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Modicon Quantum CHS 110 Hot Standby System Planning and

1. ml Fiber optic link Figure 1 Simple Backplane Configuration System Compatibility To support a hot standby system the following components must be at least the version specified You may also use a later version For modules the version is specified on a label on top of the housing near the front edge controller RIO Head NOM Module Modsoft Version 2 1 2 1 2 1 2 3 Note You also must use the CHS loadable not the HSBY loadable from the earlier S911 Hot Standby system See p 40 Introduction 6 1 2 2 1 2 3 1 2 4 A Introduction Backplane Models Any of these four Quantum backplane models may be used in your hot standby system Number of Slots Part Number 4 140 XBP 004 00 6 140 XBP 006 00 10 140 XBP 010 00 16 140 XBP 016 00 Power Supply Modules The following Quantum power supply modules may be used depending on the power requirements of the modules in your backplane Type Voltage Amps Part Number AC 115 230 Vac 3A 140 CPS 111 00 AC 115 230 Vac 8A 140 CPS 114 00 AC Redundant 115 230 Vac 8A 140 CPS 124 00 DC 24 Vdc 3A 140 CPS 211 00 DC 24 Vdc 8A 140 CPS 214 00 DC Redundant 24 Vdc 8A 140 CPS 224 00 Note the primary and standby backplanes Programmable Logic Controllers Remember you must use identical power supply modules in Quantum offers four controllers with varying capacity Make sure
2. o length Figure 19 CHS Instruction Block An output from the bottom node of the CHS instruction senses whether the configuration extension screens have been activated and allows the parameters in the screens to overrride those in the CHS instruction at startup A detailed description of the CHS instruction is provided in the Ladder Logic Block Library User Guide The Command Register The command register is defined in the top node of the CHS instruction block The bits in this register are used to configure and control various parameters of the hot standby system Configuring a Quantum Hot Standby System 43 Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 Forces standby offline if there is a logic mismatch 0 Does not force standby offline if there is a logic mismatch 1 Disables keyswitch override 0 Enables keyswitch override 1 7 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 44 Configuring 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address during switchover 0 Swaps Modbus port 2 address during switchover 1 Does not swap Modbus port 2 address during switchover _ 0 Swaps
3. 005 52 5 3 3 Keyswitch Override 0 0 c cece nce ee eens 53 5 3 4 Logic Mismatches 00 cc cece cence ene e neces 55 5 3 5 Modbus Port Address Swapping at Switchover 55 5 3 6 Modbus Plus Port Address Swapping at Switchover 56 5 3 7 The Second Configuration Extension Screen 57 5 3 8 Defining the Nontransfer Area 0 000 cee eee 58 5 3 9 The Hot Standby Status Register 0005 58 5 3 10 Defining the Transfer Area of State RAM 59 Contents 840 USE 106 00 Chapter 6 Operation lt ecsvanieesagn tea Sean see tatw ane t ee sane te 65 6 1 Starting Your Hot Standby System 0 0 ccc eee eee 66 6 2 Synchronizing Time of Day Clocks 0 cece eee eee 68 6 3 While Your System Is Running 0 ccc ccc eee eee 70 Chapter 7 Maintenance cerais tuen EDES EEEE ATR le wate ee eee a ee ee 71 7 1 Verifying Health of a Hot Standby System 00 ee eee 72 7 1 1 Automatic Confidence Tests 0 0 cee e eee eee 72 7 1 2 Checking on a Redundant Power Supply 73 7 2 Responding to Errors 2 ss docasie tno ceeds dacdebees PEINTE NE 74 7 2 1 Recognizing Errors 0c cee cee cece eee ne eaes 74 7 2 2 Startup Error accessed cha te EEE A E EAA 75 7 2 3 Communications Errors 00 eee cece eee eee 76 7 2 4 Interface Errors 0 e ees 76 7 2 5 Board Level Errors 0
4. 0 cece ccc cence eens 30 3 2 1 A Single Cable Configuration 00 00 eee 31 3 2 2 A Dual Cable Configuration 0000s 32 Chapter 4 Hardware Installation 0 cee eee eee 33 4 1 Howto Install a Hot Standby System 0 cee cee eee 34 4 2 Adding Hot Standby Capability to an Existing System 38 Chapter 5 Configuring a Quantum Hot Standby System 39 5 1 How to Configure a Hot Standby System 0 0 cece eee 40 5 1 1 The CHS loadable 4 f00 25 06 cee genet terer i enekinnban 40 5 1 2 Controlling Your Hot Standby System 41 5 1 3 Ladder Logic in a Hot Standby System 42 5 2 Using the CHS Instruction to Control Your Hot Standby System 43 5 2 1 The Command Register 00 cece eee e eee 43 5 2 2 The State RAM Transfer Area 00200 c ee eee 45 5 2 3 The Nontransfer Area of State RAM 45 5 2 4 Elements of the Nontransfer Area 0005 47 5 2 5 Defining the Nontransfer Area 000 ee 47 5 2 6 The Hot Standby Status Register 005 48 5 2 7 The Reverse Transfer Registers 00ceeeeee 48 5 2 8 A Reverse Transfer Example 0 00 0 eee eues 49 5 3 Using a Configuration Extension to Control Your Hot Standby System 51 5 3 1 The First Configuration Extension Screen 51 5 3 2 Specifying the Command Register
5. Once the system is running primary control may be exchanged between the units regardless of which is designated as A and which as B 840 USE 106 00 1 3 4 Cable Ports The CHS 110 Hot Standby modules are connected to each other by a fiber optic cable The cable has two identical strands Each strand transmits a signal in only one direction For this reason each strand must be connected to the upper transmit port on one module and the lower receive port on the other If the cable is not connected properly the hot standby modules will not be able to communicate and the hot standby system will not function The primary controller will operate without a backup The standby unit will remain offline See p 81 for details A 3 m fiber optic cable is provided in the 140 CHS 210 00 Hot Standby kit One strand of that cable is marked This is the only way to distinguish the two strands Primary Standby Transmit Transmit StrandA Receive Receive Strand B Strand B Strand A Figure 5 Correctly Crossed Fiber Optic Cable 840 USE 106 00 Introduction 13 1 4 The CHS 210 Hot Standby Kit Each 140 CHS 210 00 Hot Standby kit contains the following parts Part numbers are listed in parentheses Two CHS 110 Hot Standby modules with four fiber cable clasps 140 CHS 110 00 A 3 m duplex fiber optic cable 990 XCA 656 09 Two coaxial splitters together with two t
6. Interface error pattern The interface error pattern is discussed on p 78 CHS 110 Failure Controller CHS 110 RIO Head Status All LEDs off except READY Runs as offline OR All LEDs off except READY COM ACT displays error pattern The Com Act error patterns are described in Appendix C 80 Maintenance 840 USE 106 00 840 USE 106 00 RIO Head Failure Controller CHS 110 RIO Head All LEDs off except READY Status Stops All LEDs off except READY OR COM ACT displays error pattern The Com Act error patterns are described in Appendix C RIO Cable Failure at Primary End Controller CHS 110 RIO Head Status Stops All LEDs off except READY READY on and COM ACT blinks four times In a dual cable system if only one cable fails the Error A or Error B indicator on the RIO head will light instead and the system will continue to operate When the RIO cable fails at the primary end input data may be reset to 0 for one scan because the communication failure to the drop occurs before the broken link can be detected 7 3 2 Detecting Failures in the Standby Backplane To determine which component failed compare the status of the controller hot standby module and RIO head to the charts below Controller Failure Controller CHS 110 RIO Head All LEDs off except READY All LEDS off except READY Status Stops OR OR Interface error pattern READY on and COM ACT bli
7. a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 Step 4 Step 5 Step 6 From the loadable directory screen select Load from the top menu bar Modsoft will request a filename Type the drive designation ie a and the filename QCHSVxxx DAT Press Return Press SHIFT and Modsoft will list the loadables available to this program Select CHS Now the CHS loadable will be listed on the screen under DX Loadable Configuration Esc to the main menu Save the program When you download the program to the controllers the loadable will be included Controlling Your Hot Standby System You have a choice of methods You may control your system via a CHS instruction in ladder logic or you may use a configuration extension Each method has certain advantages The CHS Instruction If you are upgrading from a 984 Hot Standby system to a Quantum system you may port your ladder logic program by first deleting the HSBY block then relocating the program and then inserting a CHS instruction nannn nnnn nannn nannn HSBY CHS nnnn nnann A Configuration Extension The hot standby configuration extension screens in Modsoft are easier to use and more flexible you can specify the parameters in the hot standby command reg ister in a clear easy to read fashion you can customize the state RAM data transfer between the primary and standby units to help reduce scan time If you dec
8. 0 cee ee eee 84 Figure 39 Bit 12 of the Command Register 0 0 00 0000000 86 840 USE 106 00 Contents ix Figure 40 After Taking the Primary Controller Offline 88 Figure 41 Bringing the Original Primary Unit Back Online 89 x Contents 840 USE 106 00 Quick Start Procedure This outline is intended for the user who is already familiar with the guidelines and safety recommendations in this manual For detailed instructions about any step refer to the chapter in parentheses Step 1 Install the power supplies controllers RIO head processors hot standby modules and any option modules in the primary and standby backplanes ch 4 A Caution Before installing the controllers make sure that their batteries have been disconnected for at least five minutes Make sure the RIO head processors are installed in the same slot in each backplane Make sure the designation slide switch on one hot standby module is set to A and the other is set to B Step 2 Install a splitter and a self terminating F adapter between the primary RIO head processor and the RIO network Connect the coaxial cable link Then connect the cable between the splitter the other self terminating F adapter and the standby RIO head processor ch 4 Primary Standby PS PLC RIO PLC RIO O I N U 2 O I N E z i Self terminating F adapter B Splitter T Cable to
9. 16 _ 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address during switchover 0 Swaps Modbus port 2 address during switchover 1 Does not swap Modbus port 2 address during switchover _ 0 Swaps Modbus port 3 address during switchover 1 Does not swap Modbus port 3 address during switchover Figure 27 Bits in the Hot Standby Command Register The command register is specified in the first entry field of screen 1 By default the command register is set to 0 You must enter a number greater than 0 to activate the configuration extension The number you enter becomes the 4x command register For example if you enter 14 the hot standby command register will be 400014 You may enter any number in the range 1 n where n is the last configured 4x register However the command register must be part of the area of state RAM that gets transferred from the primary to the standby controller on ev ery scan 52 Configuring a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 5 3 3 therefore the number you specify for the command register must be in the range of 4x registers you specify in the fourth entry field in configuration extension screen 2 see p 57 If you are using the 12K ONLY option the command register must be one of the first 9000 4x registers the command register mu
10. A total of 10K registers of which 1K is allotted for 3x registers and 9K is allotted for 4x registers If you have configured less than 1K of 3x registers the remaining space will be used for 4x registers Likewise if you have configured less than 9K of 4x registers the remaining space will be used for 3x registers In any case the number of 4x registers transferred will be a multiple of 16 unless all 4x registers have been included The number of 4x registers may slightly exceed the allotment in order to reach the next highest multiple of 16 840 USE 106 00 300001 e e 301000 e e e 303200 400001 e 409008 409600 300001 e e 303000 e 303200 400001 e 407000 300001 e e 300700 400001 e 409312 409600 Figure 9 Examples Example 1 If you have 3200 3x and 9600 4x registers then the full allotment of 1000 3x registers will be transferred The actual number of 4x registers transferred will be 9008 that is the full allotment of 9000 registers plus 8 more to reach the next highest multiple of 16 Transfer Area Example 2 If you have 3200 3x and 7000 4x registers then all the 4x registers will be transferred The full allotment of 1000 3x registers will be transferred plus an additional 2000 3x registers to bring the total number of registers transferred to 10 000 So a total of 3000 3x registers will be transferred Example 3 If you have 700 3x and 9
11. Defining the Transfer Area of State RAM If you were using the CHS instruction in ladder logic to configure the hot standby system you would be unable to transfer any more than 12K words even though the total amount of state RAM could be as much as 64K You would be able to limit the number of 4x registers being transferred by selecting a block of registers as part of the nontransfer area but you could not limit the number of Ox 1x or 3x registers in the transfer area Using the configuration extension screens you have a great deal more flexibility in determining how much or how little state RAM gets transferred You also can manage how much gets transferred in all scans and how much gets transferred in pieces over multiple scans a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 The parameter you select in the third entry field of screen 2 determines the flexibility you have in defining your state RAM transfer area You may choose from four options 12K ONLY USER DEFINED USER DEF ADD L ALL STATERAM The remaining entry fields on screen 2 will or will not be used depending on which one of these four parameters you choose Note No matter which option you choose remember that the command register must be included in the block of registers transferred on every scan 12K ONLY The 12K ONLY option mimics the CHS instruction It gives you a predefined state RAM transfer area with
12. the transmit port of the primary is linked to the transmit on the standby two error patterns are possible 1 Ifthe program has already been loaded in the standby controller and both controllers are running then the Ready andCom Err indicators will light on the standby CHS 110 module Maintenance 840 USE 106 00 2 Ifthe program has not yet been loaded in the standby and you attempt to load it using the program update procedure then the Ready indicator will light and the Standby will blink If both fiber links fail the Com Err indicator will light on the standby CHS 110 Again replace the cable and restart the controller The unit should return to standby mode If it does not then cycle power 840 USE 106 00 Maintenance 83 7 4 Replacing Modules in a Hot Standby System 7 4 1 Hot Swap and Your Hot Standby System Hot swapping any key module in the primary or standby backplane will force that backplane offline When the module is in the primary backplane this will cause switchover Key modules include the controller remote I O head processor and the hot standby module Any time you hot swap a module you must cycle power to the backplane to ensure proper system initialization If you have hot swapped the controller you must also perform a program update using the procedure on p 85 7 4 2 Replacing a Hot Standby Module You may replace a CHS 110 module while the hot standby system is running as long as the module
13. Fiber Optic Cable Guide 97 Appendix C Com Act Error Patterns CHS 110 Hot Standby Module CRP Remote I O Head Processor 840 USE 106 00 Com Act Error Patterns 99 100 C 1 C 2 Com Act Error CHS 110 Hot Standby Module The following table shows the number of times the Com Act indicator blinks for each type of error and the codes possible for that group all codes are in hex Number of Blinks Code Error 1 6900 error in additional transfer calculation 2 6801 ICB frame pattern error 6802 head control block error 6803 bad diagnostic request 6804 greater than 128 MSL user loadables 4 6604 powerdown interrupt error 6605 UART initialization error 5 6503 RAM address test error 6 6402 RAM data test error 7 6301 PROM checksum error 8 C101 no hook timeout C102 read state RAM timeout C103 write state RAM timeout C200 powerup error CRP Remote 1 O Head Processor The following table shows the number of times the Com Act indicator blinks for each type of error and the codes possible for that group all codes are in hex Number of Blinks Code Error Slow steady 0000 requested kernel mode 2 6820 hcb frame pattern error 6822 head control block diag error 6823 mod personality diag error 682A fatal start IO error 682B bad read IO pers request 682C bad execute diag request 6840 ASCII input
14. Guide Procedure Installing a Hot Standby System Install the power supplies controllers RIO head processors hot standby modules and any option modules in the primary and standby backplanes Make sure the modules meet the version requirements listed on p 5 the modules in the primary backplane are identical to those in the standby backplane the rotary address switches on the back of each controller have been set The controllers may have different addresses For de tails on setting the switches see the Quantum Automation Series Hardware Reference Guide or the Remote I O Cable System Plan ning and Installation Guide the RIO heads are in the same slot in each backplane i 10 CHS 110 00 CHS 110 00 f co Tho sar o Ger Slide switches must be a B set in opposite positions gt Figure 13 Setting Designation Slide Switches Hardware Installation 840 USE 106 00 840 USE 106 00 Step 2 Step 3 the designation slide switch on one hot standby module is set to A and the other is set to B Caution Before installing any controller in your hot standby system make sure its battery has been disconnected for at least five minutes Note Make sure your system meets the power and grounding guidelines outlined in Appendix D of the Qua
15. Planning a Quantum Hot Standby System 31 3 2 2 A Dual Cable Configuration Primary PLC Standby PLC PS PLC RIO PLG RIO CHS O fa e in pe n rl ME Tap Drop Cable_4J MA 0185 100 a Fiber Optic Cable J Self terminatin ad F adapters elf terminating Coaxial Cable 7 F adapters Coaxial Cable Splitter MA 0186 100 Splitter at MA 0186 100 RIO Drop 2 RIO 1 0 VO 1 0 Trunk iE Line RIO Drop 3 A Trunk D SOO B Tap ae Drop Cable RIO Drop 4 lag PS RIO VO I O 1 0 Last RIO Drop AE Tap MNE Al E rir Trunk Terminators 52 0422 000 4 a U ep Drop Cable Drop Cable Trunk Terminator rr 52 0422 000 Figure 12 A Dual Cable Configuration 32 Planning a Quantum Hot Standby System 840 USE 106 00 Chapter 4 Hardware _ Installation How to install a hot standby system How to add hot standby capability to an existing system 840 USE 106 00 Hardware Installation 33 34 4 1 Step 1 How to Install a Hot Standby System This section will discuss in broad terms the procedure for installing a new hot standby system For more detailed instructions refer to the Quantum Automation Series Hardware Reference Guide or the Remote I O Cable System Planning and Installation
16. Remaining outputs not transferred 4nnnnn y Figure 30 User Defined State RAM Transfer The USER DEFINED option lets you specify the amount of each reference data type that you want transferred on each scan However it does not allow you to transfer additional data Use the fourth entry field in screen 2 to define the size of the data range All of the reference data that you specify in this field will be transferred from the primary to the standby controller on every scan except the defined nontransfer area All reference data items must be 0 or specified in multiples of 16 A minimum of 16 4x registers is required 62 Configuring a Quantum Hot Standby System 840 USE 106 00 The maximum amount of state RAM to be transferred on every scan can be up to the total amount of available state RAM 10K 32K or 64K depending on the type of Quantum controller Since you are unable to transfer additional data over multiple scans any values in the fifth and sixth entry fields will be ignored USER DEF ADDL The USER DEF ADD L option allows you to customize the transfer area and to specify additional state RAM to be transferred in chunks over multiple scans When this option is selected you must complete all the entry fields in screen 2 All of the reference data that you specify in the fourth entry field will be transferred from the primary to the standby controller on every scan except the defined nontransfer area All refere
17. System 00000000 38 Figure 19 CHS Instruction Block 0 0 eee cee eee 43 Figure 20 Bits in the Hot Standby Command Register 44 Figure 21 Nontransfer Area Within the State RAM Transfer Area 46 Figure 22 Sample CHS Instruction Block 0 00 0 0000000 47 Figure 23 Bits in the Hot Standby Status Register 000 48 Figure 24 An Example of Reverse Transfer Logic 0 00 49 Figure 25 A Further Example of Reverse Transfer Logic 50 Figure 26 Configuration Extension Screen 1 000000000000 51 Figure 27 Bits in the Hot Standby Command Register 52 Figure 28 Configuration Extension Screen 2 00000 c eee eae 57 Figure 29 Hot Standby Status Register for Configuration Extension 59 Figure 30 User Defined State RAM Transfer 0 000 000 61 Figure 31 Transferring Additional State RAM Data 4 63 Figure 32 Indicators of a Properly Functioning Hot Standby System 67 Figure 33 Logic for Synchronizing Time of Day Clocks 69 Figure 34 LED Display for a Startup Error 0 ce eee eee eee 75 Figure 35 LED Display for a Communications ETOR aee p E r eeehees 76 Figure 36 LED Display for a Board L evel Error 004 77 Figure 37 Standby Prepared For Update 0 0 0 0 84 Figure 38 Requesting Update
18. This PLC in OFFLINE mode This PLC running in primary mode This PLC running in standby mode E AE Oo a O a The other PLC in OFFLINE mode The other PLC running in primary mode The other PLC running in standby mode a OoO 8 PLCs have matching logic 0 PLCs do not have matching logic 1 This PLC s switch set to A This PLC s switch settoB 17 Il o 9 10 11 12 13 14 15 16 Figure 23 Bits in the Hot Standby Status Register In the example in Figure 22 the status register would be 40012 The Reverse Transfer Registers You can use the reverse transfer registers to transmit diagnostic data from the standby controller to the primary controller When you choose to define a nontransfer area registers 4x and 4x 1 in the nontransfer block are copied from the standby to the primary controller This is opposite from the normal forward state table transfer from the primary to the standby If you choose not to use the reverse transfer registers do not place the CHS instruction block directly against the rail in your ladder logic program so that the input to these registers will not be turned on a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 5 2 8 A Reverse Transfer Example The following example shows I O ladder logic for a primary controller that monitors two fault lamps and the reverse transfer logic that s
19. depending your Quantum controller type on every scan Any values that appear in the fourth fifth and sixth entry fields in screen 2 will be ignored Configuring a Quantum Hot Standby System 65 Chapter 6 Operation Starting your hot standby system Synchronizing time of day clocks While your system is running 840 USE 106 00 Operation 67 68 6 1 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Operation Starting Your Hot Standby System Start one controller at a time Make sure the controller you are starting first has been fully programmed the function keyswitch on the CHS 110 module is in the Run position the designation slide switches on CHS 110 modules are in oppo site positions The first controller to power up will automatically become the primary controller regardless of its designation as A or B Turn on power to the first backplane Start the controller in that backplane Turn on power to the second backplane Download the program to the standby controller either through Mod soft or by using the program update procedure on p 85 If the switches on the controllers are set to the same address you will not be able to download the program through Modsoft Use the program update procedure Start the standby controller Check the LED display If the system is functioning normally the dis play should match Figure 32 On
20. is in the current standby backplane and you follow the procedure below A Caution Do not attempt to hot swap the CHS 110 module in the primary backplane Step 1 Power down the backplane Step 2 Disconnect the fiber optic cable from the module and remove it from the backplane Step 3 Install the new module and reconnect the fiber optic cable Step 4 Restore power to the backplane 84 Maintenance 840 USE 106 00 840 USE 106 00 7 5 Step 1 Step 2 Step 3 Changing the Program and Performing a Program Update The program includes the configuration table I O map configuration extensions segment scheduler user logic all EXE loadables and the entire state RAM If you reprogram your primary controller or replace the standby controller you may use the update feature to copy the full program of the primary controller to the standby This feature not only saves time but also ensures that the controllers have identical configurations Note A program update may only be performed from the primary controller to the standby The standby controller cannot update the primary Caution Whenever installing a new controller make sure its battery has been disconnected for at least five minutes To reprogram your primary controller you must stop the standby controller as well The standby CHS 110 module must be in Off Line mode Make any changes to the program Then follow the steps below to copy the new program to the stand
21. respect to the way you configure system logic you must program all ladder logic specific to hot standby func tions in segment 1 you must not program I O control logic in segment 1 you must not schedule any I O drops in segment 1 The standby controller in a hot standby system must never execute I O logic Caution To help protect against damage to application I O devices through unexpected system actions do not reschedule segment 1 via the segment scheduler Segment 1 may contain the ladder logic for diagnostics and optional hot standby functions such as time of day clock updates a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 5 2 5 2 1 Using the CHS Instruction to Control Your Hot Standby System If you choose to use the CHS instruction in ladder logic to control the hot standby configuration the instruction must be placed in network 1 segment 1 of the ladder logic program The top node must be connected directly to the power rail by a horizontal short No control logic such as contacts should be placed between the rail and the input to the top node However other logic may be placed in network 1 Remember the ladder logic in the primary and standby controllers must be identical The three nodes in the CHS instruction define the command register the first register in the nontransfer area and the length of the nontransfer area command register nontransfer area CHS
22. specify the amount of state RAM to be transferred between the primary and standby controllers in every scan You also may define additional state RAM 0x 1x 3x and 4x registers that will be transferred in chunks over multiple logic scans Note The command register must be located in the area of state RAM which will be transferred in every scan State RAM associated with all critical I O also should be transferred in every scan Additional state RAM can be chunked and transferred over multiple scans The default settings for screen 2 are shown below 840 USE 106 00 Configuring a Quantum Hot Standby System 57 First Second Third Fourth Fifth Sixth Entry Entry Entry Entry Entry Entry 58 Field Field Field Field Field Field MAX SCANS TO INCLUDE ADD L TRANSFERS 1 255 2 DEC N Hex Dec Bin Goto Quit F1 F2 F3 F4 F5 F6 F7 Lev 8 F8 OFF F9 Quantum Hot Standby Control System Screen 2 2 STATERAM TRANSFER CONTROL r Ptrto Non Transfer Registers E G 5 400005 0 DEC Must be gt 0 Qty of Non Transfer Regs 0 4 to max 4 DEC Non Transfer area must be within STATERAM XFR AREA COUNTS defined below r STATERAM TRANSFER AREA CONTROL 12K ONLY r STATERAM XFR COUNTS 0X 16 DEC 1X 16 DEC Every Scan 3X 16 DEC 4X 16 DEC MIN 4X 16 ADD L STATERAM TRANSFER ADD LXFR COUNTS 0X 16 DEC 1X 16 DEC 3X 16 DEC 4X 16 DEC Note All above Tr
23. 0 eee ees 77 7 3 Detecting Failures in a Hot Standby System 00005 78 7 3 1 Detecting Failures in the Primary Backplane 78 7 3 2 Detecting Failures in the Standby Backplane 79 7 4 Replacing Modules in a Hot Standby System 00005 82 7 4 1 Hot Swap and Your Hot Standby System 82 7 4 2 Replacing a Hot Standby Module 82 7 5 Changing the Program and Performing a Program Update 83 7 6 Updating PLC System Executives While the System Is Running 86 7 7 Testing a Hot Standby Switchover 0 cc cece cence eens 88 7 7 1 Forcing a Switchover Manually 00005 88 7 7 2 Forcing a Switchover Through Software 89 Appendix A CHS 110 Module Specifications 0 cee ees 91 Appendix B Fiber Optic Cable Guide 02 ceceeeeeeeees 93 Bil Fiber Optic Cables 034 oe datcie ete batdhs aiid ed aiebeeea a E 94 B2 CONNECHOLS foi sa us bs SHata cys Hacet E E Heated apne aids Gllale cu diesen 94 840 USE 106 00 Contents vii viii B 38 Termination Kits swepe neee ia i ea cece tenet ene neee 94 B4 Other TOONS iene an duh i a ote dara ai a a a ee eee 6 95 Appendix C Com Act Error Patterns 0 0 0 eee es 97 C 1 CHS 110 Hot Standby Module 0 ccc cc cc eee 98 C 2 CRP Remote I O Head Processor 0 0 cece cece cece eee 98 MASX ke Joo Mere Oe A aera e a aa Sree Mees St
24. 1 How a Hot Standby System Works Both the primary and the standby backplane contain a CHS 110 Hot Standby module The module monitors its own controller and communicates with the CHS 110 module in the other backplane The primary controller keeps the standby apprised of the current state of the application by transferring state RAM values to the standby controller on every logic scan 2 1 1 State RAM Transfer A hot standby system transfers state RAM data from the primary to the standby controller while the primary controller scans and solves the ladder logic application program There are three steps in this transfer process Primary controller to CHS 110 state RAM transfer CHS 110 to CHS 110 state RAM transfer CHS 110 to standby controller state RAM transfer The state RAM transfer operation is initiated by the primary CHS 110 Hot Standby module The module requests specified state RAM information from the primary controller At the beginning of each scan the primary controller transfers the current state RAM data to the CHS 110 Hot Standby module As soon as the controller to CHS 110 transfer finishes the primary controller resumes scanning ladder logic and servicing I O The state RAM data is simultaneously transferred from the primary CHS 110 module to the standby CHS 110 module over the fiber optic link at a rate of 10 megabaud In turn the standby CHS 110 module transfers the state RAM data to the s
25. 14 of the command register If controller B is offline bit 14 will be set to 0 To put the controller in RUN mode change the state of bit 14 to 1 Controller B will immediately go into RUN mode If you have programmed a CHS instruction in ladder logic Connect Modsoft to your primary controller In the ladder logic editor place the cursor on the top node of the CHS instruction and invoke the Zoom screen Move the cursor down to the Zoom entry entitled Con troller B Run Mode bit 14 The parameter associated with that entry should be OFFLINE echoing the setting in the configuration ex tension table Simply change this parameter to RUN via the pulldown menu and close the Zoom screen Controller B will immediately go into RUN mode The advantage of options 2 and 3 is that the hot standby system does not have to be shut down in order to change its status If you find the use of the Zoom screen more comfortable than the RDE consider programming a CHS instruction into ladder logic for purposes such as this a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 5 3 4 5 3 5 Note When both a CHS instruction and the configuration extension screens are used the CHS instruction can be placed at any convenient spot in ladder logic It does not need to be in network 1 segment 1 and the top node does not need to be directly connected to the power rail Logic Mismatches To function properly the primary and the standby controlle
26. 29 3 2 Remote I O Cable Topologies In each configuration The cables connecting the RIO head processors to the RIO net work must be fitted with self terminating F adapters An MA 0186 100 coaxial splitter must be installed between the RIO head processors and the RIO network The remote drops must be connected to the trunk cable via an MA 0185 100 tap and a drop cable The last tap on a trunk cable must be terminated with a 52 0422 000 trunk terminator Remote drops must not be connected directly to the trunk cable Refer to the Remote I O Cable System Planning and Installation Guide for details 30 Planning a Quantum Hot Standby System 840 USE 106 00 3 2 1 A Single Cable Configuration Primary PLC Standby PLC PS PLC RIO CH PLC RIO CHS Fiber Optic Cable ji Self terminatin Coaxial Cable i Seif terminating F adapter F adapter Splitter MA 0186 100 pe RIO Drop 2 PS RIO I O I O VO TL ee RIO Drop 3 ne T Pa Drop Cable Tap MA 0185 100 a Drop Cable B RIO Drop 4 PS RIO I O I O 1 0 ei EA L_ E E Last RIO Drop PS RIO O 1 0 i nae 7 Tap Drop Cable a 1 T Trunk Terminatow ap T 52 0422 000 Drop Cable Figure 11 A Single Cable Configuration 840 USE 106 00
27. 3 power supply module models 6 primary controller copying full program 83 designated by slide switch 12 failure 78 function 4 Primary LED 10 program update 11 83 may be blocked through software 53 programmable logic controller PLC configuring with the update button 83 models 6 role in a hot standby system 4 Index 105 version requirement 5 PROM checksum error 77 Q quick start procedure 1 R RAM address error 77 RAM data error 77 Ready LED 10 75 76 77 redundant power supply checking health of 73 reference data editor using to access command register 44 using to change configuration extension 51 using to force switchover 89 using to update PLC system executives 86 related publications 15 remote I O cable failure 79 80 remote I O head processor backplane slot requirement 7 failure 79 80 models 7 version requirement S7 remote I O network cable requirements 28 cable type 7 diagrams 30 hardware required 30 reverse transfer operations diagrams 49 example 49 use 48 reverse transfer registers in nontransfer area 48 S scan time affected by state RAM transfer 19 106 Index segment scheduler mismatch 75 self terminating F adapters required in RIO network 7 30 slide switch function 12 mismatch 75 need for proper use 12 setting during installation 35 specifications 91 splitters provided in kit 14 required in RIO
28. 600 4x registers then all the 3x registers will be transferred The full allotment of 9000 4x registers will be transferred plus an additional 300 registers to bring the total to 10 000 plus an additional 12 registers to reach the next highest multiple of 16 In all 9312 4x registers will be transferred of the Default State RAM Transfer Area Any state RAM values above these limits will not be included in the state RAM transfer area and therefore will not be shared with the 840 USE 106 00 Theory of Operation 23 standby controller The state RAM values in the range above these limits must not contain the command register or control critical I O Customization Options If you want to set up a custom state RAM transfer area you should control your system using a hot standby configuration extension The configuration extension provides three alternatives to the default transfer area You can define the number of Ox 1x 3x and 4x reference data types that you want transferred in each scan You can define a certain amount of reference data types to be transferred on every scan with additional data to be transferred in chunks over multiple scans beginning with 0x registers and proceeding in turn with 1x 3x and 4x registers You can transfer all the configured reference data types in your systems state RAM on every scan These options allow you to design a transfer area that is as small as 16 4
29. Modbus port 3 address during switchover 1 Does not swap Modbus port 3 address during switchover Figure 20 Bits in the Hot Standby Command Register The command register must be a 4x register in the portion of the state RAM transfer area that is transferred from the primary to the standby controller on every scan It also must be outside of the nontransfer area see p 45 Caution Take precautions to make sure the register you select as the hot standby command register is reserved for this purpose and not used for other purposes elsewhere in ladder logic The values set for the bits in this register determine the system parameters at startup The register can be accessed while the system is running using a Modsoft reference data editor RDE or a Zoom screen on the CHS instruction in ladder logic a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 A 5 2 2 5 2 3 Caution If you use the command register to enable the keyswitch override while the hot standby system is running the primary controller will immediately read bits 14 and 15 to determine its own state and the state of the standby If both bits are set to 0 a switchover will occur and the former primary backplane will go offline The new primary backplane will continue to operate For a more detailed discussion of each of these command register parameters and their system performance implications refer to p 53 56 The State RAM Transfer Area A
30. Modicon Quantum CHS 110 Hot Standby System Planning and Installation Guide 840 USE 10600 Version 2 0 September 1996 GROUPE SCHNEIDER E Modicon W Square D W Telemecanique Schneider Automation Inc One High Street North Andover MA 01845 840 USE 106 00 Preface The data and illustrations found in this book are not binding We reserve the right to modify our products in line with our policy of continuous product development The information in this document is subject to change without notice and should not be construed as a commitment by Schneider Automation Inc Schneider Automation assumes no responsibility for any errors that may appear in this document If you have any suggestions for improvements or amendments or have found errors in this publication please notify us by using the form on the last page of this publication 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 the Publisher Schneider Automation Inc Caution All pertinent state regional and local safety regulations must be observed when installing and using this product For reasons of safety and to assure compliance with documented system data repairs to components should be performed only by the manufacturer MODSOFT is a registered trademark of Schneider Automation Inc The following are trademarks of Schneider Automation Inc M
31. RY PROTECT OFF Lamp Standby BATTERY FAULT Lamp 400101 000813 000814 Bit 13 Bit 14 000705 BLKM 001 ya 000715 000813 Bit 11 Bit 13 000716 000813 Bit 12 Bit 13 Configuring Figure 25 A Further a Quantum Hot Standby System Example of Reverse Transfer BLKM Transfers the Status of the Reverse Transfer Register to the Internal Coils 840 USE 106 00 First Entry Second Entry Third Entry Fourth Entry Fifth Entry Sixth Entry Seventh Entry Eighth Entry Field Field Field Field Field Field Field Field 840 USE 106 00 5 3 Using a Configuration Extension to Control Your Hot Standby System To implement a configuration extension you must access and complete two hot standby configuration extension screens in Modsoft If you are not familiar with Modsoft consult the Modsoft Programmer User Manual The first screen is used to define command register parameters The second screen is used to customize the state RAM transfer process The parameters you set in these screens will be used by the controllers at startup You may change these parameters while the hot standby system is running using the Modsoft reference data editor If you have programmed a CHS instruction in ladder logic you may also use Zoom screens to change these parameters 5 3 1 The First Configuration Extension Screen Screen 1 has eight entry fields The default settings for these fields are shown
32. Service gt Subsequent Scan 0 45 ms 1k discretes for 1xxxx Scan 2 4 ms 1k registers for 3xxxx 2 7 ms 1k registers for 4xxxx CHS 110 to CHS 110 transfer time WAIT 0 85 ms 1k discretes for Oxxxx 0 85 ms 1k discretes for 1xxxx 2 0 ms 1k registers for 3xxxx 2 25 ms 1k registers for 4xxxx If the CHS 110 to CHS 110 Transfer Takes More Time Than the Ladder Logic Program Then the Data Transfer Does Add to the Total Scan Time Total Scan Time p PLC to CHS 110 transfer time 3 ms plus 0 45 ms 1k discretes for Oxxxx Previous 9 45 ms 1k discretes for 1xxxx gt Ladder Scan and I O Service gt WAIT Subsequent Scan 2 4 ms 1k registers for 3xxxx Scan 2 7 ms 1k registers for 4xxxx CHS 110 to CHS 110 transfer time lt q 0 85 ms 1k discretes for Oxxxx p gt 0 85 ms 1k discretes for 1xxxx 2 0 ms 1k registers for 3xxxx 2 25 ms 1k registers for 4xxxx Figure 7 Hot Standby System Scan Times The next section will describe how to manipulate the state RAM transfer to reduce scan time 20 Theory of Operation 840 USE 106 00 840 USE 106 00 2 2 The State RAM Transfer Area The state RAM transfer area contains all the state RAM values that will be passed between the primary and standby controllers The size of the transfer area may be as large as the total size of your controller s state RAM or a small set of critical I O reference data types As the simplified block diagram below shows
33. When the update is completed the CHS 110 Hot Standby module will instruct the standby controller to return to the mode you have set Run or Off Line If the standby unit isin Run mode the Standby and Com Act lights will be lit If the standby unit is offline neither indicator will be lit The standby now has an identical program to the primary unit Remove the key and store it in a secure place Maintenance 87 88 7 6 Step 1 Step 2 Step 3 Maintenance Updating PLC System Executives While the System Is Running Bit 12 in the hot standby command register can be set to 1 to facilitate an executive upgrade while one of the controllers in the hot standby system continues to operate Allow exec upgrade only after application stops 0 Allow exec upgrade without stopping application 1 7 1 23 4 5 6 7 8 9 10 11 12 13 14 15 16 Figure 39 Bit 12 of the Command Register W arning Setting bit 12 to 1 overrides the safety checking protections between the primary and standby controllers in your hot standby system It is important to reset the bit to 0 as soon as the executive upgrade operation is complete This command register parameter is not under the control of the hot standby configuration extension In order to use it you must explicitly set the bit in the command register during system runtime To do this you can either use a Zoom screen on a CHS in
34. a predetermined maximum of each reference data type to be transferred The predefined transfer area consists of the following All the 0x discrete outputs in state RAM up to a maximum of 8192 including their associated histories All the 1x discrete inputs in state RAM up to a maximum of 8192 including their associated histories If the total number of registers 8x and 4x combined implemented in state RAM is 10 000 or less then all the registers plus the up down counter history table If the total number of registers 8x and 4x combined implemented in state RAM is greater than 10 000 then 10 000 registers will be transferred in accordance with the formula described on p 21 22 If you choose the 12K ONLY option entry fields four through six become irrelevant You will not be able to customize the transfer area or to transfer additional data in chunks over multiple scans Any entries in these fields will be ignored Configuring a Quantum Hot Standby System 61 USER DEFINED A Ronee Outputs transferred 000003 on every scan e e y lt Remaining outputs Onnnnn y not transferred A j pooo Inputs transferred 100003 on every scan bd Ai Remaining inputs inane not transferred 300001 Inputs transferred 300003 on every scan e Remaining inputs 3nnnnn not transferred H 400001 400002 400003 Outputs transferred 400004 on every scan 400005 400006 e e n hg
35. age and the LED display on the front panel of the hot standby module should now show that unit in Standby mode 840 USE 106 00 840 USE 106 00 Appendix A CHS 110 Module Specifications Specifications for CHS 110 Hot Standby Module Electrical Electrostatic Discharge IEC 801 2 8 kV air 4 kV contact RFI Immunity IEC 801 3 27 1000 MHz 10 V m Bus Current Required Typical 700 mA Operating Conditions Temperature 0 to 60 C Humidity 0 to 95 Rh noncondensing 60 C Altitude 15 000 ft 4500 m Vibration 10 57 Hz 0 075 mm d a 57 150Hz 1g Storage Conditions Temperature 40 to 85 C Humidity 0 to 95 Rh noncondensing 60 C Free Fall 1 m unpackaged Shock 3 shocks axis 15 g 11 ms Agency Approvals UL 508 CSA 22 2 142 CE FM Class Div 2 pending CHS 110 Module Specifications 93 Appendix B Fiber Optic Cable Guide Fiber Optic Cable Connectors Termination Kits Other Tools 840 USE 106 00 Fiber Optic Cable Guide 95 96 B 1 Fiber Optic Cable Modicon recommends the use of up to 1 km of 62 5 125 graded index duplex multimode glass fiber for all applications Most 62 5 125 cables are rated at 3 5 dB loss per km We recommend using a 3 mm diameter cable for your hot standby system as the fiber cable clasps used to maneuver the cable into the ports were designed to be used wi
36. all Ox references in the state RAM transfer area are transferred first then all 1x references followed by all the 3x references and finally all the 4x references 000001 000002 Total number of discrete 000003 outputs transferred e e y Onnnnn 100001 i 100002 Total number of discrete 100003 inputs transferred e e 1nnnnn where nnnnn isa 300001 300002 Total number of register 300003 inputs transferred k e Snnnnn multiple of 16 400001 400002 400003 400004 Total number of register 400005 outputs transferred 400006 y 4nnnnn Figure 8 State RAM Transfer Area Theory of Operation 21 22 Theory of Operation Customizing the state RAM transfer area is one way to reduce scan time Another way is to place certain registers in a nontransfer area an area contained within the transfer area but ignored during the actual state RAM transfer Note If you are customizing the size of your state RAM transfer area you must specify the number of each reference data type Ox 1x 3x and 4x as either 0 or a multiple of 16 In the case of the 4x registers there must always be at least 16 registers allotted The Default Transfer Area By default the hot standby system will automatically transfer the following from the primary to the standby controller on every scan The first 8192 points of 0x output reference data The first 8192 points of 1x input reference data
37. andby module 78 79 primary controller 78 primary RIO head processor 79 remote I O cable 79 80 standby controller 79 standby RIO head processor 80 fiber cable clasps how to snap onto cable 35 provided in kit 14 using to attach cable 37 fiber optic cable communications errors 76 failure 80 guide to ordering 94 how to connect 13 37 permissible lengths 28 104 Index provided in kit 13 14 used to link hot standby modules 7 what to order 7 fiber optic repeaters for extending coaxial cable in RIO network 28 function keyswitch description 11 in a program update 83 override capability 12 53 used to force switchover 11 88 view 11 H holdup time drop increasing 88 hot standby capability adding to existing Quantum system 38 hot standby module failure 78 79 function 4 18 hot swap 82 startup 66 view 9 hot standby system cable diagrams 30 33 controlling by CHS instruction in ladder logic 43 controlling by configuration extension 51 converting to 38 detecting failures in 78 distance between modules 28 hardware requirements 5 how it works 4 18 installing 34 normal operation 70 planning guidelines 28 31 quick start procedure 1 startup 66 hot swap 82 I O map mismatch 75 840 USE 106 00 installation 34 interface errors 76 K keyswitch description 11 in a program update 83 override capability 12 53 used to force sw
38. ansfer Counts must be multiples of 16 Note Check Hot Stby Status via CHS function Block Zoom PgDn Up to next prev Screen Figure 28 Configuration Extension Screen 2 5 3 8 Defining the Nontransfer Area You should designate a block of 4x registers as the nontransfer area These registers will be ignored when state RAM values are transferred from the primary controller to the standby Placing registers in the nontransfer area is one way to reduce scan time The nontransfer area contains the status register which is used to monitor the status of the controller It also contains a pair of registers which may be used for reverse transfer operations You may include other 4x registers in the nontransfer area to reduce scan time The first entry field in screen 2 is used to specify the first 4x register in the nontransfer area The second field is used to define the number of contiguous registers in the nontransfer block If you choose to define a nontransfer area the range of legal values for this entry field is 4 n where n is the number of configured 4x registers However when defining the nontransfer area you must meet these requirements Configuring a Quantum Hot Standby System 840 USE 106 00 The nontransfer area must be located entirely within the area of 4x registers scheduled for transfer on every scan The transfer area is defined below The command register de
39. ap terminators and four self terminating F adapaters 140 CHS 320 00 A 3 1 2 in diskette with the CHS loadable 140 SHS 945 00 This manual 840 USE 106 00 14 Introduction 840 USE 106 00 840 USE 106 00 1 5 Related Publications The following publications are referred to throughout this manual You will find them helpful in designing installing programming and maintaining your hot standby system They are available from your distributor or local Square D office Use the numbers in parentheses when ordering Quantum Automation Series Hardware Reference Guide 840 USE 100 00 Version 5 or greater Remote I O Cable System Planning and Installation Guide 890 USE 101 00 Ladder Logic Block Library User Guide 840 USE 101 00 Version 2 or greater Modbus Plus Network Planning and Installation Guide 890 USE 100 00 Modsoft Programmer User Manual 890 USE 115 00 The Quantum Automation Series Hardware Reference Guide Remote I O Cable System Planning and Installation Guide Ladder Logic Block Library User Guide andthe Modbus Plus Network Planning and Installation Guide are available as a set The part number for this Quantum Automation Series Documentation Library is 840 USE 500 00 Introduction 15 Chapter 2 Theory of Operation 840 USE 106 00 How a hot standby system works The state RAM transfer area Theory of Operation 2
40. are el de aaa E oe Batya ahd 100 Contents 840 USE 106 00 Figures Figure 1 Simple Backplane Configuration 0 0 0 000 000 0000 5 Figure 2 Front Panel of a Quantum CHS 110 Hot Standby Module Figute 3 LED Display citi scl td aces ented cat Meee Md ate cecal petgeitns Weck E tenis 10 Figure 4 Function Keyswitch Positions 00 eee eee eee 11 Figure 5 Correctly Crossed Fiber Optic Cable 0000 13 Figure 6 State RAM Transfer Timing Diagram 0 0000 19 Figure 7 Hot Standby System Scan Times 0 000 000 0 eee eee 20 Figure 8 State RAM Transfer Area 0 cee ee eee eee 21 Figure 9 Examples of the Default State RAM Transfer Area 23 Figure 10 A State RAM Transfer Area Set Up Using Multiple Scans To Transfer Data 056 o Petter Ses hk Parade bl ethno tia a Due bok E ii eden anes ale Ds 25 Figure 11 A Single Cable Configuration 0 0 00 0c ee eee eee 31 Figure 12 A Dual Cable Configuration 0 0 00 0 e eee eee 32 Figure 13 Setting Designation Slide Switches 0 0000 34 Figure 14 Installing Coaxial Cable Link 0 0 0 000 0 0000 35 Figure 15 Attaching the Fiber Cable Clasp to the Cable 36 Figure 16 Aligning the Key and Locking Ring 00 36 Figure 17 Attaching the Cable pac ek ke eee ee ete et eee ees 37 Figure 18 Converting to Hot Standby
41. below N Hex Dec Bin Goto Quit F1 F2 F3 F4 F5 F6 F7 Lev 8 F8 OFF F9 Quantum Hot Standby Control System Screen 1 2 Ptr to Command Register E G 5 400005 0 DEC cncl cfg ext 0 Command register must be within STATERAM XFR AREA COUNTS see screen 2 Keyswitch Override bit 16 DISABLED Controller A Run Mode bit 15 OFFLINE Controller B Run Mode bit 14 OFFLINE STBY Run Mode if Logic Mismatch bit 13 OFFLINE Swap Port 1 Addr at switchover bit 8 YES Swap Port 2 Addr at switchover bit 7 YES Swap Port 3 Addr at switchover bit 6 YES Note See Quantum Hot Stby Handbook for layout of CMD Reg PgDn Up to next prev Screen Figure 26 Configuration Extension Screen 1 Configuring a Quantum Hot Standby System 51 5 3 2 Specifying the Command Register The command register is used to control various parameters of the hot standby system Disables keyswitch override 0 Enables keyswitch override 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 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
42. by controller Caution To change the program you must stop both controllers and take the standby Off Line Procedure Updating the Program In the Standby Controller Put the primary controller in Run mode Make sure the standby con troller is still stopped and Off Line Push the update button on the standby unit Hold the button down Turn the key on the standby CHS 110 module to Xfer This prepares the standby unit to receive the update Maintenance 85 86 Step 4 Maintenance Primary CHS 110 00 JT STANDBY Ready Com Act I Figure 37 oS Standby Prepared For Update Standby CHS 110 00 OT STANDBY Ready 0 Now turn the key to the mode you want the standby unit to be in af ter the update Run or Off Line begin to blink Primary SSS 1400 LS CHS 110 00 Q ANDBY_ Ready Figure 38 Requesting Update The amber Standby Standby 10 Ready CHS 110 00 in co l o AN a Xer ine indicator will 840 USE 106 00 840 USE 106 00 Step 5 Step 6 Release the update button The primary controller will begin copying its full program to the standby The Standby indicator on the standby unit will continue to blink as the module processes the update
43. cking tab groove and lock should also be aligned Slide the clasp up to the locking ring Gripping the cable with the clasp plug the cable into the lower receive cable connector If it does not connect easily realign the key with the arrow and try again 36 Hardware Installation 840 USE 106 00 Connector Locking Tab Keyway Locking Ring S Fiber Cable Clasp Figure 17 Attaching the Cable Turn the cable to the right so that the tab locks securely You may leave the fiber cable clasp on the cable for future use but slide it off the boot of the cable to allow the module door to close Repeat this process with the remaining strand of cable and the upper transmit cable connector Note Remember that each strand of cable must be connected to the upper transmit cable connector on one hot standby module and the lower receive cable connector on the other If the cable is not properly connected the modules will not be able to communicate and the standby will remain offline See p 81 for details Note One strand of the cable provided in the CHS 210 Hot Standby kit will be marked for instance with the manufacturer s name This is the only way to distinguish the two strands 840 USE 106 00 Hardware Installation 37 4 2 Adding Hot Standby Capability to an Existing System To add hot standby capability to an existing Quantum system you must install a second backplane with modules identical to those in the ori
44. d Critical inputs transferred D on every scan UO Additional inputs transferred e I in chunks on multiple scans Remaining inputs not 3nnnnn transferred 400001 A 400002 Critical outputs transferred ae on every scan 400005 H 400006 Additional outputs transferred 3 in chunks on multiple scans e e Remaining outputs not transferred 4nnnnn y Figure 31 Transferring Additional State RAM Data The system transfers additional data in the following order All Ox references first All 1x references second All 3x references third All 4x references last A minimum of 512 equivalent words of each data type specified in the fifth entry field of screen 2 will be sent in a scan unless there is less than 512 words of that data type left to be transferred For example if you specify 528 additional registers to be transferred over three scans the system will send the data faster than expected The first 512 64 Configuring a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 additional registers will be transferred in the first scan and the remaining 16 registers will be transferred in the second scan On the third scan the process will begin again sending the first 512 additional registers ALL STATERAM The ALL STATERAM option in the third entry field of screen 2 transfers all the state RAM configured in your controller to a maximum of 10K 32K or 64K words
45. delines Cable topologies 840 USE 106 00 Planning a Quantum Hot Standby System 27 3 1 Guidelines for Planning a Hot Standby System Both the primary and the standby controller in your hot standby system must be ready to perform as a stand alone controller in the event that its counterpart fails Therefore you should install them with equal care according to Modicons standard planning and installation guidelines Refer to the Quantum Automation Series Hardware Reference Guide andthe Remote I O Cable System Planning and Installation Guide for details Design your system for safety first then for economy Make sure that you understand all the cautions and warnings in this manual before you begin to install your system 3 1 1 System Compatibility In order for the hot standby system to function your component modules must meet the version requirements in the table on p 5 You must use identical modules in the primary and standby racks If you have different models or different versions of the same model or different flash executive software the hot standby system will not function properly While the controllers and RIO heads must be Quantum models the remote drops may use Quantum 800 series 500 series or 200 series I O with corresponding drop processors 3 1 2 Positioning The CHS 110 Hot Standby modules are connected by fiber optic cable A 3 m cable is supplied with the kit However the primary and standby back
46. e any module in either backplane make sure that the spare module is compatible with your hot standby system Make sure also that you use the correct terminator 840 USE 106 00 840 USE 106 00 7 2 2 Startup Errors CHS 110 00 HOT STANDBY Ready Figure 34 LED Display for a Startup Error When the hot standby system detects a mismatch between the primary and standby controllers it reports a startup error The mismatch may be in the configuration segment scheduler I O map or designation slide switch positions The LEDs will display the pattern in Figure 34 The Ready indicator will be a steady green while the Com Act indicator will be blinking If the LEDs indicate a startup error and you have difficulty determining why you can access some startup error codes through software Refer to ch 3 of the Quantum Automation Series Hardware Reference Guide for details Troubleshooting 1 Make sure the designation slide switches on the CHS 110 modules are in opposite positions 2 Make sure the configuration table in the primary and standby controllers are identical 3 Make sure the segment schedulers in the primary and standby controllers are identical 4 Make sure the I O maps in the primary and standby controllers are identical Maintenance 77 78 7 2 3 Communications Errors If the CHS 110 module detects a communications error the LEDs will display the following pattern CHS 110 00 HOT STANDBY Ready Co
47. e primary and the standby controllers have the new system executive installed and the both are running the same logic program with the same state RAM values If you initiate another switchover the controller that was originally the primary will become the primary again and the controller that was originally the standby will become the standby again Attach the Modsoft programming panel to the primary controller and reset bit 12 to 0 via either the Zoom screen or the RDE Warning Executing step 9 is critical for the safety and reliability of your hot standby system Maintenance 89 7 7 7 7 1 Step 1 Step 2 Step 3 90 Maintenance Testing a Hot Standby Switchover In order to test your hot standby system you may force a switchover manually or through software Note In systems with scan times of 200 ms or greater and more than 15 RIO drops it is recommended that the drop holdup time be increased to 1 5 seconds to ensure that communication with remote drops is maintained during switchover Forcing a Switchover Manually Make sure that the standby controller has been fully programmed The function keyswitch on the CHS 110 Hot Standby module should be in the Run position The Standby indicator on the CHS 110 mod ule should be a steady amber Make sure that the designation slide switch on one hot standby mod ule is in position A and that the switch on the other hot standby mod ule is in position B Confirm that the
48. el of a Quantum CHS 110 Hot Standby Module 840 USE 106 00 Introduction 1 3 1 LED Display On the face of each CHS 110 module are five status indicators CHS 110 00 HOT STANDBY Com Err Com Act Primary Standby Figure 3 LED Display Indicator Color Message Ready Green If steady power is being supplied to the module and it has passed initial internal diagnostic tests If blinking module is trying to recover from an interface error Com Act Green If steady CHS 110 modules are communicating If blinking an error has been detected Primary Green Module is supporting primary controller Com Err Red Module is retrying communications or commu nications failure has been detected Standby Amber If steady module is supporting standby controller which is ready to assume primary role if needed If blinking program update is in progress Error messages are discussed in detail on p 76 10 Introduction 840 USE 106 00 840 USE 106 00 1 3 2 Function Keyswitch and Update Button Off Line Figure 4 Function Keyswitch Positions Beneath the LED display on the face of each CHS 110 control panel is a function keyswitch It has three positions Off Line Xfer transfer and Run You may use this switch to force transfer of control functions or to copy the full program of the primary controller to the standby Off Line Mode This mode is used to take a controller out of service witho
49. ends status data from the standby controller to the primary One fault lamp turns ON if the standby memory protect is OFF the other lamp turns ON if the memory backup battery fails in the standby Internal coil bit 000715 status bit 11 controls the STANDBY MEMORY PROTECT OFF lamp Internal coil bit 000716 status bit 12 controls the STANDBY BATTERY FAULT lamp Network 2 of Segment 1 400103 BLKM Transfers the Status of the 000801 Hot Standby Status Register 40103 to Internal Coils 00801 BLKM 001 l 400101 000815 000816 STAT Sends One Status Register Word from Bit 15 Bit 16 the Standby to a Reverse Transfer Register STAT 400101 in the Primary Enables STAT if this 001 PLC Is the Standby Figure 24 An Example of Reverse Transfer Logic Reverse Transfer Logic The logic in network 2 of segment 1 contains a BLKM instruction and a STAT instruction The standby enables the STAT Bits 000815 and 000816 are controlled by bits 15 and 16 in the hot standby status register The STAT instruction sends one status register word to 4yyyy this word initiates a reverse transfer to the primary controller Remote 1 O Logic The logic in segment 2 is scanned only by the primary controller Bits 000813 and 000814 enable the BLKM instruction which transfers status data to the internal coils at reference 000705 Configuring a Quantum Hot Standby System 49 50 Segment 2 Standby MEMO
50. fined in screen 1 must be outside the nontransfer area By default the nontransfer area is four registers long starting at register 400001 Note Ifyou are also programming a CHS instruction in ladder logic the parameters you set for the nontransfer area in the configuration extension screens must be identical to those in the CHS block 5 3 9 The Hot Standby Status Register The third register in the nontransfer area will be the status register Use this register to monitor the current machine status of the primary and standby controllers This PLC in OFFLINE mode This PLC running in primary mode This PLC running in standby mode Wout 4 Oo e e The other PLC in OFFLINE mode The other PLC running in primary mode The other PLC running in standby mode Wo 30o O PLCs have matching logic 0 PLCs do not have matching logic 1 This PLC s switch set to A This PLC s switch set to B 1 1 2 3 4a Sl Sl 7 8 9 10 11 12 13 14 15 16 The CHS interface is healthy O An interface error has been detected 1 Hot standby capability has not been activated 0 Hot standby is active 1 Figure 29 Hot Standby Status Register for Configuration Extension Note Bits 1 and 2 are used only in conjunction with a configuration extension 840 USE 106 00 Configuring a Quantum Hot Standby System 59 60 5 3 10 Configuring
51. fixed block of up to 12K words in state RAM is specified as the transfer area It consists of the following All the Ox discrete outputs in state RAM up to a maximum of 8192 including their associated histories All the 1x discrete inputs in state RAM up to a maximum of 8192 including their associated histories If the total number of registers 8x and 4x combined implemented in state RAM is 10 000 or less then all the registers plus the up down counter history table If the total number of registers 8x and 4x combined implemented in state RAM is greater than 10 000 then a total of 10 000 will be transferred in accordance with the formula described on p 21 22 The command register must be contained within the range of 4x registers in the state RAM transfer area The Nontransfer Area of State RAM You also must define a nontransfer area A nontransfer area is a tool to reduce scan time is located entirely within the range of 4x registers in the state RAM transfer area which are transferred on every scan consists of a block of four or more 4x registers Configuring a Quantum Hot Standby System 45 allows the user to monitor the status of the hot standby system Only 4x reference data can be placed in the nontransfer area These designated registers will not be transferred to the standby controller thus reducing scan time The following block diagra
52. ginal backplane Keep the following requirements in mind You must remove any local I O and distributed I O networks from the original backplane as they are not supported at switchover Local I O must be removed Po VO 1 0 E i Figure 18 Converting to Hot Standby System DIO network must be removed You need backplanes with at least four slots The components in both backplanes must meet the version requirements listed on p 5 You must install a splitter and a self terminating F adapter between the original RIO head processor and the RIO network A second cable will run from the splitter to the standby RIO head processor through a second self terminating F adapter In general you may follow the installation directions on p 34 37 However as a precaution you should first stop the controller and disconnect power to the system 38 Hardware Installation 840 USE 106 00 Chapter 5 Configuring a Quantum Hot Standby System How to configure a hot standby system Using the CHS instruction to control your hot standby system Using a configuration extension to control your hot standby sys tem 840 USE 106 00 Configuring a Quantum Hot Standby System 39 40 5 1 Step 1 Step 2 Step 3 Configuring How to Configure a Hot Standby System To configure a Quantum hot standby system you must load the CHS s
53. gisters while in the Zoom screen you will be working with the command and status pages Refer to pages 44 and 48 for diagrams of the command and status register bits Addressing the primary controller check the status register or page to make sure one unit is designated A and the other is B Make sure that both the primary and the standby controllers are in run mode and that the function keyswitch override has been enabled Maintenance 91 92 Step Step Step Step Maintenance In the command register or on the command page take the primary controller offline If you are operating on a Modbus Plus network the programming panel will automatically be communicating with the primary control ler If you are operating via the Modbus or Modbus Plus port directly connected to the original primary controller you must reconnect the proramming cable to the new primary controller and then log in again due to the port address swap The status should now show that the original primary controller is offline and that the standby is now functioning as the primary unit Check the LED displays on the hot standby modules to confirm that the switchover has taken place The Primary indicator on the original primary unit should be extinguished while the Primary indicator on the original standby unit should be a steady green In the command register or on the command page return the original primary unit to run mode The status register or p
54. he key If you turn the key on the primary unit to Xfer the hot standby system will ignore your action Run Mode When the keyswitch is in this position the controller is active and is either serving as the primary controller or is capable of taking over the primary role if needed The keyswitch on both hot standby modules should be in the Run position at all times When the standby controller is in run mode it is actively monitoring the status of the system and ready to take control if the primary unit fails Note For security or convenience you may disable the function keyswitch with a software override Once the keyswitch is disabled you may take the module on or off line through software This can be especially helpful when the module is not easily accessible See p 51 for details Designation Slide Switch A slide switch located below and to the right of the keyswitch is used to designate the controller as A or B One unit must be designated as A and the other as B The unit designated A will power up as the primary controller so long as it is ready before or at the same time as unit B Note Ifthe controllers are given identical designations the system will refuse to acknowledge them both The first unit to power up will be recognized as the primary controller It will be designated A or B according to its switch position The second unit will remain offline and the Com Act indicator will flash indicating a startup error
55. he modules further apart you should order 62 5 125 micrometer fiber optic cable with ST style connectors For further details refer to Appendix B For details regarding recommended coaxial cable please refer to the Remote I O Cable System Planning and Installation Guide Other Components To complete your hot standby system you will need one coaxial splitter for each trunk cable in the RIO network two self terminating F adapters for each trunk cable in the RIO network one trunk terminator for each trunk cable in the RIO network Introduction 7 Component Part Number Coaxial splitter MA 0186 100 Self terminating F adapter 52 0720 000 Trunk terminator 52 0422 000 Two coaxial splitters and four self terminating F adapters are included in the 140 CHS 210 00 Hot Standby kit Trunk terminators may be ordered from Modicon For details about these parts refer to the Remote I O Cable System Planning and Installation Guide 8 Introduction 840 USE 106 00 1 3 The CHS 110 Hot Standby Module Version Label Model Number Module Description Color Code LED Display Function Keyswitch Designation Slide Switch Update Button Transmit Cable Connector Receive Cable Connector 140 CHS 110 00 52 J bi Removable Door zal Figure 2 Front Pan
56. hich you want to send the additional data For example if you specify two scans in which to transfer coils 002049 003072 then coils 002049 002560 will be sent with coils 000001 002048 on one scan and coils 002561 003072 will be transferred with coils 000001 002048 on the next scan The following block diagram shows how the state RAM transfer area might be set up using multiple scans to transfer all the data i 000001 000002 Total number of discrete 000903 outputs transferred e Critical outputs transferred on every scan Additional outputs transferred in chunks on multiple scans Onnnnn I 100001 f 100002 Total number of discrete 100003 inputs transferred e 1nnnnn 4 Critical inputs transferred on every scan Additional inputs transferred in chunks on multiple scans I 300001 Total number of register 300002 inputs transferred 300003 Snnnnn Critical inputs transferred on every scan Additional inputs transferred in chunks on multiple scans 400001 400002 400003 400004 Total number of register 400005 outputs transferred 400006 y 4nnnnn Critical outputs transferred on every scan yo Additional outputs transferred y __in chunks on multiple scans Figure 10 A State RAM Transfer Area Set Up Using Multiple Scans To Transfer Data 840 USE 106 00 Theory of Operation 25 Chapter 3 Planning a Quantum Hot Standby System Gui
57. ide to control your system using the configuration extension you still may want to program a CHS instruction in ladder logic The CHS instruction allows you to use Modsoft Zoom screens which make it easier for you to access and modify the command register while the system is running Configuring a Quantum Hot Standby System 41 42 Configuring Note If both a configuration extension and the CHS instruction are used the configuration extension controls the hot standby system The only function of the CHS instruction is to provide Modsoft Zoom screens The parameters in the configuration screens are applied by the controllers at startup Once the controllers are running the Zoom screens may be used to access and modify the command register The changes will be implemented during runtime and can be seen in the status register However if the hot standby system is later stopped and then restarted the parameters specified in the configuration extension screens will go back into effect Ladder Logic in a Hot Standby System All ladder logic for hot standby functions should be in segment 1 Network 1 of segment 1 is reserved exclusively for the CHS instruction block and ladder logic directly associated with it Segment 1 When your hot standby system is running the primary controller scans all segments while the standby controller scans only segment 1 of the configured ladder logic program This has three very important implications with
58. ield controls controller A The fourth entry field controls controller B A slide switch on the front panel of the CHS 110 modules is used to determine which controller is A and which one is B Configuring a Quantum Hot Standby System 53 54 Option 1 Option 2 Option 3 Configuring Caution If you use the Zoom screen or RDE to enable the keyswitch override while the hot standby system is running the primary controller will immediately read bits 14 and 15 to determine its own state and the state of the standby If both bits are set to 0 a switchover will occur and the former primary backplane will go offline The new primary backplane will continue to operate A Software Control Example Say you have ENABLED the keyswitch override bit 16 1 and set the operating mode of controller B to OFFLINE bit 14 0 Now the system is powered up and you want to put controller B in RUN mode The keyswitch will not work so you must rely on user logic There are three ways you can proceed Change the setting on the configuration extension screen To do this you must shut down the system and make the necessary change in the screen then power up the system again Connect Modsoft to your primary controller In the ladder logic editor call up a reference data editor RDE Place the hot standby command register and the hot standby status register in the RDE The operating mode of controller B is determined by the state of bit
59. if it detects a fault Regular Data Transfers While the system is running the module will automatically transfer a predetermined amount of state RAM to the standby unit at the end of each scan This ensures that the standby is apprised of the latest conditions and is ready to take control if needed How the System Responds to Faults If one or both of the links between the hot standby modules are broken the primary controller will function as though no backup is available If the primary controller fails the standby automatically assumes control of the remote I O network Ifthe primary controller recovers from failure it assumes standby responsibilities If it cannot recover it remains offline If the standby controller fails it goes offline The primary controller functions as astand alone and continues to manage the I O networks 840 USE 106 00 Chapter 7 Maintenance Verifying health of a hot standby system Responding to errors Detecting failures in a hot standby system Replacing modules in a hot standby system Performing a program update Updating PLC system executives while the system is running Testing a hot standby switchover 840 USE 106 00 Maintenance 73 74 7 1 Maintenance Verifying Health of a Hot Standby System The hot standby modules exchange a health message approximately every 10 ms Ifthe primary has an error the standby is notified and as
60. is resetting If bits 12 16 are 01011 you know three things which controller is the standby that the remaining controller is the primary that both controllers are running the same logic If these conditions are true then the logic should clear bit 2 and set bit 1 of the time of daycontrol register The clock in the standby controller will be reset from the state table of the primary controller at the end of a scan and bit 1 will be cleared LE Note Make sure that the registers for synchronizing the time of day clocks are included in the state RAM transfer area 70 Operation 840 USE 106 00 Network 0001 40101 40001 Address of CHS Command Register 40101 First Register Reserved for Nontransfer Area in State RAM 4 Number of Registers Reserved in Nontransfer Area Network 0002 0002 0001 TODC TODC f MBIT MBIT 0001 0001 40103 CHS Status Register 42221 Mask Out Status Bits Not Required 42222 Junk Register TODC Time of day Clock Register Figure 33 Logic for Synchronizing Time of Day Clocks 840 USE 106 00 Operation 71 72 6 3 Operation While Your System Is Running Constant Internal Monitoring After your hot standby system has been started and is running normally it will continue to function automatically It constantly tests itself for faults and is always ready to transfer control from the primary to the standby
61. itchover 11 88 view 11 L LED display description 10 during normal operation 67 error messages 74 77 view 10 local I O not supported in hot standby system 4 38 logic mismatch controlling response to 55 may force standby offline 55 M Modbus Plus port addresses swapping at switchover 56 Modbus port addresses swapping at switchover 55 Modsoft version requirement 5 Modsoft reference data editor using to access command register 44 using to change configuration extension 51 using to force switchover 89 using to update PLC system executives 86 Modsoft Zoom screens using to access and modify command register 42 51 using to force switchover 89 using to update PLC system executives 86 840 USE 106 00 N NOM module version requirement 5 nontransfer area of state RAM defined 45 48 58 diagram 46 in CHS instruction block 47 P part numbers backplanes 6 cable connectors 94 cable tools third party 95 components of the hot standby kit 14 diskette with CHS loadable 14 fiber optic cable included in kit 14 various lengths 94 manual 14 power supplies 6 programmable logic controllers 6 related publications 15 remote I O head processors 7 self terminating F adapters included in hot standby kit 14 termination kit included in hot standby kit 14 termination kits third party 94 PLC system executives updating 86 power supply redundant checking health of 7
62. keyswitch on both hot standby modules has not been overriden by software Primary Standby tee gt 140 LSS 140 CHS 110 00 CHS 110 00 EEE Ready om aot aes co Off Off Line ep Une ter D j 2 A A i a B E B Figure 40 After Taking the Primary Controller Offline 840 USE 106 00 840 USE 106 00 Step 4 Step 5 Step 6 7 7 2 Step 1 Turn the key on the primary hot standby module to Off Line The standby should now be functioning as the primary controller Check to see that all LED indicators are normal and all application devices functioning properly The Standby indicator should be extin guished and the Primary indicator should be a steady green Return the key on the original primary unit to the Run position The Standby indicator should come on Original Original Primary Standby i w CHS 110 00 CHS 110 00 Ready Ready Com Act oe fae I Off Line Figure 41 Bringing the Original Primary Unit Back Online Forcing a Switchover Through Software You may force a switchover using the reference data editor or if you have programmed a CHS instruction in ladder logic you may use a Modsoft Zoom screen The instructions are the same however in the reference data editor you will be working with the command and status re
63. m Err Figure 35 LED Display for a Communications Error Troubleshooting 1 Make sure the fiber optic cables are connected properly and functioning correctly 2 Ifthe fiber optic cables are okay replace the faulty CHS 110 module 7 2 4 Interface Errors If the hot standby module detects certain errors in its interface with the controller the LED display will go out momentarily as the module tries to recover It will either return to a ready state or will report the error with a blinking Com Act indicator The Com Act error patterns are described in Appendix C Troubleshooting 1 Ifyou used the CHS function block disable it and restart the system Ifthe Ready indicator comes on the problem is in the CHS 110 module If you used a configuration extension screen go offline and change Maintenance 840 USE 106 00 840 USE 106 00 7 2 5 the configuration to a standalone system Reload the program Restart the system If the Ready indicator comes on the problem is in the CHS 110 module 2 Ifyou have replaced the hot standby module and the problem still occurs replace the other components one at a time 3 Ifthe problem still occurs replace the backplane Board Level Errors Board level errors include PROM checksum RAM data RAM address and UART errors Ifthe hot standby module detects one of these errors it will display the following pattern CHS 110 00 HOT STANDBY Ready Figure 36 LED Display for a Boa
64. m shows how the nontransfer area exists with respect to the rest of the state RAM transfer area State RAM Transfer Area 000001 000002 000003 e Onnnnn 100001 100002 100003 e 1nnnnn 300001 300002 300003 e Snnnnn 400001 Critical outputs transferred 400002 on every scan 400003 400004 Note All registers in the nontransfer Total number of register 400005 area must be in this range outputs transferred 400006 The command register must be out side the nontransfer block Additional outputs transferred 4nnnnn in chunks on multiple scans Figure 21 Nontransfer Area Within the State RAM Transfer Area Note The command register must not be placed in the nontransfer area 46 Configuring a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 5 2 4 5 2 5 Elements of the Nontransfer Area The most important part of the nontransfer area is the hot standby status register Once the system has been configured and is running the status register becomes a valuable tool for monitoring the machine states of the two controllers If you use software to change values in the command register being able to see the result of those changes in the status register is very helpful The nontransfer area also includes a pair of registers that can be used for programming reverse transfer operations Defining the Nontransfer Area The nontransfer area is defined in the middle and bott
65. nce data items must be 0 or specified in multiples of 16 A minimum of 16 4x registers is required In the fifth entry field enter the number of Ox 1x 3x and 4x data references that you want transferred as additional state RAM All reference data items must be specified in multiples of 16 You must enter a value of 16 or greater for at least one of the four reference data types A Caution If you choose USER DEF ADDL you must specify additional data to be transferred or the controller will not start Use the sixth entry field to specify the number of scans over which you want the additional data transferred In general the system divides the number of reference data elements specified in the fifth entry field by the number of scans specified in the sixth entry field Accordingly it divides the data into chunks that are transferred contiguously over the specified number of scans These chunks of data are transferred together with the regular state RAM data that has been scheduled on every scan 840 USE 106 00 Configuring a Quantum Hot Standby System 63 000001 A Critical inputs transferred 000002 1 on every scan 000003 e Additional inputs transferred r in chunks on multiple scans Remaining outputs not Onnnnn transferred 100001 Critical inputs transferred 100002 on every scan 100003 eran e Additional inputs transferred e m n in chunks on multiple scans 1nnnnn Remaining inputs not transferre
66. network 7 30 standby controller configuring with update button 83 designated by slide switch 12 failure 70 79 function 4 Standby LED 10 11 66 in a program update 83 startup 66 startup errors 75 state RAM nontransfer area defined 45 48 58 diagram 46 in CHS instruction block 47 state RAM transfer automatic 70 default 22 default parameters with configuration extension 57 how it works 18 impact on scan time 19 suspended when error detected 74 timing diagram 19 state RAM transfer area customizing 22 customizing with configuration extension 24 57 63 defined 21 diagram 21 25 fixed with CHS instruction 45 managing size to reduce scan time 21 840 USE 106 00 parameters 22 required in RIO network 7 30 status register contained in nontransfer area 47 diagram 48 58 U switchover UART errors 77 automatic 70 update button increasing drop holdup time 88 function 11 manual 11 in a program update 11 83 testing 88 synchronizing time of day clocks 68 Z T Zoom screens using to access and modify command register time of day clocks synchronizing 68 42 44 51 using to force switchover 89 trunk terminator ided in de 14 using to update PLC system executives 86 provided in kit 840 USE 106 00 Index 107
67. nks once a second The interface error pattern is discussed on p 78 CHS 110 Failure Controller CHS 110 RIO Head Status Runs as offline COM ACT displays error READY on and COM ACT pattern stops blinking The Com Act error patterns are described in Appendix C Maintenance 81 RIO Head Failure Controller CHS 110 RIO Head Status Stops All LEDs off except READY COM ACT displays error pattern After you have replaced the module and cycled power you must perform a program update as described on p 85 to ensure that the controllers will have identical programs Error codes for a blinking Com Act indicator are listed in Appendix C RIO Cable Failure at Standby End Controller CHS 110 RIO Head Status Stops All LEDs off except READY READY on and COM ACT blinks four times In a dual cable system the RIO head will give no indication if only one cable has failed Failure of Fiber Link from Standby Transmit to Primary Receive Controller CHS 110 RIO Head Status Runs as offline READY and COM ACT on COM ACT stops blinking Failure of Fiber Link from Primary Transmit to Standby Receive Controller CHS 110 RIO Head Status Runs as offline READY and COM ERR on COM ACT stops blinking First replace the cable and restart the controller The unit should return to standby mode If it does not then cycle power If the cable has been connected improperly ie
68. ntransfer area 47 placement in ladder logic 43 55 using to control hot standby system 43 840 USE 106 00 CHS loadable functions 40 loading 40 provided in kit 14 required in hot standby system 40 coaxial cable diagrams 30 in the RIO network 7 permissible lengths 28 coaxial splitters provided in kit 14 required in RIO network 7 30 Com Act LED 10 11 12 66 76 77 Com Err LED 10 76 command register accessing while system is running 44 default parameters for configuration extension 51 defined 43 diagram 44 52 86 must be transferred on every scan 52 must not be in nontransfer area 46 setting with configuration extension 51 communications terminated when error detected 74 communications errors 76 configuration extension advantages of using 41 parameters applied at restart 42 screen 1 view 51 screen 2 view 57 setting command register parameters 51 56 using to control hot standby system 51 using to customize state RAM transfer 24 configuration mismatch 75 Index 103 D designation slide switch function 12 mismatch 75 need for proper use 12 setting during installation 35 distributed I O not supported in hot standby system 38 drop holdup time increasing 88 E errors board level 77 communications 76 interface 76 PROM checksum 77 RAM address 77 RAM data 77 startup 75 types 74 78 UART 77 F failure fiber optic cable 80 hot st
69. ntroller The primary controller updates the standby controller after each scan The standby is ready to assume control within one scan if the primary fails Primary and standby states are switchable Either controller can be put in the primary state but the other must be in the standby state The remote I O network is always operated by the primary controller Note A Quantum Hot Standby system supports only remote I O It does not support local I O Role of the CHS 110 Hot Standby Module Each controller is paired with a 140 CHS 110 00 Hot Standby module The module monitors its own controller and communicates with the other hot standby module The system monitors itself continuously If the primary controller fails the hot standby module switches control to the standby which then becomes the primary controller If the standby controller fails the primary continues to operate without a backup 4 Introduction 840 USE 106 00 840 USE 106 00 1 2 1 2 1 Hardware Components in a Quantum Hot Standby System A Quantum Hot Standby system requires two backplanes each with at least four slots The backplanes must be equipped with identical compatible Quantum power supply programmable logic controller remote I O head processor CHS 110 Hot Standby module Primary Standby PS PLC RIO PLC RIO CH it a a d Ta to the RIO network O I N U ey I
70. ntum Automation Series Hardware Reference Guide Install a splitter and a self terminating F adapter between the primary RIO head processor and the RIO network Connect the coaxial cable link Then connect the cable between the splitter another self terminating F adapter and the standby RIO head processor Primary Standby PS PLC RIO PLC RIO EEE LU j O I N U 02 O I N E elf terminating adapter Coaxial cable Splitter Cable to the RIO network Figure 14 Installing Coaxial Cable Link Connect the fiber link between the hot standby modules making sure the cable is properly crossed so that the transmit cable connector of each module is linked to the receive cable connector of the other Heres how Remove the protective plastic coverings from the cable ports and the tips of the cable Snap one of the fiber cable clasps onto the cable carefully pressing the cable through the slot so that the wider end of the clasp is closest to the boot Hardware Installation 35 Cable Boot Fiber Cable Clasp Figure 15 Attaching the Fiber Cable Clasp to the Cable The key to installing the cable is to align the barrel the locking ring and the connector Barrel Key Groove Arrow Locking Ring Lock Figure 16 Aligning the Key and Locking Ring Turn the locking ring to align an arrow with the key Then align the key with the keyway As a result the lo
71. odbus Modbus Plus Quantum Automation Series Modicon Modsoft Concept DIGITAL andDEC areregisteredtrademarksof Digital Equipment Corporation IBM and IBM AT are registered trademarks of International Business Machines Corporation Microsoft and MS DOS are registered trademarks of Microsoft Corporation Copyright 1996 Schneider Automation Inc Printed in U S A Preface iii Contents Quick Start Procedure Chapter 1 Introduction 1 1 An Overview of Hot Standby Systems 1 2 Hardware Components in a Quantum Hot Standby System 1 2 1 1 2 2 1 2 3 1 2 4 1 2 5 1 2 6 1 2 7 1 3 1 1 3 2 1 3 3 1 3 4 Chapter 2 Theory of Operation 2 1 How a Hot Standby System Works State RAM Transfer Effect on System Scan Time 2 2 The State RAM Transfer Area 2 1 1 2 1 2 Chapter 3 Planning a Quantum Hot Standby System 3 1 Guidelines for Planning a Hot Standby System 3 1 1 3 1 2 840 USE 106 00 System Compatibility Backplane Models Power Supply Modules Programmable Logic Controllers Remote I O Head Processors Cable Other Components 1 3 The CHS 110 Hot Standby Module LED Display Function Keyswitch and Update Button Designation Slide Switch Cable Ports 1 4 The CHS 210 Hot Standby Kit 1 5 Related Publications System Compatibility Positioning ONNANABDBHAH ATT K Q Contents v vi 3 1 3 Electrical Safety Precautions 0 eee eeee 29 3 2 Remote I O Cable Topologies
72. oftware in your controllers The software is included on a diskette in the hot standby kit Once you have loaded the software you may choose how to proceed You may control your hot standby system through ladder logic or you may use a configuration extension The CHS Loadable The logic in the CHS loadable is the engine that drives the hot standby capability in a Quantum control system The CHS loadable gives you the ability to specify the hot standby command register which is used to config ure and control hot standby system parameters define a hot standby status register which can be used to monitor the real machine status of the system implement a CHS instruction in ladder logic Unlike HSBY a comparable loadable used for hot standby configurations in 984 controllers the CHS instruction does not have to be placed in a ladder logic program However the CHS software must be loaded to the Quantum controller in order for a hot standby system to be supported Procedure Loading the CHS Software to Your Program The CHS loadable is provided on a 31 9 in diskette 140 SHS 945 00 as part of your 140 CHS 210 00 Hot Standby kit The file is named QCHSVxxx DAT where xxx is the three digit version number of the software Insert the diskette in the disk drive In the Configuration Overview screen in Modsoft select Loadable from the top menu bar From the loadable screen select Dir from the top menu bar
73. om nodes of the instruction block The middle node specifies the first register in the nontransfer area The bottom node specifies the length of the nontransfer area The nontransfer area must be at least four registers long The first two registers in the nontransfer area are reserved for reverse transfer functions The third register in the nontransfer area is the hot standby status register The fourth register and all other contiguous 4x registers specified for nontransfer will be ignored when the state RAM values of the primary controller are transferred to the standby controller Example of a Nontransfer Area 40005 40010 CHS Figure 22 Sample CHS Instruction Block In the example illustrated in Figure 22 the nontransfer area would begin at register 40010 as defined in the middle node The length Configuring a Quantum Hot Standby System 47 48 5 2 6 5 2 7 Configuring would be 30 registers as defined in the bottom node Thus the last register in the nontransfer area would be 40089 The status register would be register 40012 the third register in the nontransfer area The command register which is defined in the top node has been placed outside the nontransfer area as required The Hot Standby Status Register The third register in the nontransfer area will be the status register Use this register to monitor the current machine status of the primary and standby controllers
74. on standby controller B are 129 130 and 131 By default this offset is maintained between port addresses in the event of switchover For example if controller B becomes the primary controller Configuring a Quantum Hot Standby System 55 as the result of switchover its Modbus ports assume the addresses of 1 2 and 3 and the comparable ports on controller A assume addresses 129 130 and 1381 The last three entry fields in screen 1 allow you to change this default condition on any or all of the Modbus ports on the two controllers in your hot standby system For example if you change the parameter for the entry Swap Port 1 Addr at switchover bit 8 to NO then no offset will be maintained at switchover and after switchover the two ports will have the same address Thus if controller A is the primary controller and its Modbus port 1 address is 1 then that port address will remain 1 after a switchover has occurred Likewise if controller B becomes the primary controller as a result of switchover its Modbus port 1 address will also be 1 t Note Ifyou change the parameter for bit 8 the port addresses will not be affected until a switchover occurs 5 3 6 Modbus Plus Port Address Swapping at Switchover In a Quantum Hot Standby system the Modbus Plus port addresses on the primary controller are offset by 32 from the comparable ports on the standby controller For example if controller A is the primary controller and its Modbus Pl
75. planes may be placed as much as 1 km apart If you will be placing the modules more than 3 m apart use 62 5 125 micrometer cable with ST style connectors Refer to Appendix B for details If you intend to place the units more than 3 m apart you must consider the effect on the RIO network and any Modbus Plus network The controllers are linked to the RIO network by coaxial cable The longer the distance between the controllers the higher the grade of trunk cable required to maintain signal integrity Refer to chapter 3 of the Remote I O Cable System Planning and Installation Guide for 28 Planning a Quantum Hot Standby System 840 USE 106 00 840 USE 106 00 3 1 3 details regarding cable grades distances and signal integrity If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network fiber optic repeaters may be used to boost the signal Refer to the Modbus Plus Network Planning and Installation Guide for details on extending a Modbus Plus network Electrical Safety Precautions When you plan the installation of the electrical cabinets which enclose the system s electronic components make sure each cabinet is connected separately to earth ground and that each backplane is connected to solid ground within its cabinet Warning To protect yourself and others against electric shock obey your national electrical code and all applicable local codes and laws Planning a Quantum Hot Standby System
76. r in a hot standby system must be solving an identical logic program which is updated on every scan by a state RAM data transfer between the two controllers By default the standby controller is set to go OFFLINE if a mismatch is detected between its user logic and that of the primary controller Switchover cannot occur while the standby controller is OFFLINE The fifth entry field in screen 1 provides you with the option to override this default If you change the parameter in this field from OFFLINE to RUN the standby controller will remain online if a logic mismatch is detected between its logic program and that of the primary controller Caution A mismatch in the I O map or configuration is not allowed under any circumstances Caution If switchover occurs when the fifth entry field of screen 1 is set to RUN and there is a logic mismatch between the two controllers the standby controller will assume primary responsibilities and will start solving a different logic program from the previous primary controller Modbus Port Address Swapping at Switchover In a hot standby system the Modbus ports on the primary controller may have addresses in the range 1 to 119 This allows an offset of 128 for comparable ports on the standby controller with a maximum address of 247 For example if controller A is the primary controller and its three Modbus ports have addresses 1 2 and 3 then the default addresses for the comparable ports
77. rd 12 Maintenance 75 76 7 2 7 2 1 Maintenance Responding to Errors Recognizing Errors When a CHS 110 Hot Standby module experiences an error it takes its controller offline It does not communicate with the other CHS 110 module or take part in state RAM data transfers The LEDs on the front panel of the module can help you locate the source of the error The display pattern tells you which controller is experiencing problems and what kind of error is occurring There are four kinds of errors associated with the hot standby system Startup errors Communication errors Interface errors Board level errors For each type of error try the suggested remedies in the order given If no remedy suggested here overcomes the error call Modicon customer service at 1 800 468 5342 for further directions Before you begin take the following safety precautions Warning To protect yourself and others against electric shock allow no one to touch energized high voltage circuits such as 115V AC Before connecting or disconnecting any high voltage component open and padlock open the disconnect switch which provides power to that component Caution To avoid damage to application I O devices through unexpected system action while disconnecting any remote I O cable disconnect only the feed through terminator from the module leaving the terminator connected to its cable Note Before you replac
78. rd Level Error The Ready indicator will be a steady green while the Com Act indicator will be blinking This is the same pattern the module displays for a startup error Follow the troubleshooting procedures for a startup error If the module does not recover replace it Troubleshooting Replace the faulty CHS 110 module Maintenance 79 7 3 7 3 1 Controller Detecting Failures in a Hot Standby System If one of the main components of the primary backplane fails control shifts to the standby If a component fails in the standby backplane the standby goes offline Likewise if the fiber cable link between the hot standby modules fails the standby goes offline This section will help you determine which component failed When you have replaced that component you must cycle power with one exception After cycling power if the backplane is now healthy it will assume the standby role If the failure was in the fiber cable the backplane may return to standby mode without cycling power If replacing the component does not solve the problem call Modicon customer service at 1 800 468 5342 for further directions Detecting Failures in the Primary Backplane To determine which component failed compare the status of the controller hot standby module and RIO head to the charts below Failure CHS 110 Controller RIO Head Status READY on and COM ACT All LEDs off except READY OR blinks four times Stops
79. st not be within the range of the non transfer area which you specify in the first two entry fields of screen 2 see p 57 Caution Make sure the register you select as the hot standby command _ register is reserved for this purpose and not used for other purposes elsewhere in ladder logic Caution If you intend to use the hot standby configuration extension to configure the command register and the CHS instruction to modify the command register during runtime make sure that you specify the same register as the command register in screen 1 and the top node of the CHS block If you use different numbers for the command register the changes that you make via the Zoom screen will not be applied to the real hot standby command register Once you specify the command register you have activated the configuration extension Keyswitch Override You may choose to override the keyswitch on the front panel of the CHS 110 modules for security or convenience If you override the keyswitch the command register becomes the means for taking the CHS 110 modules on or offline By default the keyswitch override is DISABLED The second entry field in screen 1 allows you to ENABLE it If you ENABLE the keyswitch override the OFFLINE RUN operating mode of the controllers at startup is will be determined by the parameters you set in the third and fourth entry fields However you will not be able to perform program updates The third entry f
80. struction block in ladder logic or call up the command register in a Modsoft reference data editor RDE Procedure PLC Executive Upgrade While the Hot Standby System Is Running If you want to access the command register via a Zoom screen make sure that a CHS instruction has been inserted in ladder logic before the system has been powered up While the hot standby system is running attach a Modsoft program ming panel to the primary controller Go to the ladder diagram editor LDE in Modsoft Call up the hot standby command register either in a Zoom screen on the CHS instruction in ladder logic or in the RDE If you are using a Zoom screen select the YES option for bit 12 If you are using the RDE set the value of bit 12 in the hot standby command register to 1 840 USE 106 00 840 USE 106 00 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Attach a Modsoft programming panel to the standby controller and download the new system executive to it Perform a program update from the primary to the standby controller following the procedure on p 85 At this point you have a new system executive in the standby controller along with the correct ladder logic and state RAM values Initiate a hot standby switchover Attach a Modsoft programming panel to the new standby controller and download the new system executive to it Perform a program update from the primary to the standby controller At this point both th
81. sumes the primary role If the standby has an error the primary continues to operate as a stand alone The RIO head processors also verify communication with one another periodically Automatic Confidence Tests The system automatically performs two kinds of confidence tests on the hot standby modules startup tests and run time tests Startup Tests Startup confidence testing on the CHS 110 Hot Standby modules is extensive These tests attempt to detect hardware errors in the module before you enter the application software Your system performs four startup tests Prom checksum RAM data test RAM address test Dual port RAM test If the module fails any of these tests it will remain offline and will not communicate with the other hot standby module To retest the system the power must be turned off and on again Run Time Tests These tests are performed whenever the Ready indicator is on They are executed in small slices to prevent delays in scan time The system performs three kinds of run time confidence tests Prom checksum RAM data test RAM address test 840 USE 106 00 840 USE 106 00 Checking on a Redundant Power Supply If you have a redundant power supply you may use the STAT block to check its health The redundant power supply must be I O mapped for its health to be displayed The I O module health status section of the STAT block begins at wo
82. tandby controller The following timing diagram shows how the transfer takes place 18 Theory of Operation 840 USE 106 00 Primary Rack 1 Scan gt A Solve All Segments PLC PLC to CHS 110 State RAM Transfer Over the Quantum Backplane Wi Standby Rack CHS 110 to CHS 110 State RAM Transfer Over the Fiber Optic HSBY Link v CHS 110 to PLC State RAM Transfer yan Z PLC WS Y Solve Solve Segment 1 Segment 1 lt 1 Scan Figure 6 State RAM Transfer Timing Diagram 2 1 2 Effect on System Scan Time 840 USE 106 00 When the ladder logic program being executed by the primary controller is longer than the CHS 110 to CHS 110 transfer the transfer does not increase total system scan time However if your logic ladder program is relatively short the scan will finish before the CHS 110 to CHS 110 data transfer and the data transfer will increase total system scan time Note No matter how long your transfer takes it will not cause a watchdog timeout Theory of Operation 19 If the CHS 110 to CHS 110 Transfer Takes Less Time Than the Ladder Logic Program Then the Data Transfer Does Not Add to the Total Scan Time lt Total Scan Time gt PLC to CHS 110 transfer time 3 ms plus Previous lt 0 45 ms 1k discretes for Oxxxx gt lt Ladder Scan and I O
83. th 3 mm cable The following cable meets these recommendations Vendor Part Number Description AMP 502908 1 Beige B 2 Connectors You will need four ST bayonet style connectors per cable Suggested connectors include Vendor Part Number Description AMP 503571 1 Epoxy 20 to 75 C AMP 503415 1 Epoxy 20 to 75 C AMP 501380 Epoxy 30 to 70 C 3M 6105 Epoxy 40 to 80 C 3M 6100 Hot Melt 40 to 60 C B 3 Termination Kits Suggested kits include Vendor Part Number Description AMP 501258 7 Epoxy 110 Vac only for AMP connectors AMP 501258 8 Epoxy 220 Vac only for AMP connectors 3M 8154 Epoxy 110 or 220 Vac only for 3M connectors 3M 6150 Hot Melt 110 or 220 Vac only for 3M connectors Fiber Optic Cable Guide 840 USE 106 00 840 USE 106 00 Other Tools Suggested tools include Vendor Part Number Description 3M Photodyne 9xT Optical Source Driver hand held requires light source 3M Photodyne 1700 0850 T Optical Light Source 850 nm ST connectors for 9XT 3M Photodyne 17XTA 2041 Power Meter hand held 3M 7XE 0660 J Optical Light Source 660 nm visible for 9XT use to troubleshoot raw fiber requires FC ST patch cord 3M BANAV FS 0001 FC ST Patch Cord connects FC connector on 7XE to ST 3M 8194 Bare Fiber Adapter ST compatible permits use of above source and meter to test raw fiber two required
84. that yours meets the version requirement in the table on p 5 Earlier versions will not support the hot standby system Part Number 140 CPU 113 02 140 CPU 113 03 140 CPU 213 04 140 CPU 424 02 Total Memory bytes 256 k 512k 768 k 2M Caution Before installing any controller battery has been disconnected make sure that its for at least five minutes 840 USE 106 00 840 USE 106 00 1 2 5 1 2 6 1 2 7 Remote 1 O Head Processors Quantum RIO heads are available with one or two channels Two channels are needed for dual cable systems Make sure your RIO head meets the version requirement in the table on p 5 Number of Channels Part Number 1 140 CRP 931 00 2 140 CRP 932 00 Note You must use identical versions of the RIO head processor in the primary and standby backplanes and you must place them in the same slot in the backplane If you use different versions of the same RIO module or place the RIO modules in different slots the second backplane will not go into standby mode Cable Two types of cable are used in a Quantum Hot Standby system The hot standby modules communicate with each other via fiber optic cable at arate of 10 megabaud The controllers are linked to the RIO network by coaxial cable The 140 CHS 210 00 Hot Standby kit includes a 3 m fiber optic cable with connectors Replacement cable 990 XCA 656 09 may be ordered from Modicon If you intend to place t
85. the CHS 110 module all three indi cators should be steady not blinking A blinking Com Act light sig nals that your system has detected an error On the corresponding CRP module the Ready indicator will be a steady green The Com Act indicator on the primary unit should also be a steady green while the Com Act indicator on the standby RIO head should be blinking slowly 840 USE 106 00 CHS 110 00 CRP 931 00 HOT STANDBY RIO HEAD Primary Ready Backplane Com Act Primary CHS 110 00 CRP 931 00 HOT STANDBY RIO HEAD Standby Ready Backplane Standby Figure 32 Indicators of a Properly Functioning Hot Standby System 840 USE 106 00 Operation 69 6 2 Synchronizing Time of Day Clocks In a hot standby system the primary and standby controllers have their own time of dayclocks They are not synchronized At switchover the time of day changes by the difference between the two clocks This could cause problems if you are controlling a time critical application To solve this problem program the standby controller to reset its clock from the state table provided by the primary controller If you are controlling your system via configuration extension screens put the logic for time synchronization first Otherwise put the logic for time synchronization in segment 1 but do not put it in network 1 Since both controllers run the same program you must read CHS status register bits 12 16 to make sure that only the standby clock
86. the RIO network 840 USE 106 00 Quick Start Procedure 1 Step 3 Connect the fiber cable link between the hot standby modules ch 4 Primary Standby PS PLC RIO PLC RIO CHS i i O I N jo ey a Fiber optic link T Step 4 Configure the primary controller ch 5 m Step 5 Start the primary controller ch 6 Step 6 Configure the standby controller ch 7 Step 7 Start the standby controller ch 6 2 Quick Start Procedure 840 USE 106 00 Chapter 1 Introduction Overview of hot standby systems Hardware components in a Quantum Hot Standby system The CHS 110 Hot Standby module The CHS 210 Hot Standby kit Related publications 840 USE 106 00 Introduction 1 1 An Overview of Hot Standby Systems A hot standby system is based on two identically configured programmable logic controllers linked to each other and to the same remote I O network If one controller fails the other assumes control of the network Primary and Standby Control The Quantum Hot Standby system is designed for use where downtime cannot be tolerated The system delivers high availability through redundancy Two backplanes are configured with identical hardware and software One of the PLCs acts as the primary controller It runs the application by scanning ladder logic and operating remote I O The other PLC acts as the standby co
87. us port has address 1 then the address for the corresponding port on standby controller B is 33 The numerical range for addresses for both ports is 1 through 64 Thus if the port on the primary controller has address 50 then the address for the corresponding port on the standby cannot be 82 so it will be 18 that is 82 minus 64 These addresses are automatically swapped at switchover you do not have the option to change the offset or prevent the addresses from being swapped 56 Configuring a Quantum Hot Standby System 840 USE 106 00 Note Ina significant improvement over earlier products the Quantum Hot Standby system swaps Modbus Plus addresses almost instantaneously at switchover This means that host devices which are polling the Quantum controller can be assured that they are always talking to the primary controller and that the network will experience no downtime during switchover The earlier 911 Hot Standby system with Modbus Plus capabability would lose network communications to host devices for five to 15 seconds at switchover because the primary and standby systems briefly shared the same network address However Modsoft users may lose communications with the controller in the hot standby system at switchover particularly when networks are displayed Since Modsoft does not have a retry scheme users may have to go offline and log back in 5 3 7 The Second Configuration Extension Screen Using screen 2 you can
88. ut stopping it or disconnecting power If you turn the key on the primary unit to Off Line control switches to the standby If the standby controller is taken offline the primary continues to operate without a backup Xfer Mode This mode is used to request a program update from the primary controller For a step by step description of the procedure see p 85 The primary controller is able to update the standby without any interruption in its other functions If the primary unit is in Run mode and you hold down the update button on the standby unit the hot standby modules prepare to copy the full program of the primary controller to the standby unit The program includes the configuration table I O map configuration extensions segment scheduler user logic all EXE loadables ASCII messages and the entire state RAM To complete the transfer while continuing to press the update button turn the key on the standby to Xfer The Com Act LED will go out Then turn the key to the mode you want the standby to assume after the update Run or Off Line The Standby indicator will flash Now release the update button The Standby indicator will continue to flash during the update and while the standby unit processes the update If the unit is set to run mode the Standby indicator will return to a steady amber If the unit Introduction 11 12 1 3 3 Introduction is set to offline mode the Standby indicator will go out Now remove t
89. x output registers or large enough to encompass all of your controllers state RAM 10K 32K or 64K depending on the type of Quantum controllers you are using in your hot standby system The reference data of each type 0x 1x 3x and 4x is placed in the state RAM transfer area starting at the lowest reference number 000001 for coils 100001 for discrete inputs 300001 for register inputs and 400001 for register outputs It is accumulated contiguously up to the amount of each data type you specify The total number of each reference type in the state RAM transfer area must be a multiple of 16 For example if you indicate that the number of coils in the transfer area is 96 coils 000001 000096 will be transferred from the primary to the standby controller Any 0x references beyond 000096 used in state RAM will not be transferred The additional state RAM data to be sent over multiple scans can also be of any or all of the four reference data types and must also be specified in multiples of 16 The additional reference data region for each data type starts at the lowest available reference number For example if 2048 coils are transferred on every scan 000001 002048 and you schedule 1024 additional coils for transfer over multiple scans references 002049 003072 will be used for the additional transfer data 24 Theory of Operation 840 USE 106 00 The additional transfer is handled by specifying the number of scans over w
90. xfer state 6841 ASCII output xfer 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 state 6849 building 10 byte packet 684A building 12 byte packet 684B building 16 byte packet 684C illegal IO drop number 3 6729 984 interface bus ack stuck high 4 6616 coax cable initialization error Patterns 840 USE 106 00 840 USE 106 00 6617 coax cable dma xfer error 6619 coax cable dumped data error 681A coax cable DRQ line hung 681C coax cable DRQ hung 5 6503 RAM address test error 6 6402 RAM data test error 7 6300 PROM checksum error exec not loaded 6301 PROM checksum error 8 8001 kernel PROM checksum error 8002 flash prog erase error 8003 unexpected executive return Com Act Error Patterns 101 Index A address swapping Modbus Plus ports 56 Modbus ports 55 backplane configuration 5 models 6 board level errors 77 C cable diagrams 30 distances 28 types used in hot standby system 7 cable ports description 13 swapping Modbus addresses at switchover 55 swapping Modbus Plus addresses at switchover 56 view 13 CHS 110 Hot Standby module failure 78 79 function 4 18 hot swap 82 startup 66 view 9 CHS 210 Hot Standby kit components 14 CHS instruction advantages of using 41 fixed state RAM transfer area 45 location of no

Modicon Quantum CHS 110 Hot Standby System Planning and

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