon as a Primary CPU controller detects a blank controller the Primary CPU transfers the program to the blank controller which becomes the Standby CPU After application program transfer both controllers have identical application programs NOTE The controllers need to have the same configuration with the same or no PCMCIA cards 162 35010533 07 2011 Programming and Debugging Unity Pro ATP Command If Unity Pro is connected to the Primary PLC it can launch an APT from the PLC menu Unity Pro XL lt No name gt File Edit View Services Tools Build PLC Debug Window Help m Disconnect Ctri K ak mE Q Project Browser Structural view Compare 3 Stati on in Transfer Project to PLC Ctri L Configuration Transfer Project from PLC Ctrl Shift L _ Derived Data Types rivi y Derived FB Types Gi Transfer Project from Primary to StandBy PLC 4 ee S nerances Transfer Data from File to PLC I Communication Program Transfer Data from PLC to File C Animation Tables e Operator Screens h Documentation Stop Ctri R Update Init Values with Current Values Project Backup gt Memory Consumption State Ram Viewer If Unity Pro is connected to the Standby PLC this menu item is not available Identical Configurations and Application Programs After the transfer the Primary CPU and Standby CPU have identical con
75. ation given by bit 13 is not revelant 1 Information given by bit 13 is valid 0 NOE address set to IP 1 NOE address set to IP 1 0 The hot standby has not been activated 1 The hot standby is active 90 35010533 07 2011 Configuration System Bits SW61 0 to SW61 3 These four bits display the states of the local and remote Hot Standby controllers Status of local PLC e SW61 1 0 and SW61 0 1 means the local PLC is in OFFLINE mode e SW61 1 1and Sw61 0 0 means the local PLC is running as the Primary CPU e SW61 1 1and Sw61 0 1 means the local PLC is running as the Standby CPU Status of remote PLC e 3SW61 3 0 and Sw61 2 1means the remote PLC is in OFFLINE mode e SW61 3 Land sw61 2 0 means the remote PLC is running as the Primary CPU e SW61 3 1 and SwW61 2 1 means the remote PLC is running as the Standby CPU e sSW61 3 Oand swel 2 0 means the remote PLC is not accessible System Bit SW61 4 3SW61 4 1 means that a application mismatch has been detected between the Primary CPU and Standby CPU controllers SW61 4 depends on SW60 3 being set to 1 System Bit SW61 5 SW61 5 identifies the order reported by the Copro at start time The order depends on the range of the MAC addresses e Ifthe A B designation is A then sSw61 5 0 e Ifthe A B designation is B then sSw61 5 1 NOTE The controller LCD displays either A or B System Bit SW61 6 SW61
76. ation while the process remains redundant Build Project Function Use the Build Project function to perform an application mismatch with Unity Pro NOTE Schneider Electric recommends that the Rebuild All Project not be used to create an application mismatch The Rebuild All Project function creates a completely new project even if nothing has been changed in the application 182 35010533 07 2011 Application Modifications Causing a Mismatch In the Quantum Hot Standby system all memory is allocated by a memory manager which automatically maps the logical memory to physical memory locations This dynamic data memory layout is the heart of the programming flexibility and platform independence that Unity Pro provides but on a Quantum Hot Standby system with different user logic dynamic data memory layout makes a cyclical data update very difficult Therefore mismatches occur Allowing a Mismatch An application mismatch without stopping the process controlled by the application program allows the following e modification edit online of an application program in the Standby CPU while the Primary CPU controls the process see page 188 e modification edit online of an application program in the Primary CPU while the Primary CPU controls the process see page 189 e download an offline modified application program to the Standby CPU and perform a Switchover to run the modified application program e perform a CCOTF
77. bits If the key switch is in the unlocked position fields are modifiable System Info Menu Structure of System Info menus and submenus Quantum System Info gt __ System Info _ Stop Code Stop Code gt _ System Info Rev Ldr Firmware Info gt OS EH HH HE HE __ System Info Hardware Info gt HW Rev 0000 System Info Copro Rev Copro Info gt IE System Info PLC Communications submenus System Info Screen Fields Available Option Available Description Displays Stop Code HEHH Machine stop code Description Description of the machine stop code Firmware Info Rev Ldr OS revision OS H H HH HH OSLoader revision Hardware Info HW Rev Hardware revision Copro Info IE Copro revision Fields are read only 232 35010533 07 2011 Controls and Displays LCD Settings Menu LCD Settings menus and submenus Quantum LCD Settings gt LCD Settings 0 is black LCD Contrast 100 is green LCD Settings On LCD Light time Off 1 Min 5 Min 10 Min 15 Min LCD Contrast settings submenu LCD Screen Fields Available Description Contrast Screen Displays LCD Contrast HHH Use the arrow keys to adjust the setting e Up arrow increases percent brighter e Right arrow decreases pe
78. busPort1 SWP_MBI1 oY SWP_MB2 SWP_MB3 CAL HSBY_RD Instance HSBY gt HSBY ConfigurationFound INV_KEY gt InvalidateKeypad PCA _RUN gt PLC_A Running PCB RUN gt PLC_B Running Representation in ST Representation SBY OFF gt StandbyOff EXC_UPD gt ExecUpdate SWP_MB1 gt SwapAddressModbusPortl1 HSBY_RD Instance HSBY gt HSBY ConfigurationFound INV_KEY gt InvalidateKeypad PCA _RUN gt PLC_A Running EXC_UPD gt ExecUpdate PCB RUN gt PLC_B Running SBY OFF gt StandbyOff SWP_MB1 gt SwapAddressModbusPortl 142 35010533 07 2011 Programming and Debugging Parameter Descriptions Description of the output parameters Parameter Data type Meaning HSBY BOO Li 1 Hot Standby configuration found 0 Hot Standby configuration not found NV_KEY BOO 1 The submenu for the Hot Standby PLC button is disabled 0 The submenu for the Hot Standby PLC button is not disabled PCA RUN BOO For the local rack PLC with the Hot Standby CPU A 1 Command Register is selected for RUN 0 Command Register is selected for OFFLINE PCB RUN BOO For the local rack PLC with the Hot Standby CPU B 1 Command Register is selected for RUN 0 Command Register is selected for OFFLINE SBY_OFF BOO 1 722 0 The Standby PLC switches to the OFFLINE mode as soon as both PLCs receive a different program EXC_UPD BOO
79. by CPU determines the cause 2 Standby CPU assumes control by becoming the Primary CPU Primary CPU does not receive a valid response from the Standby CPU Primary CPU operates as a non redundant Standalone PLC Finding Diagnostic Information with Unity Pro Detected errors and Switchovers are logged in the diagnostic buffer To view the buffer log select from the menu Tools Diagnostic Viewer 112 35010533 07 2011 Maintaining Detected Inoperative Conditions on Rack CPU Copro and RIO Head Communication Timeouts On every scan the transfer of data between Primary and Standby CPUs insures that they are synchronized Timers in this communication are the first level of error detection 1 2 3 The Primary CPU waits for the Standby acknowledgement A timeout here is due to an inoperative e Primary Copro e Standby CPU The Standby CPU waits for the Primary acknowledgement A timeout here is due to an inoperative e Standby Copro e Primary CPU The Primary Copro waits for the Standby acknowledgement A timeout here is due to an inoperative Standby PLC CPU Sync Link Interruption Inoperative Rack There are 3 possible cases Copro Copro link interruption This condition is detected by both Copros The Standby PLC detects the interruption and goes Offline The Primary PLC detects that the Standby PLC has disappeared reports it to the log and continues to scan the I O as a Standa
80. cation Modifications e updating Standby CPU If a complete application program transfer is done to the controller that did not receive the modified changes then both controllers have equal application programs and the Standby CPU controller is fully updated e deleted and re declared variables If due to a modification a global variable has been deleted first and then re declared this variable would be treated as a new variable even if the same name is used The update procedure must then be followed to bring the controllers to the same state NOTE The system reserves space for these variables whether they are used in the controller application program or not Unused variables consume space and require time to be transferred from the Primary CPU to the Standby CPU Therefore in the Primary CPU application program Schneider Electric does not recommend using variables that are defined but not used 35010533 07 2011 185 Application Modifications Online or Offline Modifications and Application Mismatch Modifying Application Programs Normally once a fault tolerant redundant system is configured programmed and controlling its process the system is not shut down not even for periodic maintenance However there may be situations when you may need to make modifications to the application program and continue to control the process The Application Mismatch feature allows you to modify application programs online or
81. cessing its information This means that the Primary controller sometimes has to wait for the Standby to finish processing and that the Standby sometimes has to wait for information from the Primary This requirement for aligned program execution requires that the task execution cycle is deterministic For this reason only MAST tasks are used when programming a Quantum Hot Standby system For more details about the requirement for MAST tasks and their execution in a Hot Standby context see Exclusive Use of MAST Tasks see page 49 and Adjusting MAST Task Properties see page 168 While this manual covers Switchover events in some detail a few general statements aid understanding of these subsequent topics e Much of the benefit of the Quantum Hot Standby system is its ability to detect various error conditions and when necessary initiate a Switchover The type of error detected determines the duration of the Switchover event For example e Ifthe Primary PLC is online and can communicate with the Standby PLC but detects an error that requires a Switchover it commands the initiation of a Switchover event In this instance the Switchover duration is just that required for the Switchover event which usually takes about 1 5 2 MAST tasks e Ifthe Primary PLC is no longer operable or all communications between the Primary and Standby controllers are lost an automatic Switchover occurs The duration of this type of Switchover equals 2 MAST
82. changing either from Primary Run or Standby Run to the Offline mode e received an Offline command Non Configured State In certain circumstances such as when no valid application is loaded on a PLC a Hot Standby controller enters and report itself as being in a Non Conf non configured state which is not considered as an operating mode 35010533 07 2011 45 Quantum Hot Standby System Remote I O Management Overview Remote I O is managed only by the Primary CPU which has all of the RIO features diagnostics data exchanges etc available to it The CRP Head modules are automatically configured and detect if their CPU is part of a redundant Hot Standby system or Standalone system A Quantum Hot Standby system is either e S908 system e Quantum Ethernet I O Ethernet system Primary and Standby CRP Head modules report their connection status to their CPUs Quantum Ethernet I O Ethernet CRP Head Modules IP Addresses A CRP module obtains its IP address assignment at power up as follows If the CRP is connected to Then the IP address assigned is CPUA IP address configured in Unity Pro for A CPU B IP address configured in Unity Pro for B NOTE During a Switchover the Quantum Ethernet I O Ethernet CRPs do not switch IP addresses Quantum Ethernet I O Ethernet CRP Modules and RSTP 2004 Since the CRP A has the lowest priority in a Ethernet daisy loop therefore it is the RSPT root
83. ck speed 266 MHz Coprocessor Yes Built in Ethernet Watchdog timer 250 ms software adjustable RAM 2 MByte IEC program memory and or application data and configuration IEC program memory maximum with PCMCIA card 1024 kByte 7168 kBytes Program Execution Time Kilo Instruction executed per millisecond Kins ms Execution time per instruction ms Kins 100 Boolean 65 Boolean 35 digital 100 Boolean 65 Boolean 35 digital 10 28 10 07 0 097 0 099 NOTE When considering the execution time with the RAM or the PCMCIA card the values are identical as when the program execution takes place within the CACHE memory 35010533 07 2011 209 Additional Information Reference Capacity Discrete bits 64 k any combination Registers words 64 k max Remote I O Max I O words drop 64 in 64 out Max number of remote drops 31 This information can be a mix of discrete or register I O For each word of configured I O one of the I O words must be subtracted from the total available Battery and Clock Battery type 3 V Lithium Service life 1 2 Ah Shelf life 10 years with 0 5 loss of capacity year Battery load current power off typical 14 uA maximum 420 uA TOD clock 8 0 s day 0 60 C Diagnostic Power up RAM RAM address
84. contains the following chapters Chapter Chapter Name Page A Quantum Hot Standby Additional Information 205 B Quantum Hot Standby Controls Displays and Menus 219 35010533 07 2011 203 204 35010533 07 2011 Quantum Hot Standby Additional Information A Overview This appendix describes the necessary cables design specifications error codes What s in this Chapter This chapter contains the following topics Topic Page Fiber Optic Sync Link Cable in a Hot Standby System 206 140 CPU 671 60 Specifications 209 140 CPU 671 60S Specifications 211 140 CPU 672 61 Specifications 213 CRP Remote I O Head Processor Detected Error Patterns 215 TextIDs 217 35010533 07 2011 205 Additional Information Fiber Optic Sync Link Cable in a Hot Standby System Schneider Electric Recommends Recommendations e For 140 CPU 671 60 modules use up to 4 km 2 5 mi of 62 5 125 um graded index duplex multi mode glass fiber usually referred to as OM1 type fiber This type of fiber is rated at maximum attenuation of 1 5 dB per km maximum at 1300 nm e For 140 CPU 672 61 modules use up to 16 km 9 9 mi of 9 125 um duplex single mode glass fiber usually referred to as OS1 or G652 type fiber This type of fiber is rated at maximum attenuation of 0 35 dB per km maximum at 1300 nm e Wherever possible use a multifiber cable since the cable is less expens
85. control of the system hypertext transfer protocol A networking protocol for distributed and collaborative information systems HTTP is the basis of data communication for the web 35010533 07 2011 245 Glossary I O scanning IEC 61131 3 IGMP implicit messaging INT Continuously polling the I O modules to collect data and status event and diagnostics information This process monitors inputs and controls outputs International standard programmable logic controllers Part 3 programming languages internet group management protocol This internet standard for multicasting allows a host to subscribe to a particular multicast group instruction list A series of basic instructions similar to assembly language used to program processors Each instruction is made up of an instruction code and an operand UDP IP based class 1 connected messaging for EtherNet IP Implicit messaging maintains an open connection for the scheduled transfer of control data between a producer and consumer Because an open connection is maintained each message contains primarily data without the overhead of object information and a connection identifier integer encoded in 16 bits The upper lower limits are as follows 2 to the power of 15 to 2 to the power of 15 1 Example 32768 32767 2 1111110001001001 16 9FA4 inter controller network An Ethernet based network that is part of the control network and pro
86. controller e The output Q objects and any output forcing settings e EDT DDT when they are located by the user e Sequential Function Chart SFC data types e UNLOCATED e EDT DDT when they are located by the system e Function Block EFB DFB data types The maximum amount of located data that can be transferred in the database is 128 KB for e 140 CPU 671 60 e 140 CPU 671 60S e 140 CPU 672 61 The maximum amount of unlocated data that can be transferred in the database is for e 140 CPU 671 60 1024 kB e 140 CPU 672 61 1536 kB NOTE The safety processor 140 CPU 671 60S does not use unlocated data For specific information about the command words and adjustment parameters and the maximum memory sizes of these areas refer to the Unity Pro Operating Modes Manual see Unity Pro Operating Modes For more information on the database transfer including information about the application of this information by the Standby controller refer to Quantum Hot Standby Data Transfer see page 159 42 35010533 07 2011 Quantum Hot Standby System Synchronized Program Execution Switchover Events By itself the regular exchange of system and user application data is not enough to synchronize the Standby controller with the Primary controller It is also important that the cyclical execution of tasks on each controller remains aligned so that neither controller races ahead of the other controller that is still pro
87. creen displays the following information Fields Available Options Description Available Mode M Maintenance Mode only on safety processors S Safe Mode only on safety processors State RUN Application program is running RUN Prim RUN as Primary CPU processor only on Hot Standby processors RUN Stby RUN as Standby CPU processor only on Hot Standby processors RUN OffL RUN Offline Hot Standby processor not connected to another processor STOP Application program is NOT running STOP Offline No Conf Processor has no application program Halt Detected state error in maintenance mode for safety modules 35010533 07 2011 225 Controls and Displays Fields Available Options Description Available BatL Indicates battery health e Steady battery is low e No message battery is OK Port USB Indicates that the port has activity Modbus MB Indicates Modbus Plus activity Plus mb No activity Dup Duplicate MB address ERR Detected Modbus communications error INI Initial Network Search Modbus 232 Serial port activity for RS 232 485 Serial port activity for RS 485 PCM 1 Displayed status indicates battery health of the PCMCIA card in slot 1 e Steady battery is OK e Flashing battery is low only for green PCMCIAs version lt 04 2 Displayed status indicates battery health of the PCMCIA card in slot 2 e Steady battery is
88. ction Topic Page 4 1 Operating Modes and Switchover Information 122 4 2 EFBs for Quantum Hot Standby 140 4 3 Equipment Restrictions 153 4 4 PLC Communications 158 4 5 Developing A Hot Standby Application 167 4 6 Debugging a Hot Standby Application 175 35010533 07 2011 121 Programming and Debugging 4 1 Operating Modes and Switchover Information Overview This section describes the Quantum Hot Standby operating modes switchover behavior and performance What s in this Section This section contains the following topics Topic Page Operating States and Modes 123 System Performances 127 Conditions for Switchover 128 Switchover Behavior during Application Mismatch 130 Handling Network Addresses at Switchover 132 Testing Switchover of a Quantum Hot Standby System 137 122 35010533 07 2011 Programming and Debugging Operating States and Modes Description of the Hot Standby States e Run Primary CPU The Primary CPU PLC executes the application program and updates the remote I Os If a Standby CPU is present the Primary CPU sends application data and I O to it Run Standby CPU During each cycle the PLC e checks that a Primary PLC exists e checks that there is no command from the Primary PLC e indicates to the Primary CPU that it is running well and is ready to take over the process if the Primary CPU stops e checks that there is no CPU Copro or CR
89. ctive that is not linked to the Hot Standby mode 35010533 07 2011 105 Configuration Overloaded Network Overview Example Impact on CPU If an NOE 771 xx is used to run in a 100Mb s Ethernet and a persistent overloaded network occurs the NOE 771 may go into Kernel mode This could cause the Primary CPU to go to STOP Offline An example of a persistent overloaded network would be when two ports of an Ethernet switch are linked to each other this would be seen by all Ethernet nodes connected to the sub network and result in a massive overloaded network that does not occur on properly configured network NOTE Broadcasts and especially ARPs are part of standard Ethernet traffic and will have no adverse effects on an NOE Even small storms that take up to 5 of the basic network traffic over short periods from several seconds to 2 3 minutes would not overload the NOE Itis only the massive and enduring overloaded network such as those created by a looped network cable that can cause problems for the Hot Standby system with NOEs For backplane communication the NOE has direct access DMA to the memory of the CPU module Therefore if the NOE goes into Kernel mode while accessing the CPU this may have an impact on the CPU behavior In rare cases it can even cause the Primary CPU to go to STOP Offline In this case the Standby CPU will take the hand as the Primary CPU Recommended Actions Take the following step
90. cycles any configured Watchdog for the MAST task e Local I O is not part of an automatic Switchover Local I O is managed locally by either the Primary or Standby CPU and continues to operate after a Switchover through the same controller USB Link Switchover Behavior During a switchover the USB link that is the communication between one of the PLCs and the Unity Pro workstation does not switch over The link remains with the same PLC therefore the link must be manually switched to the other CPU if necessary 35010533 07 2011 43 Quantum Hot Standby System Quantum Hot Standby Operation Modes Operating Modes Overview STOP Mode In a normally operating Quantum Hot Standby system there are two PLCs running one as the Primary PLC and one as the Standby PLC Consequently a Quantum Hot Standby system requires additional states to reflect the system status The redundant nature of the system means that the relationships between operating modes changes The following provides a quick summary of the Quantum Hot Standby operating modes and states A WARNING UNINTENDED EQUIPMENT OPERATION Verify the PLC operating mode before installing operating modifying or servicing it Failure to follow these instructions can result in death serious injury or equipment damage Before acting on a PLC always positively confirm the operating mode of both Hot PLCs by viewing their LCD displays LEDs or System Sta
91. d configurations downloaded to it so that it can participate in a Quantum EIO network A DRS provides 2 RSTP enabled ring connections one for the main ring and one for a sub ring It also manages QoS which provides a predictable level of performance for both remote I O and distributed I O traffic on the same I O network DRSs require a firmware version 6 0 or later 240 35010533 07 2011 Glossary DT date and time A data type encoded in BCD in a 64 bit format that contains the following information e the year encoded in a 16 bit field the month encoded in an 8 bit field the day encoded in an 8 bit field the time encoded in an 8 bit field the minutes encoded in an 8 bit field the seconds encoded in an 8 bit field NOTE The 8 least significant bits are not used The DT type is entered as follows DT lt Year gt lt Month gt lt Day gt lt Hour gt lt Minutes gt lt Seconds gt This table shows the upper lower limits of each field Field Limits Comment Year 1990 2099 Year Month 01 12 The leading 0 is displayed it can be omitted during data entry Day 01 31 For months 01 03 05 07 08 10 12 01 30 For months 04 06 09 11 01 29 For month 02 leap years 01 28 For month 02 non leap years Hour 00 23 The leading 0 is displayed it can be omitted during data entry Minute 00 59 The leading 0 is displayed it can be omitted during data entry Second
92. d in the program Address appears as a bar graph in the grid e Variables Indicates the topological address used in the variables Address appears as a bar graph 70 35010533 07 2011 Configuration 2 Memory Area options Using this option you designate a state RAM address Select one of four reference types M e SI SIW SMW Your choice appears in the Address field of the Address Information area Online Configuration Modification On PLCs supporting this functionality a check box is activated and appears in the CPU Editor see page 66 The Configuration Online modification is only available on certain types of PLCs see Unity Pro Operating Modes if the online modif in RUN check box is selected 35010533 07 2011 71 Configuration Using the Modbus Port Tab Viewing You may change Modbus communication options using the Modbus Port tab of the Unity Pro editor IN 1 2 140 CPU 671 60 Bei P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB T over sum Conti MB modb Anima d Hot St F vO objects Bridge Mode Modbus Port Baud Data Stop Parity Delay Addres Head Mode Protocol Bits _ _ Bits ms s Slot 1 ali Even 10 1 o RTU RS23 2 9600 v al 1_ Even 10 1 o RtU_ As23 sll9600 sll lEven
93. d packet interval The time period between cyclic data transmissions requested by the scanner EtherNet IP devices publish data at the rate specified by the RPI assigned to them by the scanner and they receive message requests from the scanner at each RPI RSTP rapid spanning tree protocol A protocol that allows a network design to include spare redundant links to provide automatic backup paths if an active link stops working without the need for loops or manual enabling disabling of backup links 35010533 07 2011 251 Glossary scanner The originator of I O connection requests for implicit messaging in EtherNet IP and message requests for Modbus TCP scanner class device An EtherNet IP node capable of originating exchanges of I O with other nodes in the network service port A dedicated Ethernet port on the Quantum Ethernet remote I O modules The port may support 3 major functions depending on the module type e port mirroring for diagnostic use e access for connecting HMI Unity Pro ConneXview to the PLC e extended to extend the device network to another subnet e disabled disables the port no traffic is forwarded in this mode SFC sequential function chart An IEC programming language that graphically represents in a structured manner the operation of a sequential PLC This graphical description of the PLC s sequential behavior and of the various resulting situations is created using simple graphic
94. de Controller A Offline Online Indicates which Controller B Offline Online controller is Offline and Online at the next start up Invalidate Keypad Disable Yes is NOT selected When selected the Enable Yes is selected nies ae Check mark displayed leplayed ict Standby submenu 78 35010533 07 2011 Configuration Item Option Value Description Standby On Offline Default If mismatch is application mismatch Offline button selected detected Standby goes Offline Online Default If button is selected Online button not selected and mismatch is detected Standby remains Standby Swap Address At Modbus Port 1 Default When selected Switchover All selected enables Modbus switchover to occur State RAM Non Start Mw 1 Starting address of Transfer Area memory area not transferred Length 1 Specify the range of the length Behavior of the CPU All sections of the Default Regarding the option in Run Offline mode MAST task selected the CPU will First section of the or will not execute the MAST task program when CPU is in Run Offline mode No section of the MAST task 1 Enter the appropriate values All values depend on Hot Standby configuration Local Drop Module Diagnostics Status Table In a Quantum Hot Standby system the CPUs exchange Drop diagnostic WORDs In a Hot Standby system the number of WORDs exchanged is increased to 32 from the Standalone 16 WORDs
95. des in Quantum Hot Standby System 99 NOE IP Address Assignment 00 000 cece eee eee eee 103 NOE Modules in Hot Standby System 00 00 c eee eee 105 Overloaded Network 0 0 0 c cee tte 106 Maintaining a Quantum Hot Standby System 107 Hot Standby Module Replacement 0 cece eee eee eee 108 Replacing a Module 0 cet tee 108 Hot Standby Health Messages 0 0 c cece eee eee 109 Verifying the Health of a Quantum Hot Standby System 109 Single Point of Detected Failure 0 0 0 c cece eee 111 Detecting and Diagnosing Inoperative Components through Health Messages is piinaa Mee eee eee aut eae Sa op die OE G EE atone 112 Detected Inoperative Conditions on Rack CPU Copro and RIO Head 113 Detecting High Speed Sync Link Interruptions 116 Troubleshooting Primary PLC 0 0 0 c eee eee eee 118 Programming and Debugging 0000eeeees 121 Operating Modes and Switchover Information 122 Operating States and Modes 0 0 00 c cece eee eee 123 System Performances 0 000 ce eee eet teens 127 Conditions for Switchover sssaaa cece eet 128 Switchover Behavior during Application Mismatch 130 Handling Network Addresses at Switchover 2 005 132 Testing Switchover of a Quantum Hot Standby System 137 EFBs for Quantum Hot Standby 0
96. dress 33 Transfer Application Program Controller A Primary CPU MB address 5 Controller B Standby CPU MB address 37 5 32 Force Switchover Controller A new Standby CPU MB address 37 5 32 e Controller B new Primary CPU MB address 5 If the Modbus Plus address is modified perform an Application Program Transfer If not performed a transfer creates a different offset address in the Standby CPU NOTE At Switchover the Quantum Hot Standby system and NOM modules swap Modbus Plus addresses almost instantaneously within one or two milliseconds This almost instantaneous Switchover means that host devices which are polling the controller must be talking to the Primary CPU controller and that the network should have minimal network interruption during Switchover NOTE When using Modbus Plus communication and OSLoader only address 1 is valid Swapping NOE IP Addresses at Switchover When used in a Quantum Hot Standby system the Quantum Ethernet TCP IP network modules 140 NOE 771 01 and 11 support address swapping at Switchover The swapping of IP addresses behaves much like the address swap of the Modbus Plus ports except that the offset is 1 instead of 32 At Switchover the modules exchange their IP addresses NOE 771 address swapping occurs automatically and can not be controlled by options selected in any of the tabs of the editor or controlled by turning ON OFF any of the b
97. e location of various detected errors that can cause a Quantum Hot Standby to change to a standalone system or become inoperative What s in this Section This section contains the following topics Topic Page Detecting and Diagnosing Inoperative Components through Health Messages 112 Detected Inoperative Conditions on Rack CPU Copro and RIO Head 113 Detecting High Speed Sync Link Interruptions 116 Troubleshooting Primary PLC 118 35010533 07 2011 111 Maintaining Detecting and Diagnosing Inoperative Components through Health Messages Inoperative Components Health Messages An inoperative component causes system changes If Then A component of the Primary CPU becomes inoperative Control shifts to Standby CPU A component of the Standby CPU becomes inoperative Standby CPU goes offline Fiber optic Sync link cable link becomes inoperative Standby CPU goes offline The Primary CPU sends a health message to the Standby CPU over Copro Sync link every 10 milliseconds Health messages over the RIO link If Then Primary CPU Sends Health Message over RIO link No communication is required with any drop Every 5 ms on RIO link All systems are OK Every scan Lack of health messages over the RIO link If Then Standby CPU does not receive health messages on neither the Copro link nor the RIO link 1 Stand
98. e the Standby PLC in the Offline mode The Offline mode ensures that the system does not try to do a Switchover while replacing a module The Primary PLC continues to control the system as a non redundant Standalone PLC during the module replacement Ensure that the new module being replaced e resides in the same position as in the Primary backplane e is the identical type of module as the module to be replaced A WARNING UNEXPECTED EQUIPMENT BEHAVIOUR Do not remove a module from the Primary PLC that is under power Hot Swapping is not allowed in the Primary PLC of a Quantum Hot Standby system Failure to follow these instructions can result in death serious injury or equipment damage 108 35010533 07 2011 Maintaining 3 2 Hot Standby Health Messages Verifying the Health of a Quantum Hot Standby System Redundant Links Because there are two links Copro and RIO between the Primary and Standby PLCs if a PLC detects an error on one link it still has a link available to send diagnostic information to the other PLC Generating and Sending Health Messages The Quantum Hot Standby modules exchange a health message approximately every 10 ms If the Primary CPU becomes inoperative the Standby CPU is notified and assumes the Primary CPU role However if the Standby CPU becomes inoperative the Primary CPU continues to operate as a standalone CPU The RIO head processors periodically verify c
99. eatures There are some important exceptions to this statement See Restricted Functions see page 157 Debug and Diagnostic The following tables presents Debug and Diagnostic operations for Quantum Hot Standby PLCs Diagnostic 140 CPU 671 60 140 CPU 671 60S 140 CPU 672 61 Diagnostic Function Block Yes Yes Yes Diagnostic Buffer Yes Yes Yes Diag buffer Max buffer size 16KB 25KB 25KB characteristics Max errors 160 254 254 Breakpoint 1 max 1 max 1 max Step by step Into over and out Yes Yes Yes Variable animation e End of MAST Watch Point e End of MAST e Watch Point e End of MAST Watch Point Link animation Yes Yes Yes Do not use breakpoints on a Primary CPU as this will cause a Switchover Debug the Control Command of the Procedure Debugging a Quantum Hot Standby application program is a two stage process 1 Debug the basic program operation on one of the Hot Standby PLCs running as a Standalone PLC When you do this all of the debug and diagnostic resources noted in the tables above are available NOTE If a standalone Hot Standby controller is not available put the Standby PLC into a Non Conf state and do this first stage of debugging on the Primary PLC 35010533 07 2011 175 Programming and Debugging 2 Debug any redundancy specific aspects of your program on a functioning redundant Hot Standby system that is not actively managing y
100. ebugging Local I O and PLC Modes Local I O is treated differently according to the operating mode of its PLC e Primary RUN The Local I Os are updated by the application running in the Primary CPU and is exchanged with Standby CPU e Standby RUN The Local I Os are updated by the application running in the Standby CPU e Run OFFLINE e All sections of the MAST task are executed e Only the first section of the MAST task is executed e No sections of the MAST task are executed NOTE The system always updates the Local I O in Run OFFLINE NOTE No data are transferred from the primary CPU to the OFFLINE CPU 35010533 07 2011 155 Programming and Debugging Module Restrictions General The Quantum Hot Standby with Unity Pro V2 0 and later versions do not support the following modules 140 NOE 311 00 140 NOE 351 00 140 CHS 110 00 140 NOA 611 10 140 NOA 622 00 140 NOL 911 10 140 HLI 340 00 156 35010533 07 2011 Programming and Debugging Application Restrictions Timer Events and I O Errors Timer events are NOT synchronized in Quantum Hot Standby applications Schneider Electric recommends not using timer events NOTE If timer events are used the detected I O errors are not exchanged between Primary CPU and Standby CPU Mast Task Cycle Time and Watchdog The Quantum Hot Standby system is optimized for applications with MAST task cycle times between e for a s908 system 30 ms and 250 ms e for
101. edundancy by maintaining its Standby PLC and associated modules in a state where they can assume the Run Primary operating mode quickly This means that the Standby PLC must have all of the information necessary to mirror the I O and data states present on the Primary PLC and that this information must be regularly updated For the Ouantum Hot Standby the collected information is called the database and the regular exchange of this database is referred to as the database transfer Just after the Primary PLC finishes reading the input values it transfers the database to its Copro which in turn transmits it over the CPU sync link to the Standby PLC Copro The Standby PLC then applies the information in the database as required The database that is cyclically transferred from the Primary PLC to the Standby PLC via the Copros and the CPU sync link includes both system data and user application data and I O In both cases some of this data is located addressable and some is unlocated The data exchanged during every MAST task are listed below System Information e LOCATED e System Bits S30 activation of MAST task S38 enabling inhibition of events tasks S50 clock write S59 clock increase S94 replace current value S117 RIO Error on Ethernet I O Network S 118 RIO Error on S908 I O Network e System Words SWO Set scanning period for MAST task SWEB 9 task Input Output inhibition SW49 53 date and time informat
102. egister I O For each word of configured I O one of the I O words must be subtracted from the total available Battery type 3 V Lithium Service life 1 2 Ah Shelf life 10 years with 0 5 loss of capacity year Battery load current power off typical 14 uA maximum 420 uA TOD clock 8 0 s day 0 60 C Power up RAM address Executive Checksum User Logic Check Processor Run Time RAM address Executive Checksum 214 35010533 07 2011 Additional Information CRP Remote I O Head Processor Detected Error Patterns Detected Error Patterns The following table displays both e Number of times the Com Act indicator blinks for each type of error e Possible codes for each type of blink The detected errors Number of blinks on Code in hex Detected Error Com Act Indicator Slow steady 0000 Requested kernel mode 2 6820 Detected HCB frame pattern error 6822 Detected head control block diag error 6823 Detected mod personality diag error 682A Detected fatal start IO error 682B Incorrect read I O pers request 682C Incorrect execute diag request 6840 ASCII input transfer state 6841 ASCII output transfer state 6842 IO input comm state 6843 IO output comm state 6844 ASCII abort comm state 6845 ASCII pause comm state 6846 ASCII input comm state 6847 ASCII output comm sta
103. en connected online 190 35010533 07 2011 Application Modifications Switchover Using Command Register System Bit SW60 1 or SW60 2 To force a Switchover by setting the bits in the Command Register do the following Step Action Open file 1 in Unity Pro Connect Unity Pro to the Primary CPU Verify the A B controller order of the Primary CPU AJOJN Set correct bit in SW60 f the connected CPU is A set Command Register bit SW60 1 to 0 e lf the connected CPU is B set Command Register bit SW60 2 to 0 NOTE Ensure that the Standby CPU switched to Primary CPU Open file 2 Connect Unity Pro to the new Primary CPU controller Set Command Register system bit used in Step 4 to 1 NOTE Verify that the Standby PLC is now online Verfify that both Primary and Standby CPUs are in Run Primary CPU and Run Standby CPU modes 35010533 07 2011 191 Application Modifications Manual Application Program Transfer Method and Application Mismatch General A manual Application Program Transfer can be performed using one of two methods e Hot Standby submenu on the front panel keypad e Command Register system bit SW60 5 Application Program Transfer Using Front Panel Keypad To transfer an application program to either the Primary CPU or Standby CPU controller using the front panel keypad do the following Step Action Access the fron
104. end of the first complete cycle but before the outputs are updated To process your application based on the type of start the program must test whether SW10 0 is reset to 0 or S1 is set to 1 at the start of first MAST task SW10 and S1 can be tested by the application in either the Primary or Standby mode 35010533 07 2011 173 Programming and Debugging Transferring Your Program to the Primary and Standby PLCs Transferring Your Program Because a Hot Standby system requires that identical application programs exist on both the Primary and Standby PLCs you must upload your application twice once to each PLC The procedure is the same for both PLCs Step Action 1 Connect the PC with Unity Pro version 3 1 or above to a USB port on the PLC 2 Use the Unity Pro command PLC gt Transfer program to PLC NOTE If your Hot Standby system is already configured and uses an Ethernet RIO head you must stop all your system before downloading a new application same recommandation after a rebuild all 174 35010533 07 2011 Programming and Debugging 4 6 Debugging a Hot Standby Application Debugging Introduction You can write an application for your Quantum Hot Standby system in almost the same manner as you would for any other Quantum PLC This is because the Quantum Hot Standby system does not require the use of special function blocks or user actions to provide most redundant f
105. ery and deterministic remote I O performance The time it takes to resolve a remote I O logic scan can be calculated and the system can recover quickly from a communication disruption Quantum Ethernet I O devices include e local rack with an Ethernet remote I O head module e remote I O drop with an Ethernet adapter module e DRS pre configured switch 250 35010533 07 2011 Glossary R rack optimized connection Data from multiple I O modules consolidated in a single data packet to be presented to the scanner in an implicit message in an EtherNet IP network remote I O drop One of the 3 types of remote I O devices in an Ethernet remote I O network A remote I O drop is a Quantum rack of I O modules that are connected to an Ethernet remote I O network and managed by an Ethernet remote adapter module A drop can be a single rack or a rack with an extension rack remote I O main ring The main ring of an Ethernet remote I O network The ring contains remote I O devices and a local rack containing a controller a power supply module and an Ethernet remote I O head module remote I O network An Ethernet based network that contains 1 standalone PLC or one Hot Standby system and remote I O devices There are 3 types of remote I O devices a local rack a remote I O drop and a ConneXium extended dual ring switch DRS Distributed I O devices may also participate in a remote I O network via connection to DRSs RPI requeste
106. es that are available Service Availably I O Scanning Available Global Data Available Modbus Messaging Available FTP TFTP Available SNMP Available HTTP Server Available DHCP Unavailable NOTE The 140 NOE 771 1 modules support a Quantum Hot Standby system starting with Unity Pro V2 0 98 35010533 07 2011 Configuration NOE Operating Modes in Quantum Hot Standby System The NOE Modes The 140 NOE 771 module modes are Primary NOE Mode The Hot Standby mode is Primary CPU and all client server services are active Standby NOE Mode The Hot Standby mode is Standby CPU and all server services are active except DHCP Standalone Mode The NOE is in a non redundant system or the CPU is not present or not healthy Offline Mode The CPU is stopped The Modicon Quantum Hot Standby and the NOE operating modes are synchronized by these conditions CPU Module Status Hot Standby State NOE Operating Mode Present and Healthy Primary CPU Primary Present and Healthy Standby CPU Standby Present and Healthy Offline Offline Present and Healthy Unassigned Standalone Not present or unhealthy N A Standalone Any of the following events affect the NOE operating mode the NOE is powered up an NOE executes a Hot Standby Switchover an NOE goes to Offline mode a new application is downloaded to the NOE IP Address Assignment at Power Up An NOE obtains its IP
107. everse Transfer Words Non Transfer Area of State RAM The designated registers in the Non Transfer Area is ignored when state RAM values are transferred from the Primary CPU controller to the Standby CPU Placing local date and I O registers in the Non Transfer Area can reduce the scan time NOTE Due to the hardware design of the Quantum Hot Standby CPU processors the scan time optimization provided by the Non Transfer Area may be very low Using the Hot Standby tab of the editor dialog designate a block of MW words as a Non Transfer area STEP Action 1 Ensure that the Hot Standby tab is selected If you want to review the process for starting Unity Pro and opening the editor dialog please see Configuring Unity Pro Dialogs see Quantum with Unity Pro Hardware Reference Manual 2 Enter the starting address in the system word Mw field The field is located in the Non Transfer Area of the Hot Standby tab 3 Enter the number of contiguous registers in the Length field The field is located in the Non Transfer Area of the Hot Standby tab Transferring Standby CPU Data to the Primary CPU The system words SW62 63 64 65 are dedicated to transfer data from the Standby CPU controller to the Primary CPU These system words can be used by the application program in the first section of the MAST task to register diagnostic information The data coming from the Standby CPU are transferred at each scan and a
108. executed in the Standby PLC 35010533 07 2011 177 Programming and Debugging 178 35010533 07 2011 Modifying and Upgrading Purpose What s in this Part This part describes for a Quantum Hot Standby system e handling logic mismatch e transferring application programs e enabling an Operating System upgrade This part contains the following chapters Chapter Chapter Name Page 5 Application Modifications 181 6 Firmware 195 35010533 07 2011 179 Modifying and Upgrading 180 35010533 07 2011 Application Modifications Overview This chapter provides information about making Quantum Hot Standby application modifications with Unity Pro What s in this Chapter This chapter contains the following topics Topic Page Quantum Hot Standby Application Mismatches 182 Online or Offline Modifications and Application Mismatch 186 Standby CPU Online Application Modifications with Application Mismatch 187 Primary CPU Online Application Modifications with Allowed Application 188 Mismatch Offline Application Modification with Allowed Application Mismatch 189 Switchover Methods with Application Mismatch 190 Manual Application Program Transfer Method and Application Mismatch 192 Recommendations for Using Application Mismatch 193 35010533 07 2011 181 Application Modifications Quantum Hot Standby Application Mismatche
109. f your programming skills in other development environments and for other devices are applicable for the Quantum Hot Standby However there are some important considerations e The application programs on both PLCs must be identical If not the PLC reports a logic mismatch If the Hot Standby PLCs are operational at the time a logic mismatch occurs the Standby controller enters the Offline operating mode If a logic mismatch exists during a simultaneous startup of both the Hot Standby PLCs one PLC starts as the Primary and the other PLC remains in the Offline operating mode If the controllers are started sequentially and a logic mismatch exists the second PLC that attempts to start starts in the Offline mode When the Hot Standby controllers test for a logic mismatch they check if the application program loaded on both PLCs are identical If the application programs on each PLC are different the result is a logic mismatch Some changes to the application programs are possible while online other changes require an offline update For more information refer to Application Modifications see page 186 e When connecting Unity Pro to a Hot Standby system keep in mind that Generally the information in Unity Pro is the same whether you connect to the Primary PLC or to the Standby PLC Most registers on the Standby PLC reflect the values provided by the Primary PLC during each MAST task Some differences between the data on the P
110. figurations and application programs In the event of a detected error in the Primary CPU and depending on the mode selected for the Standby CPU Run or Offline the Standby CPU may or may not be ready to assume the role of Primary CPU 35010533 07 2011 163 Programming and Debugging Scan Time Effect on System Scan Time The scan time of any Quantum Hot Standby system depends on the amount of data transferred Because data must be transferred from Primary CPU to Standby CPU any Quantum Hot Standby system has a higher scan time than a comparable standalone system NOTE In a Quantum Hot Standby system these 2 processors work in parallel e CPU performs application program processing e Copro performs communication transfer This reduces transfer times between the PLC and Unity Pro NOTE Do not set the period of periodic MAST task below 30 ms Difference between CPU 671 60 and 60S modules For the 140 CPU 671 60S module the scan time and the figures are similar but the transferred data are different There is no unlocated data They are replaced by private data data internally used by the application and not accessible for the user Performance Considerations in 140 CPU 67 ee A Quantum Hot Standby system increases the length of a MAST scan creating system overhead NOTE System overhead is the time required to copy the application data to the communication link layer The network scan communication between P
111. ging Appearance in LD Appearance REV_XFER Instance REV_XFER EN ENO HSBY_ConfF lag Standby PLC FirstReg TO REVI HsBy _ _ gt Primary PLC Flag Standby _PLC_SecondReg j TO_REV2 PRY _ Standby_PLC_Flag ia sBY _ __ FR_REV1 FirstRevTransReg FR_REV2 SecondRevTransReg Appearance in IL Appearance CAL REV _ XFER Instance TO REV1 Standby PLC _FirstReg TO REV2 Standby PLC SecondReg HSBY gt HSBY_ ConfFlag PRY gt Primary PLC Flag SBY gt Standby PLC Flag FR_REV1 gt FirstRevTransReg FR_REV2 gt SecondtRevTransReg Appearance in ST Appearance REV _XFER Instance TO REV1 Standby PLC FirstReg TO _REV2 Standby PLC SecondReg HSBY gt HSBY_ ConfFlag PRY gt Primary PLC Flag SBY gt Standby PLC Flag FR_REV1 gt FirstRevTransReg FR_REV2 gt SecondtRevTransReg 35010533 07 2011 151 Programming and Debugging Parameter Description Description of input parameters Parameter Data type Description TO_REV1 INT Describes the first reverse transfer register if this PLC is the Standby PLC Data in this register are transferred from the Standby CPU to the Primary CPU at each scan TO_REV2 INT Describes the second reverse transfer register if this PLC is the Standby CPU Data in this register are transferred from the Standby CPU to the Primary CPU at each scan Descriptio
112. gnment see page 103 102 35010533 07 2011 Configuration NOE IP Address Assignment Configuring a 140 NOE 771 1 Module Since the Primary and Standby PLCs in Quantum Hot Standby system must have an identical configurations the configured NOE IP addresses are the same The current local Hot Standby mode determines the IP address This table shows how the NOE IP addresses are assigned Hot Standby State IP Address Primary CPU IP address configured in Unity Pro Standby CPU IP address configured in Unity Pro 1 Transition from Primary to Offline IP address configured in Unity Pro if peer controller does not go to Primary Transition from Standby to Offline IP address configured in Unity Pro 1 IP Address Restrictions Do not use either the broadcast IP address or broadcast IP address 2 to configure a NOE module Do not configure the Primary CPU address as nnn nnn nnn 254 This causes the Standby CPU IP address to be nnn nnn nnn 255 The Standby CPU would then return the diagnostic code Bad IP configuration IP Address Transparency A WARNING UNINTENDED EQUIPMENT OPERATION For a Quantum Hot Standby configuration e Do not use the IP address configured in Unity Pro 1 e Do not use consecutive IP addresses of the IP address configured in Unity Pro Failure to follow these instructions can result in death serious injury or equipment damage When a Switchover
113. ication problem 13012 Stop PLC command 13013 Offline keypad switch 13014 Offline Command register request TextIDs for switching from Standby CPU to Primary CPU TextID Warning message 13015 Control command over ETH 13016 Control command over RIO TextIDs for swit ching from Offline to Primary CPU Standby CPU TextID Warning message 13017 Switch from Offline to Primary CPU 13018 Switch from Offline to Standby CPU 35010533 07 2011 217 Additional Information 218 35010533 07 2011 Quantum Hot Standby Controls Displays and Menus Overview This appendix describes controls and displays LED descriptions and the structure of the screen menus What s in this Chapter This chapter contains the following topics Topic Page CPU Controls and Displays 220 CPU LED Indicators 223 Using the CPU LCD Display Screens 224 35010533 07 2011 219 Controls and Displays CPU Controls and Displays Lens Cover Key Switch Reset Button The protective lens cover 2 in the CPU front panel see page 26 can be opened by sliding upwards With the lens cover open you have access to the following items e key switch e battery e reset button The key switch 4 is a security feature and a memory protection switch The key switch has two positions locked and unlocked The
114. ications with Application Mismatch 187 Primary CPU Online Application Modifications with Allowed Application Mismatenh 2 5 ic bios a a ee wk Se ew a a a i 188 Offline Application Modification with Allowed Application Mismatch 189 Switchover Methods with Application Mismatch 190 Manual Application Program Transfer Method and Application Mismatch 192 Recommendations for Using Application Mismatch 193 Chapter 6 Firmware 000 e eee eee eee eee eee 195 Firmware Levels 00 0 eee eee eee ee 196 Quantum Hot Standby Firmware Upgrade 0 0 0 eee 198 Executing the Operating System Upgrade Procedure 199 Appendices o 6 cdc cies teehee etek saw oe ed oe Gis wai 203 Appendix A Quantum Hot Standby Additional Information 205 Fiber Optic Sync Link Cable in a Hot Standby System 206 140 CPU 671 60 Specifications a na aaaea 209 140 CPU 671 60S Specifications 0 0 eee 211 140 CPU 672 61 Specifications 0 0 eee 213 CRP Remote I O Head Processor Detected Error Patterns 215 MOM D Soi cci rap eae Gace ahaha tie a ges eae Sp bea AG as oa Seated ane iaa 217 Appendix B Quantum Hot Standby Controls Displays and Menus 219 CPU Controls and Displays 000 c eee eee eae 220 CPU LED Indicators 0 cece tees 223 Using the CPU LCD Display Screens 000 e eee eee 224 Glos
115. ion SW59 updates date and time values SWEO Hot Standby Command register refer to Hot Standby Command Register see page 86 SWE61 Hot Standby Status register refer to Hot Standby Status Register see page 90 SW70 current time date SW98 99 CCOTF compatibility flags for CRA Drop modules SW108 number of currently forced bits SW109 number of forced analog channels SW152 155 Ethernet RIO Drop Errors 35010533 07 2011 41 Quantum Hot Standby System SW180 SW181 Local drop module health bits main rack and extension rack SW182 SW183 Peer drop module health bits main rack and extension rack NOTE For more information see SW180 SW183 see Unity Pro Program Languages and Structure Reference Manual SW185 339 S908 RIO Drop module health bits SW641 764 Ethernet RIO Module Health bits e Reverse System Words SWE2 65 data transferred from the Quantum Hot Standby CPU to the Primary CPU NOTE For a detailed description of these System Bits and System Words refer to the Unity Pro Program Languages and Structure Reference Manual see Unity Pro Program Languages and Structure Reference Manual User Application Data e LOCATED All M MW MD l and Q data from address 1 up to the maximum number of global address fields configured in Unity Pro s Configuration tab but no more than 128 KB A range of MWs can be defined as a non transfer area they are not transferred to Standby
116. ions must be followed Failure to use Schneider Electric software or approved software with our hardware products may result in injury harm or improper operating results Failure to observe this information can result in injury or equipment damage 2011 Schneider Electric All rights reserved 35010533 07 2011 Table of Contents Part Chapter 1 1 1 1 2 Part Il Chapter 2 2 1 Safety Information 20000 cece ee eee eee About the BOOK js ceset ewes Waites ee ee Sa Introducing the Modicon Quantum Hot Standby Modicon Quantum Hot Standby System Quantum Hot Standby Introduction 0 00 eee eee Terminology ee sos doves Sept Haak i eine vee eS Purpose and Features 20 0 cece cette ee OVEINVIOW maare ie ie a ee PP eee ee ed Redundant Hardware 0 e eee eet Quantum Hot StandBy CPU Front Panel 2 00055 Hot Standby Sync Link 0 0 0 tee 908 Hot Standby Hardware and Topology 00e eee eae Quantum Ethernet I O Hot Standby Hardware and Topology Configuration Requirements 00 00 e eee eee Establishing Redundancy 0 0 eee eee eee eee Quantum Hot Standby Operation Modes 0000000055 Remote I O Management 0 0 0 cece ee eee ee Hot Standby Programming Differences 00 00 eee Hot Standby Safety CPUs 0 000 ccc eee eens Hot Standby Safety CPU Specifics
117. ird party devices cannot They are not compatible with a Quantum Hot Standby system How to Configure Hold Up Time Value The following table describes the procedure to change the hold up time value Step Action 1 Create a RIO bus with a 140 CPU 67 60 Quantum processor and a 140 CRP _00 Head module 2 Add a rack on RIO bus with a 140 CRP _00 Head module 3 Open the Remote IO Quantum Drop dialog and change the drop hold up time Project Browser Ta N Remote IO Quantum Drop oy Station p n ey Configuration EL even LC Config ie ay 1 Local Bus Parameter Name Value GY 1 Local Quantum Drop Starting address status table 0 El on Te ae eau Ending address status table 0 H ey Derived Daj Types Drop hold up time 100ms 3 Possan y Derived FB Types In Bytes 0 a r Variabj s amp FB instances Out Bytes 0 p QW Elementary Variables Derived Variables i peoaos 10 Derived Variables C7 A r Rigth clic then clic on Open Change the value as needed 35010533 07 2011 47 Quantum Hot Standby System Hot Standby Programming Differences Overview In general programming a Quantum Hot Standby controller with Unity Pro is very similar to programming any other standalone Quantum controller using Unity Pro Unity Pro provides a user friendly IEC 61131 3 compatible development environment Most o
118. its in the command register 35010533 07 2011 135 Programming and Debugging All standard rules apply to IP addressing with the additional restriction that the IP address cannot be greater than 253 or the broadcast address minus 2 Also no other device should be assigned the IP address configured in Unity Pro 1 NOTE NOE 771 01 and 11 address swap e NOE 771 01 and 11 modules are the only Ethernet option modules that support the IP address swap in Quantum Hot Standby with Unity Pro V2 0 e NOE 771 01 and 11 modules must be configured in the same slot of the Primary CPU and Standby CPU backplanes e NOE 771 Oland 11 modules require a minimum firmware revision 2 0 or higher Quantum Ethernet I O IP Addresses at Switchover The Quantum Ethernet I O IP addresses are assigned to the CRP A and CRP B when the Hot Standby system is first configured and during a Switchover the addresses do not change 136 35010533 07 2011 Programming and Debugging Testing Switchover of a Quantum Hot Standby System Testing Methods First Time Follow these steps to conduct tests to observe e Hot Standby start up e automatic application program transfer e Switchover of control from Primary CPU to Standby CPU These tests are not necessary but helpful If your racks are horizontally parallel and within 1 meter 3 feet apart the transfer process is easier to observe Hot Standby Start up and Application Program Transfer Fol
119. ive and provides a backup in case one of the fibers is cut during installation Typical Configuration Scheme The following figure represents the direct connection with splices between two CPUs al b z A E i p Cleo o sN 0 OMOR P Explanation of direct connections above 1 MTRJ connector 2 Duplex 62 5 125 um graded index multi mode fiber optic cable Use only single mode with 140 CPU 671 60 up to 4 km 2 5 mi 3 LC connector 4 Duplex 9 125 um single mode fiber optic cable Use only single mode with 140 CPU 672 61 up to 16 km 9 9 5 Splices S 206 35010533 07 2011 Additional Information The following figures represent the direct connection with splices between two modules when using a multi fiber cable rs je e 6 Or 6 Or anni F m m oiana we Wy aan Single mode 140 CPU 672 61 CPUs up to 16 km 9 9 mi Explanation of direct connections above MTRJ MTRu fiber connector Duplex 62 5 125 um graded index multi mode fiber optic Cable LC LC fiber connector Duplex 9 125 um single mode fiber optic Cable Splices Fiber distribution box Backup fiber MTRJ jack or MTRJ coupler LC jack or LC LC coupler OOANOARWN 35010533 07 2011 207 Additional Information Optical Power Budget Calc
120. key switch is only read and deciphered by the PLC OS portion of the firmware and not by the OS loader portion The Quantum processors have a set of system menus that enable the operator to e perform PLC operations i e start PLC stop PLC e display module parameters i e communications parameters e switch to the maintenance mode in Safety processors The key positions are shown in the table below Key PLC Operation Position unlocked e System menu operations can be invoked and module parameters can be modified by the operator with the LCD and keypad u e Memory protection is OFF e You can switch to Maintenance mode in Safety processors locked e No system menu operations can be invoked and module parameters are read only amp Memory protection is ON e Safe mode forced in Safety processors Switching the key switch position from locked to unlocked or vice versa turns on the LCD s backlight NOTE For more explanations about Maintenance and Safe mode of Safety processors see Modicon Quantum Quantum Safety PLC Safety Reference Manual Pressing the reset button 12 forces a cold start of the PLC 220 35010533 07 2011 Controls and Displays LCD Display The liquid crystal display LCD 3 has 2 lines with 16 characters each with changeable backlight state and contrast The backlight handling is entirely automated to save the life of the LCDs The
121. l HSBY gt HSBY ConfigurationFound Representation in ST Representation HSBY WR Instance INV_KEY InvalidateKeypad PCA_RUN PLC_A Running PCB RUN PLC_B Running SWP_MB1 SwapAddressModbusPortl HSBY gt HSBY ConfigurationFound 148 35010533 07 2011 Programming and Debugging Parameter Description Description of the input parameters Parameter Data type Meaning INV_KEY BOOL In the submenu for the Hot Standby PLC button 1 Changes are not allowed 0 Changes are allowed PCA_RUN BOOL If 1 gt 0 then the Hot Standby A CPU on the local rack is forced into OFFLINE mode If O gt 1 and its button mode is in RUN mode then the Hot Standby A CPU is forced into the RUN mode PCB RUN BOOL If 1 gt 0 then the Hot Standby B CPU on the local rack is forced into OFFLINE mode If O gt 1 and its button mode is in RUN mode then the Hot Standby B CPU is forced into the RUN mode SWP MB1 BOOL If O and there is a Switchover then the Modbus address on port 1 of the NEW Primary CPU PLC changes e New Primary CPU PLC address old Primary CPU address e New Standby CPU PLC address new Primary CPU address 128 If 1 and there is a Switchover then the Modbus address on Port 1 of the PLC does not change e New Primary CPU PLC address old Standby CPU address e New Standby CPU PLC address old Primary CPU address SWP_MB2
122. l representation of the local bus appears in the configuration editor 2 Select the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 60S module and right click The context menu appears Select Open Module The editor appears The Summary tab is the default 35010533 07 2011 63 Configuration Using the Summary Tab Viewing Use the Summary tab of the Unity Pro editor to determine if Peer Cop and Hot Standby are enabled 1 2 140 CPU 671 60 P266 CPU Hot Standby 1 Mb Program PCNCIA EthernetHSBY Fiber optic USB MB MB dk Hot St F VO objects CPU Name Model Quantum CPU Peer Cop Enabled lot Standby Cnabled Describing Summary tab Item Option Value Description CPU Name Model Quantum CPU N A Read Only Peer Cop Disabled Enabled Read Only Peer Cop Enabled if the function is valid in the Modbus Plus menu Hot Standby Enabled Enabled Read Only 64 35010533 07 2011 Configuration Using the Overview Tab Viewing The read only Overview tab of the editor displays detailed information about the module s specifications 2 140 CPU 671 60 P266 CPU Hot Standby 1 Mb Program PCMCIA Ethernet SBY Fiber optic USB MB MB T Sum dik Hot St P266 CPU MB MB USB ETHERNET HSBY 1024K IEC AND PCMCIA SPEGIFICATIONS Model Description fi General Specifications Communications ports 1
123. le is much greater than the Standalone scan time because of the long data transfer time t nx Input Hot Standby User Logic Output gt drivers system functions drivers g TIR 42 ms cx Ee Data transfer gs Py 600 kB 102 ms 1 Hot standby MAST task cycle 150 ms 166 35010533 07 2011 Programming and Debugging 4 5 Developing A Hot Standby Application Purpose This section describes the rules for developing an application for a Quantum Hot Standby system What s in this Section This section contains the following topics Topic Page Adjusting MAST Task Properties 168 How to Program a Quantum Hot Standby Application 172 Transferring Your Program to the Primary and Standby PLCs 174 35010533 07 2011 167 Programming and Debugging Adjusting MAST Task Properties Introduction After reviewing the MAST task execution modes this topic describes adjusting the MAST task period and execution time measurement procedures A WARNING UNEXPECTED EQUIPMENT BEHAVIOR Design your application in such a way that your process is not impacted by a cycle time variation that might appear after a firmware upgrade Failure to follow these instructions can result in death serious injury or equipment damage Review of MAST Task Execution Modes The MAST task can be configured to use one of two execution modes e Cyclic mode In the cyclic execution mode M
124. llowing messages may be displayed on the 2 CPU LCDs e Primary CPU e Transferring e End of Transfer e Standby CPU e Program transfer in progress Transferring Transfer retry please wait Transfer OK Transfer NOK Can t transfer PLC reserved 160 35010533 07 2011 Programming and Debugging Validating Transfer Transfer Time The secondary CPU validates the transferred application program After validating it starts automatically as the Standby CPU The Application Program Transfer time depends on the size of the application program the larger the program the longer the time and the type of MAST scan time e fora periodic MAST the scan time is not effected by an APT e for acyclic MAST the scan time may change during an APT Updating from the Primary CPU An application program update may only be performed from the Primary CPU to the Standby CPU NOTE The Standby CPU controller cannot update the Primary CPU Transfer Size Limits In the Quantum Hot Standby 140 CPU 67s transfer size depends on the configuration For example using a card bridge you may transfer up to 7 Mb Therefore transfer the complete application program regardless of the size This transfer takes place over multiple scans and is broken up into multiple transfer packets Application Program Transfer Using the Keypad To transfer use the front panel keypad on the controller unit Primary CPU or Standby CPU The Primary CPU copies
125. lly and cannot be modified Position and configure these functions in your program in order to execute your application You can also develop other functions using the SDKC development kit elementary function block A block used in a program to perform a predefined logical function EFBs have states and internal parameters Even if the inputs are identical the output values may differ For example a counter has an output indicating that the preselection value has been reached This output is set to 1 when the current value is equal to the preselection value enable An optional block input When enabled an ENO output is set automatically If EN 0 the block is not enabled its internal program is not executed and ENO is set to 0 If EN 1 the block s internal program is run and ENO is set to 1 If a runtime error is detected ENO is set to 0 If the EN input is not connected it is set automatically to 1 242 35010533 07 2011 Glossary endianness ENO Ethernet EtherNet IP explicit messaging For multi byte numbers the big endian and little endian formats indicate the byte order in stored memory In big endian format the most significant byte is stored in the lowest first address In little endian format the least significant byte is stored in the lowest address These examples show the contents of four memory bytes address x address x 3 for the multi byte number OAO
126. lone PLC Primary Copro inoperative This condition is not detected the Primary CPU continues to scan the I O but as a Standalone PLC The Standby PLC goes Offline Standby Copro inoperative This condition is detected by both Copros The Standby PLC goes Offline The Primary PLC detects that the Standby PLC has disappeared reports it to the log and continues to scan the I O as a Standalone PLC NOTE The Primary CPU maintains continuous activity on link which allows the Standby CPU to detect a comminutions interruption as soon as possible There are 2 possible cases Inoperative Primary rack The Standby PLC detects that the Primary PLC has disappeared and takes control of the system It scans the I O as a Standalone PLC Inoperative Standby rack The Primary PLC detects that the Standby PLC has disappeared reports it to the log and continues to scan the I O as a Standalone PLC 35010533 07 2011 113 Maintaining Copro Inoperative The high speed CPU Sync link connects the Primary and Standby Copros The primary CPU communicates with the Standby CPU every 10 ms with either a e data message e health message The Primary Copro waits for an acknowledgement from the Standby Copro Detecting Copro errors If Then Primary Copro reports a detected Primary CPU controller error to the Primary CPU 1 acknowledges the detected error 2 attempts to transfer control to the other controller by sending a
127. low these steps for start up and application program transfer Step Action 1 Configure two racks with identical hardware and firmware 2 Connect to a Remote I O RIO drop see page 83 NOTE Ensure that the fiber optic Sync link cable is connected between the controllers Start Unity Pro software and configure the local rack and the Remote I O drop for your physical configuration Execute the Build Project command and save your application program Power up and connect Unity Pro to one controller NOTE The front panel keypad displays No Conf Download your application program and put the controller in the RUN mode NOTE The controller becomes the RUN Primary CPU Power up the other controller NOTE Application Program Transfer occurs automatically The other controller becomes the RUN Standby CPU Ensure the Primary CPU and Standby CPU controllers are in RUN Primary CPU and RUN Standby CPU mode 35010533 07 2011 137 Programming and Debugging Preparing to Switchover After completing the Hot Standby Start up and Application Program Transfer see page 138 procedure your Quantum Hot Standby system is ready to perform a Switchover Perform the Switchover using either e Hot Standby submenu on the front panel keypad e Command Register system bit SW60 1 or SW60 2 NOTE To observe a Switchover effect on the I O modules configure the Remote I O RIO drop with a
128. lowing topics Topic Page Quantum Hot Standby and 140 NOE 771 1 Modules 97 NOE Operating Modes in Quantum Hot Standby System 99 NOE IP Address Assignment 103 NOE Modules in Hot Standby System 105 Overloaded Network 106 96 35010533 07 2011 Configuration Quantum Hot Standby and 140 NOE 771 e1 Modules Description of the Hot Standby Solution NOTE The Quantum Hot Standby system supports up to six 140_NOE_771_ 1 Ethernet adapters The NOE communications modules supported are e 140 NOE 771 01 TCP IP 10 100 Ethernet e 140 NOE 771 11 TCP IP 10 100 Ethernet The Hot Standby NOE modules allow automatic IP address swap during a Switchover Both controllers are configured identically One controller is the Primary CPU NOE the other controller is the Secondary NOE If the Primary NOE stops the controllers Switchover and the system recovers The NOE modules coordinate the swapping of IP addresses After closing both the client and the server connections each NOE sends a swap UDP message to its peer NOE A sending NOE then waits a specified time out 500 ms for the peer swap using UDP messages Either after receiving the messages or after a time out the NOE changes its IP address 4 CAUTION LOSS OF CONTROL Use an Ethernet switch not a hub to connect Quantum Ethernet 140 NOE 771 1 modules to each other and to the network to prevent a COMMUNICATION INTERRUPTION Failure to follow these
129. m Hot Standby Introduction 16 1 2 Hot Standby Safety CPUs 52 35010533 07 2011 15 Quantum Hot Standby System 1 1 Quantum Hot Standby Introduction Overview This section describes information you need to know before starting to configure and operate a Quantum Hot Standby system What s in this Section This section contains the following topics Topic Page Terminology 17 Purpose and Features 19 Overview 20 Redundant Hardware 21 Quantum Hot StandBy CPU Front Panel 26 Hot Standby Sync Link 27 908 Hot Standby Hardware and Topology 29 Quantum Ethernet I O Hot Standby Hardware and Topology 34 Configuration Requirements 39 Establishing Redundancy 41 Quantum Hot Standby Operation Modes 44 Remote I O Management 46 Hot Standby Programming Differences 48 35010533 07 2011 Quantum Hot Standby System Terminology Hot Standby Terms This manual uses many technical terms and acronyms Some of the most commonly used are Application Program This is the software program user logic you write to provide monitoring and control for your application Copro This term is short for Coprocessor This manual uses the term Copro specifically to refer to the coprocessor that governs the exchange of data between the Hot Standby PLCs through the Sync link between the CPUs Extended rack This rack contains I O modules and is connected to the main
130. mary Run Standby Run OffLine Stop OffLine Controller B Run Prim N A Hot Standby active Hot Standby inactive Hot Standby state I O processed I O processed inactive I O processed Run Hot Standby active N A N A N A Standby I O processed Run Hot Standby inactive N A Hot Standby inactive Hot Standby OffLine I O processed I O not processed inactive I O not processed Stop Hot Standby inactive N A Hot Standby inactive Hot Standby OffLine I O processed I O not processed inactive I O not processed Description of Run Offline Use Cases The following table describes the different situations of the Run Offline state If Then The Primary CPU PLC enters Run Offline state The Standby CPU PLC takes over the process and becomes Run Primary CPU The Standby CPU PLC enters Run Offline state The Hot Standby function is no longer available The fibre optic link is disconnected The Standby CPU PLC enters Run Offline state The actual hardware configuration is different from the configuration defined in the project Either the Primary CPU or the Standby CPU PLC starts in Run Offline state A application mismatch occurs The Standby CPU PLC enters Run Offline state The Standby CPU RIO head CRP stops operating The Standby CPU PLC enters Run Offline state There is no RIO connection open Either the Primary CPU or the Standby CPU starts in RUN OFFLINE mode RUN OFFLINE State Reco
131. meters necessary to establish the connection An adapter accepts explicit message requests connected and unconnected from other devices A selection in Unity Pro that displays expert level configuration properties that help define Ethernet connections Because these properties should be edited only by people with a good understanding of EtherNet IP communication protocols they can be hidden or displayed depending upon the qualifications of the specific user A framework for the specification of a network constructed on the following e physical components and their functional organization and configuration e operational principles and procedures e data formats used in its operation A table containing elements of a single type The syntax is as follows array lt limits gt OF lt Type gt Example array 1 2 OF BOOL is a one dimensional table with two elements of type BOOL array 1 10 1 20 OF INT is a two dimensional table with 10x20 elements of type INT application response time The time a PLC application takes to react to a given input ART is measured from the time a physical signal in the PLC turns on and triggers a write command until the remote output turns on to signify that the data has been received 236 35010533 07 2011 Glossary BOOL BOOTP broadcast CCOTF CIP class 1 connection class 3 connection boolean type The basic data type in computing A BOOL variable can have eithe
132. mmendation In the RUN OFFLINE state the PLC is not configured as a PRIMARY nor a STANDBY CPU This occurs after the Hot Standby system detects an error or Hot Standby OFFLINE mode has been chosen In this state the CPU main actions are e execution of the code sections depending on the choice in the CPU Executes see page 78 menu e no data transfer from primary except for the SWE60 value 124 35010533 07 2011 Programming and Debugging e address swap management e local IO management When using communication EFBs some applications can be affected by the entire code execution It is recommended to e create a boolean variable cpu_state SW61 1 AND NOT SW61 0 e assign the section or communication block execution to this variable With such a fix unexpected EFB communication calls are avoided if the Standby CPU goes to an OFFLINE state Recovery from RUN OFFLINE when ERIO is used To recover from RUN OFFLINE due to no Drop condition e cable the drops e put one CPU of the system in the STOP mode e wait until at least one Drop has opened a connection with CRP Head To put the system in the RUN mode again carry out the procedure in Quantum Hot Standby Operating Modes Overview see page 44 Description of the Hot Standby Operating Modes A Quantum Hot Standby PLC has some restrictions in terms of changing modes The following figure shows the state diagram of the Hot Standby Quantum system i
133. mmunications menu and submenus Quantum PLC Communications gt Communications TCP IP Ethernet gt TCP IP Ethernet IP Address gt _ IP Address HEH HEH HHH HHH TCP IP Ethernet Subnet Mask gt Subnet Mask HEH HHH HHH EHH TCP IP Ethernet IP Gateway gt IP Gateway HEE FEE FEE HEH TCP IP Ethernet MAC Address gt MAC Address HHHH HH HH HH HH Communications Modbus Plus gt MB Address Modbus Plus State Communications Serial Port gt Mode Protocol Adr Rate Par DB SB gt Serial Port RS Mode RS 232 Serial Port Protocol Modbus Serial Port Unit Address 1 Serial Port Baudrate 9600 Serial Port Parity Even Serial Port Databits RTU 8 Serial Port RS Mode RS 232 Serial Port Stopbits 1 230 35010533 07 2011 Controls and Displays Submenu for TCP IP Ethernet PLC Communications submenus TCP IP Ethernet Screen Fields Available Options Description Displays Available TCP IP Ethernet IP Address 4 HEE HHH decimal Displays IP address numbers TCP IP Ethernet Subnet Mask 2 PEF HEE HHH decimal Displays Subnetwork Mask address numbers TCP IP Ethernet IP Gateway ti
134. modification of the I O configuration on the Primary PLC Creating a Mismatch Use one of these methods to create an application mismatch condition 1 select Online in the Standby CPU On Application Mismatch group in the Unity Pro Hot Standby Tab dialog This action requires the application program to be downloaded to the PLC 2 set the Command Register system bit SW60 3 to 1 This action must be performed online in the Primary CPU Transferring User Data during a Mismatch The following table shows which user data is transferred when a mismatch occurs Data Type Transferred on Application Mismatch Located variables State RAM Yes Unlocated global variables Yes not for the 140 CPU 671 60S CPU unless variables exist ONLY in modified controller DFB amp EFB instance data Yes unless data exist ONLY in modified controller SFC variable area Yes not for the 140 CPU 671 60S CPU unless associated SFC section is modified refer to Modifying an SFC Section see page 130 System Bits and Words Yes 35010533 07 2011 183 Application Modifications Using Application Mismatch with Care Ensure that there is no mismatch between I O maps or configurations A WARNING UNEXPECTED APPLICATION BEHAVIOR Ensure that both e O maps are identical e configurations are identical Failure to follow these instructions can result in death serious injury or eq
135. ms THIS ISA HSBY_ModuleSwitchaA THIS ISB HSBY_ModuleSwitchB 144 35010533 07 2011 Programming and Debugging Representation in LD Representation HSBY_ST Instance HSBY_ST EN ENO HSBY_ConfigurationF ound yy HSBY gt PLC_Offline CoN THIS_OFF gt Primary PLC ESA THIS_PRY gt Standby PEC THIS_SBY ES Remote PEC Ofline REMT_OFF C PrimaryRemote PLE REMT_PRY ae Standby R emote PLE REMT_SBY CY IdenticalPrograms LOGIC _OK C HSPN MoauleSwitcha THIS_ISA Ko HSBY_ModuleSwitchB THIS_ISB C Representation in IL Representation CAL HSBY_ST_Instance HSBY gt HSBY ConfigurationFound THIS_OFF gt PLC_Offline THIS PRY gt Primary PLC HIS SBY gt Standby_ PLC REMT_OFF gt Remote_ PLC Offline REMT PRY gt PrimaryRemote PLC REMT SBY gt StandbyRemote_ PLC OGIC_OK gt IdenticalPrograms HIS_ISA gt HSBY_ModuleSwitcha HIS_ISB gt HSBY_ModuleSwitchB 3 3 E 5 3 35010533 07 2011 145 Programming and Debugging Representation in ST Representation HSBY ST Instance H Parameter Descriptions m A A A HIS_OFF gt HIS_SBY gt EMT_OFF gt EMT_PRY gt EMT_SBY gt LOGIC_OK gt m HIS ISA gt HIS ISB gt SBY gt HSBY ConfigurationFound PLC Offline THIS PRY gt Primary PLC Standby PLC Remote PLC Offline PrimaryRemote PLC StandbyRemote PLC Identic
136. n field to field to go to the sub menu LED flashing Key active Used to move digit to digit in a modify mode field LED off Key inactive there is no e sub menu for menu option e scrolling around a screen e scrolling around a field 222 35010533 07 2011 Controls and Displays CPU LED Indicators Overview LED Description The Quantum Hot Standby CPUs has two types of indicators 1 LCD display screen 1 The default display screen serves as a controller status screen see page 224 2 LED indicators 2 The following figure shows the two types of indicators 146 CPU 67160 COM STS ge Address 1 LCD display lens cover closed 2 LED indicators The following table shows the description for the Quantum Hot Standby CPU LED indicators LEDs Indication COM CPU is controlled by the Copro hardware indicates Primary or Standby CPU activity STS CPU is controlled by the Copro firmware e Blinking system is redundant and data are exchanged between the Primary and Standby PLCs e ON system not redundant Copro booting from power on to end of self tests e OFF Copro auto test detected errors 35010533 07 2011 223 Controls and Displays Using the CPU LCD Display Screens Overview The controller LCD displays messages These messages indicate the controller status There are four levels of menus and submenus Menus are accessed
137. n interact with the Safety PLC using e Unity Pro XLS programming tool e Quantum Safety CPU keypad e Quantum Safety CPU key switch Depending on the operating mode the Safety PLC can be in different states After power up it automatically enters run state of the Safety Mode if the following 2 conditions are fulfilled e There is a valid application e The Automatic start in Run option is activated In case of an invalid application it enters the not configured no conf state of the Maintenance Mode only if the key state is unlocked in which you are able to download your project If a fault is detected the PLC enters e Halt state when running in Maintenance Mode e Error state when running in Safety Mode 56 35010533 07 2011 Quantum Hot Standby System PLC States The following figure shows the state diagram of the Quantum Safety PLC Power ON Valid application Invalid application i 7 Error or Valid t Download Halt and application y application Safe mode amp autorun i Stop Enter Maintenance Exit Maintenance Transition only in maintenance mode Operating Mode Identification The LCD display on the CPU indicates the current operating mode by showing the letters M for Maintenance Mode or S for Safety Mode The status bar field on the PLC screen indicates the current operating mode as shown in the following figure TCPIP 127 0 0 1 MAINT ENANCE H SBY A Offlne in
138. n of the output parameters Parameter Data type Description HSBY BOOL 1 This is a Hot Standby configuration 0 This is not a Hot Standby configuration PRY BOOL 1 This PLC is the Primary CPU PLC 0 This PLC is not the Primary CPU PLC SBY BOOL 1 This PLC is the Standby CPU PLC 1 This PLC is not the Standby CPU PLC FR_REV1 INT Content of first reverse transfer register sSW62 see Unity Pro Program Languages and Structure Reference Manual Output only if HSBy is 1 FR_REV2 INT Content of second reverse transfer register sSwW63 see Unity Pro Program Languages and Structure Reference Manual Output only if HSBy is 1 152 35010533 07 2011 Programming and Debugging 4 3 Equipment Restrictions Overview This section describes equipment and application restrictions in a Quantum Hot Standby system What s in this Section This section contains the following topics Topic Page Local and Distributed I O Restrictions 154 Module Restrictions 156 Application Restrictions 157 35010533 07 2011 153 Programming and Debugging Local and Distributed I O Restrictions Overview A Quantum Hot Standby has the following I O restrictions e In an Quantum Hot Standby system both Local I O and Distributed I O DIO can be used they are not part of the redundant system e Local output can be dedicated to and managed by each
139. ndby CPU and stops processing the I O As soon as the Standby CPU detects that there are no longer exchanges with the Primary CPU it takes over the role of the Primary CPU executing the user logic and processing the I O Therefore the output modules must filter the lack of exchange with the Primary CPU to avoid glitches when a Switchover occurs This is achieved by configuring the output module timeout As a result the PLC reaction time is greater than the timeout configured in the output module thereby influencing the process Safety time NOTE The behavior of the Hot Standby Safety CPU is equivalent to a Standalone Safety CPU In case of a detected error the Safety PLC enters e Halt state when running in the Maintenance Mode e Error state when running in the Safety Mode Availability of the Hot Standby Functions In addition to the standard Hot Standby functions you can use an EFB to program an automatic switchover between Primary CPU and Standby CPU to verify the ability of the Standby CPU to take over from the Primary CPU That means that the Standby CPU periodically becomes the Primary CPU and the Primary CPU becomes the Standby CPU It is recommended to avoid using the USB link during a Switchover 54 35010533 07 2011 Quantum Hot Standby System The following table lists the available Hot Standby functions in Maintenance and Safety modes Function Maintenance Mode Safety Mode Hot
140. ng Guide 3 00 140 CPU 671 60 Hot Standby 140 CPU 672 61 CCOTF see Quantum Ethernet I O System Planning Guide Quantum Ethernet I O RIO A given firmware level is backward compatibly it has all the functions of the previous versions Hot Standby Coprocessor Firmware Levels The following table gives the Quantum CPU Coprocessor firmware levels that are compatible with the CPU processor firmware CPU Firmware Compatible Coprocessor Recommended Coprocessor Version Firmware Version Version 2 11 to 2 42 2 11 2 11 2 50 to 2 51 2 50 2 50 2 60 2 60 2 60 196 35010533 07 2011 Firmware CPU Firmware Compatible Coprocessor Recommended Coprocessor Version Firmware Version Version 2 70 2 70 to 2 79 2 71 2 80 2 80 to 2 89 2 80 3 00 3 00 to 3 09 3 00 35010533 07 2011 197 Firmware Quantum Hot Standby Firmware Upgrade Overview The Firmware Upgrade feature allows the following upgrades while the Primary CPU controller continues to control the process e Operating System of the Standby CPU upgrading the firmware in the Standby coprocessor e upgrading the firmware in the Standby CRP module However during the upgrade the system is not redundant A WARNING UNEXPECTED EQUIPMENT BEHAVIOR Design your application in such a way that your process is not impacted by a cycle time variation that might appear after a firmware upgrade F
141. nt system It runs your entire application program and thereby provides the normal control functions you would expect from a standalone PLC The Primary CPU controller e executes the whole application program first section of the MAST task included e controls the Remote I O e updates the Standby CPU controller every scan program cycle The major differences of the Primary CPU from a standalone PLC are e The Primary Hot Standby controller communicates regularly with its Standby PLC so that the Standby remains ready to assume the Primary role if required e The Primary PLC monitors itself and certain associated equipment for specific conditions that dictate a Switchover to the Standby controller The role of the Standby PLC is different from a standalone PLC Its role is to remain ready to assume control of the system at a moment s notice and yet not interfere with the control asserted by the Primary controller To do so it must regularly receive application data and I O states computed by the Primary controller 35010533 07 2011 21 Quantum Hot Standby System The Standby CPU e executes only the first section of the application program MAST task e verifies the availability of the Primary CPU and CRP modules e can update the Primary CPU about the status of its CPU CRP modules and Drop connections e does not control the Remote I O The Standby PLC also regularly communicates information back to the Primary PLC using a gr
142. ntum Power Supplies 140 CPS eee 00 2 Quantum Hot Standby Controller 140 CPU 672 61 2 140 CPU 671 60 E 2 140 CPU 671 61 _ 2 140 CPU 671 61S 2 Quantum Hot Standby RIO Head 140 CRP 931 00 2 0 2 Modules 140 CRP 932 00 2 0 2 Quantum Hot Standby RIO Drop 140 CRA 931 00 See Software As needed Modules 140 CRA 932 00 Requirements As needed see page 40 Self Terminating F Adaptor 52 0411 000 2 Splitter MA 0186 100 1 Tap MA 0185 100 As needed Trunk Terminator 52 0422 000 As needed NOTE The above hardware is always required in Hot Standby systems but it does not provide a useful redundant system because no redundantly managed I O modules are included 35010533 07 2011 31 Quantum Hot Standby System 490 NRP 954 00 Fiber Optic Repeaters NPP repeaters are only used between S908 CRP RIO Drop modules 490NRP954 490NRP954 32 35010533 07 2011 Quantum Hot Standby System NFP repeaters cannot be used between the two Hot Standby CRP RIO Drop modules AN vO P S CRA 1 0 VO 35010533 07 2011 33 Quantum Hot Standby System Quantum Ethernet I O Hot Standby Hardware and Topology Quantum Ethernet I O System Components The following figure shows the single daisy chain ring architecture of a Quantum Ethernet I O Hot Standby system 8 hity Pro l 7 1A 2A CPU and Copro of Primary controller 1B 2B CPU and Copro Standby controller 3 CPU
143. o 0 Note The Command Register system bit is then returned to 0 from 1 NOTE For more details refer to Application Mismatch see page 193 35010533 07 2011 187 Application Modifications Primary CPU Online Application Modifications with Allowed Application Mismatch Procedure To make online modifications to an application program in the Primary PLC follow these steps Step Action 1 Verify that the Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Connect Unity Pro to the Primary CPU Set the Command Register system bit SW60 3 to 1 Modify online the application program a RR ow hp Perform Build Project NOTE If adding removing modules using CCOTF see Modicon Quantum Change Configuration On The Fly User Guide use Build Changes 6 Verify that Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Perform an application transfer see page 192 to the Standby CPU Set the Command Register system bit SW60 3 to 0 NOTE The Command Register system bit is then returned to 0 from 1 NOTE For more details refer to Application Mismatch see page 193 188 35010533 07 2011 Application Modifications Offline Application Modification with Allowed Application Mismatch Procedure To make offline modifications to an application program in either PLC follow these steps Step Action 1
144. odule in the local rack Distributed I O clouds are single point connections to the Quantum EIO network and are not required to support RSTP 35010533 07 2011 239 Glossary distributed I O device Any Ethernet device Schneider Electric device PC servers or third party devices that supports I O exchange with a PLC or other Ethernet communication service distributed I O network A network containing distributed I O devices that integrates a unique standalone PLC or a unique Hot Standby system I O scanning may be performed by a communication module interlinked with a remote I O head module on the local rack of an Ethernet remote I O system Distributed I O network traffic is delivered after remote I O traffic which takes priority in an Ethernet remote I O network DNS domain name server service A service that translates an alpha numeric domain name into an IP address the unique identifier of a device on the network domain name An alpha numeric string that identifies a device on the internet and which appears as the primary component of a web site s uniform resource locator URL For example the domain name schneider electric com is the primary component of the URL www schneider electric com Each domain name is assigned as part of the domain name system and is associated with an IP address Also called a host name DRS dual ring switch A ConneXium extended managed switch with one of several possible predefine
145. offline while controlling the process A WARNING UNEXPECTED EQUIPMENT BEHAVIOR Before transferring a modified application to the Standby CPU e Examine carefully all the impacts of the modifications on the application e Check that the modified application does not have adverse effects on the process Failure to follow these instructions can result in death serious injury or equipment damage 186 35010533 07 2011 Application Modifications Standby CPU Online Application Modifications with Application Mismatch Procedure To make online modifications to an application program in the Standby PLC follow these steps Step Action 1 Verfiy that the Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Connect Unity Pro to the Primary CPU Set the Command Register system bit SWE60 3 to 1 Connect Unity Pro to the Standby CPU controller Modify online the application program oO o AJ OJN Perform a Build Project NOTE If adding removing modules with CCOTF see Modicon Quantum Change Configuration On The Fly User Guide use Build Changes Verfiy that the Primary and Standby PLCs are in Run Primary CPU and Run Standby CPU modes Perform a Switchover see page 190 Note Standby CPU changes to Primary CPU Perform an application transfer see page 192 to new Standby CPU Set the Command Register system bit SW60 3 t
146. oller as a result of a switchover its Modbus port 1 address is remains at 1 Swapping Modbus Plus Addresses at Switchover In a Quantum Hot Standby system the Modbus Plus port addresses on the Standby CPU controller are offset 32 from the comparable ports on the Primary CPU controller Modbus Plus address swap behavior at Switchover Default Behavior before Switchover e Controller A Primary CPU MB address 1 Controller B Standby CPU MB address 33 1 32 32 Offset After switchover occurs e Controller A new Standby CPU MB address 33 1 32 e Controller B new Primary CPU MB address 1 NOTE Numerical address of both ports A and B range 1 64 If Primary CPU address 50 corresponding Standby CPU 18 50 32 The Modbus Plus address of the controllers can be changed using the front panel keypad Communication Modbus Plus Modify Address NOTE The Modbus Plus port will be inactive for about 10 seconds after the RUN standby CPU state is shown on the LCD display 134 35010533 07 2011 Programming and Debugging Modbus Plus address swap behavior when the address is changed Forced behavior before Switchover e Controller A Primary CPU MB address 1 e Controller B Standby CPU MB address 33 1 32 32 Offset Change address of Primary CPU 5 e Controller A Primary CPU MB address 5 Controller B Standby CPU MB ad
147. om either a BOOTP server or the MAC address Ethernet Services at Power Up The following table shows how the status of an NOE service is affected by the Quantum Hot Standby state Hot Standby State Status of NOE Services Client Services Client Server Server Services Services 1 0 Scanner Global Modbus FTP SNMP HTTP Data Messaging Unassigned Run Run Run Run Run Run Primary CPU Run Run Run Run Run Run Standby CPU Stop Stop Run Run Run Run Offline Stop Stop Run Run Run Run 100 35010533 07 2011 Configuration Hot Standby Switchover The following table describes how the NOEs coordinate a Hot Standby Switchover Step Action 1 In a Hot Standby configuration NOE A is running in the Primary PLC and NOE B is in the Standby PLC NOE A detects that its PLC has changed from Primary CPU to the Offline mode NOE A changes from Primary NOE to Offline with the same Ethernet services running and starts its watchdog timer with a 500 ms time out setting It waits for a UDP request to swap IP addresses from NOE B NOE B detects that its PLC has changed state from Standby PLC to Primary CPU NOE B stops all its Ethernet services sends a UDP request to NOE A for the synchronization of the IP address swap starts its watchdog timer with a 500 ms time out setting and waits for an UDP response from NOE A When NOE A receives the UDP request from N
148. ommunication with one another The Primary CPU sends a health message to the Standby CPU either e every 10 milliseconds when no other data is being sent on the Copro link e every 5 milliseconds if no communication is required with any drop on the RIO link If the Standby CPU never receives any message on either of these links Copro 908 RIO or Quantum Ethernet I O Ethernet RIO the Standby CPU tries to determine the cause and assumes control if necessary If the Primary CPU does not receive a valid response from the Standby CPU the Primary CPU operates as a standalone CPU Conducting Startup Tests The system automatically performs startup confidence testing on the Quantum Hot Standby Copro that attempt to detect hardware errors in the Copro before the application is allowed to run If the Copro does not pass the tests the Standby PLC remains offline and does not communicate with the other Quantum Hot Standby modules 35010533 07 2011 109 Maintaining Conducting Run Time Tests The system automatically performs run time tests whenever the Copro is in the operational state NOTE Run time tests are executed in small slices to prevent delays in scan time If the Copro does not pass the tests the Standby PLC remains offline and does not communicate with the other Quantum Hot Standby modules 110 35010533 07 2011 Maintaining 3 3 Single Point of Detected Failure Overview This section describes th
149. ory RAM CPU Application Identification Name Creation Product Date Modification Product Date Version Signature Application Option Upload Information Comments Animation Table Section Protection Application Diagnostic Application Miscellaneous Forced Bits Hot Standby PLC Hot Standby Status Peer PLC Hot Standby Status Application mismatch between PLC and Peer PLC PLC Name Variable Transfer Status Hot Standby Entire System State Only Online available 35010533 07 2011 77 Configuration Using the Hot Standby Tab Viewing the Hot Standby Tab Configure Hot Standby values in the Hot Standby tab of the Unity Pro editor 1 2 140 CPU 671 60 o x P266 CPU Hot Standby 1Mb Program PCMCIA Ethernet HSBY Fiber optic USB MB MB El Overview El Summary 3 Configuration s Modbus Port F Animation 4 Hot standby F 1 0 objects Run Mode Invalidate Keypad Controller A Online M Yes Controller B Online v Standby On Logic Mismatch Swap Address At Switchover Offline Online M Modbus Port 1 State RAM Non Transfer Area Start MW 1 Length Behaviour of the CPU in Run Offline mode CPU executes _All sections v All sections First sections No section at all Description of the Hot Standby tab A Item Option Value Description Run Mo
150. oup of System Words the Reverse Transfer Registers The content of these System Words is configurable The most common use is to provide the Primary PLC application program information about the health of the Standby controller and its associated modules Distinguishing Between Controllers The two physical controllers are assigned as either PLC A or PLC B This assignment is used to configure the IP address of the CRP RIO Head modules Distinguishing between the A and B Hot Standby CPUs allows e assigning a physical location to each CPU e defining which CPU is the Primary at system start up A WARNING UNINTENDED EQUIPMENT OPERATION Confirm the A B assignment of a PLC before taking any action on it Failure to follow these instructions can result in death serious injury or equipment damage Never assume that a PLC is in a certain operating mode before installing operating modifying or servicing it The operating modes of both Hot Standby PLCs can be determined by viewing their LCD keypads LEDs and System Status Words NOTE In a Hot Standby system the CRP IP addresses are not swapped during a Switchover At the first startup of a CPU without the A B assignment the Hot Standby menu is displayed on the keypad LCD allowing the user to assign A or B to the CPU The user can also assign change the A B assignment of the Hot Standby CPUs using the keypad LCD After modification the CPUs reset its CRP RIO Head modules N
151. our process When performing this second stage the debug and diagnostic resources in the tables above are not available A WARNING UNINTENDED EQUIPMENT OPERATION When debugging the redundancy specific aspects of your application program e Always debug your application on a fully functioning Hot Standby system e Only conduct debugging on a Hot Standby system that is not actively managing your process e Do not use the Unity Pro debug and diagnostic features except as permitted by this manual e Confirm that the interaction of the MAST task mode and duration with the Watchdog values meet the needs of your application Failure to follow these instructions can result in death serious injury or equipment damage When you are conducting the second stage of debugging confirm that you initially connect to the PLC currently acting as Primary The Standby PLC only executes section 0 of the MAST task of your application program Debug the First Section of the MAST task in Standby PLC To debug the first section in the Standby PLC application the following points have to be taken into account e All the application data that comes from the Primary PLC are displayed in a Standby animation table e Animation tables can be synchronized with watch points This is the best way to animate data in synchronization with code execution Refer to the Unity Pro Program Languages and Structure Reference Manual reference 35006144 for
152. period must take into account the longer mast task periods necessary in a redundant system The following table presents the characteristics of MAST tasks that may be adjusted by the user in Unity Pro Characteristics Unity Pro Default Values Max period ms 255 Default period ms 20 Note Set to 80 ms as an initial value for Hot Standby systems Min period ms 1 0 if the Cyclic MAST task execution mode is selected Period increment ms 1 Max Watchdog ms 1500 Default Watchdog ms 250 Min Watchdog ms 10 For more details see Adjusting Mast Task Properties see page 168 Detecting Cold and Warm Starts of a Quantum Hot Standby PLC In a Quantum Hot Standby PLC only the System Word SW10 and the System Bit S1 can be used to detect respectively a Cold Start and a Warm Start e SW10 Cold start test If the value of the SW10 0 bit representing the MAST task is set to 0 this means that the task is performing its first cycle after a Cold Start At the end of the first cycle of the MAST task the system sets the bit SW10 0 to 1 172 35010533 07 2011 Programming and Debugging e S1 Warm start test The default value of S1 Is 0 This bit is set to 1 when the device power is cycled and a data save operation is performed If this value is 1 this is an indication that the last start performed was a Warm Start It is reset to 0 by the system at the
153. plication program execution to all the output modules associated with the MAST Task 35010533 07 2011 17 Quantum Hot Standby System e Switchover This refers to the moment when application control transfers from the Primary controller to the Standby controller The Switchover event has a finite duration It can be initiated e manually e by the application program e automatically by system conditions 18 35010533 07 2011 Quantum Hot Standby System Purpose and Features Purpose Features The Quantum Hot Standby is an industrial control platform intended to provide automatic redundancy for a wide range of conditions The main components of the system are two PLCs called the main or Primary PLC and the secondary or Standby PLC which has an identical configuration as the Primary controller By being programed to detect and respond to defined system conditions the Quantum Hot Standby system can automatically transition from the Primary controller and its associated modules to the Standby controller and its identical modules This transition called the Switchover takes place in a short time the length of the watchdog plus one program cycle Because the Quantum Hot Standby detects and responds automatically to a wide range of detected error conditions you do not need to manage these detected errors in your application programs For a more complete redundancy to increase the availability of the system
154. plication Program Transfer Overview The Application Program Transfer APT feature provides you with the ability to configure the Standby CPU from the Primary CPU controller Use this feature to reprogram the Primary CPU controller or replace the Standby CPU controller because the process copies the full application program of the Primary CPU to the Standby CPU This feature not only saves time but ensures that the controllers have identical configurations The system transfers the application program over the dedicated Quantum Hot Standby communications link between the two Copros Methods of Transferring Programs Application transfer is from the Primary CPU to the Standby CPU The methods of transferring application programs are e Hot Standby submenu on the front panel keypad see page 161 Use either the Primary CPU or Standby CPU e Command Register system bit SW60 5 see page 162 An application program transfer can be performed at any time e automatic transfer see page 162 that occurs when you start a Hot Standby system for the first time The Primary CPU automatically transfers the application program to the Standby CPU e select a Unity Pro command see page 163 NOTE During application program transfer the system is no longer redundant NOTE If the Primary CPU stops before the other CPU is ready to assume the role of Primary CPU the process is no longer controlled LCD Keypad Messages During an APT the fo
155. pplication Program Transfer see page 160 as soon as possible after completing modifications 35010533 07 2011 131 Programming and Debugging Handling Network Addresses at Switchover Overview The following material describes handling network addresses at Switchover A Quantum Hot Standby system can communicate data over different network protocols e Modbus e Modbus Plus e TCP IP A WARNING UNEXPECTED EQUIPMENT OPERATION Offset address must not be assigned to another device than the peered PLC of the Hot standby system Failure to follow these instructions can result in death serious injury or equipment damage In Hot Standby applications correct address assignment must be fulfilled for proper operation of network address swap at switchover Swapping Modbus Addresses at Switchover In a Quantum Hot Standby system the Modbus port addresses are e Primary CPU 1 119 e Standby CPU Offset 128 e Maximum address 247 e Range 1 247 The Modbus port addresses can be changed using one of two methods e Communication menu in the front panel keypad e Modbus Port tab in the Unity Pro editor 132 35010533 07 2011 Programming and Debugging Changing addresses Using the Communication menu in the Front Panel Keypad Change address on either Primary CPU Standby CPU 1 Access the front panel keypad of the 1 Access the front panel keypad of the Standby Primary CPU CPU
156. r of the following two values O FALSE or 1 TRUE lt A bit extracted from a word is of type BOOL for example sMW10 4 bootstrap protocol A UDP network protocol that can be used by a network client to automatically obtain an IP address from a server The client identifies itself to the server using its MAC address The server which maintains a pre configured table of client device MAC addresses and associated IP addresses sends the client its defined IP address The BOOTP service utilizes UDP ports 67 and 68 A message sent to all devices in the subnet C change configuration on the fly A feature of Unity Pro that allows a PLC hardware change in the system configuration while the PLC is operating and not impacting other active drop operations common industrial protocol A comprehensive suite of messages and services for the collection of manufacturing automation applications control safety synchronization motion configuration and information CIP allows users to integrate these manufacturing applications with enterprise level Ethernet networks and the internet CIP is the core protocol of EtherNet IP A CIP transport connection used for I O data transmission via implicit messaging between EtherNet IP devices A CIP transport connection used for explicit messaging between EtherNet IP devices 35010533 07 2011 237 Glossary connected messaging Using a CIP connection for communication that e
157. r Date and Time Tuesday 01 January 2002 September 2003 2 12 00 00 AM M Gaptombs x Date SunMonTueWedThu Fri Sat 25 09 2203 31 1 2 3 4 5 6 PC Date and Time 7 8 9 10 11 12 13 Time 14 15 16 17 8 19 20 21 22 23 24 26 27 28 29 30 1 4 5 6 7 8 9 10 11 CD Today 9 25 2003 2 36 42 AM Update User gt PLC PLC Data 35010533 07 2011 75 Configuration Describing the Realtime Clock Tab Description of the Realtime clock tab Item Option Description PLC Date and Time Read only Indicates the current PLC date and time PC Date and Time Update PC gt PLC Updates the PLC with the PC system time User Date and Time Update User gt PLC Updates the PLC with the time set by the user Viewing the Information Tab Unity Pro Information tab dialog PLC Screen Task I Realtime clock PLC i SYSTEM INFORMATION IDENTIFICA gt MEMORY APPLICATION IDENTIFICA OPTION MISCELLA HOTSTANDBY 76 35010533 07 2011 Configuration Describing the Information Tab Description of the Information tab Item Option Value Description System Information PLC Identification PLC Range Processor Name Processor Version Hardware ID Network address PLC Mem
158. rack through Rack Expender modules and their cable Its modules are considered to be in the same backplane as the main rack In rack I O This term refers to any I O that is directly connected to the Quantum rack s backplane in the main rack or an extended rack without any intervening fieldbus connections and therefore includes all analog and discrete I O modules In rack I O is locally and non redundantly managed Local In rack I O or just Local I O in the first section of the MASK task of the Hot Standby application program Local PLC Peer PLC The Local PLC is the PLC in the Hot Standby system that you are working on The other PLC is the Peer PLC The local PLC can be the Primary or Standby and the Peer PLC can be the Standby or Primary Main rack This is the rack that supports the processors CPU module and RIO Drop adapter modules 140_CRA_93e_00 or 140 CRA 312 00 and I O modules Program cycle In a Hot Standby system the program cycle can only use the MAST task see Exclusive Use of MAST Task see page 49 The MAST task cycle is classically divided in the four main parts e input drivers all input modules associated with the MAST Task are scanned e Hot Standby system functions data exchange between CPU and Copro and system checks e user logic execution the system executes the application program relative to the MAST Task e output drivers the system applies the outputs evaluated during the ap
159. rcent darker LCD Light setting submenus Screen Displays Fields Available Description LCD Light On LCD remains on permanently or until changed Off LCD remains off permanently or until changed 1 Min LCD remains on for 1 minute 5 Min LCD remains on for 5 minutes 10 Min LCD remains on for 10 minutes 15 Min LCD remains on for 15 minutes 35010533 07 2011 233 Controls and Displays 234 35010533 07 2011 Glossary l IW M MW Q QW SW 0 9 According to the CEI standard I indicates a language object of type discrete IN According to the CEI standard Iw indicates a language object of type analog IN According to the CEI standard M indicates a language object of type memory bit According to the CEI standard smw indicates a language object of type memory word According to the CEI standard Q indicates a language object of type discrete OUT According to the CEI standard QW indicates a language object of type analog OUT According to the CEI standard Sw indicates a language object of type system word 35010533 07 2011 235 Glossary adapter advanced mode architecture array ART A The target of real time I O data connection requests from scanners It cannot send or receive real time I O data unless it is configured to do so by a scanner and it does not store or originate the data communications para
160. re available to the Primary CPU When the secondary CPU is Offline the reverse registers are not transferred to the Primary If the user does not change the value on Primary side this previous value is kept When Secondary becomes the Standby the reverse registers are updated on the Primary side 2 MAST cycles after the transition 82 35010533 07 2011 Configuration Setting Up the Quantum Hot Standby System Overview Setting up a Quantum Hot Standby system involves a number of processes summarized in the following paragraphs here and explained in detail elsewhere Mapping the Rack Extensions A Quantum Hot Standby requires two racks with at least four slots Map the two racks in an identical manner as described in Identical Configurations see page 39 Connecting Two CPUs Connect the two Quantum Hot Standby CPUs with a fiber optic cable as described in Hot Standby Sync Link Topology see page 27 Establishing the Primary CPU and Standby CPU Controllers The system determines that one of the two Quantum Hot Standby CPUs is the Primary the A CPU and that the second CPU is the Standby the B CPU refer to Establishing the Primary and Standby Controllers see page 23 and Distinguishing between Controllers see page 22 The Keypad may provide status information Therefore to view the status use the Quantum Hot Standby CPU keypad by selecting Quantum PLC Operations PLC Operations Hot Standby Hot Standby Order
161. rhead required for TCP UDP is faster UDP may be the preferred protocol for time sensitive applications where dropped datagrams are preferable to delayed datagrams UDP is the primary transport for implicit messaging in EtherNet IP V Memory entity of type BOOL WORD DWORD etc whose contents can be modified by the program currently running 35010533 07 2011 255 Glossary 256 35010533 07 2011 Index A application mismatches 181 C configure NOC 61 configuring registers 85 configuring processors 62 controller failures primary 118 CRPs com act errors 118 D detected faults 113 diagnosing hot standby 224 diagnosing processors 107 blinking 223 steady 223 diagnostics buffers 112 217 duplicate IP tests 100 F Fiber Optic Cable 490NOR00003 206 490NOR00005 206 490NOR00015 206 H Hot Standby HSBY safety CPU 53 HSBY_RD 141 HSBY_ST 144 HSBY_WR 147 I O errors 157 identical applications 182 initialized data 94 IP addresses 140 NOE 771 1 97 K key switches 225 keypads 222 L limits transfer size 167 M maintenance 107 menus high end CPUs 224 modes 99 35010533 07 2011 257 Index N NOE Ethernet modules 96 O offsets 132 operating modes 99 overhead 164 P processors 209 R reading registers 85 real time clocks 95 registers 61 command 86 status 90 93 remote I O 116 replacing a faulty
162. rimary CPU and Standby CPU Copros e exchanges data between both controllers e runs in parallel with the application program 164 35010533 07 2011 Programming and Debugging A Hot Standby system with a 140 CPU 67 is illustrated below t nx Input Hot Standby Output gt g amp drivers system functions J Cean Sesion Escon 3 drivers LJ lt 7 ms 100 kB of overhead zs O S ao Data transfer oO FARATAN 17 ms 100 kB of data e Data transfer gt 2 O 5 Y YY wo nx Input Hot Standby Output S drivers j system functions Section 1 drivers i oe 1 MAST task cycle Most of time the MAST scan is greater than the network scan However when processing some application programs additional system overhead may occur Examples 1 For this example e Standalone application scan time 80 ms e data transferred state RAM unlocated variables 100 kB The Hot Standby MAST cycle is greater than the Standalone scan time only by the Hot Standby 7 ms overhead t F x Input Hot Standby User Logic Output gt S drivers system functions drivers E 15 7 ms ex 6s Data transfer gs py 100 kB 1 Hot standby MAST task cycle 87 ms 35010533 07 2011 165 Programming and Debugging Example 2 For this example e the standalone application scan time 80 ms e data transferred state RAM unlocated variables 600 kB The Hot Standby MAST cyc
163. rimary PLC and the Standby PLC exist These exceptions include the located System Word SW61 and User Application data maintained independently on each PLC Writing values to the Standby PLC registers is ineffective because the next database transfer from the Primary PLC overwrites these values NOTE Only unlocated data in the non transferred area are not overwritten by data from the Primary PLC 48 35010533 07 2011 Quantum Hot Standby System Application Task Types In a Quantum Hot Standby system the Standby controller must remain ready to assume the role of the Primary controller This requires that both controllers run identical applications and that the Standby controller is provided with current application data and state information from the Primary controller once per scan The synchronous and deterministic transfer of the Primary controller data and state information to the Standby controller is achieved by using MAST tasks Exclusive Use of MAST Tasks Only the MAST tasks must be used in a Quantum Hot Standby system because the transfer of Primary PLC system and user application data to the Standby PLC is synchronized in each MAST task cycle refer to Second Step of Execution Time Measurement see page 170 A WARNING UNINTENDED EQUIPMENT OPERATION Do not use programming methods based on data that are not synchronized in each MAST task cycle Failure to follow these instructions can result in death se
164. rious injury or equipment damage The following programming methods are examples that must not be used in a Hot Standby application e preemptive asynchronous or interrupt driven EVENT tasks FAST tasks intermediate I O section schedulers events and edge triggers etc e U_ERIO function block They can impact the performance of the MAST tasks and cause discrepancies between Primary and Standby output values in the event of a Switchover Be careful when using explicit messages and time stamping e f explicit messages are used some messages may be sent twice and answers may be lost during a switchover e f time stamping are used some time stamps may be lost during a switchover Only MAST tasks support data synchronization between the Primary and Standby controllers 35010533 07 2011 49 Quantum Hot Standby System How Hot Standby MAST Tasks Differ Hot Standby MAST tasks are different from the normal MAST tasks from Standalone Quantum PLCs In a Quantum Hot Standby PLC the execution of a MAST task involves extra steps necessary to support redundancy These additional steps provide the following e Database transmission e Wait states to synchronize MAST task execution see Synchronized Program Execution see page 43 between the two PLCs MAST Tasks Comparison An example of a Standalone MAST task follows D Input USER LOGIC Output Drivers Drivers Input state Application program Ou
165. rs after updating the initial values of one CPU online in a redundant system e Ifyou execute a cold start and a switchover occurs to make the non updated PLC the Primary PLC the old initial values are used Value mismatches are treated in the same way as application mismatches Value mismatches give the same indications and have the same update requirements as an application mismatch 94 35010533 07 2011 Configuration Synchronizing System Timers Setting the System Timer in the Standby CPU Coniroller In a Quantum Hot Standby system the Primary CPU and Standby CPU controllers have their own system timers which are not implicitly synchronized At Switchover the Standby CPU sets its system timer with values sent by the Primary CPU This mechanism allows the new Primary CPU to run the Hot Standby application in the same context as the old Primary CPU If the timers are not synchronized then at Switchover the system timer would change by the difference between the two clocks Non synchronous clocks can cause problems in a time critical application 35010533 07 2011 95 Configuration 2 3 NOE Modules Overview This section describes how to use 140 NOEs Quantum Ethernet modules with Unity Pro in a Quantum Hot Standby system For a complete description of all NOE models see the Quantum NOE_771_xx Ethernet Modules User Guide 840_USE_116_00 What s in this Section This section contains the fol
166. s Identical Application Programs In a fault tolerant redundant system and under normal operating conditions both controllers must load the identical application programs The application program is updated every scan by transferring data from the Primary CPU to the Standby CPU Both controllers conduct tests to detect if a mismatch exists between the application programs Differences between the following conditions cause a mismatch in the application program e programs e animation tables e comments on variables e I O configuration changes in the RUN mode NOTE To exclude animation tables and comments on variables from an uploaded application without causing a mismatch e select Tools Project Settings Build tabs default e inthe Upload Information area select without When a mismatch exists a Switchover is not possible and the Standby CPU controller does not go online However there are situations when you may want to allow a mismatch between the application programs To enable this condition use the Quantum Hot Standby Application Mismatch feature NOTE Switchover cannot occur while the Standby CPU controller is offline Application Mismatch Definition Application Mismatch is a Quantum Hot Standby feature that allows a mismatch between the application programs and the I O configuration of the Primary CPU and Standby CPU Use the Application Mismatch feature to modify an application program and the I O configur
167. s 4 CRA devices and 1 DRS that count as 2 devices for a total 8 devices 32 8 24 additional devices can be added to the main ring 38 35010533 07 2011 Quantum Hot Standby System Configuration Requirements Identical Hardware and Software Identical Hardware Identical Software In previous sections we stated the requirement for identical controllers and CRP Head modules In fact the requirement for identical configurations extends to all equipment on both the Primary and Standby racks and even to the application programs To create a working Hot Standby system you must meet all of the following hardware firmware requirements or your system cannot come Online There must be identical hardware in both controllers e Identical Quantum Hot Standby controllers with identical CPU and Copro firmware identical memory cards and accessories occupying the same rack positions You can permit differing firmware versions on a temporary basis so that operational firmware upgrades see page 195 are possible e Identical In rack I O Any In rack I O must be identical including having identical firmware versions and hardware revisions if applicable and must occupy the same rack positions NOTE Since the applications are identical in both controllers the In rack I O has to be identical in both PLCs so that the Standby application can handle this O if it becomes the Primary controller e Identical module cartridges and acces
168. s 1 and 2 of the SW60 command register you can command a change in the operating modes of the Hot Standby controllers The following table describes the four commands and their results New Values Written to SW60 Resulting PLC Operating Modes Effects Bit 1 Bit 2 PLC A PLC B 0 Offline Standby e Switchover event is immediate e System remains redundant Primary 0 Offline Standby e Switchover event occurs within f one MAST task Primary e System is no longer redundant 128 35010533 07 2011 Programming and Debugging New Values Written to SW60 Resulting PLC Operating Modes Effects Bit 1 Bit 2 PLC A PLC B 1 0 Primary Offline e No Switchover event e System is no longer redundant 1 1 Primary Standby e No Switchover event e No change from initial conditions In this case we are not directly commanding a Switchover Instead we are commanding PLC A to enter an Offline state and we are relying on the system logic to recognize this and change PLC B from Standby to Primary during the next scan NOTE All changes to the command register SW60 must be written to the Primary PLC This register is copied from the Primary to the Standby PLC during each MAST task Therefore any changes you make directly to the Standby PLC s command register will be overwritten by this transfer without taking effect 35010533 07 2011 129 Programming and Debugging Swi
169. s Sw60 1 and sSwW60 2 must be set back to 1 This makes the Offline CPU go back to the online RUN Standby mode The OFFLINE ONLINE modes controlled by 3Sw60 1 and 3SW60 2 are not linked to the LCD Keypad ONLINE OFFLINE mode see page 227 A WARNING UNEXPECTED EQUIPMENT BEHAVIOR Ensure that your system does not switchover from the application program before starting a CCOTF modification Failure to follow these instructions can result in death serious injury or equipment damage System Bit SW60 3 Application mismatch see page 181 e sSw60 3 0 If an Application mismatch is detected Standby CPU is forced to OFFLINE mode e ssw60 3 1 Standby CPU operates normally even if a mismatch occurs 35010533 07 2011 87 Configuration System Bit SW60 4 Firmware upgrade e ssw60 4 1 Allows the firmware to be upgraded on the Standby CPU while the Primary CPU continues to control the process e ssw60 4 0 Allows the firmware to be upgraded and stops the Primary CPU control of the process Upgrading allows e a Hot Standby system to operate with different versions of the OS running on the Primary CPU and Standby CPU e upgrades without shutting down the process To perform the firmware upgrade see page 195 the Standby CPU must be stopped When started again the Standby CPU operates again as the Standby CPU System Bit SW60 5 Standby CPU initiates an application transfer e SwWw60 5
170. s of capacity year Battery load current power off typical 14 uA maximum 420 uA TOD clock 8 0 s day 0 60 C Power up RAM RAM address Executive Checksum User Logic Check Processor Run Time RAM RAM address Executive Checksum User Logic Check 212 35010533 07 2011 Additional Information 140 CPU 672 61 Specifications Module Specifications Processor Memory Reference Capacity Component Description Communication ports 1 Modbus RS 232 RS 485 1 Modbus Plus RS 485 1 USB 1 Ethernet used as a Hot Standby port Bus current required 2 5A Maximum number of NOE 771 11 modules 6 supported Key switch Yes Keypad Yes Feature Description Model Pentium Clock speed 266 MHz Coprocessor Yes Built in Ethernet Watchdog timer 250 ms software adjustable RAM 4 MBytes IEC program memory and or application data and configuration 3172 kBytes IEC program memory maximum with PCMCIA card 8 MBytes Discrete bits 64 kBytes any combination Registers words 64 kBytes maximum 35010533 07 2011 213 Additional Information Remote I O Battery and Clock Diagnostic Maximum I O words drop 64 in 64 out Maximum number of remote drops 31 This information can be a mix of discrete or r
171. s to protect against the unwanted effects of excessive broadcast traffic e Reduce the speed of the port allocated to communicate with the respective NOEs from 100Mb s to 10Mb s e Limit the potential effects of an overloaded network to the NOE by filtering it with an appropriate switch set with a limit of 500 packets per second Schneider Electric offers a line of a configurable ConneXium switches capable of broadcast limiting e f the Ethernet switch must be set at 100Mb s speed then set the watchdog timer to 1 5 seconds independent of the number of NOEs If the watchdog timer is set too low then the remaining system may also stop working if a persistent overloaded network occurs 106 35010533 07 2011 Maintaining a Quantum Hot Standby System Overview This chapter provides information about maintaining a Quantum Hot Standby system with Unity Pro What s in this Chapter This chapter contains the following sections Section Topic Page 3 1 Hot Standby Module Replacement 108 3 2 Hot Standby Health Messages 109 3 3 Single Point of Detected Failure 111 35010533 07 2011 107 Maintaining 3 1 Hot Standby Module Replacement Replacing a Module Replacing a Module without Stopping A module to be replaced must be in the Standby PLC in the Offline mode If the inoperative module is in the Primary PLC perform a Switchover to move the module to the Standby mode then mov
172. sary arsina ital etait brie ire etka 235 HOON sbi piven Sidach E Goin en ge wie ere eee 257 35010533 07 2011 5 35010533 07 2011 Safety Information A Important Information NOTICE Read these instructions carefully and look at the equipment to become familiar with the device before trying to install operate or maintain it The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or serious injury This is the safety alert symbol It is used to alert you to potential 35010533 07 2011 7 PLEASE NOTE A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if
173. smatch bit e f a mismatch is not allowed SFC modifications do not cause a problem When the Primary CPU application changes the Standby CPU goes to the RUN OFFLINE mode the Primary CPU application must be transferred to the secondary CPU to move it back to the RUN STANDBY mode NOTE A transfer carried out automatically by the application reduces the time that the Hot Standby function is not available to o a minimum 130 35010533 07 2011 Programming and Debugging e f a mismatch is allowed then e AnSFC modification may cause a reallocation of the block containing the SFC data This stops the exchange of this data with the Standby CPU e Also after a Switchover this SFC restarts at its initial step This may have an impact on the operation of the Hot Standby application e To reduce these impacts program the SFC in several sections The modification of one SFC does not the rest of the SFC A WARNING UNINTENDED EQUIPMENT OPERATION Ensure that the controllers contain the same application program during a Switchover Failure to follow these instructions can result in death serious injury or equipment damage If a Switchover occurs in the Run mode and there is an application mismatch between the two controllers the Standby CPU assumes Primary CPU responsi bilities and starts executing a different application program from the previous Primary CPU Remove any application mismatch by performing an A
174. sories For In rack communication and I O modules that accept such accessories any cartridges used must be identical and identically positioned and configured e Identical extended Quantum racks 140 XBP 004 00 through 140 XBP 016 00 backplanes Each PLC must contain the same number of racks The rack IDs used must be the same on each PLC e Identical Quantum 140 CPS eee ee power supplies occupying the same rack positions and ideally supplied by different circuits e Identical cabling and cabling systems fully shielded and compliant with the length requirements for the type of fieldbus you employ Identical application programs and configurations must be loaded on both Quantum Hot Standby controllers in both Primary and Secondary controllers NOTE You can temporarily permit different software on the two controllers so that operational software modification can be made while running refer to the CCOTF User Manual 35010533 07 2011 39 Quantum Hot Standby System Software and Firmware Requirements For a Quantum Hot Standby system the following software and firmware is required 140 CPU 671 60 and 140 CPU 672 61firmware 3 0 908 140 CRP 938 00 firmware 2 0 S908 140 CRA 938 00 firmware 2 0 Unity Pro 6 0 XL and XLS 140 CRP 312 00 firmware 1 0 140 CRA 312 00 firmware 1 0 40 35010533 07 2011 Quantum Hot Standby System Establishing Redundancy Database Exchange The Ouantum Hot Standby provides r
175. ss swap on Modbus port 3 when a switchover occurs e sSw60 10 1 No address swap on Modbus port 3 when a switchover occurs 89 35010533 07 2011 Configuration Hot Standby Status Register Bits in the Hot Standby Status Register The Hot Standby Status Register System Word Sw61 is read only It is used to monitor the current machine status of the Primary CPU and Standby CPU Both the Primary CPU and the Standby Offline CPU have their own copy of the Status register The Status register is not transferred between the Primary CPU and Standby CPU Each PLC updates its local Status Register based on information exchanged between the two controllers The following illustration identifies the operating options provided by the Status Register This PLC in OFFLINE mode 0 1 This PLC running in primary CPU mode 10 This PLC running in standby CPU mode 1 1 Other PLC in OFFLINE mode 0 1 Other PLC running in primary CPU mode 10 Other PLC running in standby CPU mode 1 1 PLCs have matching logic 0 PLCs do not have matching logic 1 This PLC s switch set to A 0 This PLC s switch set to B 1 1s 4 re 12 MIRON s 7 e s 4 3 2 4 0 tse 0 CPU sync is operating properly 1 CPU sync is not operating properly MSB 0 OS versions are same 1 Mismatch between OS versions 0 Copro OS version compatible with CPU 1 Copro OS version not compatible with CPU 0 Inform
176. stablishes a relationship between 2 or more application objects on different nodes The connection establishes a virtual circuit in advance for a particular purpose such as frequent explicit messages or real time I O data transfers connection A virtual circuit between 2 or more network devices created prior to the transmission of data After a connection is established a series of data is transmitted over the same communication path without the need to include routing information including source and destination address with each piece of data connection originator The EtherNet IP network node that initiates a connection request for I O data transfer or explicit messaging connectionless Communication between 2 network devices where data is sent without prior arrangement between the devices Each piece of transmitted data includes routing information including source and destination address control network An Ethernet based network containing PLCs SCADA systems an NTP server PCs AMS switches etc Two kinds of topologies are supported e flat Devices in this network belong to the same subnet e 2 levels The network is split into an operation network and an inter controller network These 2 networks can be physically independent but are generally linked by a routing device 238 35010533 07 2011 Glossary DDT determinism device network DFB DHCP derived data type A set of elements with
177. symbols simple daisy chain loop A daisy chain loop that contains remote I O devices only no switches or distributed I O devices This topology consists of a local rack containing a remote I O head module and 1 or more remote I O drops each drop containing a remote I O adapter module SNMP simple network management protocol Protocol used in network management systems to monitor network attached devices for events The protocol is part of the internet protocol suite IP as defined by the internet engineering task force IETF which consists of network management guidelines including an application layer protocol a database schema and a set of data objects SNTP simple network time protocol See NTP 252 35010533 07 2011 Glossary SOE ST sub ring subnet mask switch T gt O target sequence of events The process of determining the order of events in an industrial system and correlating those events to a real time clock structured text A structured developed language similar to computer programming languages It can be used to organize a series of instructions An Ethernet based network with a loop attached to the main ring via a DRS A sub ring may contain either remote I O or distributed I O devices The 32 bit value used to hide or mask the network portion of the IP address and thereby reveal the host address of a device on a network using the IP protocol A multi port device used to
178. t panel keypad of a controller Primary or Standby Go to PLC Operations menu Go to Hot Standby submenu AJOIN Go to Hot Standby transfer and press ENTER to confirm the transfer NOTE Verify that the transfer to Standby CPU occurs Application Program Transfer Using Command Register System Bit SW60 5 To transfer an application program from the Primary CPU to the Standby CPU using Command Register system bit SW60 5 do the following Step Action 1 Connect unity Pro to the Primary CPU 2 Set Command Register system bit SW60 5 to 1 NOTE This bit is reset 0 after the transfer 192 35010533 07 2011 Application Modifications Recommendations for Using Application Mismatch General Upload Information When using the Application Mismatch feature the following are affected Upload Information Management online modifications to the Standby CPU Application Program Transfer setting the Command Register system bit sSw60 3 Management Feature During online modifications the system detects that the application program information in the controller differs from the application program information in the computer Because this information is used later when an upload is performed the system requires you to update this information and constantly presents a confirmation dialog To avoid constant display of this dialog use the Upload Information Management feature
179. t tit HEH decimal Displays Ethernet IP Gateway address numbers TCP IP Ethernet MAC Address hexadecimal Displays MAC Medium Access read only numbers Control address Parameters can be modified only if no applications have been downloaded in NO CONF state 2 When a new PLC application has been downloaded the Ethernet address on the screen is only updated after accessing the highest level of the menu structure Modbus Plus PLC Communications submenus Fields Available Options Available Description t position Modifiable only if the key switch is in the unlocked 1 64 Enter a valid Modbus Plus address Modbus Plus State Monitor Link Modbus Plus State Normal Link Sole Station Duplicate address No Token Serial PLC Communications submenus Fields Available Options Available Description Mode 232 RS mode 485 Protocol ASCII Protocols available RTU Adr 1 247 Unit address for Modbus Switchover Primary CPU 1 119 Standby CPU 129 247 35010533 07 2011 231 Controls and Displays Fields Available Options Available Description Rate 50 75 110 134 5 150 300 600 1200 1800 2400 Baud rate 3600 4800 7200 9600 19200 bits s Par NONE Parity ODD EVEN DB 7 8 Data bits if Protocol is Modbus then RTU 8 or ASCII 7 SB 1 2 Stop
180. take control command to the Standby CPU through the RIO link Primary Copro does not respond Primary CPU controller within 5 ms to the Primary CPU 1 detects and acknowledges the error 2 attempts to transfer control to the other controller by sending a take control command to the Standby CPU through the RIO link Standby Copro Primary CPU Coprosendsatake Primary CPU Copro control command to the 1 relinquishes control and becomes the Standby CPU 2 does not expect any response Standby Copro reports a detected Standby CPU controller error to the Standby CPU 1 reports the error by sending a No Standby CPU message 2 goes offline Inoperative S908 CRP RIO Head There are 2 cases for inoperative S908 CRPs e inoperative Primary CRP This condition is detected by both the Primary and Standby PLCs The Standby PLC takes control of the system The Primary Copro goes offline e Inoperative Standby CRP This condition is detected by the Standby PLC which reports the condition to the Primary PLC and then goes offline Inoperative Quantum Ethernet I O Ethernet CRP RIO Head There are 2 cases for inoperative Ethernet CRPs e Inoperative Primary CRP This condition is detected by both the Primary and Standby PLCs The Standby PLC takes control of the system and scans the I O but as a Standalone PLC The Primary goes Offline e Inoperative Standby CRP This condition is detected by the Standby PLC and Primary Copro
181. tandby CPU to 1 with the keyboard functions for Modbus PLC Communications Communications Serial Port e for Modbus PLC Communications Communications Modbus Plus 11 Coprocessor Upgrade 1 Connect the PC to the Standby CPU using Ethernet with appropriate switch and optical cable 2 Open the OSLoader tool 3 Select the FTP communication option 4 Connect the PC to the Standby CPU using the PLC IP address read on the keypad 5 Download the Operating System to the Standby coprocessor 6 Power cycle the CPU 12 CPU Operating System Upgrade Connect the PC to the Standby CPU using Modbus or Modbus Plus Open the OSLoader tool Select the Modbus or Modbus Plus communication option Connect to the Standby CPU using address 1 Download the Operating System to the Standby CPU _ RN 13 Disconnect the PC from the Standby CPU 14 Switch off the power of the Standby CPU 15 When using an application in the PCMCIA 1 Insert the PCMCIA batteries 2 Insert the PCMCIA card in the Standby CPU 16 Power on the Standby CPU NOTE The CPU must be in the No Conf state 17 Check the Copro and Operating System versions in the CPU LCD Screen 18 Reconnect all the communication cables CRP module Ethernet cables Connect the Hot Standby Sync link fiber optic cable last 19 Check that the application program is automatically transferred to the Standby CPU
182. tchover Behavior during Application Mismatch Modifying the Application Variables If a switchover occurs during application mismatch the new Primary CPU executes its own different application program with the data received from the other controller Depending on the modification different behaviors occur Modification Effect Only code changed same variables All the variables exchanged between the controllers are equal Variables added to the initial Primary CPU Variables are not used by the new Primary CPU Variables deleted from the initial Primary CPU New Primary CPU executes application program using the latest values for these variables Variables added to the initial Standby CPU New Primary CPU executes application program using initial values for these variables Variables deleted from the initial Standby CPU New Primary CPU does not use these variables Modifying an SFC Section with Unity Pro Schneider Electric recommends not using the SFC programming language in a Hot Standby application NOTE The SFC programming language is not available for 140 CPU 671 60S Hot Standby applications NOTE Modification of existing SFC actions and transitions have no impact on the SFC execution A Switchover does not reset the SFC to its initial step If SFC is used in a Hot Standby application system reaction to online modifications depends on the setting of SW60 3 see page 87 the logic mi
183. te 6849 Building 10 byte packet 684A Building 12 byte packet 684B Building 16 byte packet 684C Illegal I O drop number 6729 984 interface bus ack stuck high 6616 Detected coax cable initialization error 6617 Detected coax cable DNA transfer error 6619 Detected coax cable dumped data error 681A Coax cable DRQ line hung 681C Coax cable DRQ hung 6503 Detected RAM address test error 6402 Detected RAM data test error 35010533 07 2011 215 Additional Information Number of blinks on Code in hex Detected Error Com Act Indicator 7 6300 Detected PROM checksum error OS not loaded 6301 Detected PROM checksum error 8 8001 Detected kernel PROM checksum error 8002 Detected flash prog erase error 8003 Unexpected OS return 216 35010533 07 2011 Additional Information TextiIDs TextIDs Definitions Textlds define the warning messages written in the diagnostic buffer TextIDs for switching from Primary CPU to Offline TextID Warning message 13001 System halt 13002 Remote IO error 13003 ETH device error 13004 ETH communication problem 13005 Stop PLC command 13006 Offline keypad switch 13007 Offline Command register request TextIDs for switching from Standby CPU to Offline TextID Warning message 13008 System halt 13009 Remote IO error 13010 ETH device error 13011 ETH commun
184. te control and data connections between the client and server The ability of 2 networked devices to independently and simultaneously communicate with each other in both directions 244 35010533 07 2011 Glossary gateway global data harsh environment A device that interconnects 2 different networks sometimes with different network protocols When used to connect networks based on different protocols a gateway converts a datagram from one protocol stack into the other When used to connect 2 IP based networks a gateway also called a router has 2 separate IP addresses one on each network Global data provides the automatic exchange of data variables for the coordination of PLC applications H Resistance to hydrocarbons industrial oils detergents and solder chips Relative humidity up to 100 saline atmosphere significant temperature variations operating temperature between 10 C and 70 C or in mobile installations high capacity daisy chain loop Hot Standby HTTP Often referred to as HCDCL a high capacity daisy chain loop uses DRSs to extend the distance between remote I O drops or connect sub rings containing remote I O drops or distributed I O devices and or distributed I O clouds to the Ethernet remote I O network A high availability Quantum control system with a second standby PLC that maintains up to date system status If the primary PLC becomes inoperable the standby PLC takes
185. the Primary CPU must be down RIO link not active 2 Standby CPU assumes control RIO Head finds the Message received from Primary CPU must be either RIO link is active 1 health message Messages are sent every 5 milliseconds from Primary CPU RIO Head to Standby CPU RIO Head 2 I O transaction data message Messages are sent from the Primary CPU RIO Head to the I O drops at the request of the controller 116 35010533 07 2011 Maintaining Facts about the I O If the message is an I O transaction the RIO Head 1 concludes an interruption occurred on the high speed data link 2 informs the Primary CPU controller to go to offline 2 If you never configure an I O drop the high speed data link could cause the Standby CPU to assume control since the Standby CPU RIO head will never receive any I O transaction message 3 After any CPU error is detected 1 RIO Head will not perform drop communication 2 RIO Head sends only health messages Standby CPU Assumes Control The Standby CPU becomes Primary CPU Step Action Result 1 After the Primary CPU controller goes A health message from the Standby offline CPU controller is the only message received by the Standby CPU RIO Head 2 Standby CPU controller listens to the high speed data link for one scan 3 If Standby CPU controller hears Standby CPU knows that the cause nothing must be on both the Primary CPU Copro and Primar
186. the last MAST cycle SW30 T1 T2 T3 T4 Wait state where T2 T2 time to copy the data base from the CPU memory to the Copro time to transmit all the data on the network and free the Copro shared memory Third Step of Execution Time Measurement In the periodic mode it appears that the execution time that is measured is lower than in the cyclic mode In certain cases the difference between the two execution modes can be large Procedure to Adjust MAST Task in Periodic Mode If the MAST task has to be configured in the periodic mode it is recommended to Step Action 1 Measure the maximum value SW31 of the MAST task in cyclic mode with the Quantum Hot Standby Primary and Standby PLCs running normally This measure has to be done in the Primary PLC with all the configured tasks active only the MAST task is recommended in a Quantum Hot Standby application Configure the periodic mode with a period at least equal to SW31 plus a margin of around 20 that is Period SW31 SW31 20 35010533 07 2011 171 Programming and Debugging How to Program a Quantum Hot Standby Application Processor Configuration There are two types of MAST task execution modes e Cyclic The MAST task executes as rapidly as possible e Periodic The MAST task delays execution if necessary to observe a user defined minimum cycle time When the periodic mode is used the user defined
187. the proper use of this system you need to become familiar with new concepts practices and restrictions to properly implement and manage the Quantum Hot Standby s redundancy NOTE Users of Premium Hot Standby Quantum legacy or other redundant systems should be aware that differences exist between the redundancy provided by these systems and that provided by the Quantum Hot Standby system The differences include terminology the conditions for switching to the standby system system requirements and restrictions etc 20 35010533 07 2011 Quantum Hot Standby System Redundant Hardware Two Controllers Primary and Standby The basic requirement for a Quantum Hot Standby system is to use two completely identical Hot Standby PLCs of one of the following types e 140 CPU 671 60 e 140 CPU 672 61 e 140 CPU 671 60S only available for a S908 RIO These controllers must have the same firmware versions and be positioned in the same slots on their respective Quantum racks They must also run the same application program In a system that is operating nominally with both controllers fully functional the two identical controllers assume one of two operating modes e One controller acts as the Primary PLC operating in the Run Primary mode e The other controller acts as the Standby PLC operating in the Run Standby mode The role of the Primary PLC is almost identical to that of a standalone PLC in a non redunda
188. this Section This section contains the following topics Topic Page Introducing Unity Pro 63 Using the Summary Tab 64 Using the Overview Tab 65 Using the Configuration Tab 66 Using the Modbus Port Tab 72 Using the Animation Tab and PLC Screen Dialogs 74 Using the Hot Standby Tab 78 Configuring the PCMCIA Cards 80 Configuring the Modbus Plus Communication Type 81 Non Transfer Area and Reverse Transfer Words 82 Setting Up the Quantum Hot Standby System 83 62 35010533 07 2011 Configuration Introducing Unity Pro Overview Unity Pro software is a fully Windows compatible application Unity Pro supports only the IEC methods of configuration No Loadables Needed Unlike legacy Modicon Quantum where the CHS module owns the control functionality the Unity Pro Modicon Quantum Hot Standby with Unity systems has the control functionality embedded in the Executive Command Register The Command Register defines the basic operational parameters of a Modicon Quantum Hot Standby with Unity solution The command register s functionality is described in Hot Standby Command Register page 86 Opening the Editor Dialog After starting Unity Pro go to the Local Bus in the Structural View of the Project Browser Step Action 1 Open the Local configuration editor either by double clicking on the Local Bus or by selecting the Local Bus and executing right click Open A graphica
189. tion The fiber optic cables are sold separately Multi mode Models for 140 CPU 671 60 Description 490NOR00003 3 m MTRJ MTRJ 490NOR00005 5 m MTRJ MTRJ VDIF0646463505 15 m MTRJ MTRJ Single mode Models for 140 CPU 672 61 490NOL10005 5 mLC LC The fiber connection between Primary CPU and Standby CPU must be a direct cable connection which reduces the components that could become inoperative in the redundant system NOTE Refer to the recommendations see page 206 for fiber optic cable use 27 Quantum Hot Standby System 4 WARNING UNEXPECTED EQUIPMENT OPERATION Do not use hubs and switches as part of the fiber optic link Failure to follow these instructions can result in death serious injury or equipment damage Interrupted Sync Link If there is break in the commutation over the Sync link cable e The Primary CPU detects the link failure and remains the Primary CPU The Standby CPU requests the Standby CRP if the Primary CPU exists The Standby CRP acknowledges that the Primary CPU does exist The Standby CPU goes Offline Connecting Two Backplanes The Primary CPU and Standby CPU backplanes may be placed as much as e 4km 2 5 miles for the 140 CPU 671 60 and 140 CPU 671 60S e 16 km 10 miles apart for the 140 CPU 672 61 28 35010533 07 2011 Quantum Hot Standby System 908 Hot Standby Hardware and Topology 908 System Components
190. to Identical RIO Head Modules see page 23 CRP modules and their connecting network racks power supplies 35010533 07 2011 25 Quantum Hot Standby System Quantum Hot StandBy CPU Front Panel Front Panel The figure shows an Hot StandBy CPU module front panel 140 G CPU 671 60 Mem Extract Ray PC CardA l 1 i e D LLL PC CardB 1 Mac Address ovos Q Model number module description color code Lens cover open LCD Display here covered by lens cover Key switch Keypad with 2 red LED indicators Modbus port RS 232 RS 485 USB port Modbus Plus port 9 PCMCIA slots A and B 10 LED indicators yellow for Ethernet communication 11 HSBY Link fiber optic communication port 12 Reset button 13 Battery user installed 14 2screws ONoOahWOND NOTE Quantum CPU are equipped with two receptacles for Schneider PCMCIA cards other cards are not accepted 26 35010533 07 2011 Quantum Hot Standby System Hot Standby Sync Link Cable Connections The Copros in the Quantum Hot Standby CPUs must be connected by a crossed fiber optic cable plugged into the HSBY Link socket PC CardB Ih hort PC CardB DO 00 34 EFE ae If the cable is not connected properly the Quantum Hot Standby processors cannot communicate and the Hot Standby system cannot func
191. tput images is read is executed is applied t The Hot Standby version of the MAST task introduces an additional step for the Hot Standby System Functions the transmission of the database from the CPU to the Copro An example of a Hot Standby version of the MAST task follows t nx Input Hot Standby USER LOGIC f Output g Drivers J system functions j Gecton 1 Gestion 2 Section 3 j Drivers Input state Copy data to Primary Application program is Output images is read Copro and Systems executed is applied checks opro ask Data transfer to Standby Copro oO The time required to transfer the database to the Copro and for the Copro to communicate this information to the Standby scales linearly with the size of the database For more information on Hot Standby MAST tasks actions and durations refer to Database Exchange see page 41 and Adjusting MAST Task Properties see page 168 50 35010533 07 2011 Quantum Hot Standby System Debugging Debugging your Hot Standby application program is now a two stage process 1 The application on a single Hot Standby PLC as if it were a standalone application This allows the use all of the debugging features available in Unity Pro such as watch points etc 2 Debug your application when it has been uploaded to two Hot Standby PLCs in a working redundant system but in a non production environment On this platform evaluate performance specific to Hot St
192. tum Hardware Reference Manual e Controls and Displays see page 220 e Using the LCD display screens see page 224 To upgrade without stopping refer to Upgrading the Operating System without Stopping see page 198 When using Modbus or Modbus Plus only address 1 is allowed for downloading Ensure that no other device on the network uses address 1 Step Action 1 Connect Unity Pro to the Primary CPU through Modbus Modbus Plus or USB 2 Set Command Register system bit Sw60 4 to 1 3 Disconnect Unity Pro from the Primary CPU 4 Note the Modbus or Modbus Plus address of the Standby CPU using the keyboard functions e for Modbus PLC Communications Communications Serial Port e for Modbus PLC Communications Communications Modbus Plus 5 Stop the Standby CPU with the keyboard functions NOTE The Standby CPU goes to STOP Offline mode the Primary CPU operates as a Standalone CPU 6 Disconnect all the communication links Hot Standby fiber optic cable Ethernet cables Modbus Plus cables from the Standby rack Switch off the power of the Standby rack When using an application in the PCMCIA card e Remove the PCMCIA card from the Standby CPU e Remove the PCMCIA batteries to empty the card contents 9 Power on the Standby CPU 35010533 07 2011 199 Firmware Step Action 10 If not set to 1 change the Modbus or Modbus Plus address of the S
193. tus Words Before running a Quantum Hot Standby system that uses an Ethernet RIO Head ensure that a least one CRA Drop has opened a connection with CRP Head module This information is accessible through e SW172 and SW173 e Mod Status LED of the CRP module for more information refer to the Quantum Ethernet I O Ethernet Remote I O Modules Installation and Configuration Guide Without a connection opened the CPU goes to RUN OFFLINE instead of the PRIMARY RUN or STANDBY RUN mode For a more detailed description of the Quantum Hot Standby operating modes including a state transitions diagram refer to Operating Modes see page 123 In the STOP mode the PLC has both e received a Stop command e successfully stopped 44 35010533 07 2011 Quantum Hot Standby System RUN Mode OFFLINE Mode There are 2 Hot Standby states in the RUN mode e Primary state The PLC has both e received a RUN command e assumed the Primary role because either it did not detect another Primary PLC or if both PLCs were started simultaneously it is PLC A e Standby state The PLC has e received a RUN command e assumed the Standby role because either it detected a Primary PLC or if both PLCs were started simultaneously it is PLC B NOTE For information about A B PLC assignment refer to Distinguishing Between Controllers see page 22 In the OFFLINE mode the PLC has e received a Run command e responded to a detected error by either
194. two identical Quantum RIO Head modules one on each rack These two modules can be e 140 CRP 931 00 for S908 I O Drops e 140 CRP 932 00 for S908 I O Drops e 140 CRP 312 00 for Ethernet I O Drops Like the controllers the rack positions and firmware versions of the CRP modules must be identical 35010533 07 2011 23 Quantum Hot Standby System CPU Sync Link A WARNING UNINTENDED EQUIPMENT OPERATION e Make an uninterrupted point to point connection between the Hot Standby CPU sync link ports e Do not connect any other Ethernet devices on the same network cabling as the CPU sync link e Do not exceed maximum Ethernet cable lengths for the type of cable selected Failure to follow these instructions can result in death serious injury or equipment damage The CPU sync link is the main communications channel for providing Quantum Hot Standby redundancy It is located between the Hot Standby labeled HSBY Link ports on the face of each controller Do not include switches and hubs on this link Refer to Hot Standby Sync Link see page 27 for details RIO Redundant Link A RIO network S908 or Ethernet is used as a redundant link for the Hot Standby system This redundant link is mandatory for some operating modes and error detection Either an S908 or Ethernet RIO CRP Head module can be used for the RIO redundant link If S908 or Ethernet RIO Drop are not needed in a Hot Standby s
195. ually exchanged and not the bandwidth configured So if the channel is set to the maximum but not used the impact on cycle time will be negligible State RAM memory The State RAM bar chart allows you to know the size of the State RAM memory used in your project in relation to the maximum memory size 35010533 07 2011 69 Configuration Using the State RAM Viewer The State RAM Viewer dialog gt State Ram Viewer 5 1 2 3 4 5 6 7 8 1112 13 14 15 16 17 18 19 oJ OJ 100 200 900 1000 1100 v lt Modules Variables Language Legend ___ Address Information HE Modules Address M 1 0 Go To MN Language Module Address WE Variables r Memory Area M Ox CW Ix O AWN Bx O MW 4x Each cell in the grid represents an address location and displays the entity stored in that location The contents of the grid may be changed by selecting options in either of two filters 1 Memory used grid options Select one or all of the three options using the check box and one to three bar graphs appear e Modules Indicates the topological address used in the modules Address appears as a bar graph in the grid e Language Indicates the topological address use
196. ugging Conditions for Switchover Commanding Manual Switchovers In addition to the system conditions see page 113 that cause an automatic Switchover a manual Switchover can be commanded by e writing to bits 1 and 2 of the Unity Command Register at SW60 see page 90 This write operation can be accomplished by e the application e issuing a Modbus request from a remote HMI e Unity Pro animation table e sending a RUN gt STOP command from Unity Pro to the Primary CPU e Offline command from the Primary CPU keypad NOTE Before doing any switchover by application program ensure that the Standby PLC is ready to assume the Primary role Refer to the Unity Pro Program Languages and Structure Reference Manual see Unity Pro Program Languages and Structure Reference Manual for more information about the SW182 SW183 and SW176 SW177 system words NOTE The intended use of user application Switchover in SW60 is to react to detected error by the application Do not use this method for periodic Switchovers NOTE If for some reason the application has to Switchover periodically the period between switchovers must not be less 120sconds Example of Switchover with PLC B Initially in Standby Mode In this example the initial state of the system is as follows e PLC A has a RUN command SW60 1 1 and is acting as the Primary e PLC B has a RUN command SW60 2 1 and is acting as the Standby By writing new values to bit
197. uipment damage Selecting the Standby CPU On Application Mismatch option allows overriding the default condition Standby CPU going offline If you change the parameter in this field from Offline to Online the Standby CPU remains online if an application mismatch is detected between the application programs of the Standby CPU and Primary CPU Updating Section Data in an Application Program All data of a section is updated every scan only if the data in the Standby CPU is the same as in the Primary CPU If the sections are equal on the Primary CPU and the Standby CPU the following section data is updated e internal states of Elementary Function Blocks EFBs used in the section for example Timers Counters and PID e all Derived Function Block DFB data blocks of each DFB instantiated in the section including nested DFBs Updating Global Data in an Application Program With Application Mismatch enabled the application program global data is updated with every scan Global data that does not exist on both controllers is not updated The application program s updated global data includes both e all declared variables in the Variable Editor e all section and transition variables The process of updating the application program global data in a Hot Standby system affects e declared variables All declared variables are updated on every scan if they are declared on both controllers 184 35010533 07 2011 Appli
198. ulation The maximum length of Hot Standby fiber optic link must be calculated by considering total loss in all components used in the path fiber optic cable optical connectors and splices e For 140 CPU 671 60 PLCs the Power Loss Budget in 62 5 125 um fiber cable equals 9 9 dB including system margin e For 140 CPU 672 61 PLCs the Power loss Budget in 9 125 um fiber cable equals 9 dB including system margin Power Loss Budget dB number of connectors x 0 35dB number of splices x 0 15dB fiber attenuation dB km NOTE There is no minimum distance requirement Max distance Cables Available The following cables are available from Schneider Electric Multi mode part numbers for 140 CPU 671 60 Description 490 NOR 000 03 3 m MTRJ MTRJ 490 NOR 000 05 5 m MTRJ MTRJ 490 NOR 000 15 15 m MTRJ MTRJ Single mode part numbers for 140 CPU 672 61 Description VDIF0646463505 5m LC LC 208 35010533 07 2011 Additional Information 140 CPU 671 60 Specifications Module Specifications Processor Memory Element Description Communication ports 1 Modbus RS 232 RS 485 1 Modbus Plus RS 485 1 USB 1 Ethernet used as a Hot Standby port Bus current required 2 5A Maximum number of NOM NOE 6 PTQ PDP MV1 and MMS modules supported any combination Key switch Yes Keypad Yes Function Description Model Punting Clo
199. uring Cold Start Cold Start Only x Enables the Cold Start Only see page 69 feature Memory Cards A N A Displays the configuration in the B N A PCMCIA Slots 66 35010533 07 2011 Configuration Modification Item Option Value Description Communication By default the bandwidth is 4x256 bytes The maximum data volume supported by the OS versions prior to exchanged each cycle between the V2 80 for the CPU and V4 60 for the NOE and CPU modules NOE For Quantum processors 4x256 e 140 CPU 311 10 4x1024 e 140 CPU 534 14 e 140 CPU 434 12 For Quantum processors 4x256 e 140 CPU 651 50 4x1024 e 140 CPU 651 60 8x1024 e 140 CPU 652 60 12x1024 e 140 CPU 671 60 e 140 CPU 672 61 State RAM Mem usage 1 A bar displays percent of memory used SM Ox 2 Size of the different memory areas eMw 4x 2 Note The values for SIW and SMW have to be divisible by 8 SI 1x 2 SIW 3x 2 Viewer N A Opens the State RAM Viewer tab which displays the allocation of used memory See the illustration following Configuration Online Online modif in RUN x This check box allows to e Add or delete discrete or analog modules e Modify Parameters NOTE These modifications can be done in RUN mode Standby configuration 1 The value expressed as a percentage and displayed on the scale depends on the memory usage of the Hot 2 Enter the appropriate values All values depend on Hot St
200. vides data exchange between controllers and engineering tools programming asset management system AMS 246 35010533 07 2011 Glossary interlink port IP address An Ethernet port on Ethernet remote I O modules allowing direct connection of distributed I O modules to the remote I O network The 32 bit identifier consisting of both a network address and a host address assigned to a device connected to a TCP IP network isolated distributed I O network jitter LD legacy remote I O An Ethernet based network containing distributed I O devices that do not participate in an Ethernet remote I O network J Jitter is the time variation in the delivery of an Ethernet packet caused by packet queuing along its network travel path Jitter can be reduced to predictable amounts by applying packet handling policies e g quality of service Q0S that grant priority to the packets of a specified type e g remote I O data packets over other packet types L ladder diagram A programming language that represents instructions to be executed as graphical diagrams very similar to electrical diagrams contacts coils etc A Quantum remote I O system using coaxial cabling and terminators literal value of an integer A value used to enter integer values in the decimal system Values may be preceded by the and signs Underscore signs _ separating numbers are not significant Example 12 0 123 45
201. which reports the condition to the Primary PLC The Standby PLC goes Offline The Primary continues to scan the I O but as a Standalone PLC 114 35010533 07 2011 Maintaining RIO Link Operations The Primary CPU sends a health message about its RIO CRP Head link to the Standby RIO Head every 5 ms Inoperative S908 RIO Link There are 3 cases of an inoperative S908 RIO link e interrupted link from Primary CRP Head This condition is detected by the Standby CRP Head The Primary Copro goes Offline The Standby PLC takes control of the system and scans the I O as a Standalone PLC e interrupted link from Standby CRP Head This condition is detected by the Standby CRP Head and the Standby PLC goes Offline The Primary PLC continues to scan the I O but as a Standalone PLC e interrupted RIO CRA Drop This condition is not detected by the Quantum Hot Standby system Inoperative Quantum Ethernet I O Ethernet RIO Link This condition is detected by the both Primary and Standby CRPs If the Standby CRP detects an inoperative Quantum Ethernet I O RIO network it cannot communicate with the Primary CPU the Standby CPU requests the Primary CPU to check RIO network via its Copro e if the Primary CPU is operational it checks the RIO connection e if the connection is OK the Primary CPU continues to control the system and the Standby CPU goes to RUN Offline e ifthe connection is inoperative there is a Switchover The Standby CPU takes
202. x the MWi values will retain their current value 68 35010533 07 2011 Configuration Cold Start Only If checked this option forces the cold start see Unity Pro Program Languages and Structure Reference Manual of the application instead of the normal warm start see Unity Pro Program Languages and Structure Reference Manual By default the Cold Start Only option is unchecked The Cold Start Only option is only supported on High End PLC since V2 7 An application using this functionality will not be e downloadable on a PLC with a previous version e executable on a PLC with a previous version e usable with Unity Pro V4 0 or lower NOTE The Cold Start Only check box is present only if the current selected PLC can support it Communication When the UNITY protocol under TCP IP is used OFS or Unity Pro it is possible to configure the maximum volume of data that can be exchanged each cycle between the CPU and the NOE modules using the Maximum Unity Data exchanged by Plc Scan option This functionality is only supported on CPU modules with OS version 2 80 or higher and on NOE modules with OS version 4 60 or higher The bandwidth set is valid between the CPU and all existing NOE modules It is not possible to set different bandwidths for each of the modules Increasing this bandwidth has an impact on the cycle time of the controller 2 ms per kbytes exchanged This impact is proportional to the amount of data act
203. xample a blocking software error e The hardware or firmware of the CPU module becomes inoperative e The CPU sync link is disconnected At a warm start the PLC restarts depending on the previous PLC operating mode Stop or Run If the previous state was Run the PLC restarts according to e operating mode of the other PLC e local PLC s operability or non operability e on whether identical applications are present on both PLCs refer to the table above 126 35010533 07 2011 Programming and Debugging System Performances Switchover Time A Switchover between the time of the detection of the event that causes a Switchover until the Standby controller takes control is less then one CPU cycle This cycle time is defined e for cyclic cycle times by the MAST watchdog period of time e for periodic cycle times by the MAST period of time Application Response Time Normally the Hot Standby system application response time ART is the same as in a Standalone system But the ART is increased by e 1 MAST watchdog if the Switchover is due to an event in the Primary CPU This increase is due to execution in the new Primary CPU of the instructions that was being executed in the old Primary CPU before the Switchover e upto 1 MAST cycle if the Switchover is due to a user command The amount of ART increase depends on the amount of data transferred 35010533 07 2011 127 Programming and Deb
204. xecution Time Measurement The execution time of the MAST task can be measured by reading system words e SW30 Execution time in ms of the last task e SW31 Execution time in ms of the longest task e SW32 Execution time in ms of the shortest task In both cyclic and periodic mode the MAST execution time is the sum of T1 T2 T3 T4 T5 of the periodic mode is not taken into account First Step of Execution Time Measurement To measure the execution time of the MAST task in a Quantum Hot Standby configuration it is advised to measure first the execution time in standalone mode or with one of the two PLC in STOP with the MAST task configured in cyclic mode In this case there is no data exchange between the two PLCs and the execution time of the Hot Standby Copro part T2 is reduced to its minimum The execution time of the last MAST cycle SW30 T1 T2 T3 T4 35010533 07 2011 169 Programming and Debugging Second Step of Execution Time Measurement In a second step the execution time has to be measured with a Primary and Standby PLC Two cases have to be taken into account 1 The data transfer has no impact on the Primary MAST task duration MAST task cycle N MAST task cycle N 1 gt T1 T2 T3 T4 5 Input Hot Standby system Output Input User Logic gs drivers functions drivers drivers v 2 oe Data transfer iS S
205. y TCP IP based messaging for Modbus TCP and EtherNet IP It is used for point to point client server messages that include both data typically unscheduled information between a client and a server and routing information In EtherNet IP explicit messaging is considered class 3 type messaging and can be connection based or connectionless 35010533 07 2011 243 Glossary explicit messaging client FBD FDR FDT FTP full duplex explicit messaging client class The device class defined by the ODVA for EtherNet IP nodes that only support explicit messaging as a client HMI and SCADA systems are common examples of this device class F function block diagram A graphical programming language that works like a flowchart By adding simple logical blocks AND OR etc each function or function block in the program is represented in this graphical format For each block the inputs are on the left and the outputs on the right Block outputs can be linked to inputs of other blocks in order to create complex expressions faulty device replacement A service that uses configuration software to replace an inoperable device field device tool The technology that harmonizes communication between field devices and the system host file transfer protocol A protocol that copies a file from one host to another over a TCP IP based network such as the internet FTP uses a client server architecture as well as separa
206. y CPU 4 Standby CPU assumes control 35010533 07 2011 117 Maintaining Troubleshooting Primary PLC Overview To determine which component has become inoperative note the e controller status displayed in the CPU LCD screen e RIO Head status displayed in the RIO Head LED screen Troubleshooting the Primary CPU This table gives the location of Primary PLC detected errors blinks four times inoperative at Primary CPU End Controller RIO Head Status Detected Error Description Status Type Stop All LEDs off except Ready on Controller A detected interface error occurred and Com Act blinks four times Offline All LEDs off except Ready on Fiber Optic A communication error was detected connection between PLCs Stop All LEDs off except Ready on RIO Head A communication error was detected and Com Act displays a detected error pattern see page 215 Stop Ready on and Com Act RIO Cable becomes In a dual cable system if only one cable is inoperative the Error A or Error B LED on the RIO Head lights up instead of stopping the system NOTE When the RIO cable becomes inoperative at the Primary CPU end the input data may be reset to 0 for one scan because the communication interruption to the drop occurs before the broken link is detected NOTE In a Quantum Hot Standby configuration without RIO drop the A and B detected error LEDs are not relevant when using CRP module with
207. y Fibs the configuration of the respective Quantum PLC for the required components These components refer to hardware that is actually connected Therefore the correct behavior of this EFB on the simulators cannot be guaranteed HSBY_WR is used to set different Hot Standby Modes for the Primary CPU Setting the respective modes means changing the Hot Standby Command register Sw60 see Unity Pro Program Languages and Structure Reference Manual whichis carried out automatically by the function block If there is no Hot Standby configuration the HSBY_ConfigurationFound output is set to 0 otherwise it is set to 1 EN and ENO can be configured as additional parameters Representation in FBD Representation HSBY_WR_ Instance HSBY_WR InvalidateKeypad INV_KEY HSBY HSBY_ConfigurationFound PLC_A Running PCA_RUN PLC_B_ Running PCB_RUN SwapAddressModbusPortl SWP_MB1 _ swe Mp2 SWP_MB3 35010533 07 2011 147 Programming and Debugging Representation in LD Representation HSBY_WR_Instance HSBY WR EN ENO InvalidateKeypad HSBY_ConfigurationF ound INV_KEY HSBY Cy PLC_A Running PCA RUN PLC_B Running PCB RUN SwapAddressModbusPort1 SWP_MB1 SWP_MB2 1 SWP_MB3 Representation in IL Representation CAL HSBY WR Instance INV_KEY InvalidateKeypad PCA_RUN PLC_A Running PCB RUN PLC_B Running SWP_MB1 SwapAddressModbusPort
208. ystem for a DIO only system you must still install S908 or Ethernet CRP Head modules and their connecting network just as you would for a RIO system S908 system without any CRA Drops 24 35010533 07 2011 Quantum Hot Standby System Ethernet systems without CRA Drops Pe P S CPU_ CRP PIS CPU_ CRP LT P S CPU_ CRP PIS CPU_ CRP D00 7 Devices T Doo li Devices In addition to the Hot Standby Sync Link see page 27 an Ethernet system has two types of connections between the CRPs that can use ConneXium extended managed switches called dual ring switches DRSs in this architecture for one side of the ring a connection with a maximum of two DRSs for a long distance connection see page 28 no Remote Drops or Distributed I O devices are allowed which can be connected between the CRPs over long distances with fibre optic cable for the other side of the ring Remote Drops or DIO devices DIO Clouds are allowed For more information refer to Dual Ring Switches see page 37 Core Hot Standby Ha rdware The basic requirements for Quantum Hot Standby system is two identical Hot Standby CPUs sync link between the CPUs refer

Quantum Hot Standby - Guillevin Industrial Automation Group

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