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AL-2006 User's Guide

1. Figure 5 2 Insertion of the AL 2006 Brother into the AL 3632 Rack 961002915 Chapter 5 Installation 820200196 Figure 5 3 AL 2006 Brother Fastening Screws 5 4 Chapter 5 Installation Installation in the Mounting Panel General Precautions The AL 2006 Brother is considered part of the AL 2002 programmable controller since it is installed in the same rack The procedures and the necessary precautions for the correct installation of the controller in the mounting panel are described in the AL 2002 MSP User s Guide Redundancy Control Panel For systems with redundant CPUs a small control panel must be installed close to the CPUs in
2. operands Pos 8 Me Outputs Outputs Pos 23 n S M 5 operands z n Pos 7 n S Pos 25 n Ms M M Pos 9 n Ms 96291002 Figure 3 16 Equivalence of Areas of Input and Output Operands between the CPU and the Remote Stations The values declared in the tables of the remote stations processed by the F REMOT 069 module should be identical to the corresponding areas in the remote station configuration table on the CPU processed by the F 2006 019 module In figure 3 16 for example the contents of position 14 of the CPU TMXXX should be equal to position 6 of the remote station position 16 of TMXXX should be equal to position 8 of and so on Example of Operand Mapping CPU Remote Stations Suppose the example system has a single CPU not redundant and has 3 remote stations connected only using electrical connections not using optical media The CPU table is used by the F 2006 019 function to configure the remote stations The data rate is 1 Mbit s the CPU and the remote stations 3 35 Chapter 3 Operating Principles have the same sub network addresses 1 and the node addresses are 1 10 11 and 12 respectively as shown in figure 3 17 Tables 3 12 and 3 13 show the CPU and remote station configuration tables it Dedicated Remote I O Stations ALNET II Network AL 2000
3. Conventions The utilized symbols throughout this guide have the following meanings e This bullet indicates a list of items or topics SMALL CAPS indicate names of keys for example ENTER KEY1 KEY2 is used for keys to be pressed simultaneously For example the simultaneous typing of the CTRL and END keys 15 indicated as CTRL END KEY1 KEY2 is used for keys to be pressed sequentially For example a message Type ALT F10 means that the ALT key should be pressed and released and then the F10 key pressed and released LARGE CAPS indicate names of files and directories Italics indicate words and characters that are typed on the keyboard or seen on the screen For example if you are asked to type C UCP1 000 these characters should be typed exactly as they appear in the guide BOLD is used for names of commands or options or to emphasize important parts of the text Warning messages present the following formats and meanings XV Preface DANGER The DANGER label indicates that risk of life serious personal injury or substantial material damage will result if the necessary precautions are not taken CAUTION The CAUTION label indicates that risk of life serious personal injury or substantial material damage can result if the necessary precautions are not The ATTENTION label indicates that personal injury or minimal material damage can result if the necessary precautions are not taken Technical Support XVi
4. 0035 60027 60026 0036 1 22 80028 Table 3 11 Example of Image Area of Operands 5 a Remote Station e output operands this group of operands is used to transfer analog values or special output modules IHMs for example from the CPU station to the remote station The number of reserved operands is determined by the value in position 9 of the table of the remote station configuration while the first M output operand corresponds to the following operand after the last of the S operand image area The F REMOT 069 function does not use the value of these operands during its processing They must be used by special instructions or functions that access these output modules in the I O bus These operands can also be used to transfer any other values from the CPU to the remote stations For example if position 9 of the table has a value of 12 and the S operand image area occupied up to the M0036 operand the M0037 to 3 33 Chapter 3 Operating Principles 3 34 M0048 operands will be used to transfer CPU values to the remote station using the AL 2006 Brother processor The number of M operands allocated for the whole output area should not exceed 112 Area of the Input and Output Operands on the CPUs The AL 2006 Brother processor transfers the areas of input operands from the remote stations to the CPU and the areas of output operands from the CPU to the remote stations The CPU and r
5. 9 table Table 3 7 shows the values used in this example 0 0 Jo 2 _ 18 3 6 4 i co p U me hn or 21 2 1 12 1000 10 __ 1000 8 _ 1000 3 1 13 10 11 1200 9 1300 4 1100 4 220 12 130 74 AJOIN 000 configuration of remote station 1 Position Value 222 3 000 NO pq Table 3 7 Contents of the Configuration Table of the I O in an Example System CPU Operand Equivalence Remote Stations Based on the configuration values of the remote station the F REMOT 069 module copies the input and output operand values plus status indications to the two areas of M operands for communication with the AL 2006 Brother processor One area corresponds to the input operands which are read by the AL 2006 Brother The other area corresponds to the output operands which are written by the AL 2006 Brother Figure 3 15 shows the structure of these two areas 3 29 Chapter 3 Operating Principles AL 2006 Remote Station Input operands M0000 F Remot 069 T O Status PUDE Digital inputs M0004 F Remot 069 E000 i Mxxxx Exxx Instructions Numeric inputs Mxxxx Output operands Mxxxx F Remot 069 Sxxx Mxxxx SXXX Instructions Numeric outputs Figure 3 15 Communications Areas of the Remote I O Stations Area of the Input Operands in the Remote Stations The area of the input operands in the remote stations always begins with the M0000 operand
6. The E 001 module for CPU 2 should be identical to that for CPU1 with the single exception of a change of name of the module called in the logic 0 CHP instruction to 2006 2 If the control program contains instructions such as ECR or LTR which can t be skipped then these instructions should be transferred to logics before the call of module P 2006 1 000 or P 2006 2 000 Refer to the Customized Use section in this chapter for more details Such instructions should not be initiated when the CPU is not in active mode but if the CPU switches from active to standby or inactive then the instructions must be ended without skipping them Logic 000 Call af 2006 1 000 and skip if 4L 2006 not ready 000 Fo 0002 7 Customized use The P 2006_1 000 and P 2006_2 000 modules provided with the AL 2006 Brother product have the following characteristics e implementation in system architectures with redundant CPU 2 remote I O stations communication at 1 Mbaud with the redundant CPU and remote stations e remote station with 6 input octets 4 output octets 10 input M operands and 8 output M operands 4 41 Chapter 4 Programming e remote station 1 with 6 input octets 4 output octets 10 input M operands and 8 output M operands e 1000 M and 90 A operand redundancy e for use with application programs with 600 ms maximum cycle time e uses and 002 M0000 to M0033 2000 5008 and A000 to
7. normal or 1 failure Forced connection of the second optical connection 0 not forced 1 or 2 Forced status of connection 1 of the second optical connection Appendix A Quick Reference Guide 0 normal 1 failure ERES E MXXXX 14 Forced status of connection 2 of the second optical connection 0 normal or 1 failure MXXXX 15 Not used reserved MXXXX 16 Communications status with remote I O device 0 MXXXX 23 Communications status with remote device 7 Configuration of Remote Stations O d jTabletypeidentfier 1 O Table type identifier 4 1 000 500 Remote station data rate 250 125 64 5 0 to 9 999 First M operand of the area that receives sends remote station values on the local CPU 6 01064 Number of remote station E operands to be read 0 to 64 Number of remote station S operands to be written 8 010108 Number of remote station M operands to be read 0 to 112 Number of remote station M operands to be written Appendix A Quick Reference Guide The parameter values of the table used in F REMOT 069 remote program module should be identical to the table used in the F 2006 019 function of the CPU program module in the part referring to the associated remote station Glossary Appendix B Glossary This appendix presents a glossary of terms and abbreviations used in this guide Active CPU In a redundant system it is the CPU that controls
8. 40000 0 Customized Use The P 2006 000 module provided with the AL 2006 Brother product has the following characteristics e implementation in system architectures with a non redundant CPU and 2 remote I O stations 4 25 Chapter 4 Programming 4 26 e data rate at 1 Mbaud with the CPU and remote stations e remote station with 6 input octets 4 output octets 10 input M operands and 8 output M operands e remote station 1 with 6 input octets 4 output octets 10 input M operands and 8 output M operands e use of and 002 M0008 to M0032 A000 and A001 operands e AL 2006 Brother processor located at position on the I O module bus For use in applications with different characteristics this P module should be modified as specified below e If the control application program has already used any of the operands mentioned before a new set of unused operands of the same types should be allocated for programming the P 2006 000 module Two TM operands 21 M operands and two A operands are required None of the operands used by the P 2006 000 module can be used in any other application program module For example if the application program is already using operands M0008 through M0012 and has operands M0188 through M192 free M0188 replace M0008 M0189 can replace M0009 and so on e Declare the AL 2006 Brother at the bus position in which it will be used In the module declaration window the R addr
9. eere nne Customized use eneral Programming Central Processing vi Table of Contents Installation of Application Pro Installation of Application Prog Declaration of Redundant Operands Declaration of Remote Stations for the AL 2006 Brother Processor vii Table of Contents E lossar viii Figures Figures Tables Tables able 3 1 Time of Failure Detection and Change of State between CPUs able 3 2 Maximum Number of Operands Configurable for Redundancy able 3 3 Maximum Number of Operands Configurable for Redundancy able 3 4 Contents of the Definition Table for the Remote I O Stations in F 2006 019 able 3 5 Configuration Positions of the I O Remote Stations able 3 6 Contents of the Remote Station Configuration Table in F REMOT 069 able 3 7 Contents of the Configuration Table of the I O in an Example System able 3 8 Remote Station Status Operands able 3 9 Remote Station Status Operands able 3 10 Example of Image Area of Operands E in the Remote able 3 11 Example of Image Area of Operands 5 in a Remote Station able 3 12 Remote I O Station Configuration Table an Example System able 3 13 Remote Station Configuration Table in an Example System able 3 14 Transfer of Remote I O Station Values able 4 1 Contents of the Remote I O Definition Table in F 2006 019 able 4 2 I O Remote Station Configuration
10. 0000 0 2006 019 0000 3 0000 1 HoH d 00004 0008 0 A LILTETL 2 00000 instruction parameters 0000 0001 0002 0008 Se 0000 3 Sea 55 0000 1 0000 2 oe aO 3 0000 1 400000 40001 0 0000 2 Sea 1 oA OOO 1 po oA 0000 2 90001 2 n 4 33 Chapter 4 Programming Logic 005 Error Logs 0001 0001 2 AR ON 4 36MDD10 36M 3e MDD0 00000 2 MOD SZ AR ON 0024 Ses 3eMOOZ4 00000 4 34 Chapter 4 Programming Se wLILILTR 0 0001 6 e000 LI L 50009 D 0008 2 1 0008 3 0002 3 0002 9 50009 Sie 0009 1 20001 6 L 50008 2 4 35 Chapter 4 Programming 500089 0 LIIS 1 0002 2 0002 2 Sie ALILILIT L Sie wILILILTR 0 64 0001 6 TEE 64 0001 6 4 D 500089 0 00010 D Seca L Se cS LIE 2 D 4 36 Chapter 4 Programming Logic 011 Transition to inactive mode due to button or error wSD DD 2 500004 TEE 0002 1 WADD 500081 95 50008 0 D AR TEE 355 0008 1 SMO O Se MODE D 00100 20000 50008 0 SC 9550008 2 00008 L 950000 3 0002 0 002 0 50008 3 ee 3650008 0 s A0000 0 36ADDO2 7 4 37 Chapter 4 Programming Logic 013 Assign of ALNET addresses and Timming Control oS 0008 PL
11. 2400 5 Subnetwork 5 3 ALNET II gt Figure 3 13 Example of ALNET Communication with Redundant If CPU 1 is in active state it has a node address of 8 while CPU 2 in backup state has a node address of 7 If CPU 1 is in backup state it has a node address of 7 while CPU 2 in active state has a node address of 8 of the remote stations are configured with a sub network address of 5 Thus communications with the supervisory program are transmitted to address 9 which always corresponds to the active CPU which controls the process no matter if this CPU is physically 1 or 2 The F END2 082 function module changes the address of the CPU according to its state Normally successive addresses are used for CPUs of the same redundant controller using an even number address for the active CPU and an odd number address for the backup CPU The normal node address of the ALNET II network address1 to 31 can be used within the same sub network 3 23 Chapter 3 Operating Principles The active CPU swapping process either manually or by active CPU failure can cause some transient failures in the network operation with possible loss of some communication and some errors are shown in the ALNET II communication status window seen in the MasterTool or AL 3830 programmer The node address of the ALNET II network configured in the C modules of the two C
12. 7 Configuration start pulse 0001 0 AL 2006 configured 0001 1 Redundancy configuration error 0001 2 Remote I O configuration error 0001 6 Launch switch to standby mode Table 4 8 A Operands Used in the P 2006 000 Module 4 22 Chapter 4 Programming Contents of Module P 2006 000 The logics that make up the P 2006 000 module are shown below Logic 000 Initialization of Remote IX configuration tables 3640000 3 AB AB ee ADDOD 7 96400071 0 9 1 w T hOQDOZ Ei 36400071 1 Sok d Sok f D 00026 00016 oe ADD 2 D ee ADOD 7 0 50 9 000 18 004 6 000 755 04 4 000 8 000 17 08 1 0 0000 8 000 1 000 9 000 00000 13 00000 C1 4 23 Chapter 4 Programming HF 0000 0 Sie ADD 3 Sie ADD 1 00004 ok A nnn 2 00000 A00003 A00000 3600004 2 3c ADDOD 3 lt lt 400001 40000 0 3 0001 0 ______________ 3tADDOD 2 900001 ADOD 1 n 36A DDUD 2 40004 2 _ 4 24 Chapter 4 Programming 0000 0 001 Module Contents The first logic of the main module of the CPU E 001 application program containing the call to the P 2006 000 module is shown below The main process control program should be inserted into the following logics 001 Logic 000 Call af P 2006 000 and skip if S4L 2006 not ready HP 2006 5 01 000 000
13. ALTUS EXPRESS get information by calling 55 51 337 3633 INTERNET e website http www altus com br e e mail altus altus com br If the equipment is already installed it is advisable to have the following information available before contacting Technical Support equipment modules used and configuration of the system installed e CPU serial number equipment revision and operating system version shown on a fixed tag on the lateral part of the equipment e information on the CPU mode of operation obtained from the AL 3830 programmer or MasterTool e contents of program module obtained from the AL 3830 programmers or MasterTool e version of programmer used Preface Manual Revisions Reference code revision and date of the current user s guide are indicated on the cover A change in revision can mean alterations in the functional specification or user s guide improvements The following report lists the corresponding alterations to every revision of this guide Revision A Date 10 02 e Initial revision of the user s guide XVII Chapter 1 Introduction Introduction The AL 2006 Brother Processor The AL 2006 Brother module is used as a coprocessor in the AL 2002 MSP Multi Station Processors and AL 2003 programmable controllers to execute the following functions e remote input and output control of AL 2002 MSP AL 2003 programmable controller using the Remote I O Network which uses the same
14. Data rate of the AL 2006 250 125 64 5 Not used reserved TM declaration of remote stations F 2006 019 Optical channel definitions 1 to 31 Node address of the controller channel of the first optical connection EBEN 2 ead second optical connection p ew connection Appendix A Quick Reference Guide ee remote station values on the local CPU 1 0 64 Number of remote station E operands to be read 0 to 64 Number of remote station S operands to be written 16 ___ 010108 Number of remote station M operands to be read 17 0 to 112 Number of remote station M operands to be written 20 1 000 500 Hemote station data rate e aoaea ON i remote station values on the local CPU 22 0 to 64 Number of remote station S operands to be written to 108 Number of remote station M operands to be read 25 0 to 112 Number of remote station M operands to be written Appendix A Quick Reference Guide TM declaration of remote I O in F 2006 019 Definition positions of all the remotes Positions Contents 010 17 Definitions of remote station 0 8 to 25 Definitions of remote station 1 26 to 33 Definitions of remote station 2 34 to 41 Definitions of remote station 3 42 to 49 Definitions of remote station 4 50 to 57 Definitions of remote station 5 58 to 65 Definitions of remote station 6 66 to 73 Definitions of remote station 7 The number of possible M operands for all the input areas sho
15. E 23 MI 8015 165 MOIS S022 2 gt 25 Remote station 2 Pos 29 Pos 30 Pos 32 Pos 31 Pos 33 Figure 3 18 Equivalence of CPU Operands Remote Stations for the Example System Inputs er tet al telat M170 wooo MUAM E000 220 M050 2093 M221 mosi M244 M074 Outputs E M 245 M075 5094 M261 M091 S126 E 262 M092 M279 109 3 39 Chapter 3 Operating Principles 3 40 Declaration of Optical Connections In positions 6 to 9 in the declaration table of the remote I O stations of F 2006 019 up to two optical connections can be specified redundant or not for the remote I O station system The first optical connection is configured in positions 6 and 7 while the second one is configured in positions 8 and 9 as shown in table 3 14 TM declaration of remote stations in F 2006 019 Optical channel definitions 0 to 31 Node address of the controller channel of the first optical connection 0 to 63 Sub network address of the first optical connection 3 ad second optical connection Sub network address of the second optical connection Table 3 14 Transfer of Remote I O Station Values In a system with a redundant optical connection the bridge
16. F 2006 019 remote error output 0001 0 AL 2006 was configured successfully 0001 1 Redundancy configuration error 0001 2 Remote I O configuration error 0001 6 Switching to standby mode is occurring 0001 7 Operand Initialization complete A0002 0 Pulse redundant CPU re energize button 0002 1 Pulse switch to inactive mode button 0002 2 Pulse AL 2006 communications error 0000 3 AL 2006 must be configured when 0000 3 0 4 29 Chapter 4 Programming A0002 4 Pulse Configuration start A0003 0 A003 1 otandby mode 003 2 003 3 Redundant CPU de energized due to error 003 4 Redundancy communication channel error Table 4 10 5 and A Operands Used 2006 1 000 and P 2006_2 000 modules 4 30 Chapter 4 Programming Contents of the P 2006 1 000 Module The logics that make up the P 2006_1 000 module are shown below Logic 000 Initialization of Redundancy and Remote Ifo Config Tables 0 50 9 000 __ 18 004 6 000 755 04 4 000 __ 8 000 117 08 12 0 0000 8 000 1 000 9 090 6 000 4 000 4 31 Chapter 4 Programming 9i A DIDOT 7 0001 1 0001 7 L Se A Dnm 2 seMDDOS ON Sek 00001 Sie A Dno 0 Se MDODDS U ON Sek 50008 Donna 3S s 000S Logic O02 Initialization af 4L 2006 results of configuration 4 000013 0002 4 40001 0 E D 0001 D 0001 2 D 00024 4 32 Chapter 4 Programming HF
17. I O network Possible values are defined in chapter Maintenance section Procedures in Case of Failure MXXXX 3 MXXXX 4 First optical connection status of connection 1 0 normal or 1 failure MXXXX 5 First optical connection status of connection 2 0 normal or 1 failure 0 not forced 1 2 0 normal or 1 failure MXXXX 8 Forced status of connection 2 first optical connection 0 normal or 1 failure MXXXX 9 0 normal or 1 failure 0 normal 1 failure 0 not forced 1 2 0 normal or 1 failure 0 normal or 1 failure 4 10 Chapter 4 Programming 23 Communications status of remote I O 7 Table 4 4 Status Indicator Operands in F 2006 019 For more details refer to the Optical Link Status Indicators section in chapter 4 Programming Also refer to the Procedures in Case of Failure section in chapter 6 Maintenance for interpreting error codes in some status indicators Usability This function can be used on AL 2002 MSP CPUs from version 1 50 onwards It can also be used on any version of AL 2003 CPU F REMOT 069 Remote 1 0 Stations Processing Function enable success configure parameter configuration error enable no communication outputs Introduction The F REMOT 069 function is run on the remote I O stations and makes copies of the values and status of local S and E operands for areas of commun
18. MSP C Node 10 SR 1 AL 2000 MSP C Nodell SR 1 AL 2000 MSP C Node 12 SR 1 Figure 3 17 Example of a System with Remote I O Stations 003 Remote I O station configuration table on CPU F 2006 019 3 36 Chapter 3 Operating Principles Table 3 12 Remote I O Station Configuration Table in an Example System 000 Remote station 0 configuration table F REMOT 069 o 50 15 X Jt20 __ 16 20 3 37 Chapter 3 Operating Principles 000 Remote station 1 configuration table F REMOT 069 __ X 8 118 Table 3 13 Remote Station Configuration Table in an Example System Figure 3 18 shows the equivalence operands obtained between the CPU and remote stations 3 38 Remote station 0 Pos 13 Pos 14 Pos 16 Pos 15 17 Remote station 1 Chapter 3 Operating Principles Remote station 0 Inputs pon ee mooo IMDA Li i 000 M133 013 E019 Mi344 M139 MOI9 Outputs M140 M020 S020 M146 M026 s033 H gt _ 147 027 M148 M028 Inputs Remote station 21 Misol M000 153 M003 T O Status 22 154 004 M161 E014 Cc 2147 Outputs 3
19. Positions able 4 3 Redundancy Configuration Positions able 4 4 Status Indicator Operands in F 2006 019 able 4 5 Contents of the Remote I O Definition Table in F REMOT 069 able 4 6 Filtering Process Configuration Operands able 4 7 TM and M Operands Used in the P 2006 000 module able 4 8 A Operands Used in the P 2006 000 Module able 4 9 TM and M Operands Used in P 2006_1 000 and P 2006_2 000 modules able 4 10 S and A Operands Used in P 2006_1 000 and P 2006_2 000 modules able 4 11 Equivalence of Remote I O and CPU Configuration Tables able 4 12 General Status Indicator Operands in F 2006 019 able 4 13 Remote I O Status Indicator Operands in F 2006 019 able 4 14 Optical Link Status Indicators in F 2006 019 able 5 1 I O Addresses for Buttons and Lamps on Redundancy Control Panel able 6 1 Conditions for Change of Redundant CPU Status by the Operator xi Preface Preface User s Guide Description This user s guide describes the AL 2006 Brother Processor for Redundancy and remote I O Stations its installation programming and operation It consists of six chapters and two appendices Chapter 1 Introduction presents the main characteristics and advantages of using the AL 2006 Brother Processor Chapter 2 Technical Description presents detailed characteristics of the product and its operation limitations Chapter 3 System Principles describes the possible methods of use
20. The guidelines for error correction may be obtained according to its code in Procedures in Case of Failure in chapter 6 Maintenance If the CPU becomes active check the contents of the operands that indicate error If they have values different from zero the respective error must be corrected Refer to the Procedures in Case of Failure section in chapter 6 Maintenance With the CPU in active mode the TX and RX REMOT I O LEDs on the AL 2006 Brother front panel should be flashing quickly and continuously If they remain off the whole installation process must be reviewed according to the recommendations presented earlier in this chapter Connect the programming terminal to the ALNET I connector of the AL 2006 Brother processor and check the ALNET II communications status Refer to the ALNET Communications Status section in chapter 6 Maintenance Reset the error counters wait for five minutes and check the communications status again If errors have occurred they are due to a problem on the physical installation of the redundant I O network or to a de energized station Refer to the ALNET II User s Guide for correcting the problem If there are no error indications either in the P 2006 module operands or in the ALNET II communications status window check whether the contents of the input and output operands are being read and written correctly from to the respective operands in the remote stations Check whether the local I O
21. a new AL 2002 cycle can start immediately e The cycle time of the AL 2002 control program is shorter than the processing time of the AL 2006 Brother When the AL 2002 control program ends the AL 2006 Brother has not ended its tasks yet So the AL 2002 control program must wait until AL 2006 Brother ends its tasks The first case resembles a controller with local I O stations where the time spent to read local I O is irrelevant The second case typically occurs with small application programs and many redundant operands configured The execution of the program waits until the end of the AL 2006 Brother processing The instantaneous runtime indication varies between small and large values and the average time tends to be shorter than the maximum time In the two types of operation the process control is executed normally since the maximum cycle time is acceptable for the type of process controlled The instantaneous maximum average and minimum application program execution cycle times can be found using the MasterTool programmer ALNET Il Communication with Redundant Controller The redundant programmable controller which consists of an active CPU and backup CPU can be connected to an ALNET II network communicating with a supervisory program or with other programmable controllers S CAUTION The ALNET II network for communication with a redundant programmable controller connected to the AL 2002 CPUs is completely independent
22. a table memory TM operand programmed as the first parameter called by the module of the F REMOT 069 application program Table 3 6 shows the meaning of each position of this table 0 Table type identifier O ______ type identifier 1000 500 Remote station data rate ooe Stonda ra remote station values on the local CPU 7 010 64 Number of remote station S operands to be written to 108 Number of remote station M operands to be read 0 to 112 Number of remote station M operands to be written Table 3 6 Contents of the Remote Station Configuration Table in F REMOT 069 The parameter values of the table used in 069 remote application program should be identical to the table used in the 2006 019 function of the CPU application program in the part referring to the same remote station For example in a system with 3 remote stations the 009 for definition of the stations on the CPU has 34 positions remote station 1 is defined in positions 18 to 25 This table is processed by the F 2006 019 function module to the configuration of the AL 2006 Brother of the CPU Remote station 1 is configured by the with 10 positions processed by the F REMOT 069 function module called by the station The values of positions 2 to 9 of of remote station 1 should be identical to positions 3 28 Chapter 3 Operating Principles 18 to 25 in the CPU s
23. address where AL 2006 Brother module is housed e TMXXXX Table operand containing the configurations of the remote I Os being used Must have at least 10 positions in order for the function to be correctly executed The contents of each position in this table are defined in the section Remote I O Configuration below TMXXXX Operand table containing CPU redundancy configurations Should have at least 16 positions in order for redundancy to be configured In the event it has fewer than 16 positions redundancy will not be used The contents of each position in this table are defined in the section Redundancy Configuration below MXXXX Specifications of the operands that will receive status information on communications with the remote I O stations with the redundant CPU and on the optical channels if employed The status values are read from or written to the memory address declared and the subsequent 23 addresses These 24 operands should be declared in the C module of the application program The contents of each operand are defined in the Status Indicators section e OPERA Not used Inputs and Outputs Description of inputs enable when this input is energized the function is called and the parameters programmed in the CHF instruction are analyzed If these are incorrect the I O communications error and redundant CPU communications error outputs of the instruction are permanently energized and th
24. and is divided into three regions e Status of I O operands occupies the first four operands in the input area M0000 a M0003 contains the status of each of the 64 E and S operands of the remote station The status of each E or S octet 1s indicated using a bit corresponding to the M status operands where the value 0 means normal operating status of the octet and the value 1 means failure or hot swapping status Tables 3 8 and 3 9 show the bits of the M status operands corresponding to the E and S operands of the remote stations The S operands are represented in the tables as E operands because the first 5 address depends on the configuration used Operand Operand 0000 0 E0000 0001 0 0016 0000 1 0001 0001 1 20017 0000 2 E0002 0001 2 20018 0000 3 E0003 0001 3 0019 0000 4 0004 0001 4 E0020 3 30 Chapter 3 Operating Principles Table 3 8 Remote Station Status Operands Operand Operand Table 3 9 Remote Station Status Operands operand image a copy of the E operand values of the remote station 15 stored beginning from the M0004 operand The number of E operands copied is determined by the value of position 6 of the table of the remote station configuration used by the F REMOT 069 function Each operand receives the value from two E operands using the number of M operands sufficie
25. be in one of the three following states Chapter 3 Operating Principles 3 16 Active the CPU is controlling the process and sends the contents of the main program operands to the backup CPU on every execution cycle of its application program It also updates the remote I O station points if applicable Standby the CPU is not in control of the process but receives the operand values of the active CPU and supervises the active CPU state In case of failure of the active CPU it switches to active and takes control of the process de energizing the other CPU If there are remote I O station points in the system the backup CPU does not access them Inactive the CPU neither controls the process nor supervises the status of the active CPU As a result it will not take control of the process in case of active CPU failure This state is used for configuring the AL 2006 Brother processor and to make maintenance on the CPU The P 2006_ 1 000 and P 2006_2 000 modules determine the mode of the CPUs using two basic principles fundamental for implementing hot standby redundant systems A single CPU is always active controlling the system The other one can be used as backup or be inactive during maintenance The time a CPU remains inactive in programming mode or de energized should be as short as possible because the system could have no control if a failure in the active CPU occurs while the other CPU is in these states Change
26. be the same as the corresponding positions in the remote configuration TM table for the CPU i e the following positions should contain the same values Remote I O Configuration TM TMOOO positions for remote stations positions at CPU F 2006 019 which should contain identical values Positions 10 to 17 of the CPU TM Positions 2 to 9 in of remote 0 Positions 18 to 25 of the CPU TM Positions 2 to 9 in TMOOO of remote 1 Positions 26 to 33 of the CPU TM Positions 2 to 9 in TMOOO of remote 2 Table 4 11 Equivalence of Remote I O and CPU Configuration Tables 4 46 Chapter 4 Programming Remote 1 0 Stations Programming precautions e The module F REMOT 069 should be present the remote station e The remote I O stations should preferably be configured with hot swap enabled for the I O modules This avoids the need to de energize the entire remote station if there is an error in one of the I O modules e The application program cycle time should be as short as possible preferably less than 15 ms in order to avoid increasing the cycle time of the main CPU application program An excessive increase in the cycle time of the main CPU application program can cause problems for the control system or even prevent its operation Specification of Redundant Operands In redundant systems the active CPU transfers the values of the operands defined in the redundancy configuration table to the backup CPU at every scan c
27. call respectively the modules P 2006_ 1 000 and P 2006_2 000 and each one of these two modules calls the F 2006 019 and F END2 082 functions and the P TEMPO 032 procedure e The remote station CPU application programs must call the module F REMOT 069 Chapter 4 Programming F 2006 019 Communication with AL 2006 Brother function enable success configure I O communication error standby 0 redundant CPU active 1 communication error Introduction The 2006 019 function is executed on the AL 2002 MSP CPU enabling it to communicate with the AL 2006 Brother processor and performing the information exchange necessary for its configuration and operation Programming Operands The CHF instruction cells used to call the function are programmed in the following manner e OPERI Specifies the number of parameters to be passed to the function in OPER3 This operand must be a memory constant with value 4 00004 e OPER2 Must be memory constant operand with value 0 00000 Specifies the number of parameters allowed to be programmed in the edit window of OPER4 As this function requires no parameters in OPER4 the value of OPER2 is 0 e OPER3 Contains the parameters that are passed to the function They are declared in an edit window when the CHF instruction 15 edited The number of editable parameters is specified OPERI being fixed at 4 for this module Chapter 4 Programming e RXXXX Bus
28. configuration should be correct in accordance with the specifications found in chapter 3 Operating Principles and chapter 4 Programming Redundancy configuration should follow the recommendations contained in the Specification of Redundant Operands section to follow in this chapter The F 2006 019 module should be included in the programmable controller Use program modules P 2006_1 000 and P 2006_2 000 for redundancy control Before operating in either active or standby mode the AL 2006 Brother processor should be configured at least once after the PC has been powered up The AL 2006 Brother does not lose its configuration on switching the AL 2002 CPU to programming mode However it is advisable to reconfigure the AL 2006 Brother at every time the AL 2002 CPU application program begins power on or switching to execution mode The redundancy control modules P 2006_1 000 and P 2006_2 000 are prepared to configure the AL 2006 Brother processor The application programs and the C configuration modules for the two redundant CPUs should be exactly identical with the exception of the redundancy control modules P 2006_1 000 and P 2006_2 000 It is suggested that the operands the application program are separated into 4 distinct areas operands used by the modules P 2006_1 000 and P 2006_2 000 e operands with remote I O values e redundant operands for processing the program non redundant operands for processing the prog
29. controlled by the AL 2006 Brother and the execution of ECR or LTR instructions in I O remote processors is not allowed It is also not allowed to connect gateways or CPUs that have such instructions to the network Related Equipment and Documents AL 2300 Branch cable Cable used to connect the CPU to the AL 2600 branch AL 2301 EIA 485 Cable Physical medium used for ALNET network AL 2600 Branch and termination Module for connection of ALNET II physical medium with AL 2300 branch cables AL 3830 Programming Software of PC series 2000 3000 and 600 MT4000 MasterTool Programming Programmer of PC series 2000 3000 and 600 in Windows MT4100 Software environment MT4000 was designed for WINDOWS 3 1X WINDOWS 95 98 and MT4100 was designed for WINDOWS NT and 2000 AL 1342 Cable for connection of Used to interconnect the AL 2006 with a serial interface of a AL 2006 to programmer microcomputer that runs AL 3830 or MT4000 MT4100 AL 1343 Cable connection Used to interconnect the AL 2006 with a DB25 serial interface AL 2006 to programmer microcomputer AL 1366 Cable connection Used to interconnect the AL 2006 processors of redundant CPUs between two AL 2006 through the REDUND connector MAN AL User Manual AL 2006 Manual with instructions for the operation of the AL 2006 2006 UT 2 7 Chapter 3 Operating Principles Operating Principles The first three sections of this chapter present t
30. correct these errors is described in the section Procedures in Case of Failure in chapter 6 Maintenance Error diagnostics and correction procedures relating to the basic functions of the CPUs the I O stations and the power sources can be found in the AL 2002 MSP User s Guide the AL 2000 MSP C User s Guide the QK800 QK801 and QK2000 MSP User s Guides and in the Technical Specifications documentation of the respective I O modules Chapter 4 Programming AL 2002 CPU General Status Indicators In the redundancy control modules P 2006_1 000 and P 2006_2 000 the operand 003 stores the current status of the CPU at its bits as described immediately below e A003 0 active e A003 1 standby e A003 2 inactive These points should be monitored at both CPUs by the supervisory program in order to display their current status to the operator Point A0003 2 should cause an alarm because indicates that this CPU 15 not able to assume as active in case of a failure in the active CPU De energization of the Redundant CPU In redundant systems if the active CPU fails then it is de energized by the backup CPU which takes over control of the process and switches to active The occurrence of this failure is signaled by the activation of the point A003 3 in the redundancy control module of the CPU which has become active either P 2006 1 000 or P 2006 2 000 The activation of point A003 3 in either CPU 1 or CPU 2 should
31. in the active CPU when its scan cycle is faster than the cycle needed to communicate with remote I O processors and redundant CPU Programming Inputs and Outputs Description of inputs e enable when this input is energized the function is processed e skip this input is activated by the application program skip condition When the application program is skipped it must be energized and when the program is being executed this input must be de energized The application program is skipped in the backup CPU Description of outputs e success indicates the successful execution of the procedure 4 19 Chapter 4 Programming Usability This function can be used on AL 2000 MSP CPU from version 1 42 onwards and AL 2003 CPU This function should be employed in the same manner as programmed in the P 2006_1 000 and P 2006_2 000 modules Improper use of this function can cause malfunction in application program timing instructions P 2006 000 Communication with Remote I Os The P 2006 000 procedure module is a routine written in relay diagram language which is provided with the AL 2006 Brother product for use in systems with Remote I Os and a single CPU without redundancy This module performs the following functions e configures the AL 2006 Brother processor e exchanges I O operand values with the AL 2006 Brother processor This P module should be called at every scan cycle of the CPU application program
32. mode or when a failure occurs For example if CPU 2 is required to switch to active mode it is simply necessary to switch CPU 1 to standby mode or else failure may occur CPUI 6 2 Chapter 6 Maintenance De energization of the active CPU causes the backup CPU to switch to active mode However it is not advisable to de energize the active CPU directly To de energize a CPU the procedures contained in De energizing or Switching CPUs to Programming Mode in this chapter should be followed De energizing or Switching CPUs to Programming Mode If it is necessary to de energize one of the CPUs the following steps should be followed in this order e if the CPU is in active mode switch it to standby and then to inactive mode e if the CPU is in standby mode switch it to inactive mode e de energize the CPU or switch it to programming mode In non redundant systems using only one CPU this can be de energized or switched to programming mode from the active mode Modifications to the Application Program Minor alterations to the application program involving only one of its modules can be carried out by loading the modified module while the CPU remains in execution mode online module loading Details of this procedure can be found in the MasterTool User s Guide or in the AL 3830 User s Guide Certain types of modification to the application program however need the program modules to be loaded with the CPU
33. network node address configuration error Procedure locate the remote I O or redundant CPU indicated by the error depending on the address of the operand where the error code 15 stored Check that the correct node address value is programmed into the Chapter 6 Maintenance correct position of the table used in the F 2006 019 module configuration Check that all node address configurations within this table are correct e Error error code 103 in one of the memory addresses programmed for F 2006 status indication Description remote I O or redundancy network sub net address configuration error Procedure locate the remote I O or redundant CPU indicated by the error depending on the address of the M operand where the error code 1s stored Check that the correct sub net address value is programmed into the correct position of the table used in the F 2006 019 module configuration Check that all sub net address configurations within this table are correct e Error error code 104 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description S operand address redundancy configuration error Procedure check the value that has been programmed for the first redundant S operand in the redundancy configuration table used in the F 2006 019 module An existing address should be used Refer to the output module declarations at the programmable controller bus e Error error code 105 in one of t
34. of change of status the button should be pressed for at least 0 5 seconds Only one button should be pressed at a time CPU No action will be performed if more than one button is pressed at the same time Possible changes of CPU status are shown in figure 6 1 Chapter 6 Maintenance ACTIVE a a redundant CPU 1s not active due to failure or manual switch to standby mode b Activation of the standby button STANDBY Activation of the standby button or d CPU was re energized INACTIVE d Activation of the inactive button Figure 6 1 Change of Status of Redundant CPUs It is not always possible to perform a change of status that has been requested by the activation of a button since certain changes depend upon specific conditions Table 6 1 shows possible changes made with the buttons and the conditions upon which they will be performed Current Status Button activated Conditions for change of current new status status to new status active standby The redundant CPU is in the standby mode able to assume control of the process active inactive The change cannot be made directly the CPU should first be switched to standby and then to inactive mode been configured correctly Table 6 1 Conditions for Change of Redundant CPU Status by the Operator There is no button to request the switch to active mode A CPU switches to active mode when the redundant CPU is changed to standby
35. of remote I O stations and redundancy with specific details of each Chapter 4 Programming refers to the method of configuring the AL 2006 Brother and remote stations in the program modules of the programmable controller Chapter 5 Installation contains the necessary procedures for the correct installation and connection of the AL 2006 Brother with the other components of the control system Chapter 6 Maintenance presents the correct method of use and error diagnostics of the control system with redundancy or remote I O stations Appendix A Quick Reference Guide contains abridged information related to the programming and configuration of the systems Appendix B Error Messages supplies a list of error messages used in the AL 2006 Brother Appendix C Glossary presents a glossary of terms including words and expressions that may be unknown or that have a specific meaning in this guide This user s manual was created assuming the reader 15 familiar with the programming and operation of the Altus Programmable Controllers as well as xiii Preface the ALNET II communications network In case of doubts over specific details related to these topics the guides cited in the following section can be consulted Related Guides For more information on the use of the AL 2006 Brother processor the following guides can be consulted e AL 3830 User s Guide e MasterTool User s Guide AL 2000 MSP C User s Guide e AL 2
36. of the operand where the error code 15 stored Perform the procedures in Basic Tests in the Event of Errors earlier in this section If the system has more than one sub net or optical fibers perform the basic tests for the bridges and check that optical fibers and the fiber optic modems are in good repair e Error error code 121 in one of the memory addresses programmed for F 2006 status indication Description attempt to use the AL 2006 Brother without configuring it Procedure perform the AL 2006 Brother configuration procedure making sure that it is completed without errors e Error error code 122 in one of the memory addresses programmed for F 2006 status indication Description multiple reception of redundancy operands Procedure check the configuration of the two CPUs reconfigure both CPUs making sure that configuration is completed without errors e Error error code 123 in one of the memory addresses programmed for F 2006 status indication Description reception of redundancy communication in active mode Procedure check the application programs and the configuration parameters of the two CPUs making sure that configuration is completed without errors Check the connections and proper operation of the redundancy data exchange channel connections e Error the diagnostic operand for communication of status between CPUs A0003 4 has value 1 Description this CPU 15 not receiving redundancy status communi
37. of the redundant CPUs after the necessary modifications are made as explained in the Customized Use section in chapter 4 Programming The P 2006_1 000 or P 2006_2 000 module should be the first procedure called in the E 001 cyclic execution module It can enable or disable the execution of the main control program using a skip instruction present in the E 001 module according to the result of AL 2006 Brother module processing The entire main control program should remain under the command of the skip coil operated by the P 2006_1 000 or P 2006_2 000 module except the instructions that cannot be skipped such as ECR and LTR Figure 3 7 shows the structure of the application program of one of the AL 2002 MSP redundant CPUs for use with the AL 2006 Brother processor P 2006_ 1 000 F 2006 019 1 001 Dan 2006 1000 Figure 3 7 Structure of the AL 2002 MSP Application program 3 9 Chapter 3 Operating Principles DANGER The P 2006_1 000 and P 2006_2 000 modules supplied with the AL 2006 Brother were created and tested for correct hot standby redundancy control of the CPUs The use of other control procedures or even the improper modification of these modules can cause the poor operation of the system and consequent implications For more details on P control modules for remote I O stations and redundancy refer to chapter 4 Programming AL 2006 Brother Processing O
38. on the CPUs The loading procedure must be carried out separately for each CPU in redundant systems keeping the other redundant CPU de energized After both redundant CPUS have been loaded and tested they can be simultaneously energized and operated together The remote stations must be energized and connected to the remote I O network so that the installation of the application programs on the CPUs may be carried out The programs of remote I O station must have been previously installed and debugged and must be running Connect the programming terminal to the ALNET I connector on the CPU Power up the CPU Switch the CPU to programming mode Delete any previous version of the program from RAM and erase the FLASH EPROM Send the application program to the CPU Switch the CPU to execution mode Check the CPU status with the programmer If an error is detected check the cause correct it and restart the loading procedure 5 13 Chapter 5 Installation 5 14 If the CPU is in execution mode wait for five seconds and check whether it is active or not monitoring the output operands that define the status in the 2006 module on the CPU P 2006_1 000 or 2006 2000 If the CPU remains inactive a configuration error has occurred in the AL 2006 Brother processor Check the error output indicated logic 004 and the error code indicated logic 005 operands M0032 and M0033 correct the error and restart the loading procedure
39. parameters programmed in the CHF instruction are analyzed If these are incorrect the parameter configuration error output is permanently energized and the success output is de energized If they are correct the function is processed 4 15 Chapter 4 Programming 4 16 configure when energized the values programmed in the CHF instruction are analyzed If these are incorrect the parameter configuration error output is energized and the success output is de energized If they are correct the success output is energized When the configure input is de energized the module executes the remote station functions The remote I O station is configured by calling the FFREMOT 069 module with the configure input activated until the success output or the error output returns energized After that the configure input should be deactivated so that the module can execute the remote station functions If the parameter configuration error output is energized the CHF instruction parameters and the configuration values should be verified The remote station configuration procedure should be carried out every time the CPU application program starts power on or mode changing to execution or after each change on the values of the configuration table e enable outputs when energized it deactivates outputs if the remote station does not receive communication from the AL 2006 Brother processor for 3 seconds If this input is de energized the
40. points on the CPU buttons and indicators of status on the redundancy control panel are operating correctly De energize the CPU and carry out the previous procedures for the redundant CPU if they have not been executed yet After the programs have been loaded on both CPUs de energize and re energize them simultaneously One of the CPUs must assume as active while the other must assume as standby If the CPUs keep changing status constantly check the contents of the tables the initialization parameters of the AL 2006 Brother processors the differences between the P 2006 1 000 and P 2006 2 000 modules of both CPUs and the logics of status control of the CPUs in these modules logics 7 8 9 and 10 Chapter 5 Installation Check whether the status of one CPU is being transmitted to the other one monitoring the M0008 and M0009 operands of each CPU These operands must be different from zero If they are not different from zero check the AL 1366 cable that connects AL 2006 Brother on both CPUs Test the change of status of the CPUs by activating the standby and inactive buttons on the redundancy control panel When a CPU 15 switched to the standby mode by pressing the button the other CPU must automatically become active A CPU can only assume as inactive if it is in the standby mode If this does not work fine check the correct reading of the buttons of the panel monitoring their inputs and check the logics from 7 to 10 of th
41. protocol as the proprietary ALNET network e implementation of programmable controller architectures with hot standby CPU redundancy Throughout the text of this guide there are various references to the AL 2002 MSP programmable controller All of these references are also valid for the AL 2003 programmable controller except when the contrary is explicitly emphasized The AL 2006 coprocessor and the I O remote stations can be connected using a standard EIA 485 cable a simple fiber optic cable or redundant fiber optic cable The remote I O stations can be made up of AL 2000 MSP C QK2000 MSP PCs or even other AL 2002 MSP or AL 2003 PCs running a special control program AL 2006 control is done using software through the F 2006 019 function inserted into a program module of the AL 2002 MSP CPU through the MasterTool or AL 3830 programming software Figure 1 1 shows a typical redundant system application with remote input and output using an AL 2006 Brother processor Chapter 1 Introduction 1 2 Redundant Central Processing 5 Remote I O Network AL 2000MSP C Remote I O Devices Figure 1 1 Example of a Redundant System with Remote I O Stations Hot Standby Redundancy With the use of an AL 2006 module systems with CPU hot standby redundancy can be implemented This configuration is built using two CPUS with identical controllers both with the same program module However only
42. the status of ALNET communications verify the node addresses sub net and data rate Check whether communication 15 being processed and whether the receive and transmit counters are continually incrementing Observe any communication errors Check the network installation the condition of cables connectors and ground connections Check whether cable connections connections between system components fastening screws supply voltage and ground cables are all in good conditions If an error is detected attempt to solve it according to the instructions found in the User s Guide or Technical Specifications of the system component on which a problem has been found Configuration Errors The errors described next are reported during the AL 2006 Brother configuration process Error error code 101 in one of the memory addresses programmed for F 2006 status indication Description remote I O or redundancy network data rate configuration error Procedure locate the remote I O or redundant CPU indicated by the error depending on the address of the operand where the error code 15 stored Check that the correct data rate value is programmed into the correct position of the table used in the F 2006 019 module configuration Check that all data rate configurations within this table are correct Error error code 102 one of the memory addresses programmed for 2006 status indication Description remote I O or redundancy
43. the system by reading the values of the input points executing the application program and updating the output points Backup CPU In a redundant system it is the CPU that supervises the active CPU It is not controlling the system but is ready to take control of the system in case of active CPU failure Bit Basic unit of information can be either 0 or 1 Bridge Equipment that connects two communications networks with similar protocols The AL 2401 or QK2401 bridges connect two ALNET II sub networks Bus A collection of logically grouped electrical signals that transfer information and controls between different elements in a subsystem Byte Unit of information composed of eight bits CPU Central processing unit Element that controls the flow of information interprets and executes instructions of a program module EPROM Nonvolatile memory erasable by ultraviolet rays Executive software It controls the basic functions of the programmable controller and the execution of program modules in a PC Flash EPROM Electronically erasable nonvolatile memory B 1 Appendix Glossary B 2 Gateway Equipment that connects two communication networks with different protocols The AL 2400 S C or QK2400 gateways allow the connection of the ALNET I network with the ALNET II network Hardware Pieces of equipment used in data processing where programs software are normally executed Hot swap Procedure of module repla
44. 002 MSP User s Guide e 2003 User s Guide e QK800 QK801 QK2000 MSP User s Guide e ALNET II User s Guide FOCOS User s Guide e AL 2401 User s Guide e QK2401 User s Guide e AL 1000 AL 2000 Technical Specifications Guide Terminology The following expressions are frequently used in the text of this guide Because of this they need to be recognized and understood PC Programmable Controller equipment made up of one CPU input and output modules and power source e CPU Central Processing Unit the main module of the PC which executes data processing e AL 3830 ALTUS program for a standard microcomputer or compatible which allows the development of program modules for the AL 2000 MSP C and AL 2002 MSP PCs among others Throughout the xiv J Preface guide this program will be referred to by its acronym or as AL 3830 programmer e MasterTool ALTUS program for a standard IBM PC microcomputer or compatible used ina WINDOWS environment which allows the development of program modules for the AL 2000 MSP C AL 2002 MSP and AL 2003 PCs among others Throughout the guide this program will be referred to by its acronym or as MasterTool programmer e The word module when referring to hardware describes components of equipment e The word module when referring to software describes components of an application program Other expressions can be found in appendix B Glossary
45. 003 operands e AL 2006 Brother processor located at position on the I O module bus e ALNET II network node address with value 2 for the active CPU and value 1 for the CPU in standby or inactive modes or undergoing configuration To enable their use in a range of applications with different characteristics these P modules should be modified as specified below If the control application program is already using any of the operands used in programming the 2006 1 000 and 2006 2 000 modules a new set of unused operands of the same types should be allocated and the P modules modified to use the new operands Two TM operands 34 M operands 1 E operand 1 S operand and 4 A operands are required For example if the application program 15 already using operands 0000 through M0010 and has operands M0180 through M213 free M0000 can be replaced with M0180 0011 by MOISI and so on e Declare the AL 2006 Brother at the bus position in which it will be utilized In the module declaration window the R address used to access this position is displayed in the corresponding position Modify the logic 3 CHF instruction to use this address e Within logic 0 CAB instruction modify the values loaded into tables 1 and 002 to the I O and redundancy configurations desired The meaning of each table position is described in F 2006 019 Communication with AL 2006 Brother function earlier in this chapter e The maximum c
46. 006_ 1 000 and P 2006_2 000 modules provided with the AL 2006 Brotherproduct These addresses may be modified according to the configuration of the I O modules used in the system Refer to Customized Use section in chapter 4 Programming The operation of the redundancy control buttons is described in the Change of Redundant CPU Status by Operator in chapter 6 Maintenance Redundant CPU Control Relays In redundant systems each CPU should have control over the other CPU s power supply de energizing it in case of failure This control 15 accomplished through a normally closed relay contact which controls the supply of energy to the other CPU as shown in figure 5 5 Chapter 5 Installation 24V m m 27 27 2 Q Un Un 24 c m c F2 Vac Figure 5 5 Redundant CPU Control Relay Connections The output point that activates the contact of each CPU uses address S0008 3 in the 2006 1 000 and P 2006 2 000 modules provided with the AL 2006 Brother product This address may be modified according to the configuration of the I O modules used in the system Refer to Customized Use section in chapter 4 Programming Only relays or contacts which have a control current capacity that is sufficient to control the power supply used for the CPUs should be employed The use of adequate noise suppressors on the relay or contacts in accordance with the recommendations in the AL 2002 Use
47. 1 05 The P 2006_1 000 and P 2006_2 000 procedure modules are routines written relay diagram language provided with the AL 2006 Brother product for use in systems with Remote I Os and CPU redundancy These modules perform the following functions e configure the AL 2006 Brother processor e exchange I O and redundancy operand values with the AL 2006 Brother processor e determine the CPU operating status with relation to redundancy active standby inactive e enable execution of the main control program depending on momentary conditions e change the addresses of the CPUs on the ALNET II network to maintain the same communications address for the active and backup CPUs thus allowing easier communication with supervisory programs and other CPUs Each P module is used in one of the two redundant CPUs defined as CPU 1 and CPU 2 respectively These P modules should be called at the beginning of every scan cycle of the application program in on each CPU see the Application Program section in chapter 3 Operating Principles Before being implemented within the CPU application programs these modules should be modified in accordance with the recommendations contained in the Customized Use section in this chapter Either the 2006 1 000 or the P 2006 2 000 module should be the first procedure to be called in the cyclical execution module E 001 It can then enable or not execution of the main control program using a ski
48. 2 082 032 2006 000 P 2006 1 000 2006 2 000 F REMOT 069 e AL 2000 subdirectory F REMOT 069 QK2000 subdirectory F REMOT 069 Remote I O Networks The AL 2006 Brother processor has a high speed network interface dedicated to the communication with remote I O processors and with the redundant CPU based ALNET II protocol It features determinism high performance easy installation of ALNET II network with quick processing of commands dedicated to the remote I O by the AL 2006 Brother processor It is possible to connect up to 8 I O remote processors in addition to a redundant CPU in the same sub network or in different sub networks The fundamental features of the remote I O network are bus topology e connection of up to 2 redundant CPUs plus 8 I O remote stations distributed in up to 3 sub networks e maximum range with no repeater 2 km with RS 485 3 km with optical fiber e programmable baud rate from 64 kbit s to 1 Mbit s e access method deterministic multimaster e physical standard EIA 485 with galvanic insulation Chapter 2 Technical Description e automatic retransmission control and error check e capacity to be used over optical fiber through fiber optic modem with greater rate and range Although the communications network with remote I O and redundant CPU uses the same format as that of ALNET II network it is exclusive for this purpose On this network communication is
49. AL 2006 User s Guide Ref 6210 004 1 Rev A 01 03 5 No part of this document be copied or reproduced in any way without the previous written consent of ALTUS S A which reserves the right to change this manual without prior notice In compliance with the Brazilian Consumer Protection Code please be aware of the following issues related to personal security as well as installation in customer s premises The industrial automation equipment manufactured by ALTUS is robust and reliable due to a rigid quality control program However electronic equipment for industrial control programmable controllers numeric controls etc can cause damage to machinery or processes controlled by them in the case of a part defect and programming or installation errors and may even cause death The user should analyze the possible consequences of these defects and add security safeguards to protect system security mainly in cases of initial installation and tests when problems are more likely to happen The user should thoroughly read the user s guides and or Technical Features before installation and use ALTUS guarantees its equipment from manufacturer defects for twelve months from the date of invoice ALTUS provides this guarantee from its manufacturing facility S o Leopoldo RS Brazil The client is fully responsible for all the expenses and risks incurred on shipping products to and from that facility This
50. AL 2006 Brother of the redundant CPU Communications Network with Remote Stations 3 14 Exchange of information between redundant CPUs and remote I O stations is carried out by the remote I O network This network uses the same physical media the same connection method and configuration as the ALNET II network In addition the optical media for the connection of one or more remote stations can be used Even though a communications network with remote stations has all the potential of the ALNET II network the number of possible sub networks is limited to 3 maximum of 2 bridge processors In the communications network with remote stations only the AL 2006 Brother processors of the same redundant PC the respective remote I O stations and at most 2 bridge processors can be connected Gateway processors or ALNET II channels of any other elements cannot be connected Furthermore the application programs of the remote stations cannot contain ECR or LTR instructions Each element connected to this network has node and sub network addresses the AL 2006 Brother processors the remote stations and any bridges The AL 2006 Brother addresses and data rate are defined using the F 2006 019 application program In remote stations these parameters are defined by the Chapter 3 Operating Principles F REMOT 069 module More information can be found in chapter 4 Programming The bridge processors are configured using R modules This configu
51. ALNET II channels of any other elements cannot be connected The program modules of the remote stations cannot contain ECR or LTR communications instructions Declaration of Redundant Operands for the AL 2006 Brother Processor Operand Type Maximum number of configurable redundant operands 008 positions 504 positions The configuration of the redundancy of numeric operands M D TM and TD as a whole may not exceed the maximum number of 2 016 bytes The number of operands represented in the previous table refers to the maximum value possible that can be configured for a determined type when no other type has been declared Appendix A Quick Reference Guide Number of bytes 2 bytes per operand D 4 bytes per operand 2 bytes per position 4 bytes per position TM of redundancy declaration in F 2006 019 Position Values Contents Table type identifier Table type identifier Node address of the other AL 2006 on the redundant CPU Sub network address of the other AL 2006 on the redundant 1 to 31 1 to 63 0 to 63 0 to 64 0 to 95 0 to 96 0 to 9 999 0 to 1 008 0 to 9 999 0 to 504 0 to 255 0 to 1 008 0 to 255 0 to 504 First redundant S operand Number of redundant S operands First redundant A operand Number of redundant A operands First redundant M operand Number of redundant M operands First redundant D operand Number of redundant D operands First redundant TM operand Number of redundant posi
52. Before being used within the CPU application program this module should be modified in accordance with the recommendations contained in the Customized Use section in this chapter The P 2006 000 should be the first procedure to be called in the cyclical execution module E 001 It updates the I O operands of the CPU with the remote station values Operands Used The tables 4 7 and 4 8 show the operands used in the P 2006 000 module which is provided with the AL 2006 Brother Processor Operands used in the P 2006 000 module Operand Contents 4 20 Chapter 4 Programming Transmission of redundancy status to other CPU Even though redundancy is not used this operand is passed to F 2006 019 function called inside P 2006 000 module 0009 Reception of redundancy state from other CPU Even udi though redundancy is not used this operand is passed to F 2006 019 function called inside P 2006 000 module 0010 Status of communication with redundant CPU via remote I O network Even though redundancy is not used this operand is passed to F 2006 019 function called inside P 2006 000 module status for all remote stations Table 4 7 TM and M Operands Used in the P 2006 000 module Operands used in the P 2006 000 module 0000 0 F 2006 success output 0000 1 F 2006 redundancy output error 0000 2 F 2006 remote output error 4 21 Chapter 4 Programming 0000 3 AL 2006 in active standby mode 0000
53. DC 5 5 Vbb 10 battery voltage Consumption 300 mA Q 5 VDC 250 mA 15 VDC 30 mA 15 VDC 70 mA 5 Vbb 30 uA battery when the system is not powered Note the battery is located in the power source Its lifetime depends on the total consumption of all modules connected to the bus that can retain memory Module dissipation 11 W Severity level of electrostatic discharge ESD according to IEC 1131 standard level 3 Immunity to radiated electromagnetic field 10V m 140 MHz according to IEC 1131 standard Protection against electric shock according to IEC 536 standard 1976 class I Software Features Configuration and communication with remote I O and redundant backup CPU through the F 2006 019 module called by the AL 2002 MSP CPU application program Chapter 2 Technical Description 2006 019 runtime ranging from 2 to 25 ms depending on the amount of data to be transferred between redundant CPUs and remote I O processors e Hot standby redundancy algorithm implemented in a relay diagram e Programmers MasterTool version 1 20 or higher AL 3830 version 3 50 or higher Software Components A floppy disk containing the following software modules necessary for the operation of the AL 2006 Brother is provided with the product e AL 2002 subdirectory F 2006 019 F END2 082 032 P 2006 000 2006 1 000 2006 2 000 F REMOT 069 e AL 2003 subdirectory F 2006 019 F END
54. ER2 OPER2 Should be a memory constant operand with value 0 00000 Specifies the number of parameters allowed to be programmed in the edit window of OPER4 As this function requires no parameters in OPERA the value of OPER2 is 0 e OPER3 Contains the parameters that are passed to the function They are declared in an edit window when the CHF instruction is edited The number of editable parameters is specified in being fixed at 3 for this module e 000 Operand table containing the configuration of the remote I O Should have at least 10 positions in order for the function to be correctly executed The contents of each position are defined in table 4 5 Chapter 4 Programming The values for positions 2 to 9 in this table should be identical to those declared in the remote I O configuration table of F 2006 019 function for the same remote I O station 4 13 Chapter 4 Programming O Table type identifier 500 Remote station TEE rate 250 125 64 0 to 9999 First M operand of the area that sends receives remote station values on the local CPU 0 to 64 Number of remote station E operands to be read 0 to 64 Number of remote station S operands to be written 0 to 108 Number of remote station M operands to be read 0 to 112 Number of remote station M operands to be written Table 4 5 Contents of the Remote I O Definition Table in F REMOT 069 Con
55. HF instruction an area of M operands is defined These operands receive a number Chapter 4 Programming of status indicators see item F 2006 019 Communication with AL 2006 Brother function in this chapter Up to two optical links can be used for communication with the remote stations each of which can be either simple only 1 connection or redundant 2 alternative connections If redundant optical links are being employed the status of these links are stored in the operands shown in table 4 15 These values are read and written by the bridge processors QK2401 which control the optical links Status indicator operands in F 2006 019 Operands Primary optical link selected 1 or 2 MXXXX 4 Status of primary optical link connection 1 0 normal 1 fail MXXXX 5 Status of primary optical link connection 2 0 normal 1 fail 0 not forced 1 or 2 0 normal 1 fail MXXXX 8 Forced status of primary optical link connection 2 0 normal 1 fail MXXXX 9 Secondary optical link selected 1 or 2 1 1 lt gt gt gt Q3 0 normal or 1 fail 0 normal or 1 fail 0 not forced 1 or 2 0 normal or 1 fail 0 normal or 1 fail Table 4 14 Optical Link Status Indicators in F 2006 019 MXXXX 6 MXXXX 9 4 55 Chapter 4 Programming 4 56 The operands MXXXX 4 MXXXX 5 and MXXXX 10 and 11 contain the connection status of
56. L 2002 and re energize the CPU With the programmer check the status of ALNET II communications check the node addresses sub net and data rate Check 1f there are communications being processed and that the reception and transmission counters are incrementing continually Observe any wrong communications Check the condition of the network installation the cables connectors and grounding leads De energize the CPU connect the redundancy status communications cable to the REDUND connector of the AL 2006 Brother and re energize the CPU The CPU should enter standby mode Monitoring logic 7 of the P 2006_1 000 or P 2006_2 000 module the bit of the M operands which appears at the leftmost contact of the logic should have value 1 and that furthest to the right value O indicating that this CPU 18 correctly reading the status information of the other CPU active mode If this is not the case perform the tests contained in General Programming Precautions in chapter 4 Programming If the problem persists replace the AL 2006 Brother processor De energize the CPU plug the communications cable into the REMOTE I O connector of the AL 2006 Brother processor and re energize the CPU The CPU should enter the standby mode Connect the AL 3830 or MasterTool programmer to the ALNET I channel of the AL 2006 Brother and check the status of ALNET communications check the node addresses sub net and data rate against those declared in the remote I O co
57. PUs should be the same with the same value as the backup CPU should have odd address When the system is initialized one of the CPUs becomes active and the F END2 082 module changes its address to the even number value Thus the C module can be modified and loaded in any CPU as long as it is in backup status so both the C modules are configured with the backup address The C module should not be directly loaded into the active CPU because loading it could cause a change in the CPU address In the example shown in figure 3 13 the C modules on both CPUs should be configured for a node address of 7 and a sub network address of 5 Specific Aspects of Remote 1 0 Stations 3 24 Remote Station Processing Up to eight remote stations can be connected to a simple programmable controller one CPU or a redundant controller two CPUs using AL 2006 Brother processors The stations consist of AL 2000 MSP C QK2000 MSP AL 2003 or AL 2002 MSP controllers executing a small application program where the F REMOT 069 function module is called This function manages data transfer between the E and S operands of the remote station and the AL 2006 Brother processors also commanding the enabling of the local I O buses During each scan cycle of the AL 2002 CPU application program the AL 2006 Brother processor copies the input point values of the remote stations to the CPU also transferring the CPU output point values to the stations This transfer
58. S HF 36 4 0002 5 END 082 350008 0 LS HF E 0002 END 082 S KM 00001 50008 0 00000 00001 36 0002 7 032 IK M 00000 Left hand Instruction parameter 00001 Right hand instruction parameter 00002 4 38 Chapter 4 Programming Contents of the P 2006 2 000 Module The P 2006 2 000 module is identical to the P 2006_ 1 000 module with the exception of the contents of logics 0 1 and 9 illustrated below Logic 000 Initialization of Redundancy and Remote Ifo Config Tables 0 500 9 000 8 004 6 000 755 04 4 000 8 oo00 77 08 12 0 000 8 000 1 000 9 000 00000 13 00000 4 39 Chapter 4 Programming 0001 1 0001 L 0001 SAO 2 Se MODUS ON 00001 64 0001 0 90009 0 ON Sou Yo suns 00002 0008 Logic 009 Communication failure with remote WO or both CPUs active 950006 0 000 1 Sie ADDO 2 Sie A DDOZ 2 Sie ADDOT L Sie MLILILIS LL Contents of the E 001 Module The first logic in the main module of the E 001 application program of CPU 1s illustrated below It contains the call to the P 2006 1 000 module The main process control program should be inserted into the following logics and 4 40 Chapter 4 Programming should be subject to enable disable control by the skip coil contained in logic 0 activated by a contact controlled by the P module
59. U is already in active mode figure 3 6 3 7 Chapter 3 Operating Principles AL 2002 Processing AL 2006 Processing AL 2006 Processing AL 2002 Processing Executive Program Program Application Program comunication 2006 019 with AL 2002 Operands CPU receives redundant operand values from the active CPU Control program New N AL 2002 comm Backup CPU Executive Program communication with AL 2002 Operands writes redundant operand values in the backup CPU New AL 2002 comm Active CPU Figure 3 6 Redundant System after Failure Repair Application program Executive Program Y Application Program F 2006 019 Control program The F 2006 019 application program configures and exchanges data with the AL 2006 Brother processor This F module is called within the 2006 1 000 and 2006 2 000 procedure modules which configure AL 2006 Brother processor control access to the points of remote I O stations the redundancy logic and the execution of the control program Each P module P 2006 1 000 and P 2006 2 000 is destined for one of the two redundant CPUs These modules accompany the AL 2006 Brother and are programmed in relay diagram language ladder and should be used in the 3 8 Chapter 3 Operating Principles application programs
60. a place that can be easily accessed by the operator The existence of this panel 1s extremely important for system operation allowing quick awareness of the status of the redundant CPUs and the execution of maintenance tasks by the operator This panel consists of eight buttons with integrated light indicators arranged in two rows of four These indicators allow the operator to view the current operating status of the CPUS to request a change of status and re energize the CPUS in case of failure as shown in figure 5 4 UCP 1 Active C Standby Inactive y Re energize Figure 5 4 Redundancy Control Panel Each row refers to a CPU and each button activates an input point The three upper buttons have built in lamp indicators which are activated by output points in order to indicate the current status of each CPU These input and output points are processed by the P 2006 000 redundancy control module as 5 5 Chapter 5 Installation described in chapter 4 Programming Table 5 1 shows the addresses of the input and output points used by the P 2006 000 module that should be connected to the buttons and indicators on the redundancy control panel lamp 5008 0 light 5008 0 lamp 5008 1 lamp S008 1 lamp 5008 2 lamp 5008 2 lamp not connected lamp not connected Table 5 1 I O Addresses for Buttons and Lamps on Redundancy Control Panel The I O addresses shown in table 5 1 are used in the P 2
61. ands M D TM and TD as a whole should not exceed the maximum number of 2 016 bytes The number of operands shown in table 3 2 refers to the maximum value that can be configured for a determined type when no other type has been declared The redundancy of the S operands is reserved for future use and should not be used 3 19 Chapter 3 Operating Principles 3 20 To determine whether a configuration is valid the number of bytes occupied by each numeric operand should be multiplied by the number stated for redundancy then added and the result should be less or equal to the maximum number of bytes possible 2 016 This restriction is not applied to the digital operands S and A which can be configured for any amount Table 3 3 presents the number of bytes occupied by each numeric operand Operand type Number of bytes ________ 2 bytes per operand D 4bytes per operand 2 bytes per position 4 bytes per position Table 3 3 Maximum Number of Operands Configurable for Redundancy Example of Calculation of Configuration Limit Six hundred M operands 100 D operands 80 TM table positions and 20 TD table positions are to be transferred to the backup CPU The total number of bytes for redundancy communication would be Number of total redundancy bytes 600 x 2 100x 4 50x 2 20 4 Number of total redundancy bytes 1 840 The total number of bytes calculated is less than the 2 016 byte limit Therefore the conf
62. anel TX REMOT I O shows that the AL 2006 Brother is sending messages over the remote I O network channel REMOTE I O connector on the front panel RX REMOT I O indicates communication on the remote I O network bus not necessarily addressed to this processor REMOTE I O connector on the front panel The front panel also has three standard DB9 female connectors REDUND redundancy communication connector for connection with the AL 2006 Brother of the redundant CPU if applicable ALNET I ALNET I communications connector allows the connection of MasterTool or AL 3830 programmers so that the operation and the communications status of the Remote I O network can be examined in detail REMOTE I O connector to ALNET II network dedicated to the connection of remote I O stations and redundant CPU if applicable Chapter 2 Technical Description 96102901A Figure 2 1 AL 2006 Brother Front Panel Chapter 2 Technical Description Technical Features Below several features identify and determine the operating limits of this product regarding its hardware software and mechanics General Features e Modes of use e single CPU with remote I O e redundant CPU with remote I O e Number of digital I O points up to 512 per remote processor total of 1 024 AL 2002 MSP or of 2 048 AL 2003 e Number of analog I O points up to 72 per remote processor e Maximum number of remote I O processors 8 e Supports hot swa
63. ation The installation of the application programs must be executed according to the procedures described in the following sections starting with the I O remote stations The loading and execution of the CPU programs can only be carried out after the application programs of the remote stations have been loaded The operations of changing the CPU status loading the program modules monitoring and forcing the variables mentioned in the following sections are described in the AL 3830 User s Guide and in the MasterTool User s Guide DANGER When the commissioning test begins before energizing any element of the control system the output points whose inadequate function may cause any harm to people or to the controlled system itself must be disconnected As the control system is debugged the output points must be checked and may be connected to the elements Installation of Application Programs on the Remote 1 0 Stations e Connect the programming terminal to the ALNET I connector in the remote station Power up the remote station e Switch the remote station to programming mode e Delete any previous version of the program from RAM Also erase the FLASH EPROM e Send the application program to the remote station e Switch the remote station to execution mode e Check the CPU status with the programmer If an error is detected check the cause correct it and restart the loading procedure e Ifthe remote station is
64. ation of the redundant CPUs Figure 3 5 shows the system after an active CPU failure 3 5 Chapter 3 Operating Principles AL 2002 Processing Executive program Application program F 2006 019 Control program 3 6 Redundant 2 Operands AL 2006 Processing Executive program communication with AL 2002 writes redundant operand values to the backup CPU New N AL 2002 comm Active CPU AL 2006 Processing AL 2002 Processing Executive program Executive program Application program communication with AL 2002 Redundant CPU Operands F 2006 019 receives redundant operand values from the active CPU Control program New AL 2002 comm Figure 3 4 Redundant System in Continuous Operation AL 2002 Processing Chapter 3 Operating Principles AL 2006 AL 2006 AL 2002 Processing Processing Processing Executive program a Application program F 2006 019 attempts to write redundant operand values Control to the backup program CPU communication with AL 2002 CPU Redundant Operands New AL 2002 comm Faulty CPU de energized Active CPU Figure 3 5 Redundant System after Active CPU Failure After automatic de energization the faulty CPU can be fixed and re energized then operating in standby mode because the redundant CP
65. b net address configured in the C module 1 node address configured in the C module 5 address programmed in the left hand CHF standby 5 address programmed in the right hand CHF active 6 sub net address configured in the C module 1 node address configured in the C module 5 address programmed in the left hand CHF standby 5 address programmed in the right hand CHF active 6 A gateway connected to the network could be configured with node address 31 and sub net address 1 Supervisory communications connected to the gateway could be sent to node addresses 2 4 and 6 for communicating with the active CPUs of PCs A B and C respectively For further details refer to the section entitled ALNET II Communication with Redundant Controller in chapter 3 Operating Principles General Programming Precautions This section describes certain essential precautions which should be taken when preparing the application programs for the CPUs and remote I O stations in order to ensure the correct operation of the system 4 44 Chapter 4 Programming Central Processing Units Precautions when programming Declare the AL 2006 Brother module in the program configuration module C module at the bus position it occupies The same R address which corresponds to the module s position on the bus should be employed in the CHF instruction of the call to the F 2006 019 module The values programmed for redundancy and remote I O
66. call F 2006 019 in operating mode configure input de energized without previous configuration of the AL 2006 Brother activates both error outputs and returns the corresponding error code to the redundant CPU communications status operand e standby 0 active 1 selects the mode of operation of the AL 2006 Brother processor after completion of the configuration process launched by the configure input Description of outputs e success with the AL 2006 Brother in configuration mode this indicates the successful completion of the configuration process After configuration with the AL 2006 Brother in active mode standby 0 active 1 input energized this output is energized for a single scan pulse at the end of every communication with the remote I Os and the standby redundant CPU With the AL 2006 Brother in standby mode standby 0 active 1 input de energized this output 15 energized for a single scan pulse every time the AL 2006 Brother receives communications with the operand values of the active redundant CPU So in operating mode configure input de energized it is expected that success output is always energized because in each scan cycle communication must take place between the active CPU and standby CPU and with all remote I O processors e I O communication error with the AL 2006 Brother in configuration mode this indicates unsuccessful completion of the configuration process Chapter 4 Programming w
67. cations from the redundant CPU 6 14 Chapter 6 Maintenance Procedure check that the redundant CPU is energized and in either active standby or inactive mode If so check that the AL 1366 cable which connects the AL 2006 Brother processors is in good condition and correctly connected Monitor the operands 0008 and 0009 or their equivalents after modification of modules P 2006_1 000 and 2006 2 000 for both CPUs The operand M0008 should contain the status of the CPU being monitored and the M0009 the status of the remote CPU If none of the previous tests reveals an error replace the cable with another identical one If the error continues substitute the AL 2006 Brother in the backup CPU If it still continues switch the active CPU to standby and replace its AL 2006 Brother processor e Error the diagnostic operands for the optical connections have value 1 M0012 M0013 M0018 M0019 in the original 2006 1 000 and P 2006 2 000 modules Description failure detected in one of the optical fibers Procedure locate the optical fiber which is causing the problem depending on the address of the M operand where the error code is stored Check its general condition its connections and the fiber optic modems to which it is connected Follow the recommendations contained in the FOCOS User s Guide the AL 2401 QK2401 User s Guide and the ALNET II User s Guide e Error one of the remote station I O octet status operands has
68. ce Mounting Devices technology double height Eurocard containing a high integration processor EPROM and RAM memories interfaces for communication with ALNET I protocol and with remote I O networks Front Panel Figure 2 1 shows AL 2006 Brother front panel The upper part of the front panel has 9 LEDs showing the operating status and the communications activities of the AL 2006 Brother identified by the following codes EX Execution shows that the AL 2006 Brother processor is in normal operating conditions ready to communicate with the AL 2002 CPU through the F 2006 019 program module PG Programming not used PC Programmable Controller this LED flashes continuously when the AL 2002 CPU is communicating with the AL 2006 Brother processor through the F 2006 019 module ER Error this LED indicates that the AL 2006 Brother processor has detected some hardware or software malfunction WD Watchdog shows that the watchdog circuit of the AL 2006 Brother is activated This circuit continuously monitors the execution of the 80C152 microcontroller disabling it in case of failure TX ALNET I indicates that the AL 2006 Brother is sending messages over the serial channel of ALNET I network ALNET I connector on the front panel 2 1 Chapter 2 Technical Description 2 2 RX ALNET I shows that the AL 2006 Brother is receiving messages over the serial channel of ALNET I network ALNET I connector on the front p
69. cement of a system without having to turn off the system Normally used in I O module swaps Inactive CPU CPU that is not active controlling the system nor standby backup supervising the active CPU and is unable to take control of the system Instruction Element that defines an operation to be executed over a group of operands within a program Interface Device that electrically or logically adapts the signal transfer between two pieces of equipment Jumper Selection key of configuration addresses composed of pins on the circuit board and a small removable connector used for selection LED Light Emitting Diode Type of semiconductor diode that emits light when stimulated by electricity Used as a light indicator Operands Elements over which the instructions act They can represent constants variables or groups of variables P 2006_1 000 Module programmed in a relay diagram language ladder which controls the redundancy and communication with remote stations on CPU 1 P 2006_2 000 Module programmed in a relay diagram language that controls the redundancy and communication with remote stations on CPU 2 PC Abbreviation of Programmable Controller Program Group of properly ordered instructions that instruct a specific machine to operate over data in order to obtain a result Programmable Controller Digital electronic equipment with hardware and software that is compatible with industrial applications Append
70. d in an AL 3632 rack power supply CPU and eight other modules AL 3632 AL 2006 gt AL 2002 Power source Figure 5 1 AL 2006 Brother Positioning in AL 3632 Rack To be installed in the rack the AL 2006 Brother module must be inserted into the plastic guides until it is totally connected into the rack backplane connector After insertion the fastening screws on the front panel of the module must be firmly tightened Figures 5 2 and 5 3 show installation procedures in detail During the rack installation procedure modules should only be handled by their front panels Fingers should never come into contact with the printed circuit board or its components in order to avoid possible damage by electrostatic discharge ESD 5 2 Chapter 5 Installation The power source of the rack must be switched off before installing the AL 2006 Brother and the other modules except for hot swappable I O modules gt Q
71. dant CPU and the remote I Os These operands are shown in table 4 13 Status indicator operands in F 2006 019 communication with redundant CPU General status of communication with remote I Os and also of remote I O 0 Table 4 12 General Status Indicator Operands in F 2006 019 In these operands the value zero means normal operation no errors Values other than zero indicate faults In the redundancy control modules P 2006_1 000 and P 2006_2 000 provided with the AL 2006 Brother product the last non zero values on these operands are memorized by the operands M0032 for 2 and M0033 for 16 Chapter 4 Programming The presence of values other than zero in the operands M0032 and M0033 which memorize status should set an alarm for the system operator and display the error identification code If the CPUs are connected via the network to a supervisory system then it is recommended that the supervisory program monitor these operands periodically and display an alarm message to the operator if either of their values 15 different from zero and show the error identification value together with its explanatory text Supervisory system may write zero on these two operands after acknowledging their alarms and fixing their causes The operand M0032 should always be monitored by the supervisory system even in systems without redundancy which use the P 2006 000 module since it indicates general AL 2006 Broth
72. dant CPU status indication Description M operand address redundancy configuration error Procedure check the value that has been programmed for the first redundant M operand in the redundancy configuration table used in the F 2006 019 module An existing controller address should be used Refer to the declaration of operands in the C module e Error error code 109 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description configuration error in the number of M operands Procedure check the value that has been programmed for the number of redundant M operands in the redundancy configuration table used in the F 2006 019 module Check that the last redundant M operand first operand plus number of operands is defined in the programmable controller Refer to the declaration of operands in the C module e Error error code 110 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description D operand address redundancy configuration error Procedure check the value that has been programmed for the first redundant D operand in the redundancy configuration table used in the F 2006 019 module An existing controller address should be used Refer to the declaration of operands in the C module Chapter 6 Maintenance e Error error code 111 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description configuration error in t
73. dress redundancy configuration error Procedure check the value that has been programmed for the first redundant TD operand in the redundancy configuration table used in the F 2006 019 module An existing controller address should be used Refer to the declaration of operands in the C module e Error error code 115 in one of the F 2006 memory addresses programmed for redundant CPU status indication 6 11 Chapter 6 Maintenance Description configuration error in the number of TD operand positions Procedure check the value that has been programmed for the number of redundant TD positions in the redundancy configuration table used in the F 2006 019 module Check that the last redundant TD position first TD operand plus number of positions is defined in the programmable controller Refer to the declaration of operands in the C module e Error error code 116 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description configuration error total number of operand bytes exceeded Procedure calculate the total number of bytes defined for redundancy operands and check against the limit allowed If this limit has been exceeded reduce the number of declared redundancy operands e Error error code 117 in one of the memory addresses programmed for F 2006 status indication Description configuration error maximum number of remote stations exceeded Procedure check that the redundancy con
74. dules and their sizes If any of the modules are missing load it and transfer it to Flash EPROM memory e Check the status of the LEDs of the AL 2006 Brother the WD ER and PR LEDs should be de energized and the EX LED should be permanently energized If this is not the case replace the module The FC LED should be flashing denoting that there is communication with the AL 2002 If it is not flashing perform the tests contained in General Programming Precautions in chapter 4 Programming the AL 2002 application program e Check the status of the remaining modules on the bus On modules with ER or ERR LEDs these should be de energized In modules with processors check that they are communicating with the AL 2002 flashing the relevant LEDs If there is a fault check that the correct application program if there 1s one 1s loaded onto the module The ACTIVE LEDs of the I O modules should be flashing If they are not check that they have been declared in the CPU application program C module and that the hot swap switch is not in standby If they are active check the input module readings monitoring E operand values and activating output points forcing S operand values Check the condition of connectors power supplies fuses and grounding If any error is detected replace the module 6 17 Chapter 6 Maintenance 6 18 After all the previous tests de energize the CPU connect the ALNET II communications cable to the A
75. e locate the remote I O or redundant CPU indicated by the error depending on the address of the operand where the error code 15 stored Perform the procedures in Basic Tests in the Event of Errors earlier in this section Attempt to locate possible sources of electromagnetic noise isolating them from the communications network e Error error code 9 in of the memory addresses programmed for F 2006 status indication Description no reply from the station to which communication was transmitted Procedure locate the remote I O or redundant CPU indicated by the error depending on the address of the operand where the error code is stored Perform the procedures in Basic Tests in the Event of Errors earlier in this section Attempt to locate possible sources of electromagnetic noise insulating them from the communications network e Error error code 100 in one of the memory addresses programmed for F 2006 status indication Description communications error with AL 2006 Brother processor Procedure Perform the procedures in Basic Tests in the Event of Errors earlier in this section for the AL 2002 MSP CPU and the AL 2006 Brother processor 6 13 Chapter 6 Maintenance e Error error code 120 in one of the memory addresses programmed for F 2006 status indication Description inactive communications error Procedure locate the remote I O or redundant CPU indicated by the error depending on the address
76. e parameters programmed in the CHF instruction are analyzed If these are incorrect the error output is energized and the success output is de energized If they are correct the node address is changed to the programmed value Description of outputs e success indicates that the node address has been successfully modified e error indicates an error in one of the CHF instruction parameters incorrect number of parameters invalid parameter type or parameter not defined in the C module of the application program or that the address value specified is outside of the range 1 to 31 Usability This function can be used on AL 2002 MSP and AL 2003 CPUs This function should be employed in the same manner as programmed in the P 2006 1 000 and 2006 2 000 modules Improper use of this function can cause malfunction in the ALNET II processing on the PC 4 18 Chapter 4 Programming P TEMPO 032 Auxiliary Time Base Control CHP enable TEMPO success skip 032 Introduction The 032 is called by the P 2006_1 000 and P 2006_2 000 modules which are responsible for redundancy control and communication with the remote I O stations It controls the time base for timing instructions within the application program avoiding delays in these instructions when the application program is skipped due to a redundancy logic decision The application program is always skipped in the backup CPU and sometimes may also be skipped
77. e P 2006_ 1 000 and P 2006_2 000 modules When one CPU 16 active and the other one is in standby switch the active CPU to programming mode with the AL 3830 programmer or the MasterTool thus simulating a failure in it Check whether this CPU has been de energized by the other in standby mode and also check whether the latter becomes active The de energized CPU should become energized again by pressing the re energize button of the active CPU Repeat the test by starting with the other CPU in the active mode If this does not work fine check the correct reading of the buttons on the panel monitoring their inputs and check the logics from 7 to 10 of the P 2006_1 000 and P 2006_2 000 modules Check also the connection of the NC relays that de energizes CPUs When one CPU 15 active and the other is in standby switch the backup CPU to programming mode with the AL 830 or MasterTool processor thus simulating a failure in it This CPU should not be de energized while the other CPU must remain active Repeat the test by reversing the status of the CPUs Check whether the declared redundant operands are being transmitted from the active CPU to the backup CPU forcing and monitoring the values on both Reverse the status of the CPUs and repeat the test for the other CPU If the operands are not being transmitted check the configuration tables and parameters of the F 2006 019 functions in the P 2006_1 000 and P 2006_2 000 modules Debugging of t
78. e success output is de energized If they are correct the communication with the AL 2006 Brother processor is proceeded configure when energized the AL 2006 Brother processor configuration procedure is launched with the parameters programmed in the CHF instruction This process can require several scans of the AL 2002 MSP CPU application program energizing the success output in the event that configuration has been successful If errors occur the I O communications error or redundant CPU communications error outputs are permanently energized and the success output is de energized 4 3 Chapter 4 Programming 4 4 The AL 2006 Brother processor configuration procedure must be run by calling the F 2006 019 module with the configure input activated until the success output or one of the error outputs returns energized After that the configure input must remain deactivated so that the AL 2006 Brother cyclic functions can be executed If any of the error outputs is energized the CHF instruction parameters the values on the configuration table and system installation should be verified The AL 2006 Brother processor configuration procedure must be launched every time the CPU application program starts power on or change to execution mode or after a change on the values of the I O or redundancy configuration tables Modifications to configuration table values will only take effect after the configuration procedure The attempt to
79. efinition of Redundant Operands As an example we will take an application program comprising the E 001 module containing the following logics 0000 1 0000 0 0000 11 0022 SiS MOUDZ S 50009 0 Si A DOO 1 SS EOD 2 0006 0 0006 0 The operands 0000 0 20000 1 0000 2 do not need to be configured as redundant because they are input points 4 48 Chapter 4 Programming The operand 0000 1 does not need to be configured as redundant It is calculated in logic 000 and used in logic 001 so its initial value at the beginning of the application program does not matter The operand 0006 0 must be configured as redundant because it is used in logic 001 before being altered So its initial value at the beginning of the application program does matter The operands 0050 and 0051 do not need to be configured as redundant As in the previous cases they are altered before being read Sometimes they are not altered 1f E0000 0 0 or E0000 1 1 but in these cases they also are not read The operands M0020 and 0021 must be configured as redundant since if the mathematical instructions in logic 0 are enabled any alteration in their values can change the result of the calculation in logic 0 M0022 and M0023 and the activation of the output point 5008 0 The operands M0022 M0023 must be configured as redundant since if the mathematical instructions in logic 0 a
80. emote station areas have the same operand distribution and size only the initial addresses of location on the CPU are modified In the remote station the initial address 15 always the 0000 operand The initial address of the areas of each remote station on the CPU is determined in the F 2006 019 module I O configuration table Figure 3 16 presents the equivalence between the CPU and remote station areas also showing the positions of the CPU configuration tables used by F 2006 019 and of the remote stations used by F REMOT 069 corresponding to each area Chapter 3 Operating Principles AL 2002 ph RN eR A SEY TMXXX F 2006 019 Remote station configuration Remote station 0 i M Inputs Inputs F REMOT 069 000 Pos 13 First Oper M My M Status Configuration M M Pos 14 n E M E operands o Pos6 n E Pos 16 n M M M operands T M Pos 8 n Outputs Outputs 15 S M 5 operands M Pos 7 m S Pos 17 M M os 17 n Ms M operands Pos 9 n Ms Remote station 1 Remote station 1 Inputs Inputs F REMOT 069 000 Pos 21 First Oper M Status Configuration M Pos 22 n E Mj o operands Pos6 n E Pos 24 n M a 08 n
81. er processor errors The error identification values allowed for these operands are described in appendix A Error Codes Errors which occur should be corrected in accordance with the recommendations contained in the section Procedures in Case of Failure in chapter 6 Maintenance Once the problem has been corrected the supervisor can force the operand to the value zero If the problem has been repaired the alarm operand will not return to zero unless the supervisory system writes zero on it Communication with Remote Station Indicators In the fourth parameter of the call to module F 2006 019 instruction CHF instruction an area of M operands is defined These operands receive a number of status indicators see item F 2006 019 Communication with AL 2006 Brother function in this chapter Table 4 14 shows the status operands related to communication between the AL 2006 Brother processor and the remote I O stations Status indicator operands in F 2006 019 MXXXX 16 Communications status of remote I O 0 also a general status for all remote I O stations MXXXX 17 Communications status of remote I O 1 18 Communications status of remote I O 2 MXXXX 19 Communications status of remote 4 53 Chapter 4 Programming 4 54 20 Communications status of remote 1 0 4 MXXXX 21 Communications status of remote I O 5 MXXXX 22 Communications status of remote I O 6 MXXXX 23 C
82. ere was AL 2006 Brother hardware error In this mode processing is interrupted and communication with the AL 2002 CPU and the programmers using the ALNET I channel is impossible When in normal operation in execution mode the AL 2006 Brother can operate in three different modes determined by the P 2006_1 000 or P 2006_2 000 module and transferred to the AL 2006 Brother using the F 2006 019 function Active after communicating with the AL 2002 CPU reading the operand values using the AL 2002 backplane the AL 2006 Brother writes the output operand values to the remote stations and writes the redundant operand values to the AL 2006 Brother processor of the backup CPU using the ALNET communications network Figure 3 9 shows this sequence of events 3 11 Chapter 3 Operating Principles AL 2002 Processing VO Bus backplane Input Operands AL 2006 Processing Executive Program Output Operands Communication Redundant Operands with AL 2002 CPU Dedicated ALNET Network Write Outputs Output Operands on Remote gt Stations Write on Badundant Redundant Operands ie Operands of Backup CPU Read Inputs Input Operands from Remote Stations New Communication with AL 2002 Figure 3 9 AL 2006 Brother Processing in Active Mode 3 12 Chapter 3 Operating Principles e Backup the AL 2006 Brother processor continuously waits for the communication of the red
83. ess used to access this position is displayed in the corresponding position Modify the logic 1 CHF instruction to use this address Within logic instruction modify the values loaded into tables 01 and 002 to the I O and redundancy configurations desired The meaning of each table position is described at section F 2006 019 Communication with AL 2006 Brother Function earlier in this chapter e Even if AL 2006 Brother redundancy processing is not being used the relevant table should still be declared for the module to function correctly 002 in 2006 000 This table must have at least 16 positions with correct values entered The quantities of redundant operands must be zero e The maximum cycle time allowed for execution of the application program C module should be configured with a 50 ms margin in relation to the actual runtime needed by the program rounding up to the next time period allowed For example if the program requires a maximum of 80 ms for execution the time limit configured in the C module should be 200 ms 80ms 50ms 130ms using the next allowed time period 200ms Exaggerated margins should be avoided 100 200 ms or greater when Chapter 4 Programming configuring the maximum cycle time since this results in an unnecessary increase in response time for the backup CPU to detect active CPU failures P 2006 1 000 and P 2006 2 000 Redundancy Control and Communication with Remote
84. figuration table used in the F 2006 019 module contains the correct number of positions e Error error code 118 in one of the memory addresses programmed for F 2006 status indication Description address configuration error in the first M operand used as input area by the remote station Procedure locate the remote I O indicated by the error depending on the address of the M operand where the error code is stored Check that the correct remote station value 15 programmed for the first M operand of the remote station input area This operand should be declared in the programmable controller Refer to the declaration of operands in the C module e Error error code 119 in one of the memory addresses programmed for F 2006 status indication 6 12 Chapter 6 Maintenance Description there are not enough M operands for the input or output areas of the remote station Procedure increase the number of M operands declared at CPUs and 2 It is also possible to reduce the number of operands used by the input and output areas of the remote station affected by changing the values in the remote I O configuration table used by the F 2006 019 module Execution Errors The errors described next are reported while the AL 2006 Brother processor is in either active or standby mode e Error error code 8 in one of the memory addresses programmed for F 2006 status indication F 20006 Description communications time out error Procedur
85. from the ALNET II network dedicated to communication with the remote I O stations connected to the AL 2006 Brother processors These two networks cannot be interconnected directly or through a bridge processor 3 21 Chapter 3 Operating Principles 3 22 Both CPUs that make up a redundant PC are connected to the ALNET II network each one having a communications address node address within the local sub network segment The redundancy mechanisms of the CPUs used allow the change of the active CPU so either CPU or CPU2 can be in active mode controlling the process This change can cause a problem for the rest of the elements connected to the network that need to communicate with the active CPU because they would not know which node address corresponds to the active CPU for use in communication To solve this problem a dynamic node mechanism changes the addresses of CPUs 1 and 2 according to their states Thus the CPU that is in active state always has the same node address while the inactive or backup CPU always has another address no matter to which CPU 1 or 2 they physically correspond For example suppose a supervisory system connected to an ALNET II network using an AL 2400 S C gateway where a redundant programmable controller is also connected whose CPUs have the node addresses of 7 and 8 with a local sub network address of 5 as shown in figure 3 13 Chapter 3 Operating Principles Supervisory Station 1
86. g the AL 2006 Brother processor The number of M operands allocated for the whole input area should not exceed 112 That is the area of input operands in each remote station should not exceed the M0111 operand it always begin in M0000 3 32 Chapter 3 Operating Principles Area of the Output Operands in Remote Stations The area of the output operands in the remote stations always starts in the first operand after the last operand used the input area and is divided into two regions lt operand image the values to be copied to the S operands of the remote station are obtained starting with the first M operand of the output area The number of S operands updated is determined by the value in position 7 of the table of the remote station configuration used by the F REMOT 069 function Each operand carries values for two S operands A sufficient number of M operands are allocated to store all of the S operands defined in Byte 0 of the M operand 15 copied to the S operand with the lowest address while byte 1 is copied to the 5 operand with the highest address For example if position 7 of the table is 9 the last M input operand is M0031 and the first S operand is 5020 the F REMOT 069 function copies the values of the M0032 to M0036 operands to the 5020 to 5028 octets according to the equivalence shown in table 3 11 0032 50021 50020 M0033 50023 50022 0034 60025 60024
87. guarantee will be automatically voided if the equipment has had any modifications performed by personnel not authorized by ALTUS The guarantee does not apply when external agents cause equipment failure by incorrect use or installation of product in addition to accidents and force majeur events ALTUS guarantees its equipment functions as explicitly described in its user s guides and or Technical Specifications and does not guarantee the satisfaction of any particular type of application of the equipment ALTUS does not recognize any other guarantee direct or implied particularly with third party offerings Additional information about ALTUS products services and offerings can be requested through writing ALTUS address can be found on the back cover of this guide ALTUS is not responsible for non registered information provided about its equipment COPYRIGHT MasterTool and QUARK are registered trademarks of ALTUS Sistemas de Inform tica S A IBM is a registered trademark of International Business Machines Corporation Table of Contents Table of Contents Table of Contents Introduction Programming 22 1 Imm nnnm nennen nnne rnn nnne rht nnne rnt nene 4 2 069 Remote I O Stations Processing Function eee enne Introduction sS DU RT 4 19 2006 000 Communication with Remote I Os
88. guration where the redundancy functions and communication with remote I O stations of the AL 2006 Brother are used together Chapter 3 Operating Principles Redundant Central Processing Units 000002 Redundancy Communication Remote I O Network Remote I O Stations Figure 3 2 System with Redundant CPU and Remote I O Stations Remote 1 0 Stations This section presents a general overview of the remote I O station processing using the AL 2006 Brother The sections that follow give more detailed information on different aspects related to this processing The AL 2006 Brother processor uses a segment of the dedicated ALNET II network network of remote I O stations for reading and writing I O values in up to 8 remote stations These remote stations can be AL 2000 MSP C QK2000 MSP AL 2003 or AL 2002 MSP controllers The AL 2006 Brother communicates with the remote stations at the same time the AL 2002 CPU executes the application program The F 2006 019 program module provides communication between the AL 2002 MSP CPU application program and the AL 2006 Brother processor When the F 2006 019 function is called by the application program the AL 2006 Brother copies the values read from the remote station inputs to the CPU operands and also searches for the CPU operand values to be written in the remote outputs After the transfer of these operand values between the 3 3 Chapter 3 Operating Principles 3 4 processo
89. he Application Program While keeping the I O remote stations and the two CPUs energized monitor and force the variables of the application program of the active CPU testing whether it is working If errors occur make the necessary changes and load the modified modules in the active CPU whenever Chapter 5 Installation possible After the errors are corrected load the modified modules also in the backup CPU e When the corrections have been made transfer the program to FLASH EPROM on both CPUs Chapter 6 Maintenance Maintenance This chapter introduces essential operation and maintenance precautions for a redundant system or one with remote I Os Change of Redundant CPU Operating Mode by the Operator Each CPU in the system can be one of three operating modes defined by the P 2006_1 000 and P 2006_2 000 redundancy control modules active standby or inactive The description of each mode and their allowed transitions is in Specific Aspects of Redundancy in chapter 3 Operating Principles The change of operating mode occurs automatically due to a failure on the CPU which is in the active mode described in the same section or manually by pressing buttons on the control panel The current status of each CPU is indicated by light indicators in the control panel as specified in chapter 5 Installation Using the buttons on this panel the operator can request a change of status of one of the redundant CPUs For a request
90. he F 2006 memory addresses programmed for redundant CPU status indication Description configuration error in the number of redundant S operands Procedure check the value that has been programmed for the number of redundant S operands in the redundancy configuration table used in the F 2006 019 module Check that the last redundant S operand first operand plus number of operands 15 defined in the programmable controller Refer to the output module declarations at the programmable controller bus e Error error code 106 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description A operand address redundancy configuration error 6 9 Chapter 6 Maintenance 6 10 Procedure check the value that has been programmed for the first redundant A operand in the redundancy configuration table used in the F 2006 019 module An existing controller address should be used e Error error code 107 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description configuration error in the number of A operands Procedure check the value that has been programmed for the number of redundant A operands in the redundancy configuration table used in the F 2006 019 module Check that the last redundant A operand first operand plus number of operands is defined in the programmable controller e Error error code 108 in one of the F 2006 memory addresses programmed for redun
91. he number of D operands Procedure check the value that has been programmed for the number of redundant D operands in the redundancy configuration table used in the F 2006 019 module Check that the last redundant D operand first operand plus number of operands 15 defined in the programmable controller Refer to the declaration of operands in the C module e Error error code 112 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description operand address redundancy configuration error Procedure check the value that has been programmed for the first redundant TM operand in the redundancy configuration table used in the F 2006 019 module An existing controller address should be used Refer to the declaration of operands in the C module e Error error code 113 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description configuration error in the number of redundant TM operands Procedure check the value that has been programmed for the number of redundant TM positions in the redundancy configuration table used in the F 2006 019 module Check that the last redundant TM position first TM operand plus number of positions is defined in the programmable controller Refer to the declaration of operands in the C module e Error error code 114 in one of the F 2006 memory addresses programmed for redundant CPU status indication Description TD operand ad
92. he possible system types that can be implemented with the AL 2006 Brother processor and the basic operating principles of remote I O stations and redundancy respectively The sections that follow present more detailed information on the different aspects of remote I O devices and redundancy For systems that do not have these characteristics these sections can be disregarded System Configurations Two basic system types can be implemented with the AL 2006 Brother processor e Single CPU with remote I O stations e Redundant CPU with remote I O stations The first type consists of a single CPU without redundancy and an AL 2006 Brother processor which communicates with the I O modules distributed in remote units Local I O modules can also be used if necessary Figure 3 1 shows a typical architecture of this type of system where the AL 2006 Brother processor does not execute the redundancy function but only communication with the remote I O stations 3 1 Chapter 3 Operating Principles 3 2 Central Processing Unit Remote I O Network Remote I O Stations AL 2000 MSP C Figure 3 1 System with Single CPU and Remote I O Station The second type contains two AL 2002 MSP processors each with an AL 2006 Brother composed of a redundant CPU The two AL 2006 Brother processors are connected to each other and with the remote stations that contain the I O points Figure 3 2 shows an example of system with this confi
93. heir probable causes and the procedures to be carried out for correcting them In addition it informs the basic error location procedures to be executed on devices with processors The procedures for correcting errors specific to the CPUs to the I O modules the power supplies and to the ALNET II network components can be found in the User s Guides or the Technical Specifications of the equipment concerned The errors have been grouped into two categories e configuration errors those which occur during system debugging and prevent the AL 2006 Brother from operating e execution errors those which occur after the AL 2006 Brother has been correctly configured during its operation Despite being considered an execution error the de energization of the active CPU by the backup CPU is described in a separate section due to the extensive description of the procedures to be followed upon its occurrence Basic Tests in the Event of Errors If errors occur or there is a suspicion of malfunction in CPUS remote stations or bridges the following basic procedure should be applied e Check the status of the LEDs on the front panel the LEDs WD and ER should be OFF and the EX LED should be ON for correct operation 6 7 Chapter 6 Maintenance 6 8 Connect the AL 3830 or MasterTool programmer and check the general status window for the PC the device should be in execution mode with no error messages Using the programmer check
94. ication with the main CPU It also allows the execution of the filtering process on the input point values and the deactivation of output points in the event of a failure of communication with the main CPU Chapter 4 Programming 4 12 Low Band Filtering Processing Low band filtering processing consists of an increase in the response delay time required before an input point changes its status For example if a remote station programmed with a delay time of 2 seconds has an input point configured for filtering in logical state 0 then this point must remain in logical state 1 for a minimum of 2 seconds for its state at the CPU to change from 0 to 1 In the event that the input value changes to and returns to in less than two seconds then the status of the CPU reception point will remain fixed at 0 In opposite states the behavior is identical 1 if the input has value 1 then this point must remain at value 0 for a minimum of 2 seconds for its state at the CPU to change from 1 to 0 The F REMOT 069 function allows the input points subject to filtering to be selected individually However the same delay time configuration applies to all points Programming Operands The CHF instruction cells used to call the function are programmed in the following manner e OPERI Specifies the number of parameters to be passed to the function in OPER3 edit window This operand must be a memory constant with value 3 00003 e OP
95. iguration 15 valid Cycle Time of the Application program of Redundant CPUs The backup CPU only executes the redundancy control routine found in the 2006 1 000 or 2006 2 000 module and always skips over the main program instructions of the control skip coil on first logic of E 001 module Because of this the runtime of the program of this CPU 15 short approximately 5 to 30 ms depending on the amount of redundant operands configured In addition to the 2006 1 000 or 2006 2 000 redundancy control module the active CPU also executes the application program of the process control and the process time can range from a few tens to hundreds of milliseconds While the AL 2006 Brother processor executes this program it also communicates with the remote I O stations and with the backup CPU A new control program scan cycle can only start after its end and after the end of the AL 2006 Brother communication with remote I O stations and redundant AL 2006 Brother Chapter 3 Operating Principles Regarding the program cycle time the active CPU can operate two distinct ways depending on the cycle time of the main control program of the AL 2002 and the number of redundant operands and remote stations configured in the AL 2006 Brother e The cycle time of the AL 2002 control program is bigger than the processing time of the AL 2006 Brother When the AL 2002 control program ends the AL 2006 Brother has already ended its tasks So
96. in execution mode check whether there are warning messages and correct the indicated problem e Activate the points of digital input modules and check through monitoring whether the values of the points are being copied to the correct M operands of the input communications area of the remote station which will be read by the CPU Test whether the programmed filtering time for the input points configured with this feature is working If the values are not being 9 12 Chapter 5 Installation correctly copied or the filtering is not working check the configuration and the F REMOT 069 module call Repeat the previous procedure for the special and analog input points If the values are not being correctly copied check the instructions of the A D conversion or the function modules used in the access to the special modules Force the M operands of the output communications area of the remote station which will be written by the CPU checking the activation of the points in the associated output modules Check the activation of the digital analog and special modules Check the runtime of the remote station program The runtime must be shorter than 15 milliseconds If not try to shorten the runtime by distributing the execution of A D D A instructions and the access to the special modules in several scanning cycles When the corrections have been carried out transfer the program to FLASH EPROM Installation of Application Programs
97. in programming mode and can t be loaded with the CPU execution mode on line e modification of the number of simple operands or tables in the C module e modification of any of the parameters of the F 2006 019 module call or of the contents of the redundancy or I O remote configuration tables Chapter 6 Maintenance 6 4 The redundancy control modules P 2006_1 000 and P 2006_2 000 only configure the AL 2006 Brother processors during the switch from programming mode to execution mode or when the CPU powers up e modifications which must be performed simultaneously in one more program modules In redundant systems in order to carry out these modifications with no interruption to the process control the following procedure should be used switch the CPU from standby to inactive mode by activating the corresponding button on the redundancy control panel e switch the same CPU to programming mode using the corresponding command on the AL 3830 or MasterTool programmer e load the new program modules with the programmer e switch the CPU to execution mode with the programmer It should automatically enter standby mode after a few seconds in inactive mode performing initialization e switch the other CPU which had been active during the process controlling the system to standby so that the CPU with the new program modules switches to active mode and takes control of the system During program updating the CPU
98. ing the table positions that refer to the number of positions should be filled in with zero Chapter 4 Programming The total number of redundant bytes to be transferred must not exceed 2016 bytes excluding S and A operands So the following equation must be true position 9 2 position 11 4 position 13 2 position 15 4 lt 2016 Status Indicators The AL 2006 Brother processor communicates cyclically with the redundant CPU with the remote I O stations and with the controller channels of the optical connection The status indicators for these communications are stored in a 23 M operand area beginning in the operand M specified in the fourth parameter of the F 2006 019 function These status indicators are shown in table 4 4 These operands can also indicate table definition programming errors at the end of the configuration process The first two operands in this area are used for the exchange of redundancy status information between CPUs 4 9 Chapter 4 Programming Status indication operands in F 2006 019 Operands MXXXX Transmits redundancy status to the other CPU Possible values are defined in chapter Maintenance section Procedures in Case of Failure MXXXX 1 Receives redundancy status from the other CPU Possible values are defined in chapter Maintenance section Procedures in Case of Failure MXXXX 2 General status of AL 2006 processor and of communication with redundant CPU through remote
99. ing hardware and software aspects and verifications necessary for smooth operation Installation in the Rack The AL 2006 Brother was designed to be used with the AL 2003 and AL 2002 MSP CPU mounted in the same rack There are 3 models of racks e AL 3630 it has room for the power supply CPU AL 2002 AL 2003 and 4 other modules The first 3 of these 4 positions may receive special modules which require an extended bus for communicating with CPU using DMA direct memory access e AL 3632 it has room for the power supply CPU AL 2002 AL 2003 and 8 other modules The first 5 of these 8 positions may receive special modules which require an extended bus for communicating with CPU using DMA direct memory access e AL 3634 it has room for the power supply CPU AL 2002 AL 2003 and other 16 modules The first 5 of these 16 positions may receive special modules that require an extended bus for communicating with CPU using DMA direct memory access The special modules that must be installed in the first three AL 3630 or five AL 3632 and AL 3634 positions for DMA access to CPU are the following at this time e AL 2006 Brother Coprocessor e AL 2005 Communication Coprocessor Chapter 5 Installation e AL 3405 Ethernet TCP IP Interface e AL 3406 Profibus DP Master Interface e AL 2008 High Performance DSP Coprocessor Figure 5 1 shows the positions where the AL 2006 may be installe
100. ion of the remote input and output stations is accomplished through a TM operand programmed as the second parameter for the F 2006 019 function This table should have at least 10 positions If there are fewer than 10 positions a configuration error occurs The contents of each position in this TM table are specified in table 4 1 4 5 Chapter 4 Programming 4 6 Position O jTabletypeidentifier O jTabletypeidentifier 1000 500 AL 2006 data rate 250 125 64 5 Not used reserved TM declaration of Remote I O stations in F 2006 019 Optical Channel Definitions EBEN a optical connection first optical connection second optical connection m Sub net address of the controller channel of the second optical connection 1 to 31 Remote station node address 1 to 63 Remote station sub net address 250 125 64 remote station values on the local CPU 0 to 64 Number of remote station S operands to be written 0 to 108 Number of remote station M operands to be read 17 0 to 112 Number of remote station M operands to be written 2 3 Chapter 4 Programming 20 1000 500 Remote station data rate 250 125 64 2 0 to 9999 First M operand of the area that sends receives remote station values on the local CPU 01064 0 64 Number of remote station E operands to be read Table 4 1 Contents of the Remote I O Definition Table in F 2006 019 Remote stations are declared f
101. is replace the module and re energize the CPU once again If the module allows hot swapping switching the CPU to standby mode is recommended in order to change the module After the swap the CPU can be returned to its active mode or be kept in standby This way the system will continue to be controlled by the other CPU with the corresponding active I O module Swapping Remote I O Modules In remote stations the I O modules can be switched in the same way as those on the CPU local bus e de energizing the remote station for I O modules which do not permit hot swapping with the remote station energized for I O modules which permit hot swapping Modules which do not allow hot swapping should be changed with the following procedure Chapter 6 Maintenance e de energize the remote station e disconnect the module from field wiring e remove the module from the bus e configure the jumpers if applicable of the new module to the address used by the old module insert the new module into the bus e reconnect the new module to field wiring e re energize the remote station On de energizing a remote station to change a module which is not hot swappable the active CPU will keep frozen the values of the input operands E and the memory operands M last read from that station until it 15 re energized WARNING The remote station should not be re energized without the new module having been inserted into the same bus
102. is done between the CPU M operands and the remote station M operands In the latter the F REMOT 069 module copies the values between Chapter 3 Operating Principles the M operands and the E and S operands Figure 3 14 shows a diagram with this transfer In addition to the digital I O point values the remote station numeric values are also transferred to the CPU and vice versa making the use of analog and special I O modules possible such as fast counters interfaces for thermocouples communication interfaces among others The instructions to access these modules when used should be inserted into the application program of the remote stations because they are not processed by the F REMOT 069 function The exact correspondence between the CPU operands and those of the remote stations is presented in the Remote Stations section in this chapter AL 2002 AL 2006 Processor Processor Input operands M F 2006 019 Output operands Remote station Input operands F Remot 069 E M Figure 3 14 Transfer of Remote I O Station Values 3 25 Chapter 3 Operating Principles 3 26 Declaration of Remote Stations for the AL 2006 Brother Each existing remote I O station should be declared to the AL 2006 Brother processor This is done using a table memory TM operand programmed as the second parameter called by the F 2006 016 application program Table 3 4 shows the meaning of each p
103. ith an error in the specifications for the remote I Os After configuration with the AL 2006 Brother in active mode standby 0 active 1 input energized this output is energized for a single scan pulse in the event of errors in communications with any of the remote I Os With the AL 2006 Brother in standby mode standby 0 active 1 input de energized this output is not energized e redundant CPU communication error with the AL 2006 Brother in configuration mode this indicates unsuccessful completion of the configuration process with an error in the redundancy specifications After configuration with the AL 2006 Brother in active mode standby 0 active 1 input energized this output is energized for a single scan pulse in the event of errors in communications with the redundant CPU With the AL 2006 Brother in standby mode standby 0 active 1 input de energized this output 1s not energized If both error outputs are activated simultaneously and continuously one of the following errors has occurred the number of parameters in OPERI is not four one of the parameters programmed OPER3 is of an invalid type of the parameters programmed in OPER3 is not defined in C module of the application program e the address R defined in the first parameter is invalid e there is AL 2006 Brother processor at the bus address declared in the first parameter Remote I O Configuration The specificat
104. ix Glossary Programming The act of preparing a program in all of its steps for a computer or similar piece of equipment Programming Language A group of rules conventions and syntax used to create a program A group of symbols used to represent and communicate information or data between people and machines RAM Memory where all the addresses can be randomly and directly read or written It is volatile and needs a battery in order to avoid data loss when power is turned off Redundant CPU Corresponds to the other CPU of the system in relation to the one the text of the user s guide is referring to For example the redundant CPU of CPU 2 is CPU 1 and vice versa Redundant System System that contains backup or duplicated elements for the execution of certain tasks which can tolerate determined types of failure without affecting the execution of the task Remote Station Pieces of equipment that allows the reading and writing of input and output points of the controlled process communicating their values with the active CPU Serial Channel Device that allows the connection and communication of data between two or more pieces of equipment using a common standard Software Computer programs procedures and rules related to the operation of a data processing system Scan cycle A complete execution of an operating system and of the application program of a PC Commissioning test Final debugging procedure of the control sy
105. n Mode Inactive 16 Operation States Active 16 Operation States Standby 16 C 2 Installation in the Panel 5 Installation of AL 2006 1 Redundancy Configuration 8 Configuration Example 47 Configuration of Redundant Operands 46 Description 2 Operands 48 Related Equipment 7 Remote I O Stations Configuration 5 Remote I O Stations Configuration 12 Description 3 Programming 46 S Software Components 6 Software Features 5
106. nfiguration tables Check if there are communications being processed and that the reception and transmission counters are incrementing continually Observe any wrong communications Check the condition of the remote I O network installation the cables connectors and grounding leads If the addresses data rate and network installation are correct and no OK reception is indicated replace the AL 2006 Brother processor Appendix A Quick Reference Guide Quick Reference Guide This appendix contains abbreviated information related to the programming and configuration of the systems for quick access Detailed explanations are not included in this section but can be found in the specific sections throughout the user s guide Remote 1 0 Networks General characteristics of the remote I O networks dedicated ALNET 11 Parameter Node address 1 to 31 Sub network address 1 to 63 Maximum number of sub networks maximum of 2 bridge processors Data rate 1 000 500 250 125 64 All the elements connected to the same network segment must be configured with the same sub network address All the elements connected to the same network segment must be configured with different node addresses Appendix A Quick Reference Guide In the communications network with remote stations only the AL 2006 Brother processors of the same redundant PC its I O remote stations and any eventual bridge processors can be connected Gateway processors or
107. ns and the redundant AL 2006 Brother Instantaneous time refers to the last execution cycle The minimum and maximum times are the lowest and highest instantaneous time obtained reinitializing each 25 seconds The average time corresponds to the arithmetic mean of the last 256 instantaneous times obtained These times directly depend on the number of redundant operands and on the number of remote I O station operands configured 3 41 Chapter 4 Programming Programming This chapter introduces the modules procedures and functions used in the implementation of systems with the AL 2006 Brother processor It also provides information on programming precautions the use of redundant operands and on the diagnosis of failures Systems with Remote 1 0 and no Redundancy Systems of this type consist of one CPU and up to 8 remote stations with I O points The procedure and function modules described in this user s guide are used in the following manner e The CPU application program must call the module P 2006 000 and this module calls the function F 2006 019 e The remote station CPU application programs must call the module F REMOT 069 Systems with Remote I O and Redundancy Systems of this type consist of two CPUs operating redundantly and up to 8 remote stations with I O points The procedure and function modules described in this user s manual are used the following manner e The redundant CPUs application programs must
108. ns to zero If the CPUs are connected to a supervisory system it is recommended that this system include commands to force the operands corresponding to the optical connections employed to zero MXXXX 7 MXXXX 8 MXXXX 13 14 In this way the operator is able to reset the connections to the normal status as soon as repairs have been made The operands MXXXX46 and 12 can be forced to the value 1001 or 1002 in order to force a change in which redundant connection 15 in use for maintenance of one of the connections After being forced to the value 1001 or 1002 the operand MXXX X46 MXXXX 12 should be forced back to 1000 in order that connection switching is re enabled 1 so that the system switches connections automatically if there is a failure in the connection being used at the time Chapter 4 Programming For example if communications are using connection and it is necessary to perform maintenance on it the use of connection 2 can be selected by forcing the operand MXXXX 6 to the value 1002 The switch will only be accomplished if connection 2 is in the normal status 5 0 The switching can be confirmed at operand 3 which should indicate value 2 after switching from connection 1 to connection 2 After the switching the operand MXXXX 6 should be forced to the value 1000 The operands MXXXX 3 through MXXXX 8 and MXXXX 9 through MXXXX 14 correspond to positions 34 thr
109. nt to contain all the E operands defined in 000 Byte 0 of the M operand receives the E operands with the lowest address while byte 1 receives the E operand with the highest address For example if 3 31 Chapter 3 Operating Principles position 6 of the table were 15 the F REMOT 069 function copies the E000 to E014 octet values to the M0004 to M0011 operands in the positions shown in table 3 10 M0011 __ ______ 0014 Table 3 10 Example of Image Area of Operands the Remote e Input M operands this group of operands is used to transfer analog values or special input modules fast counter for example from the remote station to the CPU The number of reserved operands is determined by the value of position 8 of the table of the remote station configuration while the first M input operand corresponds to the following operand after the last M operand of the image area of the E operands The F REMOT 069 function does not modify the value of these operands during its processing because they are updated by special instructions or functions that access these input modules in the I O bus These operands can also be used to transfer any other remote station values to the CPU For example if position 8 table has a value of 20 and the image area of the E operands occupies up to the 0011 the 0012 to M0031 operands will be used to store the values to be copied to the CPU usin
110. o the odd value in the left hand CHF instruction The values chosen for node addresses the CHF instruction should be unique on the sub net and between 1 and 31 The C modules for CPU 1 and CPU 2 should be configured with the same node address This address should be the same as the odd address chosen in the left hand CHF instruction in logic 13 of the 2006 1 000 and 2006 2 000 modules Example Consider a system with 3 redundant PCs connected on sub net 1 of an ALNET II network redundant PC e CPUI sub net address configured in the C module 1 node address configured in the C module 1 address programmed in the left hand CHF standby 1 address programmed in the right hand CHF active 2 e CPU2 sub net address configured in the C module 1 node address configured in the C module 1 address programmed in the left hand CHF standby 1 4 A3 Chapter 4 Programming redundant PC e CPUI e CPU2 redundant PC e CPUI e CPU2 address programmed in the right hand CHF active 2 B sub net address configured in the C module 1 node address configured in the C module 3 address programmed in the left hand CHF standby 3 address programmed in the right hand CHF active 4 sub net address configured in the C module 1 node address configured in the C module 3 address programmed in the left hand CHF standby 3 address programmed in the right hand CHF active 4 C su
111. oltages are correct replace the power supply e De energize the power supply reconnect the module at the rightmost position of the bus and re energize the power supply Repeat this procedure for each module on the bus from right to left fimshing with the AL 2002 processor checking that the power supply voltage LEDs remain energized Chapter 6 Maintenance As each module is inserted check that it snaps into place correctly and check the fixing screws and connectors If the insertion of one of the modules causes one of the power supply voltages to fail replace it with a spare If a module with an application program is replaced the program must be loaded to the new module according to the instructions contained in its User s Guide The module which has been removed should be sent to Altus Support e Once all the modules have been inserted check the WD LEDs of the system modules If any of the LEDs are lit replace the corresponding module e Connect the AL 3830 or MasterTool programmer to the AL 2002 and check the general status window of the programmable controller the device should be in execution mode with no error messages displayed If there is an error try to solve the problem following the error description and instructions contained in the AL 2002 MSP User s Guide Onthe programmer refer to the module directory window and check the integrity of the CPU application program verifying the presence of all program mo
112. ommunications address for the active CPU allowing the active CPU to be referred easily in communications from other stations on the network PCs supervisor stations For further details refer to the ALNET II Communication with Redundant Controller section in chapter 3 Operating Principles Programming Operands The CHF instruction cells used to call the function are programmed in the following manner e OPERI Specifies the number of parameters to be passed to the function in OPER3 This operand must be a memory constant with value 1 KM 00001 4 17 Chapter 4 Programming e OPER2 Should be a memory constant operand with value 0 00000 Specifies the number of parameters allowed to be programmed in the edit window of OPER4 As this function requires no parameters in OPER4 the value of OPER2 is 0 e OPER3 Contains the parameters that are passed to the function They are shown in an edit window when the CHF instruction is edited The number of editable parameters is specified in OPER being fixed at 1 for this module or Operand specifying the new node address to be assumed by the PC If this is programmed as a constant and values from 1 to 31 can be defined If it is programmed as an M operand its contents should be within the interval 1 to 31 e OPERA Not used Inputs and Outputs Description of inputs e enable when this input is energized the function is called and th
113. ommunications status of remote I O 7 Table 4 13 Remote I O Status Indicator Operands in F 2006 019 In the redundancy control modules P 2006_1 000 and P 2006_2 000 provided with the AL 2006 Brother product these operands in the range M0024 through 0031 In these operands the value zero indicates normal operation no errors Values other than zero indicate faults The presence of values other than zero at these operands should set an alarm for the system operator and display the error identification value If the CPUs are connected via the network to a supervisory system then it is recommended that the supervisory system monitor these operands periodically and display alarm messages for the operands if any of their values is different from zero and show the error identification value or its explanatory text The supervisory system should monitor only those operands which correspond to existing remote stations For example if the system has just three remote stations the supervisory system should monitor operand 16 MXXXX 17 and MXXXX 18 only The error identification codes allowed for these operands are described in appendix A Error Codes Errors which occur should be corrected in accordance with the recommendations contained in the section Procedures in Case of Failure in chapter 6 Maintenance Optical Link Status Indicators In the fourth parameter of the call to module F 2006 019 instruction C
114. one of them controls the system active CPU while the other remains in standby mode backup CPU verifying that the first one is working correctly In case of a failure in the controlling CPU the backup CPU assumes control of the system avoiding interruptions to the process The CPU swap is done very quickly so that the absence of control during the change is as short as possible The AL 2006 Brother processors are used to transfer the main operand values from the active to the backup CPUS at each program scan cycle assuring that both CPUs are synchronized if a switchover is needed The hot standby method of redundancy control is acceptable for processes that allow short periods of absence of control in the range of hundreds of milliseconds Many industrial processes allow periods of this magnitude in case of failures and can be controlled by redundant systems using this method Chapter 1 Introduction AL 2006 Brother Applications e Control system and energy distribution e Security interlocking systems e Control system of continuous processes such as chemical plants refineries cellulose production etc e Oil extraction platforms e Systems with points of input and output distributed over a large area 1 3 Chapter 2 Technical Description Technical Description The AL 2006 Brother processor was designed for safe operation in rigorous industrial environments It is composed of a multilayer circuit board with SMD Surfa
115. osition in this table to configure two remote stations Position 0 Table type identifier O Table type identifier 1000 500 Data rate of the AL 2006 250 125 64 5 Not used reserved TM declaration of remote stations F 2006 019 Optical channel definitions eO optical connection EBEN asd second optical connection ENSE connection TM declaration of remote stations in F 2006 019 Remote 0 definitions 1 to 31 Remote station node address 1 to 63 Remote station sub network address 12 13 4 5 1000 500 Remote station data rate 250 125 64 0 to 9999 First M operand of the area that receives sends remote station values on the local CPU 1 0 to 64 Number of remote station E operands to be read 0 to 64 Number of remote station S operands to be written 0 to 108 Number of remote station M operands to be read Chapter 3 Operating Principles 17 010 112 Number of remote station operands to be written TM declaration of remote I O stations in F 2006 019 Remote 1 Definitions Position Contents 8 1 to 31 Remote station node address 19 1 to 63 Remote station sub network address 20 1000 500 Remote station data rate 250 125 64 21 0 to 9999 First M operand of the area that receives sends remote station values on the local CPU 0 to 64 Number of remote station E operands to be read Number of remote station S operands to be written Number of remote station M operand
116. ough 40 of the for the channels of the bridge processors connected to the system s fiber optic modems Forcing the application program operands MXXXX 3 to 8 and MXXXX 9 to MXXXX 14 to the values 1000 1001 and 1002 will make the AL 2006 Brother processor launch commands to force positions 34 to 40 in the of the corresponding bridge processor channel Further details can be found in the sections entitled Status Indicators of Optical Connection in chapter 4 Programming in the AL 2401 User s Guide and the FOCOS User s Guide Remote Station Octet Status Indicators The first four M operands of the input area of each remote station contain the status of each I O octet of the station one bit per octet as described tables 3 7 and 3 8 of the section Area of Input Operands in Remote Stations in chapter 3 Operating Principles The value 0 indicates normal operation of the octet while value 1 indicates that the octet is deactivated for hot swapping or that there is a fault in the module or bus If the CPUs are connected via the network to a supervisory system it is recommended that this system periodically monitor the status of the octets of each remote and display an alarm message to the operator if they return values other than zero 4 57 Chapter 5 Installation Installation This chapter introduces the procedures necessary for the correct installation of the AL 2006 Brother processor introduc
117. output points remain permanently enabled Description of outputs success with the configure input energized this indicates the successful configuration of the remote station With the configure input de energized this indicates that the function was processed correctly e parameter configuration error indicates an error in one of the CHF parameters incorrect number of parameters invalid parameter type or parameter not defined in the C module of the application program or that one of the values specified the remote configuration table is incorrect e no communication if the enable outputs input is energized this indicates the absence of communications with the CPU s AL 2006 Brother processor If the enable outputs input is de energized then this output remains de energized permanently Usability This function can be used on the following CPUs AL 2003 AL 2000 MSP from version 1 42 onwards AL 2000 MSP C from version 1 12 onwards Chapter 4 Programming QK2000 MSP from version 1 12 onwards and AL 2002 MSP from version 1 50 onwards F END2 082 Modification of ALNET II Node Address enable Success error Introduction The F END2 082 function allows the modification of the PC node address the ALNET II network to values different from those originally configured in the C module under application program control This characteristic 15 used in redundant systems to maintain the same c
118. p instruction within the E 001 module depending on the results of the AL 2006 Brother module processing 4 27 Chapter 4 Programming The whole control program should be under the control of the skip coil activated by either the P 2006_1 000 or the P 2006_2 000 module with the exception of instructions which do not accept skipping them such as ECR and LTR See Contents of the E 001 Module later in this chapter Operands Used Tables 4 9 and 4 10 show the operands used in the P 2006_1 000 and P 2006_2 000 modules which are provided with the AL 2006 Brother 0002 Delay on activation of button for switching to standby mode M0003 Delay in switching to standby mode when both CPUs are in active state mode CPU remote network M0016 Forced status of primary optical link connection 2 M0017 Secondary optical link selected M0018 Status of secondary optical link connection 1 M0019 Status of secondary optical link connection 2 M0020 Secondary optical link forced connection M0021 Forced status of secondary optical link connection 1 4 28 Chapter 4 Programming status for all remote stations M0026 Communications status of remote 2 M0027 Communications status of remote 3 M0033 Memory status of communication with remote stations Table 4 9 TM and M Operands Used in P 2006_1 000 and P 2006_2 000 modules 0000 0 F 2006 019 success output 0000 1 F 2006 019 redundancy error output 0000 2
119. p of I O modules individually or by bus in remote I O processors that have such feature e Hot stand by redundancy with transfer of up to 2 016 bytes of operand values to the backup CPU upon each scanning of the application program of the active CPU 1 008 M operands or 1 008 TM table positions or 504 D operands or 504 TD table positions Several types of operands can be simultaneously configured for the transfer observing the total limit of 2 016 bytes e Interface for integrated high speed communications network multimaster system dedicated ALNET II protocol EIA 485 standard Remote I O e LEDs showing the processor status on the front panel e Intel 80C152 microcontroller as main processor e Clock frequency 15 MHz e Watch dog timer e Capacity to operate with the AL 2002 MSP AL 2003 CPUs Ambient air temperature to 60 C exceeds IEC 1131 standard e Storage temperature 25 to 75 according to IEC 1131 Standard e Relative humidity 5 to 95 non condensing according to IEC 1131 standard level RH2 Chapter 2 Technical Description Weight packed 570 g unpacked 420 g MTBF 40 000 hours 40 C calculated according to MIL HDBK 217F standard Protection IP30 against accidental access by tools without protection against water according to Pub 144 standard 1963 considering the installed product Electrical Features Supply voltages received from backplanet 5 VDC 5 15 VDC 5 15 V
120. perands The first instruction which writes the value to the operand should always be executed should always be enabled can t be skipped This category includes operand points activated by single coils operands which receive values in movement mathematical or conversion functions The operand 000 1 in the previous example is always written with a value at the end of logic 0 coil before being used in logic 1 Failure Diagnostics 4 50 The identification of failures 1s a topic of fundamental importance in any control system Alarm signals should be generated in order that the operators execute the appropriate maintenance procedures Diagnostics assume a special importance in redundant systems in which the process control frequently proceeds normally even when an isolated fault has occurred in one of its component parts Despite the appearance of normal operation this failure should be signaled and corrected to guarantee the safety and availability of the system This section describes the mechanisms for identifying errors related to redundancy processing or the remote I Os For each type of error the procedures for setting alarms which should be included in the supervisory station and or application program in order that the operators may perform the necessary corrective action Depending on the failure the PC application program may take some automatic corrective actions like shutting down the system to a safe state The way to
121. perating Modes The AL 2006 Brother processor after activation can work in four different operating modes shown in figure 3 8 ENERGIZATION INITIALIZATION EXECUTION WATCHDOG Change of status after some time Change of status due to some error Figure 3 8 Operating Modes of the AL 2006 Brother 3 10 Chapter 3 Operating Principles Initialization Mode the EX PG PC and ER LEDs are lit on the front panel indicating that the AL 2006 Brother is initializing its processing variables This mode occurs soon after the programmable controller is powered up taking about 3 seconds and then passing to the execution or error mode Execution Mode the LED EX is lit on the front panel In this mode the AL 2006 Brother is operating normally and is able to communicate with the AL 2002 CPU using the F 2006 019 module When this communication is taking place the PC LED flashes continuously Error Mode the ER LED is lit This mode indicates that there was some kind of malfunction in the PC during processing either a program checksum error or the maximum cycle time was exceeded You can find out the specific cause of the error by connecting AL 3830 or MasterTool programmers on the ALNET I channel and opening the PC status information window In this mode the AL 2006 Brother does not allow communication with the AL 2002 CPU using the F 2006 019 module Watchdog Mode the WD LED 1s lit This indicates that th
122. position The new module must have been configured for the same address as the original if there are jumpers Remote I O Communications Network 6 6 The TX and RX REMOT I O LEDs on the AL 2006 Brother processor front panel should flash rapidly during normal operation The communications status can be checked in greater detail using the MasterTool or AL 3830 programmers making sure that the remote I O network has been installed and is operating correctly For this do as follows e Connect the programming terminal communications cable to the ALNET I connector on the AL 2006 Brother processor e Check the ALNET II communication status in the corresponding window of the AL 3830 or MasterToll programmers e Reset error and communications counters Chapter 6 Maintenance e Wait 5 minutes Check the communications status once again If errors have occurred during this period refer to the ALNET II User s Guide for diagnostics and correction procedures In correctly specified and installed systems with low noise levels the error level should remain at 0 for long periods of time It is recommended that this test be carried out periodically for all AL 2006 Brother processors and remote stations to ensure the proper installation of the ALNET II network Procedures in Case of Failure This section introduces the most common errors that may happen during the use of the AL 2006 Brother processor and includes explanations for t
123. processor channel connected to fiber optic modem controls the redundancy of the two connections This channel executes periodical tests to verify the status of the two optical connections and chooses the connection to be used for communication With the address of this channel declared to F 2006 019 the AL 2006 Brother periodically reads the statuses of the two optical connections providing them to the application program by means of the status indication operands It also allows the application program to select the active connection at the moment Similarly in systems with simple optical connections not redundant the status indication of the optical connection can also be read by the AL 2006 Brother processor and used by the application program For more details refer to the Status Indicators of Optical Connection section in chapter 4 Programming in the ALNET II User s Guide and the FOCOS User s Guide Update Time of Remote 1 0 Stations The time the AL 2006 Brother occupies in each cycle to access all the remote stations and transfer the operands to the redundant CPU can be found using the MasterTool or AL 3830 programmers Simply connect the programmer serial channel cable to the AL 2006 Brother ALNET I connector of the active CPU Chapter 3 Operating Principles and open the CPU status information window The AL 2006 Brother minimum maximum average and instantaneous cycle runtimes are presented to access the remote I O statio
124. r s Guide is indispensable Chapter 5 Installation Installation of the Communications Network 5 8 AL 2006 Brother processor communicates with the remote I O stations and with the redundant CPU through a dedicated ALNET II network Even though it has a specific purpose this network uses the same elements of ALNET communications network as a physical media among programmable controllers The elements are listed below Electrical physical media e 2300 branch cable for the connection of a station to the network e 2600 module for connection of branches and network termination e AL 2301 network cable Optical physical media FOCOS e AL 2401 bridge processor for the interconnection of sub networks AL 2410 modem for the connection of optical channels e AL 2513 power source for fiber optic modems e AL 2610 rack for 16 fiber optic modems AL 2611 rack for 3 fiber optic modems e A 2320 cable for connection of fiber optic modem to bridge processor or PCs Network architecture may be quite flexible as allowed by the ALNET II standard but for Brother application it is limited to 3 sub networks Figure 5 6 shows an architecture using electrical media with 2 remote stations Figure 5 7 shows an architecture with the maximum number of sub nets and optical connections with 4 remote stations For greater data exchange efficiency between CPUs and remote I O stations a data ra
125. ram The ALNET II network node addresses configured in the C modules of the two CPUs should be identical with the same value odd for the backup CPU Refer to the ALNET Communication with Redundant Controller section in chapter 3 Operating Principles 4 45 Chapter 4 Programming e During execution of the F 2006 019 module the call to module E 018 remains disabled The execution of E 018 is postponed until the end of the processing of F 2006 019 if it should have been called during its execution The time taken to process F 2006 019 depends on the number of redundant operands and remote stations with which it is configured to operate In application program configurations with more than 500 redundant operands or more than 4 remote stations E 018 module call periods of less than 50 ms should not be employed within the application program of the AL 2002 CPU e Important points for verification in the remote I O configuration tables e The values in the configuration table positions should be within the limits specified in tables 3 4 and 3 6 in chapter 3 Operating Principles e Each AL 2006 and remote I O processor must have a unique ALNET II address composed by a node address and a sub net address The ALNET II sub net address and baudrate should be the same for both the AL 2006 and all the remote stations when optical communications are not being employed e The values in the TMOOO table for the remote stations should
126. ration 15 described in detail in AL 2401 or QK2401Technical Specifications For addressing of the communications networks with remote stations the same configuration principles applicable to the ALNET networks are valid all the elements connected to the same network segment should be configured with the Same sub network address from 1 to 63 all the elements connected to the same segment of the network should be configured with different node addresses from 1 to 31 For more specific details on the configuration and use of the ALNET II networks refer to the ALNET II User s Guide Use of FOCOS Optical Network A group of I O remote stations or even all the remote stations can be connected over long distances through the optical fibers of the FOCOS system taking advantage of the characteristics of the great immunity to electromagnetic interference and electric insulation Optical channels can be simple or redundant guaranteeing a high availability in environments with risk of damage to the cables For more information on the use and configuration of the FOCOS optical system refer to the FOCOS User s Guide Specific Aspects of Redundancy States of Redundant CPUs The P 2006 1 000 CPU 1 and P 2006 2 000 CPU2 modules of the application program determine the operating state of each CPU supervise the active CPU and control the execution of the main control program If the CPU is powered up and in execution mode it can
127. re disabled any change in their values can alter the activation of the output point 5008 0 The operand M0024 must be configured as redundant since an alteration in its value can cause the activation of the coil 006 0 Therefore for this example the operands M0020 to 0024 and A006 should be defined as redundant Usual Declarations of Redundant Operands In the majority of cases the decision on whether to configure an operand as redundant is based upon certain tendencies depending on the instruction in which the operand will be utilized The two following sections describe these tendencies They are included in order to orient the user and not as a substitute for the analysis of every operand in accordance with the criteria described above Operands which should Normally be Declared as Redundant Operands used in counting instructions counters and timers Operands which are modified by instructions which can be disabled or skipped A or 5 operand points activated by on off coils A operand points used in pulse relay instructions 4 49 Chapter 4 Programming e Operands which are not modified by instructions within the application program but which are written over the communications network by other PCs or either by programming or supervisory stations Operands which do not Normally need to be Declared as Redundant e Operands which are always modified by an instruction before being used by another scratchpad o
128. red from to M operands in the AL 2002 MSP CPU Redundancy This section presents a general overview of the redundancy process using the AL 2006 Brother The sections that follow present more detailed information for several aspects related to this process The AL 2006 Brother allows the implementation of redundant systems in hot stand by configuration In this redundancy architecture the control CPUs are duplicated where one is the active CPU and the other one is the backup CPU The active CPU executes the application program controlling the process The backup CPU only executes a small part in the beginning of the program supervising the operation of the active CPU If the backup CPU detects a failure in the operation of the active CPU the latter is turned off and the backup CPU goes into the active mode assuming control of the system In order for this switchover be carried out without disturbing the control of the process bumpless transfer at each scan cycle of the application program the active CPU copies the contents of its main operands to the same operands the backup CPU The AL 2006 Brother processors are used to transfer these redundant operand values from the active CPU to the backup CPU and at the same time the active CPU executes the application program Thus the backup CPU can assume control of the process with the most currently available status of the active CPU Figure 3 4 shows the normal continuous oper
129. rom table position 10 onwards with each remote occupying 8 positions The function of each of the eight positions 15 identical for all 8 remote stations Table 4 2 I O Remote Station Configuration Positions The remaining remote stations are configured in the subsequent positions each occupying 8 positions as shown in table 4 2 The declaration table should contain the correct number of positions to define the number of remote stations that will be used For example if the system has 3 remote stations then the table should be declared with 34 positions positions 0 through 33 in the C module of the CPU application program Chapter 4 Programming 4 8 Redundancy Configuration The definitions necessary for CPU redundancy operation are achieved through a TM operand programmed as the third parameter for the F 2006 019 function and specified in table 4 3 This table should have at least 16 positions for redundancy to be implemented If there are fewer than 16 positions the table will not be processed No error occurs but the AL 2006 Brother only accepts the I O configuration If there are more than 16 positions the additional positions will be ignored Position O jTabletypeidentifier 0 O Table type identifier 0 2 7 0 1 2 3 4 5 Table 4 3 Redundancy Configuration Positions The Redundancy Configuration table should contain 16 positions For operands types not used in redundancy process
130. rs the AL 2002 MSP begins to execute a new cycle of the application program while the AL 2006 Brother writes the output values and continuously reads the remote station input values to supply the most current values to the CPU on the next F 2006 019 module call Figure 3 3 shows the basic processing of the remote I O stations by the AL 2006 Brother processor and AL 2002 CPU AL 2002 AL 2006 Processing Processing Executive Executive program program Application program communication with AL 2002 CPU F 2006 019 Operands Output writes values to the remote output stations reads values from remote input stations new AL 2002 comm Figure 3 3 Processing of the Remote I O Stations by the AL 2006 Brother If the execution of the AL 2002 MSP application program finishes before the AL 2006 Brother communicates with all of the remote stations a new program cycle is not executed and the 2006 019 function is continuously called until the AL 2006 Brother finishes all communications with the I O stations The AL 2006 Brother allows reading E digital inputs and M analog inputs and special modules remote station operands to the CPU M operands It can Chapter 3 Operating Principles also write CPU M operand values for the S digital outputs and M analog outputs and special modules operands of the remote stations The operands of the remote stations are always transfer
131. rs of both CPUs communicate through the AL 1366 cable to exchange information on the redundancy status among the CPUs The AL 1366 cable has two DB9 male connectors that must be connected to the REDUND connectors on the front panel of the AL 2006 Brother processors The connectors must be tightened using the screws Commissioning The commissioning test consists of the final debugging of the control system when the programs of all remote stations and CPUS are executed together after being developed and verified individually The commissioning test must be performed when all the equipment of the system has already been correctly installed according to the previous recommendations in this chapter and to the guidelines presented in the respective guides The commissioning test is carried out as follows 1 Installation of application programs in the I O remote stations 2 Installation of the application programs on the CPUs 3 Commissioning of the application program Before installing application programs it is necessary to check whether the recommendations presented in the General Programming Precautions section in chapter 4 Programming have been followed Also check whether the versions of the execution software for the CPUs and I O remote stations allow the execution of the F 2006 019 and F REMOT 069 modules Refer to Usability in the sections that describe each module in chapter 4 Programming 5 11 Chapter 5 Install
132. s of CPU States The change of CPU states is carried out by the P 2006_1 000 or P 2006_2 000 modules and can occur due to the detection of failures on the active CPU or commands activated by the user through local input points on the CPUs On each CPU there are input points that should be connected to buttons so that the CPU can be switched to standby and inactive modes Figure 3 11 presents the possible changes of CPU states Chapter 3 Operating Principles ACTIVE a Failure or Standby button pressed on Active CPU b Standby button pressed on Active CPU STANDBY c Standby button pressed on Inactive CPU or power on of a CPU while another is already active INACTIVE d Inactive button pressed on Backup CPU Figure 3 11 Changes of Redundant CPU States Detection of Active CPU Failure The backup or standby CPU supervises the operation of the active CPU to detect failures This supervision is done using a redundant procedure using two simultaneous methods avoiding change of state without a real active CPU failure as shown in figure 3 12 e Communication between AL 2006 Brother processors using redundancy serial channel AL 1366 cable using this dedicated communications channel a CPU receives information about the current status of the other redundant CPU in a quick and efficient way e Communication using the Remote I O network dedicated ALNET II backup CPU should periodically receive comm
133. s to be read 0 to 112 Number of remote station M operands to be written Table 3 4 Contents of the Definition Table for the Remote I O Stations in F 2006 019 The declaration of the remote stations 15 done from position 10 in the table each remote station occupying 8 positions as shown in table 3 5 The function of each one of the 8 positions is identical for all of the 8 remote stations declaration of remote 1 0 stations in F 2006 019 Contents Definitions of remote station 0 Definitions of remote station 1 Definitions of remote station 2 Definitions of remote station 3 Definitions of remote station 4 Definitions of remote station 5 Definitions of remote station 6 Definitions of remote station 7 Table 3 5 Configuration Positions of the I O Remote Stations The declaration table should contain the correct number of positions to define the remote stations to be used For example if the system has 3 remote stations the table should be declared with 34 positions positions O to 33 in the C module of the PC application program 3 27 Chapter 3 Operating Principles Additional information on the use of the F 2006 019 module or on the configuration process of the AL 2006 Brother can be found in chapter 4 Programming Remote Station Configuration Each remote I O station should be configured so that the AL 2006 Brother processor can properly communicate with it This configuration is done using the contents of
134. set an alarm for the system operator If the CPUs are connected via the network to a supervisory system then it is recommended that the supervisory system monitor these auxiliary points periodically and display alarm messages to the operator if they are activated The CPU in which the fault occurred remains de energized and should be re energized as defined in the Procedures in Case of Failure section in chapter 6 Maintenance The operand 003 3 is deactivated on re energization of the CPU 4 51 Chapter 4 Programming 4 52 Redundancy Communication Failure The auxiliary point 003 4 is energized when one of the CPUs fails to receive the information that the redundant CPU is in active standby or inactive over the communication channels The activation of point 003 4 in either CPU 1 or CPU 2 should set an alarm for the system operator This alarm occurs in one of the CPUs when the other is de energized or the communication among both CPU is not working AL 2006 Brother General Status Indicators In the fourth parameter of the call to module F 2006 019 instruction CHF instruction an area of M operands is defined These operands receive a number of status indicators see item F 2006 019 Communication with AL 2006 Brother function in this chapter Within this area two M operands provide the general status of the configuration and operation of the AL 2006 Brother processor and of its communications with the redun
135. stant operand specifying the filtering time in tenths of a second to be applied to the I O points where filtering is enabled Possible values range from to 200 corresponding to results from no effect up to 20 seconds of filtering e MXXXX This operand and the following 31 operands specify which of the input points processed by the function should be subject to filtering Each bit that is ON at one of these M operands enables filtering at a corresponding E operand Bits that are OFF deactivate the filtering process Table 4 6 illustrates the correlation between M and E operands with the purpose of defining filtering points 4 14 Chapter 4 Programming Table 4 6 Filtering Process Configuration Operands Each M operand allows the definition of two E operands The E operands listed on the right hand side of the column 2000 2002 correspond to bits through 7 of the M operand byte L The E operands listed on the left hand side of the column E001 E003 correspond to bits 8 through F of the M operand byte H For example if the M0030 operand is programmed in module F REMOT 069 then to enable filtering for point E027 2 bit M0043 A 0030 13 bit 2 8 byte should be ON To disable filtering for E024 5 bit 0042 5 M0030 12 bit 5 0 byte L should be OFF OPER4 Not used Inputs and Outputs Description of inputs enable when this input is energized the function 15 called and the
136. status with one CPU in active and the other one in standby mode While there is no CPU in standby the system will be operating non redundantly 1 if a failure occurs in the active CPU there would be no standby to take over In redundant systems the security of the system 15 fundamentally based on the existence of spare components in stock for the rapid replacement of defective system elements Procedures to be performed on the de energized CPU Remove the cables plugged into the ALNET II connectors on the AL 2002 processors and the REMOTE I O on the AL 2006 Brother From the 2006 Brother processor also remove the cable plugged into the REDUND connector These cables should remain disconnected throughout this procedure until an item explicitly requests its reconnection e Check that the power cables and grounding leads in good conditions Check the fuses in the power supply If they are burnt out replace them with fuses of the correct value e Loosen the fixing screws and disconnect all of the modules on the CPU bus Re energize the CPU pressing the re energize button of the another CPU on the redundancy control panel e Check that the input voltages for the power supply are within the limits specified in its Technical Specifications e Check that the LEDs on the power supply indicate the existence of all voltages and absence of failures If any of the voltage LEDs is not energized but the input v
137. stem when the programs of all the remote stations and CPUs are executed together after having been developed and verified individually Watchdog Electronic circuit used for verifying the integrity of the operation of a piece of equipment B 3 Index A Application program 8 Application Program Installation on Remote I O Stations 12 Application Program 1 Commissioning 11 Debugging 15 E 001 24 39 F 2006 019 2 F END2 082 16 069 11 Installation on the CPUs 13 Modifications 3 P 2006 000 19 P 2006 1 000 and P 2006 2 000 26 Programming Precautions 43 032 18 Applications 1 3 1 Command Panel Redundancy Command 5 6 Communications Network Configuration 15 Description 6 Installation 11 Tests 6 Connection Cables 7 Appendix C Index p Diagnostics Fault Indicators 49 Status Indicator Operands 9 Electrical Features 5 Errors Active CPU Failure 16 Basic Tests 8 Configuration 8 Detection of Active CPU Failure 17 Execution 13 F Front Panel 1 Connectors 2 LEDs 1 G General Features 4 I O Modules Swapping at the CPU 5 C 1 Appendix Index Swapping at the Remote stations 5 Remote Stations Configuration 26 28 Example of Configuration 35 Operands 29 Update Time 40 E o em Operating Modes Description 10 Switching to Programming Mode 3 Operating State Changing 1 Operatio
138. te of 1 Mbit s should be used In consequence the total length of electrical sub nets should be less than 100 meters When longer networks are used optical media should be used to keep the 1 Mbit s rate Chapter 5 Installation Redundant Central Processing Units Redundancy Communication Power supply Power supply Remote DON TTN Network 1 2000 5 Remote Units AL 2000 MSP C Figure 5 6 Typical Architecture of a Simple System 5 9 Chapter 5 Installation Communication Power supply Power supply Dedicated 3 ALNET AL 2000 MSP C Network Remote I O Units SNI AL 2000 MSP C gt AL 2600 Splitter AL 2401 C Bridges AL 2410 Fiber optic modems SN2 SN3 AL 2000 MSP C AL 2000 MSP C AL 2410 Fiber optic modems Figure 5 7 Architecture of a System with an Optical Network 5 10 96162966A Chapter 5 Installation The procedures for the installation of network components such as architecture information operational limits and the specific characteristics of ALNET II networks can be found in the ALNET II User s Guide Installation of Redundancy Communication When redundant CPUs are used the AL 2006 Brother processo
139. the input operands of the remote stations before the first execution of its application program so that the program can be executed with the most current process values Transfer Operands from the Active CPU to the Backup CPU In order for the backup CPU to continue the control process starting from the Same situation in the active CPU after the occurrence of a failure the latter two conditions are fundamental the application programs of the two CPUs should be identical and the main operand values of the active CPU should be copied to the backup CPU at every scan cycle The latter condition is carried out by the AL 2006 Brother processors During each scan cycle of the application program of the active CPU its AL 2006 Brother processor transmits the operand values configured for redundancy to the redundant AL 2006 Brother so that they are copied to the identical operands of the backup CPU If the active AL 2006 Brother cannot communicate with the backup AL 2006 Brother due to absence deactivation or failure a new cycle of the active CPU program is executed maintaining control of the process The E S A M D TM and TD operands can be transferred to the redundant CPU within the limits presented in table 3 2 E Operand Type Maximum number of redundant operands E 1008 positions 504 positions Table 3 2 Maximum Number of Operands Configurable for Redundancy The configuration of the redundancy of numeric oper
140. the optical links In these operands the value zero indicates normal operation no errors Values other than zero indicate faults in the optical connections that should set an alarm for the system operator If the CPUs are connected via the network to a supervisory system then it is recommended that the supervisory system monitor these operands periodically and display alarm messages to the operator if any of their values is different from zero The operands MXXXX 3 9 can also be monitored in redundant systems to indicate which connections are selected If an error in one of the optical connections 15 detected it should be corrected in accordance with the recommendations contained in the section Procedures in Case of Failure in chapter 6 Maintenance After correcting the connection fault the corresponding operand MXXXX 7 MXXXX 8 13 or MXXXX 14 should be forced to the value 1000 at the active CPU The connection will once more be considered as in a normal status as a result of this forcing and the equivalent status indicator operand MXXXX 4 MXXXX 5 and 10 and MXXXX 11 will return to the value zero If there is still an error after the repair the connection will return to the error status in a few moments due to the tests that the bridge processor performs periodically The operands MXXXX 7 MXXXX 8 MXXXX 13 or MXXXX 14 only used for forcing Their monitoring value always retur
141. tions of TM operands First redundant TD operand Number of redundant positions of TD operands CO Position Values Contents 4 0 Table type identifier O JTabltypeidenifier _ 00 2 1031 Node address of the other AL 2006 on the redundant CPU _ PERE redundant 4 0063 JFirstredundant S operand 5 064 _ redundant S operands 6 0095 FirstredundantA operand 7 0096 NumberofredundantA operans 11 1 8 ____ 0109 999 FirstredundantMoperand 9 ____ 010 1 008 Number redundant M operands 10 0109 999 FirstredundantDoperand 11 00504 NumberofredundantDoperands 11 12 00255 First redundant TM operand 13 ____ 010 1 008 Number of redundant positions of TM operands 14 0255 First redundant TD operand ___ 0 15 ___ 010504 Number of redundant positions of TD operands _______ 15 redundancy configuration table must 16 positions The positions of the table referring to the number of operands or number of positions should contain zero for the operands not used in the redundancy process Redundancy configuration of the S operands is reserved for future use providing that positions 4 and 5 contain the value zero Appendix A Quick Reference Guide Declaration of Remote Stations for the AL 2006 Brother Processor 0 ______ type identifier O Table type identifier 1 000 500
142. uld not exceed 112 in each remote station Or the area of input operands each remote station should not exceed the MO111 operand The number of M operands possible for all of the output areas should not exceed 112 in each remote station Appendix Quick Reference Guide Status Indication Operands for the AL 2006 Brother Processor ndication of status operands in F 2006 019 MXXXX 4 MXXXX 5 MXXXX 6 MXXXX 7 MXXXX 8 MXXXX 9 MXXXX 10 MXXXX 11 MXXXX 12 MXXXX 13 Contents Transmits redundancy status to the other CPU Receives redundancy status from the other CPU General status of the AL 2006 processor and of the communication with the redundant CPU by the Remote I O network Selected connection of the first optical connection 1 or 2 Status of connection 1 of the first optical connection 0 normal or 1 failure Status of connection 2 of the first optical connection 0 normal or 1 failure Forced connection of the first optical connection 0 not forced 1 or 2 Forced status of connection 1 of the first optical connection 0 normal or 1 failure Forced status of connection 2 of the first optical connection 0 normal or 1 failure selected connection of the second optical connection 1 or 2 otatus of connection 1 of the second optical connection 0 normal or 1 failure otatus of connection 2 of the second optical connection 0
143. undant operand values coming from the AL 2006 Brother of the active PC After receiving all of the redundant operand values from the active PC s previous scan cycle the AL 2006 Brother writes them to the operands of the backup CPU in the next communications interruption created by the backup CPU F 2006 019 procedure call Figure 3 10 shows the behavior of the AL 2006 Brother in backup mode AL 2002 Processing AL 2006 Processing VO Bus backplane Executive Program Redundant Operands Communication with AL 2002 ae Dedicated ALNET Network Receive Redundant Operands Redundant Operands from Active CPU Figure 3 10 AL 2006 Brother Processing in Backup Mode e Configuration the AL 2006 Brother processor examines the contents of the parameters programmed in the CHF instruction of the F 2006 019 module call verifying its consistency and initializing its control variables for the new configuration In this mode the AL 2006 Brother does not Chapter 3 Operating Principles communicate with the remote stations nor with the AL 2006 Brother of the redundant CPU Before operating in the active or backup modes the AL 2006 Brother processor should have been configured at least once after the PC has been energized In any of these three operating modes the AL 2006 Brother can process commands in the ALNET I protocol received from its corresponding connector and serially exchange information with the
144. unication from the active CPU 3 17 Chapter 3 Operating Principles Redundant Central Processing Units 5 5 Serial Redundancy Communication AL 1366 cable Figure 3 12 Communications Channels between Redundant CPUs If the backup CPU detects active CPU failure simultaneously using the two communications channels it takes control of the process becoming active and de energizing the redundant CPU The de energization of the CPU in which the failure was detected guarantees the absence of this CPU in the control process The two existing ways for the detection of failures in the active CPU increases the security of the control system allowing it to support single failures such as serial interface damage in the backup PC or disconnection of cables without attempting to change the state since the active CPU 15 in good conditions The time necessary for detecting a failure and changing the backup CPU to active mode depends on the maximum cycle time for the application program configured in the C module of the CPUs For the P 2006 1 000 or P 2006 2 000 modules supplied these times are shown in table 3 1 Maximum cycle time for the program Maximum time for the backup configured in the C module CPU to become active 400 ms 400ms Table 3 1 Time of Failure Detection and Change of State between CPUs Chapter 3 Operating Principles When the backup CPU becomes active the AL 2006 Brother processor reads all
145. value 1 Description one of the modules of the remote station 1s de energized for replacement or the corresponding bus has a fault Procedure each bit of these operands corresponds to the status of an octet at a remote station Locate the C module which corresponds to the octet and check whether it is in hot swapping mode switching it back to normal operation if necessary If all the bits for all octets on the bus are energized check whether the bus is in hot swapping mode checking its power supply if applicable Perform the procedures in Basic Tests in the Event of Errors earlier in this section on the remote station noting any errors reported for the bus Active CPU Failure If the CPU which is in standby mode detects a failure in the active CPU the backup CPU switches to active mode taking control of the process Simultaneously it de energizes the CPU in which the failure has been detected guaranteeing that the error will not interfere with the control process 6 15 Chapter 6 Maintenance 6 16 After the failure one of the CPUs remains in the active mode controlling the process and the other is de energized The procedures described below should be performed in order to locate the failure on the CPU which has been de energized and this CPU must be switched back to standby mode The repair of the failure in the de energized CPU should be performed as quickly as possible so that the system can return to its redundant
146. whose program is being changed should remain as short as possible in programming mode and in the inactive mode For this reason it is advisable that the new modules are already modified and ready for loading before starting the process of program switching The behavior of the new modules can then be analyzed and tested If it 1s desirable to go back to the previous program just switch the active CPU with the new modules to standby and the CPU with the original program will take control of the system once more If the new program is correct the same modification process should be repeated for the other CPU and both CPUs will have the same program with the exception of the redundancy control modules P 2006 1 000 and 2006 2 000 Chapter 6 Maintenance Swapping I O Modules on the Local Bus Non redundant Systems In non redundant systems the swapping of I O modules on the local bus is achieved in one of two ways e de energizing the CPU for I O modules which do not permit hot swapping e the CPU energized for I O modules which permit hot swapping The swapping of modules should be performed according to the procedures contained in the AL 2002 MSP User s Guide Redundant Systems For redundant systems if the module to be switched does not allow hot Swapping then the CPU should be de energized in accordance with the procedure defined in De energizing or Switching CPUs to Programming Mode in this chapter After th
147. ycle This transfer is necessary so that the backup CPU 15 able to assume control of the system in the same state as the active CPU if there is a failure in the active CPU or if a switchover takes places for another reason It is not necessary to transfer all the operands of the active CPU application program to the redundant CPU at every scan cycle In order to optimize system performance only those operands essential to the operation of redundancy should be transferred Each application program should be analyzed and the operands which should be transferred must be defined and grouped in contiguous addresses to avoid the communication of unused operands As a general rule to decide whether an operand should be declared as redundant an analysis should be made of whether a modification in its value will have any influence on the way the application program will behave when it runs the next cycle Those M operands which receive input values from the remote I O stations do not need to be configured as redundant since the AL 2006 Brother in the backup CPU will automatically read the input points when it becomes the active CPU before executing the application program for the first time 4 47 Chapter 4 Programming The operands utilized by the redundancy control modules P 2006_1 000 and P 2006_2 000 cannot be configured as redundant In redundant systems at least one operand must be configured as redundant Example of D
148. ycle time allowed for execution of the application program C module should be configured with 50ms margin in relation to the actual runtime needed by the program rounding up to the next time period allowed For example if the program requires a maximum of 80 ms to execute the time limit configured in the C module should be 200 ms 80ms 50115 130ms using the next allowed time period 200ms Exaggerated margins should be avoided 100 200 ms or greater when 4 42 Chapter 4 Programming configuring the maximum cycle time since this results in an unnecessary increase in response time for the backup CPU to detect active CPU failures e Ifthe maximum cycle time allowed for execution of the application program is to be configured at a value greater than 600 ms then the value constant KM 00008 should be modified to KM 00012 in the TEE instruction with the operand 0006 in logic 11 of both modules P 2006_1 000 and P 2006_2 000 e f AL 2002 CPUs are connected to an ALNET II communications network the values of the call to F END2 082 module instruction parameters should be modified within logic 13 of the 2006 1 000 and 2006 1 000 modules In this logic the left hand CHF instruction configures the node address which the CPU assumes in standby or inactive state and should be an odd value The right hand CHF instruction configures the node address which the CPU assumes in the active mode and should be an even value subsequent t

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