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Schneider Electric Stroller 840 USE 106 0 User's Manual

1. RIO Drop 4 z N iN iN Last RIO Drop dM AAA T Tap MA 0185 100 Drop Cable RG 6 97 5750 000 Trunk Terminator i Hebe Me less T 52 0422 000 Drop Cable RG 6 97 5750 000 140 CHS 320 00 kit includes 2 Splitters 4 F Adapters 2 Terminators See CHS 210 Hot Standby Kit for entire HSBY kit contents 140 CHS 210 00 Premade RG 6 Drop Cable 50 14m AS MBII 003 140 43m AS MBII 004 840 USE 106 00 January 2003 59 Planning a Quantum Hot Standby System A Dual Cable Configuration Diagram of a Dual Cable Standby system Configuration Primary PLC The following diagram shows a dual cable configuration for the Quantum Hot Standby PLC Fiber Optic Cable T Self terminating T F Adapters Coaxial Cable Self terminating 52 0411 000 Coaxial Cable F Adapters Splitter MA 0186 100 52 0411 000 Splitter MA 0186 100 RIO Drop 2 Trunk Cable RG 11 97 5951 000 Trunk Trunk ea E A m Line Line RIO Drop 3 H i I i l l orca 42 eMA 0185 100 E J RG 6 97 5750 000 Tapa m Drop Cable RIO Drop 4 RG 6 97 5750 000 I d I d d Last RIO Drop T em Cable Pt Tap E HN E RG 6 97 5750 000 7 A Trunk Term
2. Hot Standby State IP Address Primary Configured IP Address Standby Configured IP Address 1 Transition from Primary to Offline Configured IP Address if peer controller does not go to Primary Transition from Standby to Offline Configured IP Address 1 Note Offline Results depend on whether or not the other controller is detected as in transition into the primary state If Current IP is the configured IP Address then change the IP Address to the configured IP Address 1 For continued Ethernet communication the new Primary NOE must have the same IP Address as the former Primary NOE The IP Address in the Secondary NOE an NOE in the secondary state is IP Address 1 The NOEs integrated in the Hot Standby configuration coordinate this swapping IP Address with the management of Ethernet services used Note Do not use the address IP 1 For a Hot Standby system do not use consecutive addresses of the configured IP Address If you configure the last IP Address 255 NOE returns diagnostic code Bad IP configuration 168 840 USE 106 00 January 2003 Ethernet Hot Standby Solution NOE Operating Modes and Hot Standby The NOE Modes The NOE modes are e Primary Mode The Hot Standby state is primary and all services are active e Secondary Mode The Hot Standby state is standby and all server services are except DHCP e Standalone Mode Occurs when NOE
3. 840 USE 106 00 January 2003 29 Overview of Quantum Hot Standby Application size For basic mechanisms data and program transfer the IEC HSBY and the 984 HSBY system operate in the same manner The data transfer during normal operation accomplished by copying the state RAM from the Primary to the Standby causes differences in terms of application size In IEC HSBY a part of the state RAM is used to transport the IEC application data from the Primary to the Standby Therefore the size of IEC application data cannot exceed the configured size of the state RAM itself The absolute maximum for IEC application data is 128K 64K words of state RAM For the size of an IEC application s executable code there is also a limit of 568K under Concept 2 1 2 2 The IEC application s executable code limit was increased to 1 Megabyte for Concept 2 5 Quantum IEC Hot IEC Language programs only no 984 Ladder Logic permitted Standby To bring a Standby on line Overview e Primary and Standby controller executives must be equal e Primary and Standby IEC Projects must have the same name and the applications must be equal e On line changes to the Primary are permitted e With Concept 2 1 2 2 the Standby controller is taken off line as soon as the first Primary on line change is made The Primary program must be transferred to the Standby before it can be brought back on line e Concept 2 5 supports Logic Mismatch in the Hot Standby configurati
4. 840 USE 106 00 January 2003 131 Using a Quantum IEC Hot Standby System Hot Standby Status Register Hot Standby Status Register IEC Heap Size The third register in the nontransfer area is the Hot Standby status register Use this register to monitor the current machine status of the Primary and Standby controllers This PLC in OFFLINE mode This PLC running in primary mode This PLC running in standby mode I EE AO NO The other PLC running in primary mode The other PLC in OFFLINE mode 0 1 The other PLC running in standby mode 1 1 0 1 PLCs have matching logic 0 PLCs do not have matching logic 1 Supported only with Concept 2 5 or higher This PLC s switch settoA 0 This PLC s switch settoB 1 1 2 SHAS Se Oe ieee enon eon UO The CHS interface is healthy 0 An interface error has been detected 1 Hot standby capability has not been activated 0 Hot standby is active 1 Note Bit 16 in Modicon convention shown in the diagram above is bit 0 in IEC convention Setting bit 16 means writing a 0x0001 As described in Theory of IEC HSBY Operation p 43 the IEC Heap is transferred from the Primary to the Standby controller through a reserved partition of state RAM This partition consists of a contiguous block of 3x registers they are the so called IEC HSBY Registers Since they are part of s
5. 3nnnnn 400001 AO 400003 400004 400006 4000 LEELEE 4nnnnn Where nnnnn is a multiple of 16 36 840 USE 106 00 January 2003 Theory of 984 HSBY Operation 1 Reduce the reference configuration to minimum requirements Ox 1x 3x 4x Minimizing the state RAM area is one way to reduce scan time 2 Another way is to define registers in a non transfer area an area contained within the state RAM transfer area but ignored during the actual state RAM transfer 3 Use the HSBY configuration extension to define transfer amounts Note If you are customizing the size of your state RAM transfer area you must specify the number of each reference data type 0x 1x 3x and 4x as either 0 or a multiple of 16 In the case of the 4x registers there must always be at least 16 registers allotted 840 USE 106 00 January 2003 37 Theory of 984 HSBY Operation Default Transfer Area Automatic Transfer By default the Hot Standby system automatically transfers the following from the Primary to the Standby controller on every scan e The first 8192 points of Ox output reference data e The first 8192 points of 1x input reference data e Atotal of 10K registers of which 1K is allotted for 3x registers and 9K is allotted for 4x registers In any case the number of 4x registers transferred is a multiple of 16 unless all 4x registers have been included The number of 4x registers may slig
6. Maintenance Step Action Return the key on the original Primary unit to the Run position The Standby indicator should come on Bringing the Original Primary Unit Back Online 840 USE 106 00 January 2003 203 Maintenance Forcing a Switchover Through Software You can force a switchover using the RDE or if you have programmed a CHS instruction in ladder logic a Zoom screen The instructions are the same however in the RDE you are working with the command and status registers while in the Zoom screen you are working with the command and status pages Step Action 1 Addressing the Primary controller Check the status register or page to be sure one unit is designated A and the other is B Be sure that both the Primary and the Standby controllers are in run mode and that the function keyswitch override has been enabled In the command register or on the command page take the Primary controller offline If you are operating on a Modbus Plus network the programming panel is automatically communicating with the Primary controller If you are operating via the Modbus or Modbus Port directly connected to the original primary controller you must reconnect the programming cable to the new Primary controller and then log in again due to the port address swap Result The status should now show that the original Primary controller is offline and that the Standby is now fun
7. 140 CHS 110 00 HOT STANDBY Ready Fault Run Bal Low Pwr ok Modbus Com En Modbus Error A Com Act Error B Primary Mem Prt Standb 1 Be sure the fiber optic cables are connected properly and functioning correctly 2 If the fiber optic cables are in good condition replace the faulty CHS 110 module If the Hot Standby module detects certain errors in its interface with the controller the LED display goes out momentarily as the module tries to recover It either returns to a ready state or reports the error with a blinking Com Act indicator The Com Act error patterns are described in Com Act Error Patterns p 209 1 If you used the CHS function block disable it and restart the system If the Ready indicator comes on the problem is in the CHS 110 module If you used a configuration extension screen go offline and change the configuration to a standalone system Reload the program Restart the system If the Ready indicator comes on the problem is in the CHS 110 module 2 If you have replaced the Hot Standby module and the problem still occurs replace the other components one at a time 3 If the problem still occurs replace the backplane 840 USE 106 00 January 2003 185 Maintenance Board Level Errors PROM RAM UART LED Display fora Board Level Error Troubleshooting Board level errors include PROM checksum RAM data RAM address and UART errors If the Hot Standby module d
8. 400101 000813 000814 Bit 13 Bit 14 000705 BLKM 001 000715 000813 Bit 11 Bit 13 000716 000813 Bit 12 Bit 13 BLKM Transfers the Status of Reverse Transfer Register to Internal Coils Standby MEMORY PROTECT OFF Lamp Output Coil 000208 Standby BATTERY FAULT Outpt Coil som eie ta toil dy a 000209 84 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System 6 3 Using Configuration Extension Introduction Purpose What s in this Section This section describes using the HSBY Configuration Extension This section contains the following topics Topic Page Configuration Extension 86 Hot Standby Dialog 87 Bits in the Hot Standby Command Register 88 Keyswitch Override and Run Mode 90 A Software Control Example 91 Standby on Logic Mismatches 92 Transfer All State RAM 94 Hot Standby Status Register for Configuration Extension 95 Advanced Options 96 Defining the Transfer Area of State RAM 97 Transferring Additional State RAM Data 100 Scan Transfers 102 840 USE 106 00 January 2003 85 Using a Quantum 984 HSBY System Configuration Extension Hot Standby The configuration of the 984 Hot Standby can be done with the Hot Standby dialog Dialog and or with the CHS instruction of the LL984 instruction library Concept shown Configuration Extensions x Data Protection TCP IP Ethernet Peer Cop
9. E a G Prog Data a Safety Buffer Used for Future changes additions Program Data Configured Program Data Unused DFB Instance Data Free Memory for addtl DFB Instance Data 840 USE 106 00 January 2003 53 Theory of IEC HSBY Operation 54 840 USE 106 00 January 2003 Planning a Quantum Hot Standby System 4 At a Glance Purpose What s in this Chapter This chapter describes how to plan a Quantum Hot Standby System This chapter contains the following topics Topic Page Guidelines for Planning a Hot Standby System 56 Electrical Safety Precautions 57 Remote I O Cable Topologies 58 A Single Cable Configuration 59 A Dual Cable Configuration 60 840 USE 106 00 January 2003 55 Planning a Quantum Hot Standby System Guidelines for Planning a Hot Standby System Primary and Standby Controllers Positioning Both the primary and the standby controller in your Hot Standby system must be ready to perform as a stand alone controller in the event that its counterpart fails Therefore you should install them with equal care according to Modicon s standard planning and installation guidelines Refer to the Quantum Automation Series Hardware Reference Guide 840 USE 100 00 and the Remote I O Cable System Planning and Installation Guide 890 USE 101 00 for details Design your system for safety first the
10. Fiber Optic HSBY link 128K 128K bytes bytes State RAM amp IEC Heap download Standby Rack Comm Diag Comm Diag E 1 Scan Note The size of 128K bytes state RAM memory in the timing diagram being transferred with each scan is not a fixed value It expresses the maximum amount of data handled by the CHS module during a data transfer This is a hardware limitation Therefore the maximum State RAM limitation for the IEC user is 128 K bytes Unlike a 984 HSBY system the Standby controller doesn t solve any logic With the new execs delivered with Concept 2 5 the Standby Controller solves logic in Section 1 48 840 USE 106 00 January 2003 Theory of IEC HSBY Operation Overall PLC Scan Time PLC to CHS Data Transfer Rate State RAM The overall scan time for the IEC HSBY supporting PLC type is outlined in the IEC Scan Time Increase Table below IEC Scan Time Increase CPU HSBY Baseline Configuration Scantime Increase because of HSBY CPU 434 12 CPU 534 14 0x 1536 1x 512 3x 512 4x 1872 IEC HSBY registers 3x 700 40 ms Calculating the PLC specific data transfer rate in a Hot Standby system leads to the following result CPU 434 12 534 14 1 9 ms byte The following table lists the number of bytes required for reference storage Coil 0x 3 bits Discrete 1x 3 bits Input Register 3x 2 bytes Holdin
11. except READY ACT blinks four times Primary End one cable fails the Error A or Error B indicator on the RIO head lights instead and the system continues to operate When the RIO cable fails at the Primary end input data may be reset to 0 for one scan because the communication failure to the drop occurs before the broken link is detected 840 USE 106 00 January 2003 189 Maintenance Detecting Failures in the Standby Backplane Troubleshooting To determine which component failed compare the status of the controller Hot Components Standby module and RIO head to the chart below Controller CHS 110 RIO Head Failure Description Stops All LEDs off except All LEDS off except Controller The Interface error READY OR COM ACT READY OR patterns are described in displays error pattern READY on and Com Act Error Patterns COM ACT blinks p 209 once a second Runs as offline COM ACT displays READY on and CHS 110 The Com Act error error pattern COM ACT stops patterns are described in blinking Com Act Error Patterns p 209 Stops All LEDs off except COM ACT displays RIO Head After you have replaced READY error pattern the module and cycled power you must perform a program update to ensure that the controllers have identical programs Error codes for a blinking Com Act indicator are listed in Com Act Error Patterns p 209 Stops All LEDs off except READY on and RIO Cable In a dua
12. 6128 6128 2 6128 2 8 13788 Bytes Total 17659 bytes scan time offset 17659 1 6ms 28ms This application therefore would have an overall scan time in Hot Standby 40 ms reference with CPU 424 02 Ox added by HSBY 36 ms standalone scan time 28 ms offset through configuration increase 104 ms Note No matter how long your transfer takes it does not cause a watchdog timeout 840 USE 106 00 January 2003 35 Theory of 984 HSBY Operation The State RAM Transfer and Scan Time Reduce Scan Time This section describes manipulating the state RAM transfer to reduce scan time Note The state RAM transfer area contains all the state RAM values that are passed between the Primary and Standby controllers The size of the transfer area may be as large as the total size of your controller s state RAM or a portion containing critical I O reference data types As the simplified block diagram below shows all 0x references in the state RAM transfer area are transferred first then all 1x references followed by all the 3x references and finally all the 4x references Total number of discrete outputs transferred Total number of discrete inputs transferred Total number of register inputs transferred Total number of register outputs transferred 600001 DODDOZ popoca a E Onnnnn 100001 100007 En n Li E E 1nnnnn 200001 Ione SLO
13. PLC scan time 8 8 ms scan Data Memory The consumption of data memory is 54 305 bytes DFB instance data 22 496 bytes program data used 76 801bytes used for data 840 USE 106 00 January 2003 151 Additional Guidelines for IEC Hot Standby Data Memory Continued This value alone is not enough to verify whether or not the application fits since we need to know how many IEC HSBY Registers 3x can be reserved to carry the data from the Primary to the Standby controller The diagram below shows that 11 022 words out of 65 024 are already taken for I O references and located variables Therefore the maximum for IEC HSBY Registers would be 65 024 11 022 54 002 words 108 000 bytes This is more than what is actually used for application data 76 801 bytes so that the application would fit IEC Hot Standby requirements The maximum size of the safety buffer for future modifications would be 108 000 76 801 31 199 bytes which is 31 199 76 801 41 Depending on how much safety buffer is required for this particular application the final size of the IEC HSBY Registers could be determined That together with the table presented in Theory of IEC HSBY Operation p 43 would give an idea about the application s overall scan time when operated in IEC Hot Standby mode 152 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby Memory Partition Memory Partition The f
14. 0 __ Enables keyswitch override 1 Sets Controller A to OFFLINE mode 0 Sets Controller A to RUN mode 1 Sets Controller B to OFFLINE mode 0 Sets Controller B to RUN mode 1 Forces standby offline if there is a logic mismatch 0 ___ Does not force standby offline if there is a logic mismatch 1 Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 1 2 3 S so 8 amp 8 8 9 10 11 i 13 14 15 16 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address during switchover 0 Swaps Modbus port 2 address during switchover 1 Does not swap Modbus port 2 address during switchover 0 Swaps Modbus port 3 address during switchover 1 Does not swap Modbus port 3 address during switchover You may enter any number in the range 1 n where n is the last configured 4x register However e The command register must be part of the area of state RAM that gets transferred from the Primary to the Standby controller on every scan 88 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System e Therefore the number you specify for the command register must be in the range of 4x registers you specify in the State RAM area in State RAM dialog If you are using the 12K option the command register must be one of the first 9000 4x registers e The command register must not be within the range of the nontransfer area which you s
15. 840 USE 106 00 Version 2 840 USE 106 00 January 2003 25 Overview of Quantum Hot Standby 1 4 984 HSBY and IEC HSBY Introduction Purpose This section describes 984 HSBY and IEC HSBY What s in this This section contains the following topics Section Topic Page 984 HSBY 27 IEC HSBY 28 26 840 USE 106 00 January 2003 Overview of Quantum Hot Standby 984 HSBY 984HSBY Architecture System Compatibility In a 984 HSBY system the user application is written in 984 ladder logic HSBY mode can be activated by implementation of a CHS loadable function block into logic like the earlier PLC systems used the HSBY loadable function block 984 HSBY may also be activated as a configuration extension that allows additional features to be configured For details refer to Using a Quantum 984 HSBY System p 67 Quantum 984 Hot Standby involves e Concept Version 2 1 or greater Modsoft Version 2 3 or greater Proworx Version 1 5 or greater e All Quantum Controllers e The existing CHS Modules and Execs CHS 110 00 Changes to the running application are possible only by download changes to the Primary controller whereby the Standby goes offline until it gets updated again by using the UPDATE push button refer to Replacement p 192 Minimum Module Versions to Support 984 HSBY Module Version PV SV 140 CPU x13 Ox 2 1 All 140 CPU 424 02 2 1 All
16. Memory Partition 133 State RAM Size 134 840 USE 106 00 January 2003 129 Using a Quantum IEC Hot Standby System Nontransfer Area of State RAM Nontransfer Area The nontransfer area contains the Hot Standby status register which is used to monitor the states of both controllers You may include other 4x registers in the nontransfer area to reduce scan time The Start field is used to specify the first 4x register in the nontransfer area The Length field is used to define the number of contiguous registers in the nontransfer block If you choose to define a nontransfer area the range of legal values for this entry field is 4 n where n is the number of configured 4x registers However when defining the nontransfer area the command register first entry of the Hot Standby dialog must be outside the nontransfer area 130 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System The following block diagram shows how the nontransfer area exists with respect to the rest of the state RAM transfer area State RAM Transfer Area TEE OCC 2n Onnnnn 00001 S00 300003 3nnnnn Actual transferred registers Nontransfer area is excluded from Total number of configured state RAM transfer 4x registers Actual transferred registers Note The command register must not be placed in the nontransfer area No more than one block can be defined as the nontransfer area
17. 140 CPU x34 1x All All 140 CRP 93x 00 2 1 All 140 NOM 2xx 00 2 1 All 840 USE 106 00 January 2003 27 Overview of Quantum Hot Standby IEC HSBY IEC HSBY Architecture IEC Hot Standby means Programming an application with the choice of 5 different IEC compliant languages FBD LD SFC IL and ST 1 The IEC HSBY system uses the same hardware architectures as 984 HSBY System for its basic operations For example state RAM data transfer and Switchover control are the same but there are some differences compared to the 984 HSBY system PLC firmware upgrade is allowed without shutting down the system with Concept 2 5 or higher Earlier versions of Concept require shutting down the system to upgrade PLC firmware RIO is serviced differently With Concept 2 5 or higher it is now possible to download the same application to Primary and to the Standby controller The result is that the Hot Standby system will be fully setup equalized with identical applications in both controllers Earlier versions of Concept require you to use the UPDATE bush button refer to Using a Quantum IEC Hot Standby System p 109 on the CHS module in the Standby rack to equalize both controllers Therefore the same application including the configuration will be running in both controllers There s no CHS function block used in IEC 28 840 USE 106 00 January 2003 Overview of Quantum Hot Standby
18. 162 840 USE 106 00 January 2003 157 Additional Guidelines for IEC Hot Standby Use Constants Instead of Equal Literals Equal Literals In the diagram below when multiple EFB instances use the same fixed value as input they are using equal literals This is not much logic but there is already a lot of data to save actually it s 12 bytes The trick is to declare a constant of type REAL with the value 1 0 and use that in the logic instead of always assigning equal literals to the inputs The point is Every literal no matter what value it has is stored separately in data memory program data area this brings up the advantage that it could be modified due to a download change Literals are rarely modified therefore the modified logic in the diagram below would be more appropriate The four times allocated literal with the value 1 0 has been replaced with a one time allocated constant that has the value 1 0 as well This little change saved 12 bytes of data memory since the type REAL takes 4 bytes and now needs to be allocated 3 times less Ac 1 9 MUL_REAL ADD_REAL real At gt gt real_B real C gt J gt real_D 1 0 1 0 1 8 1 10 SUB REAL ADD REAL real Ep gt real F real Go t DL real H 1 0 gt lt 1 0 gt 158 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby Use Constan
19. 2003 Theory of 984 HSBY Operation How a 984 HSBY System Works 984 Theory Stages of State RAM Transfer State RAM Transfer Both the Primary and the Standby backplanes contain a CHS 110 Hot Standby module The modules monitor their own controller CPU and communicate with each other via fiber link The Primary controller keeps the Standby informed of the current state of the application by transferring state RAM values to the Standby controller during every logic scan RIO head communications are also verified A Hot Standby system transfers state RAM data from the Primary to the Standby controller while the Primary controller scans and solves the ladder logic application program There are three steps in this transfer process 1 Primary controller to Primary CHS 110 state RAM transfer 2 Primary CHS 110 to Standby CHS 110 state RAM transfer 3 Standby CHS 110 to Standby controller state RAM transfer The Primary CHS 110 Hot Standby module initiates the state RAM transfer operation The module requests specified state RAM information from the Primary controller Atthe beginning of each scan the Primary controller transfers the current state RAM data to the CHS 110 Hot Standby module As soon as the transfer controller to CHS 110 finishes the Primary controller resumes scanning user logic and servicing I O The state RAM data is simultaneously transferred from the Primary CHS 110 module to the St
20. Standby Slide switches must be set in opposite positions Update Button 196 840 USE 106 00 January 2003 Maintenance Step Action Turn the key to the mode you want the Standby unit to be in after the update Run or Off Line Result The amber Standby indicator begins to blink Updating Standby Slide switches must be set in opposite positions Update Button Release the update button Result The Primary controller begins copying its full program to the Standby The Standby indicator on the Standby unit continues to blink as the module processes the update When the update is completed the CHS 110 Hot Standby module instructs the Standby controller to return to the mode you have set Run or Off Line If the Standby unit is in Run mode the Standby and Com Act lights are lit If the Standby unit is offline neither indicator is lit The Standby now has an program identical to the Primary unit Remove the key and store it in a secure place 840 USE 106 00 January 2003 197 Maintenance Updating PLC System Executives in a 984 HSBY System Updating PLC Bit 12 in the Hot Standby command register can be set to 1 to facilitate an executive System upgrade while one of the controllers in the Hot Standby system continues to operate Executives CAUTION Overriding the Safety Checking Protection Hazard Setting bit 12 to 1 overrides the safety checki
21. Symax Ethernet IEC Hot Standby MMS Ethernet M 384 Hot Standby Profibus DP aes Hee 86 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Hot Standby Dialog Hot Standby The Hot Standby dialog is shown below it can be activated through Configure Hot Dialog in Standby Concept Concept shown Hot Standby x Command Register Command Register 4x 1 r Run Mode Swap Address at Switchover Controller A Offline ETE er Pati Controller B Offline v Modbus Port 2 7 Standby On Logic Mismatch Offline V Modbus Port 3 C Running r Keyswitch Override Enable Advanced Options r State RAM Transfer All State RAM Non Transfer Area Stat 4x 0 Length 0 Options Cancel Help 840 USE 106 00 January 2003 87 Using a Quantum 984 HSBY System Bits in the Hot Standby Command Register Specifying the The command register is used to control various parameters of the Hot Standby Command system Register Command The command register is specified in the first entry field of the Hot Standby dialog Register By default the command register is set to 400001 If register 400001 is used elsewhere enter another number greater than 0 The number you enter becomes the 4x command register For example if you enter 14 the hot Standby command register is 400014 Disables keyswitch override
22. This section helps you determine which component failed When you have replaced that component you must cycle power with one exception After cycling power if the backplane is now operating it assumes the Standby role If the failure was in the fiber cable the backplane may return to Standby mode without cycling power If replacing the component does not solve the problem call Schneider Electric customer support at 1 800 468 5342 for further directions 188 840 USE 106 00 January 2003 Maintenance Detecting Failures in the Primary Backplane Troubleshooting To determine which component failed compare the status of the controller Hot Components Standby module and RIO head to the chart below Controller CHS 110 RIO Head Failure Type Description Stops All LEDs off All LEDs off except READY on and The Interface error patterns except READY READY COM ACT blinks are described in Com Act OR COM ACT four times Error Patterns p 209 displays error pattern Runs as offline All LEDs off All LEDs off except CHS 110 The Com Act error patterns except READY READY are described in See Com OR COM ACT Act Error Patterns p 209 displays error pattern Stops All LEDs off All LEDs off except RIO Head The Com Act error patterns except READY READY OR COM are described in Com Act ACT displays error Error Patterns p 209 pattern Stops All LEDs off READY on and COM RIO Cable Failure at In a dual cable system if only
23. controller and communicates with the other Hot Standby module The system monitors itself continuously If the Primary controller fails the Hot Standby module switches control to the Standby which then becomes the Primary controller If the Standby controller fails the Primary continues to operate without a backup 16 840 USE 106 00 January 2003 Overview of Quantum Hot Standby Hardware Components in a Quantum Hot Standby System Components A Quantum Hot Standby system requires two backplanes each with at least four slots The backplanes must be equipped with identical compatible Quantum Programmable logic controller Remote I O head processor CHS 110 Hot Standby module Cables See Fiber Optic Cable Guide p 213 Power supply Other components Backplanes I O Modules Splitters as required The following illustration shows the hardware components in a Quantum Hot Standby System Primary Standby Cable to the RIO Network Note The order of the modules in the backplanes must be the same 840 USE 106 00 January 2003 17 Overview of Quantum Hot Standby The CHS 110 Hot Standby Module Topology The following diagram shows the module s front panel which consists of e LED Display e Function Keyswitch e Designation slide switch e Update Button e Fiber optic cable ports CHS 110 Front The following figure shows the module s front panel Panel Controls Version Labe
24. ek 161 Reduce the Use Of Complex Data Structures 20000 eee eee 162 Ethernet Hot Standby Solution 163 Ata GANGE Lowe me pr RE PN aa e Ed 163 Overview of Hot Standby Solution for NOEs 00 0 ce eee eae 164 Hot Standby Topology 0 0 cece eect eh 166 NOE Configuration and Hot Standby 0 0 0 e eee eee eee 167 IP Address Assignment 0 000 cee eee nee 168 NOE Operating Modes and Hot Standby 0c eee eee eee 169 Address Swap Times 6 0 0 eee tet ee 173 Network Effects of Hot Standby Solution 0 000 cece eee eee 174 MaintOnanCe s i isis ke n nag aed ataee see ee dee eee 177 AL a Glance 4 diction ee ru Seek T ttn ub OS 177 Health of a Hot Standby System 0 0 0 cece eee 179 l troductiorn xo ay aes had ace beer ra cbe qu He CEREALES 179 Verifying Health of a Hot Standby System liiieees lesen 180 Additional Checks recia co LET te ae erc et ite RR ERE e ign 181 EIfOISa 23 ut batch Les CO es o det deu NEA LEE avian bys hac lene entes 183 Introduction soc ee Ie a EE UCUAFRADERBSRADUAEAUA AUS 183 Start p EITOLS oo tea DUC REDE DIENUN Gee ls 184 Communications Errors llle 185 Board Level Ertors e x Rex tret bue e ele RICE e doi 186 Fallures rir Ere e ps Ux PC er PA NT REN Hie 187 Introduction iz oso peti Rs bs pe Swan Da NT US PAIN id hes 187 Detecting Failures in a Hot Standby System 0 000000 e eee eee 1
25. less reducing the general memory transfer size The term future modification focuses on changes to the system that do not need the Primary controller to be stopped which is a download change You should try to reduce the size of configured 3x Registers for IEC usage by adjusting it to what s really used in terms of your particular needs regarding future modifications That s why the term safety buffer is used with IEC Hot Standby The diagram above illustrates that the unused parts of the program data and DFB instance data areas make up the safety buffer The important thing is that the size of the safety buffer is a configuration item therefore it cannot change without shutting down the system just as with any other configuration change Memory To help optimize the size of the safety buffer and therefore the total amount of IEC Prediction Dialog HSBY Registers to be transferred use the Memory Prediction dialog to determine an appropriate final configuration This optimization with Concept 2 5 can be done offline The Memory Prediction dialog shows in the Hot Standby Memory section the numbers of bytes configured and used To determine the number of 3X registers divide the number of bytes by two As shown below there are 10000 IEC HSBY registers configured and 78 3 of them are used There is therefore a safety buffer of approximately 22 of the registers to allow for future application changes After making changes to the IEC HSBY
26. lowest reference number 000001 for coils 100001 for discrete inputs 300001 for register inputs and 400001 for register outputs It is accumulated contiguously up to the amount of each data type you specify The total number of each reference type in the state RAM transfer area must be a multiple of 16 For example if you indicate that the number of coils in the transfer area is 96 coils 000001 000096 are transferred from the Primary to the Standby controller Any Ox references beyond 000096 used in state RAM are not transferred The additional state RAM data to be sent over multiple scans can also be of any or all of the four reference data types and must also be specified in multiples of 16 The additional reference data region for each data type starts at the lowest available reference number For example if 2048 coils are transferred on every scan 000001 002048 and you schedule 1024 additional coils for transfer over multiple scans references 002049 003072 are used for the additional transfer data The additional transfer is handled by specifying the number of scans over which you want to send the additional data For example if you specify two scans in which to transfer coils 002049 003072 then coils 002049 002560 are sent with coils 000001 002048 on one scan and coils 002561 003072 are transferred with coils 000001 002048 on the next scan 40 840 USE 106 00 January 2003 Theory of 984 HSBY Opera
27. module to the Standby CHS 110 module over the fiber optic link at a rate of 10 megabaud In turn the Standby CHS 110 module transfers the state RAM data to the Standby controller 46 840 USE 106 00 January 2003 Theory of IEC HSBY Operation System Scan Time Effect on System Scan Time The effect on system scan time of any Hot Standby system depends on how much state RAM is going to be transferred from Primary to Standby A Hot Standby system always has a higher scan time than a comparable standalone system The following has been done to provide information that allows you to forecast a Hot Standby system s scan time e Calculation of overall scan time for a normal Hot Standby baseline configuration containing minimum logic as a reference e Calculation of a PLC specific constant that expresses the increase of overall scan time related to an increase of memory to be transferred The normal Hot Standby configuration state RAM contains e In the local rack power supply CPS PLC CPU RIO Head CRP 93x Hot Standby module CHS e In one remote IO drop equipped with 8 I O modules power supply CPS and remote adapter CRA e Only the logic for the scan time evaluation 840 USE 106 00 January 2003 47 Theory of IEC HSBY Operation Transfer diagram The following shows a transfer diagram 1 Scan Primary Rack A ee State RAM amp IEC Heap download State RAM amp IEC Heap download Over the
28. new function has been added with Concept 2 5 that allows the selection of section s that will not be transferred from the Primary controller to the Standby controller with the exception of SFC sections SFC sections are always transferred every scan A benefit of selecting section s to not be transferred is that it allows you to reduce the number of IEC Hot Standby registers in the configuration and thus reduce Hot Standby scan time The type of sections that should be slected for non transfers are those that do not have to be updated for every scan i e Section that loads recipe This new function should be used along with guidelines for optimizing an IEC application for IEC Hot Standby Operation to reduce HSBY scan time found in Additional Guidelines for IEC Hot Standby p 147 The use of this feature requires initial planning of your Hot Standby project to insure that logic not requiring an update fore every scan is segregated into its own section s so that they can be selected for non transfer Logic elements that can be used in non transfer sections are those that have no internal states e g contacts coils etc Logic elements that should not be used in non transfer sections are those that have internal states e g timers counters etc since the internal state needs to be updated on every scan After sections are selected for nontransfer the number of IEC Hot Standby registers can be reduced To insure that you have enough
29. registers in the configuration reinvoke the Memory Prediction dialog to view the effect on the Hot Standby Memory 142 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System A screenshot of the Memory Prediction dialog is shown below Memory Prediction x M IEC Memory Available 545116 Byte 100 0 Free Byte sn OS Used System 1024 Byte 0 2 96 Section Code Byte Yo Section Data 1088 Byte 0 2 DFB Code Byte 96 DFB Instance data 6380 Byte 1 2 EFB Library 7768 Byte 1 4 96 Upload information 0 Byte 0 0 Diagnostic information 0 Byte 0 0 Recommended reserve 4096 Byte 0 8 96 Reusable after optimization 0 Byte 0 0 LL 984 Memory 1 Available 63198 Byte 100 0 Used for code 0 Byte 0 0 Global Data 2 Configured 20000 Byte 100 0 Used 44 Byte 0 2 Reusable after optimization 0 Byte 0 0 Hot Standby Memory Configured 10000 Byte 100 0 Used 7831 Byte 78 3 Details Help 840 USE 106 00 January 2003 143 Using a Quantum IEC Hot Standby System Memory Memory Statistics HSBY online used for downsizing the number of 3x Registers Statistics for IEC Hot Standby data Memory Statistics 144 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Synchronizing Time of Day Clocks Primary and Secondary controller time of day clocks Elementary Function Block EFB to set the PLC s tim
30. retest the system the power must be turned off and on again Run Time Tests These tests are performed whenever the Ready indicator is on They are executed in small groups to prevent delays in scan time The system performs three kinds of run time confidence tests e Prom checksum e RAM data test e RAM address test 180 840 USE 106 00 January 2003 Maintenance Additional Checks Checking on a Redundant Power Supply Responding to and Recognizing Errors If you have a redundant power supply you may use the STAT block to check its operation The redundant power supply must be I O mapped for its status to be displayed The I O module status section of the STAT block begins at word 12 When a CHS 110 Hot Standby module experiences an error it takes its controller offline It does not communicate with the other CHS 110 module or take part in state RAM data transfers The LEDs on the front panel of the module can help you locate the source of the error The display pattern tells you which controller is experiencing problems and what kind of error is occurring There are four kinds of errors associated with the Hot Standby system e Startup errors e Communication errors e Communication errors e Interface errors e Board level errors For each type of error try the suggested remedies in the order given If no remedy suggested here resolves the error call Schneider Electric customer support at 1 800 468 534
31. running normally it continues to function automatically It constantly tests itself for faults and is always ready to transfer control from the Primary to the Standby if it detects a fault While the system is running the module automatically transfers all state RAM to the Standby unit at the end of each scan This ensures that the Standby is aware of the latest conditions and is ready to take control if needed If one or both of the links between the Hot Standby modules is not functioning the Primary controller functions as though no backup is available If the Primary controller fails the Standby automatically assumes control of the remote I O network If the Primary controller recovers from failure and a power cycle is completed then it assumes Standby responsibilities If it cannot recover it remains offline If the Standby controller fails it goes offline The Primary controller functions as a standalone and continues to manage the I O networks 146 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby 8 At a Glance Purpose What s in this Chapter This Chapter discusses optimizing an IEC application to run better in an IEC Hot Standby environment and specifically how to save data memory This includes existing and newly developed IEC applications This chapter contains the following sections Section Topic Page 8 1 General Application Requirements 149 8
32. the extra state ram Description The Command Status Registers dialog is used to control or monitor various parameters of a Quantum Hot Standby system 840 USE 106 00 January 2003 219 ProWORX Nxt Configuration Command Go to the ProoWORX Command Status Registers Dialog Screen Status Registers dialog screen Command Status Registers Command Register c ERE J Yes Offline Yes EJ Ys Enabled e Disabled 220 840 USE 106 00 January 2003 ProWORX Nxt Configuration Field and functions The following table describes the functions of the fields of the Command Status Registers dialog screen Field Function Swap Port 1 Use to specify if Modbus Port 1 address on primary PLC will change to the standby PLC Modbus Port 1 address when a switchover from primary to standby occurs The 2 options for this field are Yes address changes on switchover No address does not change on switchover Swap Port 2 Use to specify if Modbus Port 2 address on primary PLC will change to the standby PLC Modbus Port 2 address when a switchover from primary to standby occurs The 2 options for this field are Yes address changes on switchover e No address does not change on switchover Swap Port 3 Use to specify if Modbus Port 3 address on primary PLC will change to the standby PLC Modbus Port 3 address when a switchover from primar
33. to make online changes to one controller and the same online changes to the other controller to get matching logic again To equalize both controllers you should either push the Transfer button of the CHS module or do a completer download to the controller which did not receive the download changes e The change of a literal during animation called quickwrite will cause the whole section not to be updated or transferred to the Standby Controller 840 USE 106 00 January 2003 125 Using a Quantum IEC Hot Standby System Updating Project With a logic mismatch project global data will be updated with every scan Global Global Data data that do not exist on both controllers is not updated The project global data that is updated includes e All variables declared in the Variable Editor e All Constants declared in the Variable Editor e All section and transition variables Hot Standby behavior for project global data updating is e All declared variable constant will be updated every scan as long as they are declared on both controllers e facomplete download is done to the controller that did not receive the download change then both controllers will have equal logic and therefore the Standby controller gets updated fully e If due to a download change a project global variable constant has been deleted first and then redeclared this variable constant would be treated as a NEW variable constant even if the same name is us
34. you may force a switchover manually or through Standby software Switchover Note In systems with scan times of 200 ms or greater and more than 15 RIO drops it is recommended that the drop holdup time be increased to 1 5 seconds to ensure that communication with remote drops is maintained during switchover Forcing a Take the following steps to force a switchover manually Switchover Acti Manually Step ction 1 Be sure that the Standby controller has been fully programmed 2 Place the function keyswitch on the CHS 110 Hot Standby module in the Run position Observe that the Standby indicator on the CHS 110 module is steady amber Be sure that the designation slide switch on one Hot Standby module is in position A and that the switch on the other Hot Standby module is in position B 840 USE 106 00 January 2003 201 Maintenance Step Action 5 Confirm that the keyswitch on both Hot Standby modules has not been overridden by software After Taking the Primary Controller Offline Primary Standby 6 Turn the key on the Primary Hot Standby module to Off Line Result Standby should now be functioning as the Primary controller T Check to see that all LED indicators are normal and all application devices are functioning properly The Standby indicator should be extinguished and the Primary indicator should be a steady green 202 840 USE 106 00 January 2003
35. 00001 0000s 100002 Li a 1nnnnn 200001 SO000S SOS E a 3nnnnn 400001 GLEE k krg 400003 400004 400005 450008 LEETE L 4nnnnn Where nnnnn is a multiple of 16 Note No 3x registers configured for IEC HSBY 52 840 USE 106 00 January 2003 Theory of IEC HSBY Operation Layout of completely transferred state RAM in an IEC Hot Standby system Layout of The diagram below illustrates that a significant piece of the controller s state RAM is transferred RAM taken as a transfer buffer for copying the IEC heap from the Primary to the Standby controller The transfer header is located at the very top of the transfer buffer The transfer header contains information about the Primary s exec version time synchronization information and the IEC application s version This information allows the Standby controller once it received the transfer buffer to decide whether to remain online or go offline When online the Standby controller copies the Primary s IEC heap out of the transfer buffer into its internal memory which ensures the Standby s IEC data consistency State RAM Compl xferred EC Header es P Exec Vers T Timing Info jg Li Li r L x lt i eS nj r a f ue j r n o Gg oO J x Oo a ir uw x lt 3 i T D o Ke S uw o el m No 3x regs 9 5 Configured amp 5 for IEC HSBY o m re o c 6 S t E tt i x 32 b x 5
36. 01380 Epoxy 30 to 705C 3M 6105 Epoxy 40 to 805C 3M 6100 Hot Melt 40 to 605C Suggested kits include Vendor Part Number Description AMP 501258 7 Epoxy 110 Vac only for AMP connectors AMP 501258 8 Epoxy 220 Vac only for AMP connectors 3M 8154 Epoxy 110 or 220 Vac only for 3M connectors 3M 6150 Hot Melt 110 or 220 Vac only for 3M connectors 214 840 USE 106 00 January 2003 Fiber Optic Cable Guide Other Tools Suggested Tools include Vendor Part Number Description 3M 9XT Optical Source Driver hand held photodyn requires light source e 3M 1700 0850 T Optical Light Source 850 nm ST Photody connectors for 9XT ne 3M 17XTA 2041 Power Meter hand held 3M 7XE 0660 J Optical Light Source 660 nm visible for 9XT use to troubleshoot raw fiber requires FC ST patch cord 3M BANAV FS 0001 FC ST Patch Cord connects FC connector on 7XE to ST 3M 8194 Bare Fiber Adapter ST compatible permits use of above source and meter to test raw fiber two required 840 USE 106 00 January 2003 215 Fiber Optic Cable Guide Other Tools Other Tools Suggested tools include Vendor Part Number Description 3M 9XT Optical Source Driver hand held Photody requires light source ne 3M 1700 0850 T Optical Light Source 850 nm ST Photody connectors for 9X
37. 05 400006 e e k Remaining outputs not transferred 4nnnnn Y User Defined Use the State RAM area to define the size of the data range All of the reference data State RAM that you specify in this area is transferred from the Primary to the Standby controller Transfer on every scan except the defined nontransfer area All reference data items must be 0 or specified in multiples of 16 A minimum of 16 4x registers is required The maximum amount of state RAM to be transferred on every scan can be as much as the total amount of available state RAM 10K 32K or 64K depending on the type of Quantum controller 840 USE 106 00 January 2003 99 Using a Quantum 984 HSBY System Transferring Additional State RAM Data Additional Data If the Transfer Additional State RAM check box is activated additional State RAM could be transferred In the Additional State RAM area enter the number of 0x 1x 3x and 4x data references that you want to be transferred as additional state RAM All reference data items must be specified in multiples of 16 You must enter a value of 16 or greater for at least one of the four reference data types CAUTION Transfer Additional State RAM Hazard If you choose Transfer Additional State RAM you must specify additional data to be transferred or the controller will not start Failure to follow this precaution can result in injury or equipment damage Use the Extra Transfer
38. 1 Disconnect from the PLC and start the Firmware Loader Utility Perform a firmware download to the standby controller Do a program update from the Primary to the Standby controller as described in Using a Quantum 984 HSBY System p 67 or Using a Quantum IEC Hot Standby System p 109 Atthis point you have a new system executive in the Standby controller with the correct ladder logic and state RAM values Initiate a Hot Standby switchover Perform a firmware download to the new Standby controller Refer to Concept V 2 2 User s Manual 840 USE 483 00 Now both the Primary and the Standby controllers have the new system executive installed and both are running the same logic program with the same state RAM values If you initiate another switchover the controller that was originally the Standby becomes the Standby again Note Some Exec upgrades may be because of new versions of Concept and in certain cases the project may have to be converted before downloading Reconnect to the Primary controller and reset bit 12 of the Hot Standby command register back to 0 via either the Zoom screen or the RDE 840 USE 106 00 January 2003 199 Maintenance Updating PLC System Executives in an IEC HSBY System Updating PLC System Executives Quantum IEC Hot In a Pre Concept 2 5 IEC Hot Standby System it s not possible to update the PLC System executives without shutting down the process
39. 2 State RAM 155 8 3 Efficiency Tips 157 840 USE 106 00 January 2003 147 Additional Guidelines for IEC Hot Standby 148 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby 8 1 General Application Requirements Introduction Purpose What s in this Section This section describes general application requirements for an IEC Hot Standby system This section contains the following topics Topic Page Memory Savings 150 Memory Statistics 151 Memory Partition 1538 840 USE 106 00 January 2003 149 Additional Guidelines for IEC Hot Standby Memory Savings Memory Savings The reasons that memory savings are important to IEC Hot Standby are e The full amount of data memory is restricted to what the IEC HSBY Register can be set to which can never exceed 64K words 128K e The bigger the configured state RAM is the higher the overall scan time Since the IEC HSBY Registers are part of the state RAM the overall scan time gets lower with every saved byte of data memory The restriction of the size of executable code to a maximum of 568K is not important since any IEC application is closer to the limit of 128K of data than to the limit of 568K executable code Therefore all optimization in terms of either making a bigger IEC application fit into the IEC Hot Standby environment or just to make an existing application run faster
40. 2 for further directions 840 USE 106 00 January 2003 181 Maintenance Safety Precautions Before you begin take the following safety precautions WARNING ELECTRIC SHOCK HAZARD To protect yourself and others against electric shock allow no one to touch energized high voltage circuits such as 115V AC Before connecting or disconnecting any high voltage component open and padlock open the disconnect switch which provides power to that component Failure to follow this precaution can result in death serious injury or equipment damage WARNING Avoid Damage to Application I O Devices To avoid damage to application I O devices through unexpected system action while disconnecting any remote I O cable disconnect only the feed through terminator from the module leaving the terminator connected to its cable Failure to follow this precaution can result in death serious injury or equipment damage Note Before you replace any module in either backplane be sure that the spare module is compatible with the Hot Standby system Be sure that you use the correct terminator 182 840 USE 106 00 January 2003 Maintenance 10 2 Errors Introduction Purpose This section will help you determine component failure and causes What s in this This section contains the following topics Section Topic Page Startup Errors 184 Communications Err
41. 31002766 02 Quantum Hot Standby Planning and Installation Guide 840 USE 106 00 Version 4 0 Schneider Electric Table of Contents Chapter 1 1 1 Chapter 2 Safety Information 0 0 cee eee eee eee 9 About the Book ws 3 2 ic es as oil E REY IA es 11 Overview of Quantum Hot Standby 13 Ata Glaree s uoto oec e dote tially es Fn nein marital tak ate 13 Control si S ense ec pn I EVE A ANE Axa Roe ee 15 IntrOdUctlon ume hU MES a ee eet ds 15 Primary and Standby Control 0 0 0 0 cette ee 16 Hardware Components in a Quantum Hot Standby System 17 The CHS 110 Hot Standby Module 00 0 cece eee eee 18 ie cuD m 21 Modes of Operation 0 cette tees 21 GabliG i222 ix ater ases Gatto teda Reta elec d E av ae ncaa Teton hE at ag 23 Introd ction 2p us oie een eg eee eee ee dee er dee ee ee 23 Fiber Optic Gable o yeas ape ted bee tn bead 24 The CHS 210 Hot Standby Kit 6 eee 25 984 HSBY and IEC HSBY iuiuuslselsllslls sees 26 INtTFOGUCHION sasea And od ee Re Se edax ENG 26 OB4sHISBY us sius ah be t onte cie on LA Ede Rr ist 27 IEC ntel e A fastest hk amassed e EA ees ted doro ien 28 Theory of 984 Ladder Logic HSBY Operation 31 Ata Glance see RR Sec YI e eld v 31 How a 984 HSBY System Works 0000 cee eee eens 32 System Scar Time eee ee ERI Bt bo eb ee aN 33 The State RAM Transfer and Scan Time 0000 c
42. 7 A advanced options 96 C cable diagrams 59 distances 56 topologies 58 CHS 110 Hot Standby module 16 28 32 46 startup 104 CHS 210 Hot Standby kit 25 CHS instruction 70 coaxial cable diagrams 58 permissible lengths 56 coaxial splitters required in RIO network 58 Com Act indicator 139 LED 105 command register diagram 118 must not be in nontransfer area 77 complex data structures 162 configuration extension controlling the Hot Standby system 72 dialog screen 218 using configuration extension screens 115 using to control Hot Standby system 114 connectors 214 CRP Remote I O 211 D DFB instance data 44 reducing 161 E elementary function block 145 error patterns 210 Exec 44 F fiber optic cable connecting 24 permissible lengths 56 fiber optic repeaters for extending coaxial cable in RIO network 56 840 USE 106 00 January 2003 223 Index H health message 180 Hot Standby Theory of Operation 164 Hot Standby kit 24 Hot Standby status register 78 132 Hot Standby system cable diagrams 58 distance between modules 56 installation 61 normal operation 108 planning guidelines 56 startup 104 timing 173 topology 166 hot swapping 193 HSBY 13 IEC heap 44 128 IEC HSBY 28 IEC logic 114 IP address 128 K keyswitch 20 override 119 L ladder logic 72 application program 32 LED display during normal operation 105 recognizing
43. 7 6301 PROM checksum error 8 8001 kernel PROM checksum error 840 USE 106 00 January 2003 211 Com Act Error Patterns Number Code Error Blinks 8 8002 flash prog erase error 8 8003 unexpected executive return 212 840 USE 106 00 January 2003 Fiber Optic Cable Guide At a Glance Purpose What s in this Chapter This Appendix describes specifications for the fiber optic cable This chapter contains the following topics Topic Page Fiber Optic Cable 214 Other Tools 216 840 USE 106 00 January 2003 213 Fiber Optic Cable Guide Fiber Optic Cable Recommen dations Connectors Termination Kits Schneider Electric recommends the use of up to 1 km of 62 5 125 graded index duplex multimode glass fiber for all applications Most 62 5 125 cables are rated at 3 5aB loss per km We recommend using a 3 mm diameter cable for your hot Standby system because the fiber cable clasps used to maneuver the cable into the ports are designed to be used with 3 mm cable The following cable meets these recommendations Vendor Part Number Description AMP 502086 1 Black AMP 502908 1 Beige You need four ST bayonet style connectors per cable Suggested connectors include Vendor Part Number Description AMP 503571 1 Epoxy 20 to 475C AMP 503415 1 Epoxy 20 to 475C AMP 5
44. 88 Detecting Failures in the Primary Backplane 200e eee aee 189 Detecting Failures in the Standby Backplane 00 ee eee 190 Failure of Fiber Link from Primary Transmit to Standby Receiver 191 Replacement i teia eene fedem hoe hare bee 192 Introduction z eme MREOGCRR ERR cae aU EAM CERA ORE ES 192 Replacing a Hot Standby Module 2 0 0 eee eee ee 193 Changing the Program and Performing a Program Update 194 Updating PLC System Executives in a 984 HSBY System 198 Updating PLC System Executives in an IEC HSBY System 200 Eesti urne cess ERREUR ODE RES EXE RR RR eles P EEG Iw RE RU ea 201 Forcing a Switchover 1 0 eect tees 201 Chapter 11 Appendices Appendix A Appendix B Appendix C Specifications for CHS 110 Hot Standby 205 Specifications 25 td bec pedet een et de denk E i ELE RR Maced qos 205 DICTUS 207 Appendices for Quantum Hot Standby Planning and Installation Guide 207 Com Act Error Patterns 000 c eee eee eee 209 A aGlatC6 coer eoe hose fae ced E dm ettet tetas ot te Nat tal aah coal n 209 CHS 110 Hot Standby Module Error Patterns 000005 210 CRP Remote I O Head Processor Error Patterns 00e ee eee 211 Fiber Optic Cable Guide 0 cece eee ee eee 213 Ata Glance usce Rer EARS gainer bbs etr eet satus 213 Fiber Optic Cable lsllsese
45. Architecture As shown below Quantum IEC Hot Standby involves e Concept Version 2 1 or greater e Two High End Quantum Controllers CPU 434 12 or CPU 534 14 e The existing CHS Modules and Execs CHS 110 00 The existing RIO Heads with version 2 0 Execs or greater CRP 93x e All five IEC 1131 languages can be used however 984 Ladder Logic cannot be used The following diagram shows the Quantum IEC Hot Standby Architecture Quantum IEC Hot Standby Architecture Concept V 2 1 or higher No Ladder Logic Modbus Plus Quantum Controllers 586 140CPU53414 EIE 486 140CPU43412 TERT Existing CHS module Bae hardware and Execs FIBER OPTIC CHS LINK Existing Remote I O modules and Execs sacra pue With Concept 2 1 2 2 changes to the running application are possible only by download changes to the Primary controller whereby the Standby controller goes offline until it gets updated again by using the UPDATE push button refer to Updating PLC System Executives in an IEC HSBY System p 200 Concept 2 5 supports the Logic Mismatch option on the Hot Standby Configuration Extension which allows the Standby controller to remain online with a different program than the Primary controller Note Unlike Concept 2 1 with Concept 2 2 2 5 it is possible to make changes to the IEC logic offline and download them as online changes later It is not necessary to be connected to the controller at the time of editing the IEC logic
46. Beneath the LED display on the face of each CHS 110 control panel is a function keyswitch It has three positions Off Line Xfer transfer and Run You may use this switch to force transfer of control functions or to copy the full program from the Primary controller to the Standby The following illustration shows a function keyswitch with three positions Off LIne Xfer and Run Of lun ums Line Xfer Run L a T a Note For security or convenience you can disable the function keyswitch with a software override Once the keyswitch is disabled you can set the module to run or offline mode with software This can be especially helpful when the module is not easily accessible A slide switch located below and to the right of the keyswitch is used to designate the controller as A or B One unit must be designated as A and the other as B Use the Standby Update Button to initiate the Primary to Standby program transfer You must have the keyswitch in transfer mode Note If the controllers are given identical designations the system refuses to acknowledge them both The first unit to power up will be recognized as the Primary controller It is designated A or B according to its switch position The second unit remains offline and the ComAct indicator flashes indicating a startup error Note Once the system is running Primary control may be exchanged between the units regardless of which is designated a
47. Cable Connections The CHS 110 Hot Standby modules are connected by a fiber optic cable The cable has two identical strands Each strand transmits a signal in only one direction For this reason each strand must be connected between the upper transmit port on one module and the lower receive port on the other If the cable is not connected properly the Hot Standby modules are not able to communicate and the Hot Standby system does not function The Primary controller operates without a backup The Standby unit remains offline A 3 meter fiber optic cable is provided in the 140 CHS 210 00 Hot Standby kit One strand of that cable is marked with the manufacturer s name This is the only way to distinguish the two strands This illustration shows CHS 110 Hot Standby modules connected by a fiber optic cable Transmit Receive 24 840 USE 106 00 January 2003 Overview of Quantum Hot Standby The CHS 210 Hot Standby Kit Contents of Kit Each 140 CHS 210 00 Hot Standby kit contains the following parts Part numbers are listed in parentheses Two CHS 110 Hot Standby modules with four fiber cable clasps 140 CHS 110 00 A 3 meter duplex fiber optic cable 990 XCA 656 09 Two coaxial splitters together with two tap terminators and four self terminating F adapters 140 CHS 320 00 A 3 1 2 in diskette with the CHS loadable 140 SHS 945 00 Quantum Hot Standby Planning and Installation Guide
48. Command Register 119 Enable Keyswitch Override 120 Advanced Options Concept 2 5 122 Standby on Logic Mismatch 124 Swapping Addresses at Switchover 127 116 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Hot Standby dialog Activation of Hot The Hot Standby dialog is shown below it can be activated through Configure Hot Standby Dialog Standby Concept 2 5 shown Command Register Command Register 4x Run Mode r Swap Address at Switchover Controller A ottine V Modbus Port 1 I Modbus Port 2 Controller B oftine v Modbus Port 3 Standby On Logic Mismatch Enable Keyswitch Override Offline Running Advanced Options State RAM m Non Transfer Area Start 4x o Length o Cancel Help 840 USE 106 00 January 2003 117 Using a Quantum IEC Hot Standby System Specifying the Command Register Bits in the Hot The command register controls various parameters of the Hot Standby system Standby Command Register Disables keyswitch override 0 Enables keyswitch override 1 Sets Controller A to OFFLINE mode 0 Sets Controller A to RUN mode 1 Sets Controller B to OFFLINE mode 0 Sets Controller B to RUN mode 1 Forces standby offline if there is a logic mismatch 0 Does not force standby offline if there is a logic mismatch 1 Supported only with Co
49. E rem oiv ete RRIEDADUCER Ead EN ET 134 Section Transfer Control lille 135 Section Transfer Control liliis eee 135 Op ration iet uoo scu bias lage Poe eee Edi Par eu Rae 138 Starting Your Hot Standby System lissilil lees lesse 138 Normal Operation z na oet tei OR E roe t eR EEG EA Mia 140 Introd ctiOn a a e poked thes EASY neue ire 140 Memory Scantime optimization llle 141 Synchronizing Time of Day Clocks l i 145 While Your System Is Running sls 146 Additional Guidelines for IEC Hot Standby 147 Ata Glance one eR uar P dE RN IE td ua DN ERE T Rie 147 General Application Requirements 000 c eee eee eee 149 InttOQUCtlOn z eee Rp RDERTeRULE big NE Lee e EY ee ee 149 Memory Savings ssssssssseeseee eet eee 150 Memory Statistics ee Dep E wee A LEUR te ane UL Re eer 151 8 2 8 3 Chapter 9 Chapter 10 10 1 10 2 10 3 10 4 10 5 Memory Partition eor Ro ERO v xe Pa Boe ae 153 State RAM xeu dacs Tubes uU OP Eno des Pac bad dulce Rd alga she anea 155 Efficient Use of State RAM sssssssesseee eee ee 155 Efficiency TIPS sc vet E EROR EXE XO ri aor Rer deb ns 157 Introduction uerb e eus d ER PEDES 157 Use Constants Instead of Equal Literals 00 0 eleesess 158 Use Constants Instead of Open Inputs nauan eee eee eee 159 Programmed Logic i si sisted te ae Ree Sok ape RR Eee a RM RA
50. EC Hot Standby check box Extensions When exiting the Configuration Extension dialog with OK the CHS Hot Standby Screen loadable is automatically added to the project but this requires the loadable being part of the Concept environment refer to Loading the Software p 112 There is a second loadable with the name IHSB added as well It is needed for the program transfer from Primary to Standby In turn when the IEC Hot Standby check box is unchecked the CHS and IHSB loadables are removed from the project automatically The following diagram shows the Configuration Extensions dialog box Concept Configuration extensions dialog IEC Hot Standby activated Configuration Extensions x CI Data Protection ICP IP Ethernet Peer Cop Symax Ethernet MMS Ethernet 1984 Hot Standby Profibus DP men e IEC Hot Standby ensures that the Primary and Standby controllers contain identical IEC applications so that backup is always available in case of a Primary controller failure The configuration of the IEC Hot Standby must be done with the Hot Standby dialog 840 USE 106 00 January 2003 115 Using a Quantum IEC Hot Standby System 7 2 Hot Standby Dialog Introduction Purpose This section describes the Quantum Hot Standby Dialog What s in this This section contains the following topics Section Topic Page Hot Standby dialog 117 Specifying the Command Register 118 Hot Standby
51. EC language control code Application Downloaded IEC language control code and data 44 840 USE 106 00 January 2003 Theory of IEC HSBY Operation IEC Heap Program Data Area The most important new terms to understand in IEC Hot Standby are the IEC Heap the Currently used IEC Heap Size and the Maximum IEC Heap Size The program data area has a default size of 16 KByte whenever a new Concept project is created Its size may be adjusted to the amount of memory that s really needed for a particular application This can be done in the Memory Statistics Dialog while Concept is not connected to the PLC This dialog can be activated through Online gt Memory Statistics Configure size of program data area at the Memory Statistics dialog in offline mode Note Changing the configured size of the program data area results in a complete download of the application no download changes are possible The maximum size of the IEC heap is the maximum amount of memory available for data in any particular IEC application What this means in terms of IEC HSBY is shown in the diagram in A State RAM transferred p 52 840 USE 106 00 January 2003 45 Theory of IEC HSBY Operation How an IEC HSBY System Works IEC Theory State RAM Transfer State RAM Defined State RAM Transfer Initiated Both the Primary and the Standby backplanes contain a CHS 110 Hot Standby module The modules monitor their own cont
52. Enabled Global Data N A Enabled Modbus Messaging Enabled Enabled FTP TFTP FTP Enabled Enabled SNMP Enabled Enabled HTTP Server Enabled Enabled DHCP N A Disabled 840 USE 106 00 January 2003 165 Ethernet Hot Standby Solution Hot Standby Topology Hot Standby The following diagram shows a Hot Standby system the relationship between the Interconnection two redundant systems Two CHS 110 modules are connected via a fiber optic link The RIOs are connected both to each other and to the RIO Drops I R oro C P U moz Fiber Optic T Connector Ethernet Switch Drop Drop Note The following three items are important 1 The two systems must be identical 2 The order of the modules in each rack must be the same 3 The software revisions must be the same In the preceding diagram the NOEs are connected to the same switch Connecting to the same switch is recommended but not required Connecting to the same switch is recommended because the NOEs communicate with each other in order to swap the IP address There are two reasons for connecting to the same switch e If afailure to communicate between the NOEs occurs the time to swap increases e Therefore to minimize the probability of a failure connect the two NOEs to the same switch The other requirement for the switches is that they are on the same sub network 166 840 USE 106 00 Januar
53. IEC Hot Standby registers configured go to the Memory Prediction dialog to view Hot Standby Memory usage See Normal Operation p 140 Additionally you can perform an analyze program under the project menu item If you do not have enough IEC Hot Standby registers then you will receive an error message This message will indicate the minimum number of registers needed A safety buffer should be added to this value to configure space for future program modifications The reduction of the IEC Hot Standby registers is a change in the configuration and requires a complete download of the project i e the Hot Standby process has to be stopped Selecting sections to be not transferred without reducing IEC Hot Standby registers has no effect on the Hot Standby scan time 840 USE 106 00 January 2003 135 Using a Quantum IEC Hot Standby System The section data that will not be transferred when its Update Hot Standby control is set to no Update are e internal states of EFBs used in the section e links All DFB Instance data blocks of each DFB instantiated in the section including nested DFBs local Variables inside any DFB instantiated in the section Section Hot Standby transfer status is changed using the Project Browser Offline with Hot Standby project open open the Project Browser With your mouse select the section whose Hot Standby tranfer status you want to modify and right click Click on Update Hsby to change Transfer State
54. If two NOEs power up simultaneously a resolution algorithm determines the Primary NOE and after determining the Primary NOE the resolution algorithm assigns the configured IP Address to the Primary NOE and then assigns the configured IP Address 1 to the Secondary NOE Offline Mode at Power up Sequence table Offline Mode at Power up Sequence Result Controller A powers up before controller B e IP Address of controller A is configured IP Address e IP Address of controller B is the configured IP Address 1 Both controller A and controller B power up The resolution algorithm will assign controller A a the same time the configured IP address and will assign controller B the configured IP address 1 The NOE performs a duplicate IP test by issuing an ARP request to the configured IP Address If a response is received within 3 seconds the IP Address remains at the Default IP and blinks a diagnostic code If no IP configuration exists the NOE remains in standalone mode and the IP Address must be obtained from either a BOOTP server or from a MAC address 170 840 USE 106 00 January 2003 Ethernet Hot Standby Solution Power Up and Ethernet Services Hot Standby Switchover The process of powering up affects the status of client server services To clarify what happens during a power up the following section describes the power up effects on the Ethernet services The following table sh
55. Instead you must follow the steps in the table below Concept 2 5 IEC Hot Standby System allows the upgrading of the controllers executives without shutting down the system See Advanced Options Section B122 CAUTION Executing the Steps Hazard Following the procedural steps in order is critical for the safety and reliability of your Hot Standby system Failure to follow this precaution can result in injury or equipment damage The following table shows the steps in a Quantum IEC Hot Standby Controller Exec Standby Upgrade Procedure Controller Exec Step Action Upgrade Procedure 1 Stop the process being controlled 2 Stop both controllers 3 Load the new Execs in both controllers 4 Download the project to the primary controller Note Some Exec upgrades may be because of new versions of Concept and in certain cases the project may have to be converted before downloading Note The Primary controller must be started 5 Load the project into the Standby Controller via the fiber optic CHS link in Transfer mode 6 Start the Standby Controller Note You can do this by using the CHS fiber optic update procedure without using Concept Result The IEC Hot Standby System will now come up and run in Normal Recommended Operation 200 840 USE 106 00 January 2003 Maintenance 10 5 Testing Forcing a Switchover Testing a Hot To test your Hot Standby system
56. L Components EDI SECT CTRL 4 disable BOOL hsby State BYTE 840 USE 106 00 January 2003 137 Using a Quantum IEC Hot Standby System 7 5 Operation Starting Your Hot Standby System Preconditions Starting the Note Start one controller at a time Be sure e the controller you are starting first has been fully programmed e the function keyswitch on the CHS 110 module is in the Run position e the designation slide switches on CHS 110 modules are in opposite positions The first controller to power up automatically becomes the Primary controller System regardless of its designation as A or B Step Action 1 Turn on power to the first backplane 2 Start the controller in that backplane 3 Turn on power to the second backplane 4 Transfer the program from the Primary to the Standby controller by putting the keyswitch in transfer position and pressing the update push button on the Standby s CHS module refer to Using a Quantum 984 HSBY System p 67 138 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Start Standby The following table shows the steps to starting Standby be as follows Step Action 1 Start the Standby controller 2 Check the LED display If the system is functioning normally the display should e Onthe CHS 110 module all three indicators should be steady not blinking A blinking C
57. M values that are passed between the Primary and Standby controllers The size of the transfer area is as large as the total size of your controllers state RAM As the simplified block diagram below shows all Ox references in the state RAM transfer area are transferred first then all 1x references followed by all the 3x references and finally all the 4x references In the Quantum HSBY system IEC HSBY does not allow customizing the transfer area This means the whole state RAM is transferred in IEC HSBY except for the nontransfer area an area contained within the transfer area but ignored during the actual state RAM transfer Placing registers in the nontransfer area is one way to reduce scan time because the Primary controller to CHS transfer time is shorter With Concept 2 5 a new function called Section Transfer Control has been added which can be used to reduce scan time See Section Transfer Control p 135 for further information on this feature Note No matter how long your transfer takes it does not cause a watchdog timeout 840 USE 106 00 January 2003 51 Theory of IEC HSBY Operation All State RAM transferred The following diagram shows the state RAM transfer area Total number of discrete outputs transferred Total number of discrete inputs transferred Total number of register inputs transferred Total number of register outputs transferred DODOCH EE E m a goaa a E Onnnnn 1
58. O 73 Using the CHS Instruction Block siesleseleeee eese 74 Introduction o mtt ais ais EE ERES ARIEREITORE OI REPAS 74 Using CHS Instruction Block lssseseeleee ree 75 Command Register 0 6 eect nnn 76 Elements of the Nontransfer Area llle 78 Zoom screen of CHS Instruction 0 0 cee 80 The Hot Standby Status Register 0 00 cc cece eee eee 81 The Reverse Transfer Registers 0 0 c eect ete eee 82 Reverse Transfer Logic Example llle 83 Using Configuration Extension 000 cece eee 85 Introductlori aD Sas eoe ES Rho o tela AT ORE E Eur 85 Configuration Extension lisse 86 Hot Standby Dialog i0 oi arora evista aes TENES 87 Bits in the Hot Standby Command Register 0 0 cece eee eee 88 Keyswitch Override and Run Mode nananana naana cee cee eee eee eens 90 A Software Control Example 0000 c cece tenes 91 Standby on Logic Mismatches 0 0 0 cece eee eee 92 Transfer All State RAM 20 0 0 cee eee 94 Hot Standby Status Register for Configuration Extension 95 Advanced Options 5 xiu edere eet ERE Ee ee Gea 96 6 4 Chapter 7 7 1 7 2 7 8 7 4 7 5 7 6 Chapter 8 8 1 Defining the Transfer Area of State RAM 2 0000 e ee eee ee eee 97 Transferring Additional State RAM Data 00 cece eee eee 100 Scan Transfers ecc See eee ea eee AA 102 Ope
59. Secondary services 6 As soon as NOE B receives the UDP response from NOE A or after its watch dog timer times out it swaps IP Addresses and starts Ethernet services as Primary 7 After NOE A senses that its local controller changes state from Offline to Standby it changes to Secondary accordingly 840 USE 106 00 January 2003 171 Ethernet Hot Standby Solution Step Action 8 The Secondary NOE now becomes the Primary NOE 9 Primary NOE opens all client connections and listens for all server connections and re establishes those connections 10 Simultaneously Secondary NOE listens for all server connections and re establishes those connections Additional The following list provides additional information about the NOE s IP addressing Switchover process resulting from a Hot Standby switchover Information e Some MSTR IEC Function blocks will not complete their transaction as a result of the IP Address swap In this case the MSTR IEC Function block will return the error code 0x8000 e While the NOE is in the process of performing the above actions a new MSTR IEC Function block may become active No resou rces are available to service the new MSTR IEC Function block Therefore the NOE will not service this new MSTR IEC Function block and all three output lines will be low Going to Offline When either the CPU stops or the Hot Standby state goes to offline mode two events o
60. T ne 3M 17XTA 2041 Power Meter hand held Photodyn e 3M 7XE 0660 J Optical Light Source 660 nm visible for 9XT use to troubleshoot raw fiber requires FC ST patch cord 3M BANAV FS 0001 FC ST Patch Cord connects FC connector on 7XE to ST 3M 8194 Bare Fiber Adapter ST compatible permits use of above source and meter to test raw fiber two required 216 840 USE 106 00 January 2003 ProWORX Nxt Configuration C ProWORX Nxt Hot Standby Configuration Extension Description Use the Hot Standby Configuration Extension dialog to specify Hot Standby configuration parameters for a Quantum Hot Standby System It allows the type of state ram to be transferred between primary and standby PLC the non transfer area Ver 2 xx Quantum PLCs with CHS loadable and the command register It is activated from the Network Editor Select Config Extension on the Configuration menu and select HSBY Extension from the Tree Control 840 USE 106 00 January 2003 217 ProWORX Nxt Configuration Configuration Go to the ProWORX Configuration Extensions Dialog Screen In the left window Extensions pane highlight config extensions Hot Standby Quantum Dialog Screen conuomaron Extension onfig Extensions Lo MEAE 218 840 USE 106 00 January 2003 ProWORX Nxt Configuration Field and The following table describes the functions of the fields of the config extensions functions Hot Standby Quantum dialo
61. The Project Browser can also be used to view a project s section s Hot Standby Transfer State Sections that will not be transferred will have a to the left of the section name See the screen shot of the Project Browser below m Project HSBYEXEC er stby ie LD monitor e SCB4 JEEP EB FBD pum 2 m Minimize A EBD fano E pem Close j dam i snl Move Properties 2 scr5 ED syss Memory prediction E pump Delete fan0 Update Hsby EBD dam EBD sump05 136 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Transfer Status Byte The Section Hot Standby Transfer Status Byte can be read by an operator panel or by Data Acquisition System The purpose of the byte is to provide feedback to the Application to indicate whether the Section Data is being transferred to the Standby controller If a fault occurs then the Primary Controller Application or the SCADA System will take appropriate measures to indicate a fault A fault could occur if e the programmer disables the section from transferring e modifications are made to the sections but changes are not downloaded to both controllers This would cause the primary and the standby sections to be different e the Standby controller is not present In the example below the section name is LD1 To access this in the Primary Controller application you would use the variable LD1 hsbyState Select Component of Type BOO
62. Time entry field to specify the number of scans over which you want the additional data to be transferred In general the system divides the number of reference data elements specified in the fifth entry field by the number of scans specified in the sixth entry field Accordingly it divides the data into groups that are transferred contiguously over the specified number of scans These groups of data are transferred with the regular state RAM data that has been scheduled on every scan 100 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Additional Data The diagram below illustrates transfer of additional State RAM data 000001 D Critical inputs transferred 000002 on every scan 009003 Additional inputs transferred I in chunks on multiple scans e Remaining outputs not Onnnnn transferred 100001 Critical inputs transferred 100002 on every scan VORNE Additional inputs transferred s in chunks on multiple scans 4nnnnn Remaining inputs not 1 transferred 300001 Critical inputs transferred 300002 1 on every scan 200003 Additional inputs transferred in chunks on multiple scans Remaining inputs not 3nnnnn Y transferred A 400001 400002 Critical outputs transferred 400003 on every scan 400004 y 400005 400006 Additional outputs transferred s in chunks on multiple scans e Remaining outputs not transferred 4nnnnn Y The system transfers additional data in
63. USE 106 00 January 2003 Appendices Appendices for Quantum Hot Standby Planning and Installation Guide At a Glance The appendices for the Quantum Hot Standby Planning and Installation Guide are included here What s in this The appendix contains the following chapters Appendix Chapter Chapter Name Page A Com Act Error Patterns 209 B Fiber Optic Cable Guide 213 C ProWORX Nxt Configuration 217 840 USE 106 00 January 2003 207 Appendices 208 840 USE 106 00 January 2003 Com Act Error Patterns At a Glance Purpose What s in this Chapter This Appendix describes error patterns for the HSBY This chapter contains the following topics Topic Page CHS 110 Hot Standby Module Error Patterns 210 CRP Remote I O Head Processor Error Patterns 211 840 USE 106 00 January 2003 209 Com Act Error Patterns CHS 110 Hot Standby Module Error Patterns CHS 110 Error The following table shows the number of times the Com Act indicator blinks for each Patterns type of error and the codes possible for that group all codes are in hex Number Blinks Code Error 1 6900 error in additional transfer calculation 2 6801 ICB frame pattern error 2 6802 head control block error 2 6803 bad diagnostic request 2 6804 greater than 128 MSL user loadables 4 6604 powerdown interrupt error 4 6605 UART i
64. ains the following sections 2 Chapter Section Topic Page 10 1 Health of a Hot Standby System 179 10 2 Errors 183 10 3 Failures 187 10 4 Replacement 192 10 5 Testing 201 840 USE 106 00 January 2003 177 Maintenance 178 840 USE 106 00 January 2003 Maintenance 10 1 Health of a Hot Standby System Introduction Purpose This section describes checking the health of a Hot Standby System What s in this This section contains the following topics Section x Topic Page Verifying Health of a Hot Standby System 180 Additional Checks 181 840 USE 106 00 January 2003 179 Maintenance Verifying Health of a Hot Standby System Health Messages The Hot Standby modules exchange a health message approximately every 10 ms If the Primary has an error the Standby is notified and assumes the Primary role If the Standby has an error the Primary continues to operate as a standalone The RIO head processors also verify communication with one another periodically Automatic The system automatically performs two kinds of confidence tests on the Hot Standby Confidence modules Tests e Startup tests e Run time tests Startup Tests The system performs four startup tests Prom checksum RAM data test RAM address test Dual port RAM test If the module fails any of these tests it remains offline and does not communicate with the other Hot Standby module To
65. andby CHS 110 module over the fiber optic link at a rate of 10 megabaud In turn the Standby CHS 110 module transfers the state RAM data to the Standby controller Note Schneider Electric defines State RAM as RAM memory that is used to hold register and discrete inputs and outputs and internal data storage State RAM is allocated to the four different reference types Oxxxx 1xxxx 3xxxx and 4xxxx 32 840 USE 106 00 January 2003 Theory of 984 HSBY Operation System Scan Time Effect on System When the ladder logic program being executed by the primary controller is longer Scan Time than the CHS 110 to CHS 110 transfer the transfer does not increase total system scan time However if the ladder logic program is relatively short the scan finishes before the CHS 110 to CHS 110 data transfer and the data transfer increases total System scan time The following timing diagram shows how the transfer takes place Primary Rack a 1 Scan PLC Solve All Segments E PLC to CHS 110 State RAM Iransfer over the Quantum Backplane r F a CHS 110 to CHS 110 State RAM Transfer Over Fiber Optic HSBY Link Standby Rack CHS 110 A SLA MC CHS 110 to PLC State RAM Transfer rF F PLC SPP TLL 4 Solve Segment 1 Solve Segment 1 1 Scan m The effect on system scan time of any Hot Standby system depends very much on how much state RAM is going to be transferred from Primary to Standby A Hot Standby system alwa
66. andby configuration Note To ensure correct operation of the HSBY system the user must I O map at least 1 RIO drop and 1 I O module This will ensure the proper diagnostic information is transfered between Primary and Standby CRPs This section contains the following topics Topic Page Configuring 984 HSBY 70 Configuration Extension 72 CHS Instruction 73 840 USE 106 00 January 2003 69 Using a Quantum 984 HSBY System Configuring 984 HSBY CHS software The CHS Loadable Installing the CHS loadable into the 984 Environment To configure a 984 HSBY system you must load the CHS software into the controllers The software is included on a diskette in the Hot Standby kit Once you have loaded the software you can choose how to proceed You may control your Hot Standby system through ladder logic or you can use a configuration extension The logic in the CHS loadable is the engine that drives the Hot Standby capability in a Quantum control system The CHS loadable gives you the ability to e specify the Hot Standby command register which is used to configure and control Hot Standby system parameters e define a Hot Standby status register which can be used to monitor the real machine status of the system e implement a CHS instruction in ladder logic Unlike HSBY a comparable loadable used for Hot Standby configurations in 984 controllers the CHS instruction does no
67. ant languages is made for a good reason For many different application problems the best way to solve them depends heavily on what language has been selected for its implementation Of course the language selection is also a matter of the preferences of the programmers and those who maintain the application The user should be free in his decision about which of the IEC languages to select for his particular application Because of the different focus of the IEC compliant languages it is difficult to compare them It should be mentioned however that the SFC language consumes more data in accomplishing a stepwise program execution compared than what one would expect from the implementation of that feature in another language The overall data consumption of SFC steps ranges between 20 to 25 bytes per step which does not include any data from transition sections 162 840 USE 106 00 January 2003 Ethernet Hot Standby Solution At a Glance Purpose This chapter describes configuring and then using the Hot Standby solution with the NOE 771xx product line which supports Ethernet communication The chapter covers solution relevant topics such as IP Address assignment NOE modes and Hot Standby states address swap times and network effects on the Hot Standby solution What s in this This chapter contains the following topics 2 Chapter Topic Page Overview of Hot Standby Solution for NOEs 164 Hot S
68. buted I O networks from the original backplane because they will not be supported at switchover The diagram below shows that local I O must be removed Local VO mist bae Tem os aid TI DIO network musz ba Tem ow aid You need backplanes with at least four slots The components in both backplanes must meet the version requirements listed You must install a splitter and a self terminating F adapter between the original RIO head processor and the RIO network A second cable runs from the splitter to the Standby RIO head processor through a second self terminating F adapter In general you may follow the installation directions in this Chapter However as a precaution you should first stop the controller and disconnect power to the system 66 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System 6 At a Glance Purpose This chapter reviews the procedures for operating a Quantum 984 HSBY System What s in this This chapter contains the following sections 2 Chapter Section Topic Page 6 1 Configuration 69 6 2 Using the CHS Instruction Block 74 6 3 Using Configuration Extension 85 6 4 Operation 103 840 USE 106 00 January 2003 67 Using a Quantum 984 HSBY System 68 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System 6 1 Configuration Introduction Purpose What s in this Section This section describes Hot St
69. by unit 840 USE 106 00 January 2003 191 Maintenance 10 4 Replacement Introduction Purpose This section describes replacing a Hot Standby module What s in this This section contains the following topics Section Topic Page Replacing a Hot Standby Module 193 Changing the Program and Performing a Program Update 194 Updating PLC System Executives in a 984 HSBY System 198 Updating PLC System Executives in an IEC HSBY System 200 192 840 USE 106 00 January 2003 Maintenance Replacing a Hot Standby Module HotSwap and the Hot Standby System Replacement Procedure Hot swapping any key module in the Primary or Standby backplane forces that backplane offline When the module is in the Primary backplane this causes switchover Key modules include the controller remote I O head processor and the Hot Standby module Any time you hot swap a module you must cycle power to the backplane to ensure proper system initialization If you have hot swapped the controller you must also perform a program update using the proper procedure You may replace a CHS 110 module while the Hot Standby system is running as long as the module is in the current Standby backplane and you follow the procedure below CAUTION Primary Backplane Hazard Do not attempt to hot swap the CHS 110 module in the Primary backplane Failure to follow this precaution can result in injury or
70. ccur 1 NOE mode goes to Offline 2 NOE uses the IP Address of the present configuration IP Address Assignment and Going Offline HSBY State IP Address Assigned ls Primary to Offline Configured IP Address if other controller does not go to Primary Standby to Offline Configured IP Address 1 172 840 USE 106 00 January 2003 Ethernet Hot Standby Solution Address Swap Times Description The following table details what the time for an Address swap comprises such as the time to close connections time to swap IP addresses or time to establish connections The following table shows the swap time for each of the Ethernet services Service Typical Swap Time Maximum Swap Time Swap IP Addresses 6 ms 500 ms I O Scanning 1 initial cycle of I O Scanning 500 ms 1 initial cycle of I O scanning Global Data For times please see the 500 ms 1 CPU scan 840USE11600 Quantum NOE 771 xx Ethernet Modules User Guide Client Messaging 1 CPU scan 500 ms 1 CPU scan Server Messaging 1 CPU scan the time of the client reestablishment connection 500 ms the time of the client reestablishment connection FTP TFTP Server The time of the client reestablishment connection 500 ms the time of the client reestablishment connection SNMP 1 CPU scan 500 ms 1 CPU scan HTTP Server The time of the client reestablishm
71. controller B are 129 and 130 By default this offset is maintained between port addresses in the event of switchover For example if controller B becomes the Primary controller as the result of switchover its Modbus ports assume the addresses of 1 and 2 and the comparable ports on controller A assume addresses 129 and 130 The three check boxes allow you to change this default condition on any or all of the Modbus ports on the two controllers in your Hot Standby system For example if you deselect the parameter Modbus Port 1 then no offset is maintained at switchover and after switchover the two ports have the same address Thus if controller A is the Primary controller and its Modbus port 1 address is 1 then that port address remains 1 after a switchover occurs Likewise if controller B becomes the Primary controller as a result of switchover its Modbus port 1 address is also 1 Note If you change the selections the port addresses are not affected until a Switchover occurs In a Quantum Hot Standby system the Modbus Plus port addresses on the Standby controller are offset by 32 from the comparable ports on the Primary controller For example if controller A is the Primary controller and its Modbus Plus port has address 1 then the address for the corresponding port on Standby controller B is 33 The numerical range for addresses for both ports is 1 through 64 Thus if the port on the Primary controller has address 50 t
72. ctioning as the Primary unit Refer to Command Register p 76 Check the LED displays on the Hot Standby modules to confirm that the switchover has taken place The Primary indicator on the original Primary unit should be extinguished while the Primary indicator on the original Standby unit should be a steady green In the command register or on the command page return the original Primary unit to RUN mode The status register or page and the LED display on the front panel of the Hot Standby module should now show that unit in Standby mode 204 840 USE 106 00 January 2003 Specifications for CHS 110 Hot Standby 1 1 Specifications Specifications for CHS 110 Hot Electrical Standby Electrostatic Discharge IEC 801 2 8 kV air 4 kV contact RFI Immunity IEC 801 3 27 1000 MHz 10 V m Bus Current Required Typical 700 mA Operating Conditions Temperature 0 to 60 C Humidity 0 to 95 Rh noncondensing 60C Altitude 15 000 ft 4500 m Vibration 10 57 Hz Q 0 075 mm d a 57 150Hz 9 1g Storage Conditions Temperature 40 to 85 C Humidity 0 to 95 Rh noncondensing 60 C Free Fall 1 m unpackaged Shock 3 shocks axis 15 g 11 ms Agency Approvals Electrical UL 508 CE CSA 22 2 142 FM Class Div 2 pending 840 USE 106 00 January 2003 205 Specifications for CHS 110 Hot Standby 206 840
73. dby configuration the instruction must be placed in network 1 segment 1 of the ladder logic program The top node must be connected directly to the power rail by a horizontal short No control logic such as contacts should be placed between the rail and the input to the top node However other logic may be placed in network 1 Remember the ladder logic in the Primary and Standby controllers must be identical The three nodes in the CHS instruction define the command register the first register in the nontransfer area and the length of the nontransfer area Execute HSBY I HSBY System ACTIVE Unconditionally command register Enable Command 1 nontransfer PLC cannot communicate Register area with its CHS module CHS Enable Nontransfer Area lenath Configuration extension 9 screens are defining the HSBY configuration The bottom output node of the CHS instruction indicates whether the configuration extension screens have been activated and allows the parameters in the screens to override those in the CHS instruction at startup A detailed description of the CHS instruction is provided in the Ladder Logic Block Library User Guide 840 USE 106 00 January 2003 73 Using a Quantum 984 HSBY System 6 2 Using the CHS Instruction Block Introduction Purpose This section describes using the CHS Instruction Block What s in this This section contains the fol
74. e having a newer or older firmware version than the one on the Primary controller Note This option is available only in Hot Standby systems already running with Concept 2 5 122 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System IEC HSBY System Executive Upgrade Procedure The following table shows the steps to upgrade the controller s executive in an IEC HSBY system Note You must first have both controllers running in Concept 2 5 Step Action 1 Connect to the Primary controller with Concept and use the reference data editor to set bit 12 of the Hot Standby command register to 1 Disconnect from the Primary controller Use the Executive Loader to download the new executive to the Standby controller Connect to the Standby controller with Concept and download the project NOTE Projects developed with versions of Concept earlier than 2 5 must be imported into Concept 2 5 using the Converter Start the Standby controller Verify that the Standby controller is in Run Mode and the CHS module indicates that the Standby Controller is now in Standby mode Disconnect from the controller Initiate a Hot Standby switchover using the Key Switch Download the Executive to the new Standby Controller using the Executive loader 10 Use the transfer button on the CHS module to transfer the program to the Standby controller Verify that the Standby co
75. e first The function keyswitch on the CHS 110 module is in the Run position gnation slide switches on CHS 110 modules are in opposite positions controller to power up will automatically become the primary controller regardless of its designation as A or B Starting the The following chart provides the appropriate steps for starting your Hot Standby System System Step Action 1 Turn on power to the first backplane Download the program to the controller Start the controller in that backplane Turn on power to the second backplane 2 3 4 5 Download the program to the standby controller If the switches on the controllers are set to the same address you will not be able to download the program Use the keyswitch program update procedure Start the standby controller Check the LED display If the system is functioning normally the display should match Indicators of a Properly Functioning Hot Standby System shown in the illustration below On the CHS 110 module all three indicators should be steady not blinking A blinking Com Act light signals that your system has detected an error On the corresponding CRP module the Ready indicator is a steady green The Com Act indicator on the primary unit should also be a steady green while the Com Act indicator on the standby RIO head should be blinking slowly 104 840 USE 106 00 January 2003 Using a Quantum 984 HSBY S
76. e of day clock In a Hot Standby system although the Primary and Secondary controllers have their own time of day clocks they are not implicitly synchronized At switchover the time of day changes by the difference between the two clocks This could cause problems if you are controlling a time critical application Assign the time of day clock eight 4x registers in the Specials dialog of the configurator Be sure that none of these 4x registers resides in the nontransfer area all of them need to be transferred to the Standby controller after each scan Then use somewhere in the IEC logic the SET TOD EFB which resides in the system library under the HSBY group SET TOD S PULSE TOD CNF D WEEK MONTH DAY YEAR HOUR MINUTE SECOND While the full IEC Hot Standby system is running meaning the Standby controller is also online your application logic should trigger rising edge of the S PULSE input the EFB This would then not only set the time of day clock in the Primary but the one in the Standby as well at the same time The trigger on the clocks might again run at slightly different speeds this time set process should be repeated periodically for example within a period of 1 minute 840 USE 106 00 January 2003 145 Using a Quantum IEC Hot Standby System While Your System Is Running Constant Internal Monitoring Regular Data Transfers After your Hot Standby system has been started and is
77. e update Run or Off Line The Standby indicator flashes Release the update button The Standby indicator continues to flash during the update and while the Standby unit processes the update If the unit is set to run mode the Standby indicator returns to a steady amber If the unit is set to offline mode the Standby indicator extinguishes Remove the key 840 USE 106 00 January 2003 21 Overview of Quantum Hot Standby Run Mode Note If you turn the key on the Primary unit to transfer the Hot Standby system ignores your action When the keyswitch is in this position the controller is active and is either serving as the Primary controller or is capable of taking over the Primary role if needed The keyswitch on both Hot Standby modules should be in the Run position at all times When the Standby controller is in Run mode and the standby indicator is on it is actively monitoring the status of the system and is ready to take control if the Primary unit fails 22 840 USE 106 00 January 2003 Overview of Quantum Hot Standby 1 3 Cabling Introduction Purpose What s in this Section This section describes cabling for CHS 110 Hot Standby modules This section contains the following topics Topic Page Fiber Optic Cable 24 The CHS 210 Hot Standby Kit 25 840 USE 106 00 January 2003 23 Overview of Quantum Hot Standby Fiber Optic Cable
78. ea in the configuration extension screens must be identical to those in the CHS block CHS Quantum Hot Standby Control System c x Page fr 72 Command Register 400001 INT o i Enable Key Switch Override 400001 BIT16 Enable Controller A in Run Mode 400001 BIT15 Run Mode Controller B in Run Mode 400001 BIT14 Run Mode Don t Force Standby offline if Logic Mismatch 400001 BIT13 Don t Force Allow Exec Upgrade Without Stopping 400001 BIT12 Without Stopping ARNING Setting this Option overrides all safety checking between the primary and Hot Standby controllers Use with extreme caution Reset it after use Do not Swap Modbus port 1 400001 BITOS address during Switchover Do not Swap Modbus port 2 address during Switchover SANT tee Do not Swap Modbus port 3 400001 BITOG address during Switchover No Swap No Swap No Swap See Quantum Hot Standby Handbook for Layout of CMD Reg raps Help 80 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System The Hot Standby Status Register Hot Standby Status Register Bits in the Hot Standby Status Register The status register is register 40012 the third register in the nontransfer area The command register which is defined in the top node has been placed outside the nontransfer area as required The third register in the nontransfer area is the status register Use this register to monit
79. ece eee eae 36 Default Transfer Area liliis 38 Gustomizing Options 52 sae xor ewan hace pect Pada REOR IRE 40 GUSIOM SCANS i oes reb n e oS y emper P E 41 Chapter 3 Chapter 4 Chapter 5 Chapter 6 6 1 6 2 6 3 Theory of IEC HSBY Operation slsss 43 Ata Glane PP 43 IEC Hot Standby Definitions 0 0 0 cc es 44 How an IEC HSBY System Works ees 46 System Scan Time llssseseesesseeeeelee rn 47 State Ram Transfer and Scan Time lssselel lees essen 51 Layout of completely transferred state RAM in an IEC Hot Standby system 53 Planning a Quantum Hot Standby System 55 Ata Glance DEIN 55 Guidelines for Planning a Hot Standby System 0 000 eee ee eee 56 Electrical Safety Precautions 000 cece eens 57 Remote I O Cable Topologies llis 58 A Single Cable Configuration llle 59 A Dual Cable Configuration l l ees 60 Installation s uL UR ERR ERE owe 61 How to Install a Hot Standby System liliis lle eeeess 61 Using a Quantum 984 HSBY System 67 AtaGlance lle YARD EE Sete cae pu b eed 67 Configurations x oua eee E Ie dae t ere A NL e ER eR ges 69 Introduction s oppi eee erue cre A pe dp ce e ce UR sect 69 Configuring 984 HSBY 2 cette eee 70 Configuration Extension 0 0 eect tte eee 72 GEIS InStr ctioli ure eR eERIRLRSEE MAP neAEEERBS ERA
80. ed The update procedure must be followed to bring the controllers to an equalized state Note This is true whether these variables constants are used in the controller program or not Unused variables consume space and require time to be transferred from the Primary to the Standby controller It is not recommended to have many variables that are defined but not used in the Primary controller program Nontransfer Area Although customizing transfers is not an option you should designate a block of 4x of State RAM registers as the nontransfer area These registers are ignored when state RAM values are transferred from the Primary controller to the Standby Placing registers in the nontransfer area is one way to reduce scan time because the Primary PLC to CHS transfer time is shorter See State RAM p 129 for more detail 126 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Swapping Addresses at Switchover Modbus Port Swap Address at Switchover Modbus Plus Port Address Swapping at Switchover In a Hot Standby system the Modbus ports on the Primary controller may have MEM addresses in the range of 1 to 119 This allows an offset of 128 for comparable ports on the Standby controller with 247 the maximum number of addresses For example if controller A is the Primary controller and its two Modbus ports have addresses 1 and 2 then the default addresses for the comparable ports on Standby
81. eeeeeeee III 214 Other To0ls x res v xr Rr ed A NA d ea rn arsit eel 216 ProWORX Nxt Configuration eesseeessese 217 ProWORX Nxt Hot Standby Configuration Extension 217 ee laid de ete aero bho eee aie gate he eaten asit b s 223 Safety Information Important Information NOTICE Read these instructions carefully and look at the equipment to become familiar with the device before trying to install operate or maintain it The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure The addition of this symbol to a Danger or Warning safety label indicates A that an electrical hazard exists which will result in personal injury if the instructions are not followed This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death serious injury or equipment damage A WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death serious injury or equipment damage N CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in injury or e
82. ent connection 500 ms the time of the client reestablishment connection 840 USE 106 00 January 2003 173 Ethernet Hot Standby Solution Network Effects of Hot Standby Solution Overview Browsers Remote Clients Local Clients The Hot Standby solution is a powerful feature of NOEs a feature that increases the reliability of your installation Hot Standby uses a network and using the Hot Standby feature over a network can affect the behavior of e Browsers e Remote and Local clients e O Scanning service e Global Data service e FTP TFTP server The following are factors you may encounter while using the Hot Standby solution Note In Hot Standby configuration the NOE s I O scanner is enabled If a browser requests a page and during the process of downloading that page an IP Address swap occurs the browser will either hang or time out Click the Refresh or Reload button Hot Standby swaps affect remote clients An NOE will reset under the following conditions e Remote Connection Request during Hot Standby Swap If a remote client establishes a TCP IP connection during a Hot Standby swap the server closes the connection using a TCP IP reset e Hot Standby Swap during Remote Connection Request If a remote client makes a connection request and a Hot Standby swap occurs during the connection request the sever rejects the TCP IP connection by sending a reset e Outstanding Re
83. equipment damage Hot swapping any key module in the Primary or Standby backplane forces that backplane offline When the module is in the Primary backplane this causes switchover The following table shows the replacement procedure Step Action 1 Power down the backplane 2 Disconnect the fiber optic cable from the module and remove it from the backplane Install the new module and reconnect the fiber optic cable Restore power to the backplane 840 USE 106 00 January 2003 193 Maintenance Changing the Program and Performing a Program Update Updating the Primary and Standby The program includes the configuration table I O map configuration extensions segment scheduler all EXE loadables and the entire state RAM including user logic Note Program downloads e Change program means a complete program change e Update program means to update the user logic If you reprogram your Primary controller or replace the Standby controller you may use the update feature to copy the full program of the Primary controller to the Standby This feature not only saves time but also ensures that the controllers have identical user logic If program changes include any of the above or replacing the Standby controller the Standby must be in dim awareness before a keyswitch update can be performed Note A program update can only be performed from the Prima
84. erride CAUTION Animation Mode or Reference Data Editor Hazard If you use the animation mode or reference data editor RDE of Concept to enable the keyswitch override while the Hot Standby system is running the Primary controller immediately reads bits 14 and 15 to determine its own state and the state of the Standby Failure to follow this precaution can result in injury or equipment damage If both bits are set to 0 a switchover occurs and the former Primary backplane goes offline The new Primary backplane continues to operate A Software For example Control Example You have enabled the keyswitch override and set the operating mode of controller B to Offline Now the system is powered up and you want to put controller B in RUN mode The keyswitch does not work so you must rely on user logic There are two ways you can proceed 120 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Options for Software Control Example Option 1 Stage Description Comment 1 Change the setting on the Hot To do this you must shut down the Standby dialog System and make the necessary change in the dialog then power up the system again 2 Download the new configuration Option 2 Stage Description Comment 1 Connect Concept to your Primary controller 2 Call up the Reference Data Editor RDE 3 Place the Hot Standby command The operating mode of co
85. errors 181 logic scan 32 46 MAC address 128 maximum IEC heap size 44 N nontransfer area of state RAM command register must not be placed in the nontransfer area 76 placing registers 128 O off line mode 21 P primary controller 16 28 program data 44 program update 194 200 R reduce scan time 36 redundant power supply 181 reference data editor 121 remote I O network cable requirements 56 diagrams 58 hardware required 58 reverse transfer registers 82 run mode 22 run time confidence tests 180 S scan time 142 self terminating F adapters required in RIO network 58 slide switch 20 standby controller 16 28 failure 108 Standby LED 105 startup error 184 state RAM 30 IEC HSBY 46 stages of transfer 32 state RAM transfer automatic 108 224 840 USE 106 00 January 2003 Index state RAM transfer area defined 76 status register 94 Switchover automatic 108 swapping addresses 93 System scan time 33 47 T time of day clocks synchronizing 106 timing diagram 33 transfer buffer 53 transfer mode 21 transfer process 32 troubleshooting 184 trunk terminator required in RIO network 58 840 USE 106 00 January 2003 225 Index 226 840 USE 106 00 January 2003
86. ers IEC Hot Standby Data in the above dialog the bigger the transfer buffer for the IEC heap and therefore the bigger the IEC application may be See State RAM p 155 840 USE 106 00 January 2003 133 Using a Quantum IEC Hot Standby System State RAM Size State RAM Size State RAM Total 3x l Total 2 Transfer buffer for IEC heap compl xferred Note The size of the configured state RAM in an IEC Hot Standby project has a significant impact on the system s scan time Once a logic scan is finished the next does not start before all state RAM data has been transferred to the CHS module Once the number of IEC HSBY Registers has been set you may deactivate the IEC Hot Standby configuration extension and activate it again later the number of IEC HSBY registers remains the same The following diagram shows the IEC State RAM Map 1 Header aly d er or future i RR a Program data changes i 9 moe prog data used additions i configured Program data rh unused e o o r 2 O 7 uu o i oO 2 a g DFB instance No 3x regs g data configured for S IEC HSBY 3 x free memory 4 for addtl DFB E instance data 134 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System 7 4 Section Transfer Control Section Transfer Control Section Transfer Control Description Using Section Transfer Control A
87. etects one of these errors it displays the following pattern The diagram below shows a LED Dislplay for a Board Level Error 140 CHS 110 00 HOT STANDBY Ready Fault Run Bal Low Pwr ok Modbus Com En Modbus Error A Com Act Error B Primary Mem Prt Standby The Ready indicator is a steady green while the Com Act indicator blinks This is the same pattern the module displays for a startup error Follow the troubleshooting procedures for a startup error If the module does not recover replace it Replace the faulty CHS 110 module 186 840 USE 106 00 January 2003 Maintenance 10 3 Failures Introduction Purpose This section helps you determine component failure and causes What s in this This section contains the following topics Section Topic Page Detecting Failures in a Hot Standby System 188 Detecting Failures in the Primary Backplane 189 Detecting Failures in the Standby Backplane 190 Failure of Fiber Link from Primary Transmit to Standby Receiver 191 840 USE 106 00 January 2003 187 Maintenance Detecting Failures in a Hot Standby System Main If one of the main components of the Primary backplane fails control shifts to the Components of Standby If a component fails in the Standby backplane the Standby goes offline the Primary Likewise if the fiber cable link between the Hot Standby modules fails the Standby Backplane goes offline
88. f up to 12K words in state RAM is specified as the transfer area It consists of the following All the Ox discrete outputs in state RAM up to a maximum of 8192 including their associated histories All the 1x discrete inputs in state RAM up to a maximum of 8192 including their associated histories If the total number of registers 3x and 4x combined implemented in state RAM is 10 000 or less then all the registers plus the up down counter history table If the total number of registers 3x and 4x combined implemented in state RAM is greater than 10 000 then a total of 10 000 is transferred in accordance with the previously described formula See Default Transfer Area p 38 Nontransfer Area You also must define a nontransfer area in the middle node of the the CHS Within the State instruction block A nontransfer area RAM Transfer Area e isatool to reduce scan time e is located entirely within the range of 4x registers in the state RAM transfer area which are transferred on every scan e consists of a block of four or more 4x registers e allows the user to monitor the status of the Hot Standby system third register of non transfer area 76 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Nontransfer Area Within the State RAM Transfer Area Only 4x reference data can be placed in the nontransfer area These designated registers are not transferred to the Standby controller thus reducing scan time The follo
89. g Register 4x 2 bytes plus 2 bits IEC HSBY Register 3x 2 bytes 840 USE 106 00 January 2003 49 Theory of IEC HSBY Operation Example This example shows the effect of a configuration change from baseline as shown in the IEC Scan Time Increase Table See Overall PLC Scan Time p 49 A particular application has a standalone scan time of 25 ms in a PLC of type CPU 434 12 The state RAM to be transferred consists of 200 coils 0x 300 discrete inputs 1x 150 input registers 3x 400 holding registers 4x and 14000 IEC HSBY registers 3x The state RAM difference to the reference configuration is Effects of a Configuration Change from Baseline Ox 200 1536 1336 1336 3 8 501 Bytes 1x 300 512 212 213 3 8 80 Bytes 3x 150 512 362 962 2 724 Bytes 4x 400 1872 1472 1472 2 1472 2 8 3312 Bytes IEC Hot Standby regs 14000 3x 14000 2 28000 bytes Total 28000 501 80 724 3312 23383 bytes Scan time offset 23383 1 9ms 44ms This application therefore would have an overall scan time in Hot Standby 40 ms reference with CPU 434 12 534 14 25 ms logic solve 44 ms offset through memory increase 109 ms 50 840 USE 106 00 January 2003 Theory of IEC HSBY Operation State Ram Transfer and Scan Time Reduce Scan Time The state RAM transfer area contains all the state RA
90. g screen Field Function Command Register Use to specify the 4x register that will be used as the command register Use this register to control various parameters of the Hot Standby system Non Transfer Area Start Address Use to specify first 4x register of a group of registers that will not be transferred from primary to standby PLC Non Transfer Area length Use with the start address to specify the number of 4x registers that will not be transferred State RAM Transferred Use to select State Ram transfer options All State Ram all configured state ram transferred e Routine only all state ram defined in routine transfer table e Default 12K e All Ox and 1X discretes up to 8192 each transferred e All3xand 4x registers configured transferred if combined they total less than 10000 e 1000 3x and all 4x registers up to combined total of 1000 transferred if configured combined total of 3x and 4x registers is greater than 1000 e Routine and Extra all state ram defined in routine transfer table and extra transfer table Routine Transfer Table Use to define the state ram 0x 1x 3x 4x to be transferred every scan Each input must be a multiple of 16 and 4x requires minimum of 16 Extra Transfer Table Use to define the state ram 0x 1x 3x 4x to be transferred in multiple scans Each input must be a multiple of 16 e Scans to Transfer Used to specify the number of scans in which to transfer
91. gic program which is updated on every scan by a state RAM data transfer between the two controllers By default the Standby controller is set to go offline if a mismatch is detected between its user logic and that of the Primary controller Switchover cannot occur while the Standby controller is Offline The radio buttons provide you with the option to override this default If you change the parameter in this field from Offline to Running the Standby controller remains online if a logic mismatch is detected between its logic program and that of the Primary controller CAUTION Mismatch Hazard A mismatch in the I O map or configuration is not allowed under any circumstances Failure to follow this precaution can result in injury or equipment damage CAUTION Switchover Hazard If switchover occurs when the radio button is set to Running and there is a logic mismatch between the two controllers the Standby controller will assume Primary responsibilities and will start solving a different logic program from the previous Primary controller Failure to follow this precaution can result in injury or equipment damage 92 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Swap Address at Switchover Modbus Plus Port Address Swapping at Switchover In a Hot Standby system the Modbus ports on the Primary controller may have MEM addresses in the range of 1 to 119 This al
92. he trunk cable via an MA 0185 100 tap and a 97 5750 000 RG 6 drop cable e The last tap on a trunk cable must be terminated with a 52 0422 000 trunk terminator Remote drops must not be connected directly to the trunk cable Refer to the Remote I O Cable System Planning and Installation Guide 890 USE 1001 00 for details Note If you are using a HSBY for data logging the RIO heads must be configured and connected with coaxial cable e f you are using 984 you must configure 2 or more segments e f you are using IEC you must configure 2 or more RIO drops Note For illustrations of both single cable and double cable configurations please see A Single Cable Configuration p 59 and A Dual Cable Configuration p 60 58 840 USE 106 00 January 2003 Planning a Quantum Hot Standby System A Single Cable Configuration Diagram of a The following diagram shows a single cable configuration for the Quantum Hot Single Cable Standby system Configuration Primary PLC Standby PLC T Fiber Optic Cab T Coaxial Cable W Self terminating Self terminating F adapter F adapter 52 0411 000 FILE 52 0411 000 RIO Dropia Trunk Cable Trunk RG 11 97 5951 000 L E L RIO Drop 3 i i E Tap MA 0185 100 E z E Drop Cable i J d RG 6 97 5750 000 Tap MA 0185 100 F Drop Cable RG 6 97 5750 000
93. hen the address for the corresponding port on the Standby can not be 82 so it will be 18 that is 50 minus 32 These addresses are automatically swapped at switchover you do not have the option to change the offset or prevent the addresses from being swapped 840 USE 106 00 January 2003 127 Using a Quantum IEC Hot Standby System IP Address Swapping at Switchover Nontransfer Area of State RAM Note The Quantum Hot Standby system swaps Modbus Plus addresses almost instantaneously at switchover This means that host devices which are polling the Quantum controller can be assured that they are always talking to the Primary controller and that the network has no downtime during switchover The Quantum network option module NOE 771 Ethernet TCP IP supports address swapping at switchover when used in a Hot Standby system This behaves pretty much like the address swap of the Modbus Plus ports except that the offset is 1 instead of 32 So when having the NOE 771 installed with an IP address of AAA BBB CCC DDD configured the module in the Primary rack is going to take that one The module in the same slot of the Standby rack takes address AAA BBB CCC DDD 1 In case DDD 254 DDD 1 is going to be 1 and at switchover the modules exchange their IP addresses The address swap feature of the NOE 771 cannot be controlled it is always activated Note NOE 771 XX is the only Ethernet option module that supports
94. htly exceed the allotment in order to reach the next highest multiple of 16 Any state RAM values above the limits shown in the following diagram are not included in the state RAM transfer area and therefore are not shared with the Standby controller The state RAM values in the range above these limits must not contain the command register or control critical I O 38 840 USE 106 00 January 2003 Theory of 984 HSBY Operation The diagram below shows examples of the data transfer area for different configurations of 3x and 4x registers 309001 m H anxano npo mah RR RR RR Apnd 400806 305007 kd rgi Ima angor eee ee hh dk AU ZI uoa A0 La AUDUKIT aua Ammo Example 1 If you have 3200 3x and 9600 4x registers then the full allotment of 1000 3x registers will be transferred The acutual number of 4x registers transferred will be 9008 that is the full allotment of 9000 registers plus 8 more to reach the next highest multiple of 16 Transfer Area Example 2 If you have 3200 3x and 7000 4x registers then all the 4x registers will be transferred The full allotment of 1000 3x registers will be transferred plus an additional 2000 3x registers to bring the total number of registers transferred to 10 000 So a total of 3000 3x registers will be transferred Example 3 If you have 700 3x and 9600 4x registers then all the 3x registers will be transferred The full allotment of 9000 4x regis
95. igation of the PLC specific data transfer rate in a Hot Standby system leads to the following results CPU x13 0x 1 6 ms byte CPU 424 02 2 0 ms byte CPU 434 12 1 9 ms byte CPU 534 14 State RAM The following table lists the number of bytes required for reference storage in state RAM Coil 0x 3 bit Discrete 1x 3 bit Input Register 3x 2 bytes Holding Register 4x 2 bytes plus 2 bit Based on the data shown in the tables above you may forecast the overall scan time of a Hot Standby system once you know how much state RAM is going to be transferred and the time required for a particular logic application to be executed in a standalone system 34 840 USE 106 00 January 2003 Theory of 984 HSBY Operation Example This example shows the effect of a configuration change from baseline as shown in the Scan Time Increase Table in PLC Scan Times p 34 A particular HSBY application has a standalone scan time of 36 ms in a PLC of type CPU 424 02 The state RAM to be transferred consists of 3000 coils 0x 2500 discrete inputs 1x 2500 input registers 3x and 8000 holding registers 4x The state RAM difference to the reference configuration is shown in the Effects of a Configuration Change from Baseline table below 0x3000 1563 1464 3 8 549 Bytes 1464 1x2500 512 1988 3 8 746 Bytes 1988 3x2500 1212 1288 2 2576 Bytes 1288 4x8000 1872
96. imary and Secondary NOEs to the same switch because e Communication failures between the NOEs increases the time to swap e Connecting two NOEs to the same switch minimizes the probability of a communication failure Note Schneider Electric recommends that a switch is used to connect the NOEs to each other or to the network Schneider Electric offers switches please contact a local sales office for more information The NOE waits for either a change in the controller s Hot Standby state or the swap of UDP messages Then the NOE performs one of two Hot Standby actions If the NOE 1 Detects that the new Hot Standby state is either primary or standby The NOE changes the IP address 2 Receives a swap UDP message The NOE transmits a Swap UDP message and swaps the IP address 164 840 USE 106 00 January 2003 Ethernet Hot Standby Solution All client server services I O Scanner Global Data Messaging FTP SNMP and HTTP continue to run after the switchover from the old to the new Primary NOE Note Failure of an NOE module is not a condition for the primary system to leave the primary state Hot Standby and The NOE 771 family provides different Ethernet services Some services are NOE Module enabled or disabled in a Hot Standby system The following table shows which Functionality services are enabled and disabled Service NOE 771 x0 NOE 771 x1 I O Scanning Disabled
97. in 64 840 USE 106 00 January 2003 Installation Diagram of Aligning Key and Locking Ring Attaching the Cable The diagram below illustrates the alignment of the key and locking ring Connedor Locking Tab Mey wi Locking Ring Fiber Cable Clasp Turn the cable to the right so that the tab locks securely You may leave the fiber cable clasp on the cable for future use but slide it off the boot of the cable to allow the module door to close Repeat this process with the remaining strand of cable and the upper transmit cable connector Note Remember that each strand of cable must be connected to the upper transmit cable connector on one Hot Standby module and the lower receive cable connector on the other If the cable is not properly connected the modules will not be able to communicate and the Standby will remain offline Note One strand of the cable provided in the CHS 210 Hot Standby kit is marked for instance with the manufacturer s name This is the only way to distinguish the two strands 840 USE 106 00 January 2003 65 Installation Adding Hot Standby Capability to an Existing System Converting to Hot Standby System To add Hot Standby capability to an existing Quantum system you must install a second backplane with modules identical to those in the original backplane Keep the following requirements in mind You must remove any local I O and distri
98. in IEC Hot Standby mode will decrease the size of data memory Assessing The assessment of an existing IEC application that will be put into IEC Hot Standby Existing IEC mode is fairly simple Just download the application to the CPU 534 14 or 434 12 or Applications into the 32 bit simulator with one of the Quantum CPUS selected This requires having IEC Hot Standby not activated in the configuration Once the application is downloaded you can view the memory consumption in the Memory Statistics dialog while being Equal connected to the PLC or the simulator The diagram below shows the Memory Statistics dialog after having an example application downloaded to the PLC The consumption for executable code of this particular application is 357 724 bytes user program 414 980 bytes EFB library 972 704 bytes used for executable code The executable code s size is less than the limit of 568K therefore the application fits the IEC Hot Standby requirements 150 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby Memory Statistics Memory The following screen shows memory statistics Statistics Concept shown Total memory 488 048 Bytes 100 0 Zz Free memory 61 040 Bytes 125 Used memory User program 357 724 Bytes 73 3 X EFB library 14 980 Bytes 31 X DFB instance data 54 304 Bytes 11 1 X rProgram Data Configured 28 000 Bytes 1000 Zz Used 22 96 Bytes 80 3
99. in standby mode 1 1 PLCs have matching logic 0 PLCs do not have matching logic 1 c This PLC s switch set to A 0 This PLC s switch set to B 1 1 2 3 14 5 6 7 8 9 10 11 12 13 14 15 16 The nontransfer area must be at least four registers long The first two registers in the nontransfer area are reserved for reverse transfer functions The third register in the nontransfer area is the Hot Standby status register The fourth register and all other contiguous 4x registers specified for nontransfer are ignored when the state RAM values of the Primary controller are transferred to the Standby controller 78 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Example of a In the example the nontransfer area begins at register 40010 as defined in the Nontransfer Area middle node The length is 30 registers as defined in the bottom node Thus the last register in the nontransfer area is 40039 Execute HSBY Unconditionally t ann HSBY System ACTIVE Enable Command Register 40010 PLC canner communicate with its module CHS Enable Nontransfer Area 93 bii aiar configuration 840 USE 106 00 January 2003 79 Using a Quantum 984 HSBY System Zoom screen of CHS Instruction Zoom Screen When both a CHS instruction and the Hot Standby configuration extension are used the parameters you set for the nontransfer ar
100. in this Section This section describes Primary and Standby Control for a Quantum Hot Standby system This section contains the following topics Topic Page Primary and Standby Control 16 Hardware Components in a Quantum Hot Standby System 17 The CHS 110 Hot Standby Module 18 840 USE 106 00 January 2003 15 Overview of Quantum Hot Standby Primary and Standby Control Description Role of the CHS 110 Hot Standby Module The Quantum Hot Standby system is designed for use where downtime cannot be tolerated The system delivers high availability through redundancy Two backplanes are configured with identical hardware and software One of the PLCs acts as the Primary controller It runs the application by scanning user logic and operating remote I O The other PLC acts as the Standby controller The Primary controller updates the Standby controller after each scan The Standby is ready to assume control within one scan if the Primary fails Primary and Standby states are switchable Either controller can be put into the Primary state but to do this the other must be in the Standby state The remote I O network is always operated by the Primary controller Note A Quantum Hot Standby system supports only remote I O It does not support local I O or distributed I O DIO Each controller is paired with a 140 CHS 110 00 Hot Standby module The module monitors its own
101. inator MA 0185 000 Pd P 52 0422 000 Trunk Terminator Premade RG 6 Drop Cable 50 14m AS MBII 003 140 43m AS MBII 004 Drop Cable CE RG 6 97 5750 000 140 CHS 320 00 kit includes 2 Splitters 4 F Adapters 2 Terminators See CHS 210 Hot Standby Kit for entire HSBY kit contents 140 CHS 210 00 60 840 USE 106 00 January 2003 Installation How to Install a Hot Standby System Procedure This section discusses the procedure for installing a new Hot Standby system For more detailed instructions refer to the Quantum Automation Series Hardware Reference Guide 840 USE 100 00 or the Remote I O Cable System Planning and Installation Guide 890 USE 101 00 Installing a Hot e Install the power supplies controllers RIO head processors hot standby Standby System modules and any option modules in the primary and standby backplanes Be sure e The modules meet the version requirements listed in Overview of Quantum Hot Stanaby p 13 e The modules in the primary backplane are identical to those in the standby backplane Note The order of the modules in the backplanes must be the same e The rotary address switches on the back of each controller are set The controllers may have different addresses It is strongly recommended that the rotary address switches be set to the same address to eliminate any network address conflicts The same advice a
102. ion extension screen as follows e Specify the parameters in the Hot Standby command register e Define a nontransfer area to help reduce scan time The parameters in the configuration screens are applied by the controllers at startup You can change the settings behavior of the IEC Hot Standby system after already having downloaded the configuration to the controller Do this either by setting or resetting the particular bits of the Hot Standby command register or by using the Hot Standby specific EFBs of the System library Note If the Hot Standby system is later stopped and then restarted the parameters specified in the configuration extension screens go back into effect In the Concept 2 1 2 2 Hot Standby system there is no logic executed in the Standby controller This is different from the 984 Hot Standby system where the Standby controller executes the logic of segment 1 In the Concept 2 5 Hot Standby system the Standby controller executes section 1 logic this is similar to the way segment 1 is handled in a 984 Hot Standby System Section 1 may contain logic for diagnostic and optional Hot Standby functions such as battery coil status Do not program I O control logic in section 1 114 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Using the The Configuration Extension offers two check boxes regarding Hot Standby Since Configuration you are using the IEC environment check the I
103. is in a non redundant system or if the CHS module is not present or is not healthy e Offline Mode CPU is stopped CHS module is in Offline mode The Hot Standby and the NOE operating mode are synchronized by the conditions described in the following table CHS Module Status HSBY State NOE Operating Mode Present and Healthy Primary Primary Present and Healthy Standby Secondary Present and Healthy Offline Offline Present and Healthy Unassigned Standalone Not present or unhealthy N A Standalone Any one of four events will affect the NOE operating mode These four events occur when the NOE is powered up when an NOE executes a Hot Standby switchover when an NOE goes to offline mode or when a new application is downloaded to the NOE 840 USE 106 00 January 2003 169 Ethernet Hot Standby Solution Power Up and IP Address Assignment The process of powering up affects the NOE s IP Address assignment To clarify what happens during a power up the following two sections describe the power up effects on IP Address assignment and Ethernet services An NOE obtains its IP Address assignment at power up as follows If the HSBY state is Then the IP Address assigned is Unassigned Configured IP Address Primary Configured IP Address Secondary Configured IP Address 1 Unassigned to Offline See the Offline Mode at Power up Sequence table following
104. is running normally it will continue to function automatically It constantly tests itself for faults and is always ready to transfer control from the Primary to the Standby if it detects a fault While the system is running the primary CHS module will automatically transfer a predetermined amount of state RAM to the Standby unit each scan This ensures that the Standby is ready to take control if needed If one or both of the links between the Hot Standby modules are broken the Primary controller will function as though no backup is available If the Primary controller fails the Standby automatically assumes control of the remote I O network If the Primary controller recovers from failure it assumes Standby responsibilities If it cannot recover it remains offline If the Standby controller fails it goes offline The Primary controller functions as a stand alone and continues to manage the I O networks 108 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System At a Glance Purpose What s in this Chapter This chapter presents operating procedures for the IEC HSBY This chapter contains the following sections Section Topic Page 7 1 Configuration 111 7 2 Hot Standby Dialog 116 7 3 State RAM 129 7 4 Section Transfer Control 135 7 5 Operation 138 7 6 Normal Operation 140 840 USE 106 00 January 2003 109 Using a Quantum IEC Hot Standby Sys
105. isters in the nontransfer area to reduce scan time The Start field is used to specify the first 4x register in the nontransfer area The Length field is used to define the number of contiguous registers in the nontransfer block If you choose to define a nontransfer area the range of legal values for this entry field is 4 n where nis the number of configured 4x registers However when defining the nontransfer area you must meet these requirements e The nontransfer area must be located entirely within the area of 4x registers scheduled for transfer on every scan The transfer area is defined in the State RAM dialog e The command register first entry of the Hot Standby dialog must be outside the nontransfer area Note If you are also programming a CHS instruction in LL984 the parameters you set for the nontransfer area in the Hot Standby dialog must be identical to those in the CHS block e The third register in the nontransfer area is the Hot Standby status register Use this register to monitor the current machine status of the Primary and Standby controllers 94 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Hot Standby Status Register for Configuration Extension Status Register Note Bits 1 and 2 are used only in conjunction with a configuration extension for Configuration h E T S0 3 n is in mode extension This PLC running in primary mode 1 0 This PLC running i
106. l Model Number Module Description Color Code LED Display l Function Keyswitch d J Designation Slide Switch L Update Button L Transmit Cable Connector Receive Cable Connector __ M0035300 18 840 USE 106 00 January 2003 Overview of Quantum Hot Standby LED Display The following illustration shows five status indicators on the face of each CHS 110 module 140 CHS 110 00 HOT STANDBY Ready Fault Run Modbus Error A Com Act Error B Primary Mem Prt Standb The following table shows the five status indicators Indicator Color Message Ready Green If steady power is being supplied to the module and it has passed initial internal diagnostic tests If blinking module is trying to recover from an interface error Com Act Green If steady CHS 110 modules are communicating If blinking an error has been detected Primary Green Module is Primary controller Com Err Red Module is retrying CHS communications or CHS communications failure has been detected Standby Amber If steady module is Standby controller and is ready to assume Primary role if needed If blinking program update is in progress Error messages are discussed in detail in Com Act Error Patterns p 209 840 USE 106 00 January 2003 19 Overview of Quantum Hot Standby Function Keyswitch Designation Slide Switch and Update Button
107. l FALSE gt BITS bool FALSE gt BIT10 bool_FALSE BIT11 bool_FALSE BIT12 bool_FALSE BIT13 bool_FALSE BIT14 bool_FALSE BIT15 word A 160 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby Programmed Logic Reduce DFB Instances Every DFB instance consumes a certain amount of overhead data memory which grows with the number of input and output pins To make the ratio between the fixed overhead and the DFB internal logic s data as small as possible DFBs should be used only when they cover a really big part of specialized logic That means when a DFB contains just one section with a few blocks of FBD LD or a few lines of IL ST logic you should probably consider replacing it with a macro that links the DFB logic directly to the program logic Although if a DFB is used just a few times like 1 to 10 times consider not changing it since the data memory savings might be too small to be worth the work When some complicated logic has to be implemented especially when it comes to numeric algorithms none of the IEC languages allow a really data efficient implementation Therefore when a DFB should cover some of those kinds of logic it is worth implementing it as an EFB instead EFBs are implemented in C C language which allows highly effective implementations of any kind of logic To implement EFBs Schneider Electric offers the Concept EFB Toolkit But it sh
108. l cable system the READY COM ACT blinks Failure at RIO head gives no Transmit to Standby Receive four times Standby End indication if only one cable has failed Runs as offline READY and COM ACT COM ACT stops Failure of Fiber on blinking Link from Standby Transmit to Primary Receive Runs as offline READY and COM ERR COM ACT stops Failure of Fiber Refer to following on blinking Link from Primary description 190 840 USE 106 00 January 2003 Maintenance Failure of Fiber Link from Primary Transmit to Standby Receiver Fiber Optic Cable Replace the cable and restart the controller The unit should return to Standby mode If it does not cycle the power on the Standby unit If the cable has been connected improperly i e the transmit port of the Primary is linked to the transmit on the Standby two error patterns are possible e If the program has already been loaded in the Standby controller and both controllers are running then the Ready and Com Err indicators light on the Standby CHS 110 module e lf the program has not yet been loaded in the Standby and you attempt to load it using the program update procedure then the Ready indicator lights and the Standby blinks If both fiber links fail tne Com Err indicator lights on the Standby CHS 110 Again replace the cable and restart the controller The unit should return to Standby mode If it does not cycle the power on the Stand
109. large data memory benefits compared to the work needed to achieve it 154 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby 8 2 State RAM Efficient Use of State RAM Configured State RAM Registers Since in IEC Hot Standby all the configured state RAM registers and bits are transferred on every scan from the Primary to the Standby it is worth having every part of that area provide a purpose for the application Sometimes application designers decide to have gaps between the I O references of each RIO drop for future changes but usually those gaps never get filled up so there is always a certain amount of unused state RAM references However unused references require memory space and are transferred every scan which increases the overall scan time The better method is to assign contiguous I O references without gaps This means the designer should not be concerned about the actual reference number an I O point occupies Just give it a number and a name and reference it in the IEC logic by name This way whenever the actual state RAM reference number changes it would not have any impact on the logic itself because the name does not change The positive effect is that all the configured state RAM is actually used and Ram size therefore minimized In Concept 2 1 this downsizing of the configured state RAM is especially important with coils 0x and discretes 1x In that and earlier version
110. le System Planning and Installation Guide 890 USE 101 00 for details regarding cable grades distances and signal integrity If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network fiber optic repeaters may be used to boost the signal Refer to the Modbus Plus Network Planning and Installation Guide 890 USE 100 00 for details on extending a Modbus Plus network 56 840 USE 106 00 January 2003 Planning a Quantum Hot Standby System Electrical Safety Precautions Safety Precautions WARNING To protect yourself and others against electric shock obey your national electrical code and all applicable local codes and laws When you plan the installation of the electrical cabinets which enclose the system s electronic components be sure each cabinet is connected separately to earth ground and that each backplane is connected to solid ground within its cabinet Failure to follow this precaution can result in death serious injury or equipment damage 840 USE 106 00 January 2003 57 Planning a Quantum Hot Standby System Remote I O Cable Topologies Cable Connections In each configuration e The cables connecting the RIO head processors to the RIO network must be fitted with self terminating F adapters e An MA 0186 100 coaxial splitter must be installed between the RIO head processors and the RIO network e The remote drops must be connected to t
111. le having a newer or older firmware version than the one on the Primary controller 96 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Defining the Transfer Area of State RAM Additional RAM With 984 Hot Standby you may define additional state RAM 0x 1x 3x and 4x registers that are transferred in groups over multiple logic scans State RAM dialog To open the State RAM dialog deactivate Transfer All State RAM and then use the Options button State RAM associated with all critical I O also should be transferred in every scan Additional state RAM can be grouped and transferred over multiple scans Concept shown State RAM State RAM Transfer User Defined M r Number of References to Transfer Coils 0xxxx 0 Input Regs 3xxxx 0 Discrete Inputs 1xxxx 0 Output Regs 4xxxx 0 r Additional State RAM Transfer Additional State RAM Extra Transfer Time 1 255 A r Number of References to Transfer Coils 0xxxx 0 Input Regs 3xxxx 0 Discrete Inputs 1xxxx 0 Output Regs 4xxxx 0 OK Cancel Help If you use the CHS instruction to configure the Hot Standby system you are unable to transfer any more than 12K words even though the total amount of state RAM could be as much as 64K words You can limit the n
112. llustration of the IEC State RAM Map Map State RAM compl xferred Header HE acy m er T a or tuture r PE at Program data changes i gino _ prog data used additions configured Program data he unused mit 38 Total 1x J Total 0x I Space as big as IEC heap alle i5 e iu DFB instance No 3x regs data 2 configured for 5 IEC HSBY a 5 2 oO 8 E un 3 x free memory o E for addtl DFB E EN instance data a ms Na eat e ume D D Um Ot 840 USE 106 00 January 2003 141 Using a Quantum IEC Hot Standby System IEC application To maintain consistency of the IEC application s data between the Primary and data Standby controllers the IEC heap is transferred through a reserved area in the 3x register range the so called IEC HSBY Registers The size of this reserved area is assigned in the PLC Memory Partition dialog refer to Aaditional Guidelines for IEC Hot Standby p 147 The size of the IEC HSBY Registers can never be smaller than the size of the IEC heap application data otherwise the copy and transfer mechanism does not work The size of the configured state RAM has a significant impact on a Hot Standby System s scan time The more memory state RAM that is transferred on every scan the slower the scan for details refer to Theory of IEC HSBY Operation p 43 If future modifications to the IEC application are expected to be small the safety buffer can be correspondingly
113. lowing topics Section Topic Page Using CHS Instruction Block 75 Command Register 76 Elements of the Nontransfer Area 78 Zoom screen of CHS Instruction 80 The Hot Standby Status Register 81 The Reverse Transfer Registers 82 Reverse Transfer Logic Example 83 74 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Using CHS Instruction Block CHS Instruction The command register is defined in the top node of the CHS instruction block The Block bits in this register are used to configure and control various parameters of the Hot Standby system The command register must be a 4x register in the portion of the state RAM transfer area that is transferred from the Primary to the Standby controller on every scan It also must be outside of the nontransfer area Disables keyswitch override 0 Enables keyswitch override 1 Sets Controller A to OFFLINE mode 0 Sets Controller A to RUN mode 1 Sets Controller B to OFFLINE mode 0 Sets Controller B to RUN mode 1 Forces standby offline if there is a logic mismatch 0 Does not force standby offline if there is a logic mismatch 1 Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 Tet stets s 7 fe o ro n va eo na fis is 0 Swaps Modbus port 1 address during switchover 12 Does not swap Modbus port 1 address during switchover 0 Swaps Modbus port 2 address during switchover 1 Doe
114. lows an offset of 128 for comparable ports on the Standby controller with 247 the maximum number of addresses For example if controller A is the Primary controller and its two Modbus ports have addresses 1 and 2 then the default addresses for the comparable ports on Standby controller B are 129 and 130 By default this offset is maintained between port addresses in the event of switchover For example if controller B becomes the Primary controller as the result of switchover its Modbus ports assume the addresses of 1 and 2 and the comparable ports on controller A assume addresses 129 and 130 The check boxes allow you to change this default condition on any or all of the Modbus ports on the two controllers in your Hot Standby system Modbus ports on the two controllers in your Hot Standby system For example if you deselect the parameter Modbus Port 1 then no offset is maintained at switchover and after switchover the two ports have the same address Thus if controller A is the Primary controller and its Modbus port 1 address is 1 then that port address remains 1 after a switchover occurs Likewise if controller B becomes the Primary controller as a result of switchover its Modbus port 1 address is also 1 Note If you change the selections the port addresses are not affected until a Switchover occurs In a Quantum Hot Standby system the Modbus Plus port addresses on the Standby controller are offset by 32 from the co
115. mparable ports on the Primary controller For example if controller A is the Primary controller and its Modbus Plus port has address 1 then the address for the corresponding port on Standby controller B is 33 The numerical range for addresses for both ports is 1 through 64 Thus if the port on the Primary controller has address 50 then the address for the corresponding port on the Standby cannot be 82 so it is 18 that is 50 minus 32 These addresses are automatically swapped at switchover you do not have the option to change the offset or prevent the addresses from being swapped Note The Quantum Hot Standby system swaps Modbus Plus addresses almost instantaneously at switchover This means that host devices polling the Quantum controller can be assured that they are always talking to the Primary controller and that the network experiences no downtime during switchover 840 USE 106 00 January 2003 93 Using a Quantum 984 HSBY System Transfer All State RAM Transfer All State RAM check box Nontransfer Area Hot Standby Status Register It is not possible to define a special State RAM or additional State RAM range to be transferred if this check box is activated The nontransfer area contains the Hot Standby status register which is used to monitor the states of both controllers It also contains a pair of registers which may be used for reverse transfer operations You may include other 4x reg
116. mpletely transferred state RAM in an IEC Hot Standby system 53 840 USE 106 00 January 2003 43 Theory of IEC HSBY Operation IEC Hot Standby Definitions Definitions The following are IEC Hot Standby definitions Exec Quantum controller operating system with integrated IEC language support IEC runtime system Program Data A continuous memory block containing all program variables including e Non located IEC variables and constants declared in variable editor e Links in FBD and LD sections e Stack loop variables in IL and ST e SFC states e Literals e Pointer lists e Internal states of EFBs DFB Instance Data Multiple memory blocks containing e Internal data of each DFB instance e Process diagnostics buffer e Mirror buffer 1 Byte per configured Ox 1x reference only Concept 2 1 and older e Used references list 1 Bit per configured Ox 1x reference IEC Heap One continuous memory block containing e Program data e DFB instance data Maximum IEC Heap Size 128 KByte together with state RAM If 10K Words 20 KByte of state RAM are used already for I O references the max IEC heap size would be 128 KByte 20 KByte 108 KByte Currently used IEC Heap Size DFB instance data plus configured program data area size State Table Also called state RAM controller references for both real world I O and internal referenced located variables Project Concept program file containing controller configuration and I
117. n for economy Be sure that you understand all the cautions and warnings in this manual before you begin to install your system For the Hot Standby system to function your component modules must meet the version requirements in Overview of Quantum Hot Standby p 13 You must use identical modules in the primary and standby racks If you have different models or different versions of the same model or different flash executive software the Hot Standby system will not function properly Note The order of the modules in the backplanes must be the same While the controllers and RIO heads must be Quantum models the remote drops may use Quantum 800 series 500 series or 200 series I O with corresponding drop processors The CHS 110 Hot Standby modules are connected by fiber optic cable A 3 meter cable is supplied with the kit However the primary and standby backplanes may be placed as much as 1 km apart If you will be placing the modules more than 3 m apart use 62 5 125 micrometer cable with ST style connectors Refer to Fiber Optic Cable Guide p 213 for details If you intend to place the units more than 3 meters apart you must consider the effect on the RIO network and any Modbus Plus network The controllers are linked to the RIO network by coaxial cable The longer the distance between the controllers the higher the grade of trunk cable required to maintain signal integrity Refer to Chapter 3 of the Remote I O Cab
118. n standby mode 1 1 The other PLC in OFFLINE mode 0 1 The other PLC running in primary mode 1 0 The other PLC running in standby mode 1 1 PLCs have matching logic 0 PLCs do not have matching logic 1 This PLC s switch sat to A 0 This PLC s switch sat to B 1 10 11 12 13 14 The CHS interface is healthy 0 An interface error has been detected 1 Hot standby capability has not been activated 0 Hot standby is active 1 95 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Advanced Options Advanced Options button When pressing the Advanced Options button in the Hot Standby dialog you get the opportunity to allow different firmware versions on the Primary and Standby controller while running in full Hot Standby mode Concept shown WARNING Selecting Without Stopping overrides all safety checking between Primary and Hot Standby controllers Use with extreme caution Exec Upgrade 1 C Without Stopping Application Stopped This lets you upgrade the controllers step by step to a new firmware version without having to shutdown the system Since this is only necessary in rare situations it is recommended that you disable this mode by configuration and to enable it by the reference data editor or Zoom screen when needed By default the controllers must have the same versions of firmware This means the Standby controller would not go online whi
119. ncept 2 5 or higher Allows exec upgrade only after application stops 0 Allows exec upgrade without stopping application 1 Supported only with Concept 2 5 or higher B 7F 8 i 11 12 13 14 15 16 0 Swaps Modbus port 1 address during switchover 1 Does not swap Modbus port 1 address on switchover 0 Swaps Modbus port 2 address during switchover 1 Does not swap Modbus port 2 address on switchover 0 Swaps Modbus port 3 address during switchover 1 Does not swap Modbus port 3 address on switchover Note Bit 16 in Modicon convention shown in the diagram above is bit 0 in IEC convention Setting bit 16 means writing a 0x0001 into the command register Specify The command register is specified in the first entry field of the Hot Standby dialog Command By default the command register is set to 400001 If register 400001 is used Register elsewhere enter another number greater than 0 The number you enter becomes the 4x command register For example if you enter 14 the hot Standby command register is 400014 118 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Hot Standby Command Register Range Keyswitch Override and Run Mode You may enter any number in the range 1 n where n is the last configured 4x register However e the command register must be part of the area of state RAM that gets transferred from the Primary to the Standby controlle
120. nchronization in segment 1 but do not put it in network 1 Since both controllers run the same program you must read CHS status register bits 12 16 to be sure that only the standby clock is resetting If bits 12 16 are 01011 you know three things e which controller is the Standby e that the remaining controller is the Primary e that both controllers are running the same logic If these conditions are true then the logic should clear bit 2 and set bit 1 of the time of day control register The clock in the Standby controller will be reset from the state table of the Primary controller at the end of a scan and bit 1 will be cleared Note Be sure that the registers for synchronizing the time of day clocks are included in the state RAM transfer area 106 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System The following diagram shows synchronizing time of day clocks Network 1 of Segment 1 40001 Address of CHS Command Register 40101 First Register Reserved for Nontransfer Area in State RAM 4 Number of Registers Reserved in Nontransfer Area Network 2 of Segment 1 40103 CHS Status Register 42221 Mask Out Status Bits Not Required 42222 Junk Register TODC Time of day Clock Register 840 USE 106 00 January 2003 107 Using a Quantum 984 HSBY System While Your System Is Running Constant Internal Monitoring After your Hot Standby system has been started and
121. ng protections between the Primary and Standby controllers in your Hot Standby system It is important to reset the bit to 0 as soon as the executive upgrade operation is complete Failure to follow this precaution can result in injury or equipment damage Even if it is possible to have this command register parameter be prepared for this operation it is strongly recommended not to have it set by configuration extension and to set it only when needed To do this you can either use a Zoom screen on a CHS instruction block in ladder logic or call up the Hot Standby command register in the Reference Data Editor RDE Upgrading the If you want to access the command register via a Zoom screen make sure that a PLC executives CHS instruction has been inserted in ladder logic before the system is powered up while Hot While the Hot Standby system is running connect to the Primary controller with Standby system Concept Go to the LL984 Editor and call up the Zoom screen when having the CHS is running instruction inserted 198 840 USE 106 00 January 2003 Maintenance Steps to Upgrade PLC executives while Hot Standby is running Zoom or RDE Step Action 1 Call up the Hot Standby command register either in a Zoom screen or in the RDE If you are using the Zoom screen select the Without Stopping option for bit 12 If you are using the RDE set the value of bit 12 in the Hot Standby command register to
122. nitialization error 5 6503 RAM address test error 6 6402 RAM data test error 7 6301 PROM checksum error 8 C101 no hook timeout 8 C102 read state RAM timeout 8 C103 write state RAM timeout 8 C200 powerup error 210 840 USE 106 00 January 2003 Com Act Error Patterns CRP Remote I O Head Processor Error Patterns Error Patterns The following table shows error patterns Number Code Error Blinks Slow steady 0000 requested kernel mode 2 6820 hcb frame pattern error 2 6822 head control block diag error 2 6823 mod personality diag error 2 682A fatal start IO error 2 682B bad read IO pers request 2 682C bad execute diag request 2 6840 ASCII input xfer state 2 6841 ASCII output xfer state 2 6842 IO input comm state 2 6843 IO output comm state 2 6844 ASCII abort comm state 2 6845 ASCII pause comm state 2 6846 ASCII input comm state 2 6847 ASCII output comm state 2 6849 building 10 byte packet 2 684A building 12 byte packet 2 684B building 16 byte packet 2 684C illegal IO drop number 3 6729 984 interface bus ack stuck high 4 6616 coax cable initialization error 4 6617 coax cable dma xfer error 4 6619 coax cable dumped data error 4 681A coax cable DRQ line hung 4 681C coax cable DRQ hung 5 6503 RAM address test error 6 6402 RAM data test error 7 6300 PROM checksum error exec not loaded
123. nstruction This requires the CHS loadable to be installed into your application nnnn nnnn HSBY nnnn nnnn nnnn CHS nnnn 840 USE 106 00 January 2003 71 Using a Quantum 984 HSBY System Configuration Extension Controlling the Hot Standby System by Configuration Extension Ladder Logic ina Hot Standby System With the Hot Standby configuration extension screens You can specify the parameters in the Hot Standby command register and customize the state RAM data transfer between the Primary and Standby units to help reduce scan time If you decide to control your system using the configuration extension you still may want to program a CHS instruction in ladder logic The CHS instruction allows you to use Zoom screens which allows you to access and modify the command register while the system is running Note If both a configuration extension and the CHS instruction are used the configuration extension controls the Hot Standby system The only function of the CHS instruction is to provide Zoom screens The parameters in the configuration screens are applied by the controllers at startup Once the controllers are running the Zoom screens may be used to access and modify the command register The changes are implemented during runtime and can be seen in the status register However if the Hot Standby system is later stopped and then restarted the parameters
124. nt of the location of the producer The communication port has only one multicast address In this network service the Hot Standby controllers are viewed like only one station The Primary NOE publishes the Hot Standby application variables and receives the subscription variables The Secondary NOE global data service is in a stopped state When the Hot Standby swap occurs the Primary NOE stops the Global Data service The NOE does not publish the local variable during a swap And after the swap the new Primary NOE starts to publish application variables and to receive the subscription variables The File Transfer Protocol Trivial File Transfer Protocol FTP TFTP server is available as soon as the module receives an IP address Any FTP TFTP client can logon to the module Access requires the correct user name and password Hot Standby allows only one active FTP TFTP client session per NOE module When the Hot Standby swap occurs the Primary and Secondary NOEs close the FTP TFTP connection If a user sends an FTP TFTP request during the swap the communication is closed Whenever you re open communication you must re enter a user name and a password 840 USE 106 00 January 2003 175 Ethernet Hot Standby Solution 176 840 USE 106 00 January 2003 Maintenance 10 At a Glance Purpose This chapter discusses maintenance procedures for the HSBY system What s in this This chapter cont
125. ntroller B is register and the Hot Standby status determined by the state of bit 14 of the register in the RDE command register If controller B is offline bit 14 is set to 0 4 To put the controller in RUN mode Controller B immediately goes into RUN change the state of bit 14 to 1 mode Note The advantage of option 2 is that the Hot Standby system does not have to be shut down in order to change its status 840 USE 106 00 January 2003 121 Using a Quantum IEC Hot Standby System Advanced Options Concept 2 5 Advanced When selecting the Advanced Options button in the Hot Standby dialog you get the Options button opportunity to allow different firmware versions on the Primary and Standby controller while running in full Hot Standby mode Advanced Options WARNING Selecting Without Stopping overrides all safety checking between Primary and Hot Standby controllers Use with extreme caution Exec Upgrade Without Stopping f Application Stopped Cancel Help This lets you upgrade the controllers step by step to a new firmware version without having to shutdown the system Since this is only necessary in rare situations it is recommended that you disable this mode by configuration and to enable it by the reference data editor when needed By default the controllers must have the same versions of firmware This means the Standby controller would not go online whil
126. ntroller is in Run Mode and the CHS mode indicates that the Standby Controller is now in Standby Mode 11 The Hot Standby Controller Executives have now been uprgaded without stopping the process 840 USE 106 00 January 2003 123 Using a Quantum IEC Hot Standby System Standby on Logic Mismatch Overview Logic Mismatch for Concept 2 5 To function properly the Primary and the Standby controller in a Hot Standby system must be solving an identical program which is updated on every scan by a state RAM data transfer between the two controllers By default the Standby controller is set to go Offline if a mismatch is detected between its program and that of the Primary controller Switchover cannot occur while the Standby controller is Offline CAUTION I O Map Configuration Hazard A mismatch in the I O map or configuration is not allowed under any circumstances Failure to follow this precaution can result in injury or equipment damage CAUTION Switchover Hazard If switchover occurs when the radio button is set to Running and there is a logic mismatch between the two controllers the Standby controller will assume Primary responsibilities and will start solving a different logic program from the previous Primary controller Failure to follow this precaution can result in injury or equipment damage Concept 2 5 and the new PLC Executives delivered with it su
127. ollowing screen shows a PLC Memory Partition Concept shown PLC Memory Partition x Maximum State Memory 65024 State Memory Used 11022 State Memory Usage 16 Discretes Coils Oxxxx 2048 Discrete Inputs 1xxxx 2048 rRegisters Input registers 3xxxx 128 Holding registers Axxxx 9000 IEC Applications Optimization of IEC Hot Standby applications concentrates on two issues Optimization e Very efficient use of state RAM for purposes other than IEC HSBY Registers See 311 following e Very efficient use of IEC application data See 2 following 840 USE 106 00 January 2003 153 Additional Guidelines for IEC Hot Standby IEC Applications 1 There are 64K words of state RAM as a maximum for IEC HSBY Registers in an Optimization IEC Hot Standby application Using as little state RAM as possible for other Continued purposes besides IEC HSBY Registers allows running medium sized IEC applications in IEC Hot Standby mode When using the IEC application data very efficiently the size of the application can grow from medium to large 2 To optimize an IEC application to consume as little memory as possible takes some effort and may reduce the maintainability of the application Therefore you should always try to reduce data memory to what is needed The efficient use of the State RAM as described in the following section should be considered whenever possible It provides
128. om Act light signals that your system has detected an error e Onthe corresponding CRP module the Ready indicator is a steady green The Com Act indicator on the Primary unit should also be a steady green while the Com Act indicator on the Standby RIO head should be blinking slowly Illustrations of the Primary and Standby Backplanes are shown below Primary Backplane Standby Backplane 140 CHS 110 00 HOT STANDBY Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A Com Act Error B Primary Mem Prt Standby 140 CHS 110 00 HOT STANDBY Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A Com Act Error B Primary Mem Prt Standb RIO Head Modbus Error A Com Act Error B Primary Mem Prt Standb RIO Head HOT STANDBY Active Ready Fault Modbus Error A Com Act Error B Primary Mem Prt Standby 840 USE 106 00 January 2003 139 Using a Quantum IEC Hot Standby System 7 6 Normal Operation Introduction Purpose This section describes Quantum IEC Hot Standby normal operation What s in this This section contains the following topics Section Topic Page Memory Scantime optimization 141 Synchronizing Time of Day Clocks 145 While Your System Is Running 146 140 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Memory Scantime optimization IEC State RAM An i
129. on The CHS loadable is provided on a 3 1 2 diskette 140 SHS 945 00 as part of your 140 CHS 210 00 Hot Standby kit The file is named QCHSV xxx DAT where xxx is the three digit version number of the software Step Action 1 Insert the diskette in the disk drive 2 Either create a new Concept project or open an existing one and have a PLC selected With the menu command Project Configurator open the configurator 4 With Configure Loadables open the dialog box Loadables Press the command button Unpack to open the standard Windows dialog box Unpack Loadable File Select the loadable file click the button OK and it is inserted into the list box Available 112 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Concept Loadables Installation Screen The following diagram shows a Concept loadables installation screen IIS ETSI Bytes Available 643210 Bytes Used 525888 Available Installed nstall s z Remove Unpack Warning Confirm user loadables are valid for your PLC Edit The CHS loadable is now part of the Concept environment and may be installed into a project configuration whenever needed 113 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Controlling the Hot Standby System by Configuration Extension Configuration Extension IEC Logic in a Hot Standby System Use the Hot Standby Concept configurat
130. on extension This option allows the Standby controller to remain online with a different program than the primary controller e Primary controller on line changes may include e Addition of sections e Addition of DFBs allows pre qualification of user changes in an office environment e Logic Mismatch e With Concept 2 1 2 2 itis not possible to load a new version of the application on Standby bring it on line and transfer control to make it the new Primary e Under Concept 2 5 with Logic Mismatch enabled a new version of the application can be downloaded to the Standby controller and brought online Control can then be transferred to the Standby controller to make it the new Primary controller e To upgrade the controller Execs e With Concept 2 1 2 2 the process must be stopped Then Primary and Standby controllers must be stopped and downloaded individually e Under Concept 2 5 the controller executives can be upgraded while the process continues to run 30 840 USE 106 00 January 2003 Theory of 984 Ladder Logic HSBY Operation 2 At a Glance Purpose This chapter covers the 984 Hot Standby and its theory of operation What s in this This chapter contains the following topics 2 Chapter Topic Page How a 984 HSBY System Works 32 System Scan Time 33 The State RAM Transfer and Scan Time 36 Default Transfer Area 38 Customizing Options 40 Custom Scans 41 840 USE 106 00 January
131. or the current machine status of the Primary and Standby controllers In the example the status register is 40012 This PLC in OFFLINE mode 0 1 This PLC running in primary mode 1 0 This PLC running in standby mode 1 1 The other PLC in OFFLINE mode 0 1 The other PLC running in primary mode 1 0 The other PLC running in standby mode 1 1 PLCs have matching logic 0 PLCs do not have have matching logic 2 1 This PLC s switch set to A 0 This PLC s switch set to B 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 840 USE 106 00 January 2003 81 Using a Quantum 984 HSBY System The Reverse Transfer Registers Reverse Transfer You can use the reverse transfer registers to transmit diagnostic data from the Standby controller to the Primary controller When you choose to define a nontransfer area registers 4x and 4x 1 in the nontransfer block are copied from the Standby to the Primary controller This is opposite from the normal forward state table transfer from the Primary to the Standby If you choose not to use the reverse transfer registers do not connect the CHS bottom input to the rail in your ladder logic program so the inputs to these registers are not enabled 82 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Reverse Transfer Logic Example A Reverse The following exam
132. ors 185 Board Level Errors 186 840 USE 106 00 January 2003 183 Maintenance Startup Errors LED Display fora When the Hot Standby system detects a mismatch between the Primary and Startup Error Standby controllers it reports a startup error The mismatch may be in the configuration including segment scheduler I O map or designation slide switch positions The LEDs display the error pattern The Ready indicator is a steady green while the Com Act indicator blinks If the LEDs indicate a startup error and if you have difficulty determining why you can access some startup error codes through software Refer to Chapter 3 of the Quantum Automation Series Hardware Reference Guide for details Troubleshooting Take the following troubleshooting steps Step Action 1 Be sure the designation slide switches on the CHS 110 modules are in opposite positions 2 Be sure the configuration tables in the Primary and Standby controllers are identical 3 Be sure the segment schedulers in the Primary and Standby controllers are identical 4 Be sure the I O maps in the Primary and Standby controllers are identical 184 840 USE 106 00 January 2003 Maintenance Communications Errors LEDs Troubleshooting Interface Errors Troubleshooting If the CHS 110 module detects a communications error the LEDs display the following pattern LED display for a communications error
133. ould be noted that EFBs do not allow animation of their internal data at runtime like DFBs do Even with EFBs you should avoid having any unused input and output pins because every pin takes the data memory that its data type requires 840 USE 106 00 January 2003 161 Additional Guidelines for IEC Hot Standby Reduce the Use Of Complex Data Structures Reduce Use of Complex Data Structures Usually when complex data structures are used the probability that each of its members are actually used is fairly low Additionally when complex data structures are passed as variables or links each superfluous input output pin link or variable has a lot more impact on data consumption than when using primitive data types This is especially true whenever the MOVE EFB is involved of which the usage should be reduced to the absolute minimum or to none at all Whenever the result of some preceding logic gets assigned to a variable make sure that this variable is the final target for that value not just an intermediate storage Intermediate variables are often used for loosening the logic between different sections However it makes sense to reduce the full amount of global variables not only in terms of data memory savings but also in terms of application overview Handle the selection of arrays as data types for variables carefully since the selected array is often bigger than needed The choice of all different IEC compli
134. ows how the status of an NOE service is affected by the Hot Standby state HSBY State Status of NOE Services Client Services Client Server Services Server Services I O Scanner Global Data Modbus FTP SNMP HTTP Messaging Unassigned Run Run Run Run Run Run Primary Run Run Run Run Run Run Secondary Stop Stop Run Run Run Run Offline Stop Stop Run Run Run Run The following steps describe how NOEs coordinate the Hot Standby switchover Step Action 1 NOE A installed in a HSBY rack detects that is local controller changed from Primary to Offline 2 NOE A changes its HSBY state from Primary to Offline with the same Ethernet Services running starts its watch dog timer with 500 ms timeout setting and expects from its peer NOE an UDP request to swap the IP Address 3 NOE B installed in peer HSBY rack detects that its local controller changed state from Secondary to Primary 4 NOE B stops all Ethernet services sends an UDP requestto its peer NOE NOE A for the synchronization of the IP Address swap starts its watch dog timer with 500 ms timeout setting and then waits for an UDP response from its peer NOE 5 Once NOE A receives the UDP request from NOE B or after its watch dog timer times out it stops all Ethernet services sends an UDP response to NOE B no UDP response is sent to NOE B for watch dog timeout case swaps IP Address as Secondary and starts
135. pecify in the nontransfer area of the Hot Standby dialog CAUTION Hot Standby Command Register Hazard Be sure the register you select as the Hot Standby command register is reserved for this purpose and not used for other purposes elsewhere in user logic Failure to follow this precaution can result in injury or equipment damage CAUTION Hot Standby Dialog Hazard If you intend to use the Hot Standby dialog to configure the command register and the CHS instruction to modify the command register during runtime make sure that you specify the same register as the command register in Hot Standby dialog and the top node of the CHS block If you use different numbers for the command register the changes that you make via the Zoom screen are not applied to the real Hot Standby command register Failure to follow this precaution can result in injury or equipment damage 840 USE 106 00 January 2003 89 Using a Quantum 984 HSBY System Keyswitch Override and Run Mode Keyswitch and Run Keyswitch Override You may choose to override the keyswitch on the front panel of the CHS 110 modules for security or convenience If you override the keyswitch the command register becomes the means for taking the CHS 110 modules on or offline By default the keyswitch override is disabled The Hot Standby dialog allows you to enable it If you enable the keyswitch override the Offline Running o
136. perating mode of the controllers at startup is determined by the values you set to bits 14 and 15 of the command register These bits are represented as the Run Mode for controller A and B depends on designation slide switch Remember that when the keyswitch override is enabled you can not initiate a program update program xfer at the CHS 110 module in the Standby rack As long as the keyswitch override is disabled the settings for the Run Mode can be ignored CAUTION Keyswitch Override Hazard If you use the Zoom screen or RDE to enable the keyswitch override while the Hot Standby system is running the Primary controller immediately reads bits 14 and 15 to determine its own state and the state of the Standby Failure to follow this precaution can result in injury or equipment damage If both bits are set to 0 a switchover occurs and the former Primary CPU goes offline The new Primary CPU continues to operate 90 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System A Software Control Example Using Software For example you enabled the keyswitch override and set the operating mode of Control controller B to Offline Now the system is powered up and you want to put controller B in RUN mode The keyswitch does not work so you must rely on user logic There are three ways you can proceed Option 1 Change the setting on the Hot Standby dialog To do this you must shut down the s
137. ple shows I O ladder logic for a Primary controller that monitors Transfer Logic two fault lamps and the reverse transfer logic that sends status data from the Example Standby controller to the Primary One fault lamp turns ON if the Standby memory protect is OFF the other lamp turns ON if the memory backup battery fails in the Standby Network 1 of Segment 1 400005 400100 CHS 30 Network 2 of Segment 1 BLKM transfers the status of the 400103 Hot Standby status register 000801 40103 to internal coils 00801 BLKM 001 STAT sends one register Word from 400101 the standby to a reverse transfer STAT register 400101 in the primary 00081 5 00081 6 001 Bit 15 Bit 16 Enables STAT if this PLC is the Standby 840 USE 106 00 January 2003 83 Using a Quantum 984 HSBY System Reverse Transfer Logic Remote I O Logic The logic in network 2 of segment 1 contains a BLKM instruction and a STAT instruction The Standby enables the STAT Bits 000815 and 000816 are controlled by bits 15 and 16 in the Hot Standby status register The STAT instruction sends one status register word to 400101 this word initiates a reverse transfer to the Primary controller Internal coil bit 000715 status bit 11 controls the STANDBY MEMORY PROTECT OFF lamp Internal coil bit 000716 status bit 12 controls the STANDBY BATTERY FAULT lamp Segment 2
138. pplies to the NOM For details on setting the switches see the Quantum Automation Series Hardware Reference Guide or the Remote I O Cable System Planning and Installation Guide 840 USE 106 00 January 2003 61 Installation The following diagram illustrates installation of a Hot Standby System Side switches be rmn a Setting The designation slide switch on one Hot Standby module is set to A and the other is Designation set to B Slide Switches CAUTION HAZARD Before installing any controller in your Hot Standby system be sure its battery has been disconnected for at least five minutes Failure to follow this precaution can result in injury or equipment damage Note Be sure your system meets the power and grounding guidelines outlined in Appendix D of the Quantum Automation Series Hardware Reference Guide 840 USE 100 00 Connect Network The following diagram shows how to connect the network Step Action 1 Install a splitter and a self terminating F adapter between the primary RIO head processor and the RIO network Connect the coaxial cable link Connect the cable between the splitter another self terminating F adapter and the standby RIO head processor 62 840 USE 106 00 January 2003 Installation Network The following diagram illustrates the network connections Connections Sel terminating F adapter Coa
139. pport the Standby on Logic Mismatch option in the Hot Standby Configuration Extension Logic mismatch allows you to make online changes to the program of the Standby or Primary controller while the HSBY system continues to run the process The Standby on Logic Mismatch option also allows up to date process data to be transferred from the Primary controller after download of the modifications 124 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Updating Project Section Data All DATA of a section will be fully updated every scan if it is equal to its counterpart on the Primary controller Section DATA will not be updated at all if it is not equal to its counterpart on the Primary controller The section data that is updated if the sections are equal on Primary and Standby controllers is e Internal states of Elementary Function Blocks EFBs used in the section Timers Counters PID etc e All Derived Function Block DFB Instance data blocks of each DFB instantiated in the section including nested DFBs Hot Standby behavior for the section update process is e With matching logic all section data gets updated on the Standby controller e After you do an online change to a section none of its local data gets updated To get it updated again the controllers logic has to be equalized via the CHS transfer button or a complete download to the Primary controller with differing logic e lt is not possible
140. quests If there is an outstanding request the NOE will not respond to the request but the NOE will reset the connection The NOE will do a Modbus logout if any connection has logged in During a swap the NOE will reset all client connections using a TCP IP reset 174 840 USE 106 00 January 2003 Ethernet Hot Standby Solution I O Scanning Service Global Data Publish Subscribe Service FTP TFTP Server The I O Scanning provides the repetitive exchange of data with remote TCP IP nodes I O devices While the PLC is running the Primary NOE sends Modbus Read Write read or write request to remote I O devices and transfer data to and from the PLC memory In the secondary controller the I O scanning service is stopped When the Hot Standby swap occurs the Primary NOE closes all connections with I O devices by sending a TCP IP reset The I O scanning service in this NOE is standby After the swap the new Primary NOE re establishes the connection with each I O devices It restarts the repetitive exchange of data with these re connections The Hot Standby NOE is one station within a distribution group Distribution groups exchange application variables Exchanging application variables allows the system to coordinate all the stations in the distribution group Every station publishes local application variable in a distribution group for all other stations and can subscribe to remote application variables independe
141. quipment damage 840 USE 106 00 January 2003 9 Safety Information PLEASE NOTE Electrical equipment should be serviced only by qualified personnel No responsi bility is assumed by Schneider Electric for any consequences arising out of the use of this material This document is not intended as an instruction manual for untrained persons 2003 Schneider Electric All Rights Reserved 10 840 USE 106 00 January 2003 About the Book At a Glance Document Scope This manual contains complete information about programmable controller Hot Standby systems Validity Note This documentation applies to Concept Related Documents Title of Documentation Reference Number Quantum Automation Series Hardware Reference Guide 840 USE 100 00 Remote I O Cable System Planning and Installation Guide 890 USE 101 00 Ladder Logic Block Library User Guide 840 USE 101 00 Modbus Plus Network Planning and Installation Guide 890 USE 100 00 Concept V 2 5 User s Manual 840 USE 493 00 Concept V 2 5 Installation Instructions 840 USE 492 00 Concept V 2 5 Block Library IEC 840 USE 494 00 Concept V 2 5 Block Library LL984 840 USE 496 00 Concept EFB User s Manual 840 USE 495 00 Product Related Schneider Electric assumes no responsibility for any errors that may appear in this Warnings document If you have any suggestions for improvements or amendments or have found er
142. r on every scan e therefore the command register must not be within the range of the nontransfer area which you specify in the nontransfer area of the Hot Standby dialog CAUTION Hot Standby Command Register Hazard Be sure the register you select as the Hot Standby command register is reserved for this purpose and not used for other purposes elsewhere in user logic Failure to follow this precaution can result in injury or equipment damage You may choose to override the keyswitch on the front panel of the CHS 110 modules for security or convenience If you override the keyswitch the command register becomes the means for taking the CHS 110 modules on or offline By default the keyswitch override is disabled The Hot Standby dialog allows you to enable it If you enable the keyswitch override the Offline Running operating mode of the controllers at startup are determined by the values you set to bits 14 and 15 of the command register These bits are represented as the Run Mode for controller A and B depending on the designation slideswitch Remember that when the keyswitch override is enabled you cannot initiate a program update program xfer at the CHS 110 module in the Standby rack As long as the keyswitch override is disabled the settings for the Run Mode may be ignored 840 USE 106 00 January 2003 119 Using a Quantum IEC Hot Standby System Enable Keyswitch Override Keyswitch Ov
143. ration xci oe ies ERE Spoke PERO dks Rye ae Chyna EDEN d 103 Introduction nre RRBIRCDLERHRMPPPTRIMeT env REVISE Se eed 103 Starting Your Hot Standby System liisisilel else eee 104 Synchronizing Time of Day Clocks lisse elles 106 While Your System Is Running sisse 108 Using a Quantum IEC Hot Standby System 109 Ata Glance nebst eR Eur ELE enna heads pud kde ipa Re 109 Configuration eic Per puce ete ec bn emm Poem Reese m E tees 111 Introduction esanean nne ele epee as deed ewe E ce ee en 111 Loading the Software 0 cece ett eee 112 Controlling the Hot Standby System by Configuration Extension 114 Hot Standby Dialog terea cenean We edie eee ee eee E 116 Introduction se nsn Ak ee eats RUE eileen te 2 a kta e tae Phos oe A TREE 116 Hot Standby dialog 9 sec Ep kp ea E da ee ees 117 Specifying the Command Register 0 0 cece eee eee 118 Hot Standby Command Register 0 00 c cece eee eee 119 Enable Keyswitch Override llle 120 Advanced Options Concept 2 5 0 0 c eect eee 122 Standby on Logic Mismatch 0 00 aeaaaee 124 Swapping Addresses at Switchover 00 cece eee eee eee ees 127 State RAM russe hn ee a ee ee Y REO 129 INTOODUCTION MED 129 Nontransfer Area of State RAM 000 cece eee 130 Hot Standby Status Register uaaa aaaea cee 132 Memory Partition 0 2 cee e RR mn 133 State RAM SIZ
144. roller CPU and communicate with each other via fiber link The Primary controller keeps the Standby informed of the current state of the application by transferring state RAM values to the Standby controller during every logic scan RIO head communications are also verified A Hot Standby system transfers state RAM data from the Primary to the Standby controller while the Primary controller scans and solves the IEC logic application program There are three steps in the transfer process Stage Description 1 Primary controller to Primary CHS 110 state RAM transfer 2 Primary CHS 110 to Standby CHS 110 state RAM transfer 3 Standby CHS 110 to Standby controller state RAM transfer Note Schneider Electric defines State RAM as RAM memory that is used to hold register and discrete inputs and outputs and internal data storage State RAM is allocated to the four different reference types Oxxxx 1xxxx 3xxxx and 4xxxx The state RAM transfer operation is initiated by the Primary CHS 110 Hot Standby module The module requests specified state RAM information from the Primary controller Atthe beginning of each scan the Primary controller transfers the current state RAM data to the CHS 110 Hot Standby module As soon as the controller to CHS 110 transfer finishes the Primary controller resumes scanning user logic and servicing I O The state RAM data is simultaneously transferred from the Primary CHS 110
145. rors in this publication please notify us No part of this document may be reproduced in any form or means electronic or mechanical including photocopying without express written permission of the Publisher Schneider Electric 840 USE 106 00 January 2003 11 About the Book User Comments We welcome your comments about this document You can reach us by e mail at TECHCOMM Q modicon com 12 840 USE 106 00 January 2003 Overview of Quantum Hot Standby 1 At a Glance Purpose This chapter presents a brief overview of the Hot Standby system including a description of Primary and Standby control components the Hot Standby module LEDs and switches modes of operation 984 and IEC HSBY and the application size Throughout the rest of this book the Quantum Hot Standby system is referred to as HSBY An HSBY system is based on two identically configured programmable logic controllers linked to each other and to the same remote I O network If one controller fails the other assumes control of the I O system What s in this This chapter contains the following sections 2 Chapter Section Topic Page 1 1 Control 15 1 2 Operation 21 1 3 Cabling 23 1 4 984 HSBY and IEC HSBY 26 840 USE 106 00 January 2003 13 Overview of Quantum Hot Standby 14 840 USE 106 00 January 2003 Overview of Quantum Hot Standby 1 1 Control Introduction Purpose What s
146. ry controller to the Standby The Standby controller cannot update the Primary Note To put the Standby into dim awareness remove the battery for at least 5 minutes CAUTION Battery Hazard Whenever installing a new controller be sure its battery has been disconnected for at least five minutes Failure to follow this precaution can result in injury or equipment damage 194 840 USE 106 00 January 2003 Maintenance Before You Begin CAUTION Program Change Hazard To change the program you must stop both controllers and take the Standby controller Off Line Failure to follow this precaution can result in injury or equipment damage To download a new program to your Primary controller you must stop the Standby controller as well The Standby CHS 110 module must be in Off Line mode Make any changes to the program Then follow the steps below to copy the new program to the Standby controller 840 USE 106 00 January 2003 195 Maintenance Updating The following table demonstrates how to update the Standby procedure Standby Acti Procedure Step chen 1 Put the Primary controller in Run mode Be sure the Standby controller is still stopped and Off Line 2 Push the update button on the Standby unit Hold the button down 3 Turn the key on the Standby CHS 110 module to Xfer This prepares the Standby unit to receive the update Updating
147. s A or B 20 840 USE 106 00 January 2003 Overview of Quantum Hot Standby 1 2 Operation Modes of Operation HSBY Modes of Operation Off Line Mode Transfer Mode HSBY has three Modes of Operation 1 Off Line Mode 2 Transfer Mode 3 Run Mode These modes are described below This mode is used to take a controller out of service without stopping it or disconnecting power If you turn the key on the Primary unit to Off Line control switches to the Standby If the Standby controller is taken offline the Primary continues to operate without a backup This mode is used to request a program update of the Standby controller from the Primary controller For a step by step description of the procedure refer to Replacement p 192 The Primary controller is able to update the Standby without any interruption in its other functions If the Primary unit is in Run mode and you hold down the update button on the Standby unit the Hot Standby modules prepare to copy the full program of the Primary controller to the Standby unit The program includes the configuration table I O map configuration extensions segment scheduler user logic all EXE loadables ASCII messages and the entire state RAM To complete the transfer while continuing to press the update button turn the key on the Standby to transfer The Com Act LED extinguishes Turn the key to the mode you want the Standby to assume after th
148. s not swap Modbus port 2 address during switchover Swaps Modbus port 3 address during switchover 1 Does not swap Modbus port 3 address during switchover CAUTION Hot Standby Command Register Hazard Take precautions to be sure the register you select as the Hot Standby command register is reserved for this purpose and not used for other purposes in ladder logic Failure to follow this precaution can result in injury or equipment damage The values set for the bits in this register determine the system parameters at startup The register can be accessed while the system is running using a reference data editor RDE or a Zoom screen on the CHS instruction in ladder logic 840 USE 106 00 January 2003 75 Using a Quantum 984 HSBY System Command Register Command Register The State RAM Transfer Area CAUTION Command Register Hazard If you use the command register to enable the keyswitch override while the Hot Standby system is running the Primary controller immediately reads bits 14 and 15 to determine its own state and the state of the Standby If both bits are set to 0 a switchover occurs and the former Primary CPU goes offline The new Primary CPU continues to operate Failure to follow this precaution can result in injury or equipment damage The command register must be contained within the range of 4x registers in the state RAM transfer area A fixed block o
149. s of Concept these state RAM references are not accessed directly but rather indirectly through the so called Mirror Buffer This is a continuous block of memory part of DFB instance data in which at the beginning of every scan the Ox and 1x states are copied mirrored At the end of every scan the states of the mirror buffer are copied back into the Ox and 1x area During the scan the IEC logic accesses the mirrors of the Ox and 1x references instead of accessing them directly The data memory behind the mirror buffer is that every coil and discrete is represented by a byte in the mirror buffer not by a bit The reason for this was to facilitate generation of the IEC application executable code Note In Concept 2 1 each configured 0x 1x reference consumes per default 1 byte ofthe DFB instance data area which is IEC data and is going to be transferred from Primary to Standby on every scan and that in turn extends the overall scan time It does not matter whether a particular discrete reference is used in IEC logic or not when it s configured it takes one byte in the mirror buffer 840 USE 106 00 January 2003 155 Additional Guidelines for IEC Hot Standby Configured State RAM Registers Continued Efficient Use of IEC Application Data With Concept 2 2 the mirror buffer does not exist anymore but it s still worth not having significantly more state RAM references configured than actually used The actual
150. specified in the configuration extension screens go back into effect All ladder logic for Hot Standby functions should be in segment 1 Network 1 of segment 1 is reserved exclusively for the CHS instruction block and ladder logic directly associated with it e program all ladder logic specific to Hot Standby functions in segment 1When the Hot Standby system is running the Primary controller scans all segments while the Standby controller scans only segment 1 of the configured ladder logic program This has very important implications with respect to the way you configure system logic e do not program l O control logic in segment 1 do not schedule any I O drops in segment 1 e the Standby controller in a Hot Standby system must never execute I O logic 72 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System CHS Instruction Using CHS Instruction Using the CHS Instruction to Control Your Hot Standby System CAUTION Reschedule Segment Hazard To help protect against damage to application I O devices through unexpected system actions do not reschedule segment 1 via the segment scheduler Failure to follow this precaution can result in injury or equipment damage Segment 1 may contain the ladder logic for diagnostics and optional Hot Standby functions such as time of day clock updates If you choose to use the CHS instruction in ladder logic to control the Hot Stan
151. t have to be placed in a ladder logic program However the CHS software must be loaded into the Quantum controller in order for a Hot Standby system to be supported The following steps are only necessary if the CHS loadable is not already part of your 984 installation The CHS loadable is provided on a 3 1 2 diskette 140 SHS 945 00 as part of your 140 CHS 210 00 Hot Standby kit The file is named QCHSVxxx DAT where xxx is the three digit version number of the software Step Action 1 Insert the diskette in the disk drive 2 Either create a new Concept project or open an existing one and have a PLC selected With the menu command Project Configurator open the configurator 4 With Configure Loadables open the dialog box Loadables Press the command button Unpack to open the standard Windows dialog box Unpack Loadable File Select the loadable file click the button OK and it is inserted into the list box Available Modsoft If you are using Modsoft refer to the Modicon Quantum Hot Standby System Planning and Installation Guide 840 USE 106 00 Version 1 Paragraph 5 1 1 70 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System Controlling the Hot Standby System by CHS instruction If you are upgrading from a 984 Hot Standby system to a Quantum system you may port your ladder logic program by first deleting the HSBY block then relocating the program and then inserting a CHS i
152. tandby Topology 166 NOE Configuration and Hot Standby 167 IP Address Assignment 168 NOE Operating Modes and Hot Standby 169 Address Swap Times 173 Network Effects of Hot Standby Solution 174 840 USE 106 00 January 2003 163 Ethernet Hot Standby Solution Overview of Hot Standby Solution for NOEs Please Note Description of the Hot Standby Solution The Quantum Hot Standby system supports up to four NOE 771 Ethernet connections For a more detailed description of the physical set up of a Hot Standby system refer to the Quantum NOE 771 xx Ethernet Modules User Guide 840USE11600 Chapter 9 Hot Standby The Hot Standby solution provides bumpless transfer of I O using remote I O The NOE Hot Standby support now allows automation IP Address change Both controllers are configured identically One controller is the Primary NOE the other controller the Secondary NOE In case of a failure the controllers switchover and the system recovers quickly The NOEs coordinate the swapping of IP addresses After closing both the client and the server connections each NOE sends a swap UDP message to its peer NOE The sending NOE then waits a specified timeout 500 ms for the peer swap of UDP messages Either after receiving the messages or after a timeout the NOE changes its IP address Note NOEs must communicate with each other in order to swap IP Addresses Schneider Electric recommends that you connect the pr
153. tate RAM they are never more than 64K words 128 KByte To ensure full data consistency in case of a switchover all data of the Primary s IEC application must be transferred to the Standby in every scan The IEC heap which contains all the to be transferred data may not be bigger than the transfer buffer that carries the IEC heap from the Primary to the Standby controller 64K words 132 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System Memory Partition IEC HSBY The number of IEC HSBY Registers size of transfer buffer is set to the maximum Registers whenever the IEC Hot Standby configuration extension is activated the first time for a particular project So after having the IEC Hot Standby configuration extension activated the state RAM is fully occupied with the default values for Ox 1x 3x 4x and the remaining maximum for IEC HSBY Registers 3x The dialog that follows shows how the number of IEC HSBY Registers can be modified The diagram below shows a PLC Memory Partition Concept shown PLC Memory Partition x Maximum State Memory 65024 State Memory Used 65018 State Memory Usage 99 r Discretes Coils Oxxxx 1536 Discrete Inputs 1xxxx 512 r Registers Input registers 3xxxx 512 Holding registers Axxxx 1872 IEC Hot Standby Data Input registers 3xxxx 52018 CREME NN Note The higher the number of IEC HSBY Regist
154. tem 110 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System 7 1 Configuration Introduction Purpose What s in this Section This section describes Quantum IEC Hot Standby configuration Note To ensure correct operation of the HSBY system the user must I O map at least 1 RIO drop and 1 I O module This will ensure the proper diagnostic information is transferred between Primary and Standby CRPs Remote I O Processor This section contains the following topics Topic Page Loading the Software 112 Controlling the Hot Standby System by Configuration Extension 114 840 USE 106 00 January 2003 111 Using a Quantum IEC Hot Standby System Loading the Software Loading and Concept 2 5 Load Software into Controllers Installing the CHS loadable into the Concept Environment Starting with Concept 2 5 the CHS loadable is a part of the Concept install If you are using Concept 2 5 and for some reason the loadable is deleted it can be reinstalled using the following procedure To configure a Quantum Hot Standby system load the CHS software into the controllers The software is included on a diskette in the Hot Standby Kit Once you have installed the software you can activate the IEC Hot Standby configuration extension The following steps are only necessary if the CHS loadable is not already part of your Concept installati
155. ters will be transferred plus an additional 300 registers to bring the total to 10 000 plus an additional 12 registers to reach the next highest multiple of 16 In all 9312 4x registers will be transferred 840 USE 106 00 January 2003 39 Theory of 984 HSBY Operation Customizing Options Custom State RAM Transfer Area If you want to set up a custom state RAM transfer area you can control your transferred amounts using a Hot Standby configuration extension refer to Aaditional Guidelines for IEC Hot Standby p 147 The configuration extension provides three alternatives to the default transfer area e You can define the number of Ox 1x 3x and 4x reference data types that you want transferred in each scan e You can define a certain amount of reference data types to be transferred on each scan with additional data to be transferred in groups over multiple scans beginning with Ox registers and proceeding in turn with 1x 3x and 4x registers e You can transfer all the configured reference data types in your system s state RAM on every scan These options allow you to design a transfer area that is as small as 16 4x output registers or large enough to encompass all of your controllers state RAM 10K 32K or 64K depending on the type of Quantum controllers you are using in your Hot Standby system The reference data of each type 0x 1x 3x and 4x is placed in the state RAM transfer area starting at the
156. the IP address swap all other NOEs will take the IP address that s being configured for them no matter if they reside in the Standby or Primary rack NOE 771 XX modules must be configured in the same slot of the Primary and Standby Backplanes NOE 771 XX requires minimum firmware revision 1 10 or higher Note Even if the built in I O Scanner of the NOE 771 00 module is used for data exchange or I O modules this mechanism does not provide full uninterrupted communication in case of a switchover Some connection losses may occur and or some non actual data may be provided by the I O Scanner Therefore Schneider Electric does not recommend applying this feature for I O serving Although customizing transfers is not an option you should designate a block of 4x registers as the nontransfer area These registers are ignored when state RAM values are transferred from the Primary controller to the Standby Placing registers in the nontransfer area is one way to reduce scan time because the Primary PLC to CHS transfer time is shorter See State RAM p 129 for more detail 128 840 USE 106 00 January 2003 Using a Quantum IEC Hot Standby System 7 3 State RAM Introduction Purpose This section describes Quantum IEC Hot Standby State RAM What s in this This section contains the following topics Section Topic Page Nontransfer Area of State RAM 130 Hot Standby Status Register 132
157. the following order All Ox references first All 1x references second All 3x references third e e e e All 4x references last 840 USE 106 00 January 2003 101 Using a Quantum 984 HSBY System Scan Transfers Data Type A minimum of 512 equivalent words of each data type specified in the Additional State RAM area are sent in a scan unless there are less than 512 words of that data type left to be transferred For example if you specify 528 additional registers to be transferred over three scans the system will send the data faster than expected The first 512 additional registers are transferred in the first scan and the remaining 16 registers are transferred in the second scan On the third scan the process begins again sending the first 512 additional registers 102 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System 6 4 Operation Introduction Purpose This section describes Hot Standby operation What s in this This section contains the following topics Section Topic Page Starting Your Hot Standby System 104 Synchronizing Time of Day Clocks 106 While Your System Is Running 108 840 USE 106 00 January 2003 103 Using a Quantum 984 HSBY System Starting Your Hot Standby System Preconditions Note Start one controller at a time Be sure e The controller you are starting first has been fully programmed e The desi Th
158. tion Custom Scans Setting up The following block diagram shows how the state RAM transfer area might be set Custom Scans up using multiple scans to transfer all the data ji p001 7 Total number of discrete EKEKIZ Critical outputs transferred on outputs transferred 000003 every scan T Additional outputs transferred i Onnnnn 1 in chunks on multiple scans i i Total number of discrete Lal Critical inputs transferred on inputs transferred 100003 every scan I Additional inputs transferred 1nnnnn in chunks on multiple scans H Total number of register anon Critical inputs transferred on inputs transferred 300017 every scan 300003 T i Additional inputs transferred in chunks on multiple scans 3nnnnn T D Total number of register pi Critical outputs transferred on ransferred na every scan outputs transfe 400003 y ZA 20005 0005 i Additional outputs transferred ins in chunks on multiple scans Li 840 USE 106 00 January 2003 41 Theory of 984 HSBY Operation 42 840 USE 106 00 January 2003 Theory of IEC HSBY Operation At a Glance Purpose What s in this Chapter This chapter presents the Theory of Operation for the IEC Hot Standby system This chapter contains the following topics Topic Page IEC Hot Standby Definitions 44 How an IEC HSBY System Works 46 System Scan Time 47 State Ram Transfer and Scan Time 51 Layout of co
159. ts Instead of Open Inputs Programmed The number of unused pins should be reduced to the absolute minimum so as to Logic not waste any memory for hidden allocated memory that is used nowhere But there are some cases where this is just not possible as in the example below AF 13 MUL_REAL ADD_REAL real A real B real C C gt real D real 1 OO gt real 1 O0 gt 18 1 10 SUB REAL ADD REAL real E real F real G C gt real H real_1_00 gt real_1_00 gt Therefore the logic should look like the diagram below 4 11 BIT TO WORD bool A BITO word A bool B BIT1 bool C 7 BIT2 BIT3 BIT4 BITS BIT BIT BITS BITS BIT10 BIT11 BIT12 BIT13 BIT14 BIT15 840 USE 106 00 January 2003 159 Additional Guidelines for IEC Hot Standby Programmed The only problem with logic programmed like that is for every open pin there is as Logic Continued much memory allocated as its data type requires In this case there are 13 bytes of unused memory allocated To reduce those 13 bytes to just 1 byte means connecting a constant to every open pin that makes the logic work as if the pin was open This is always equivalent to zero or FALSE in this case Therefore the logic should look like the diagram below 1 11 BIT TO WORD bool A BITO bool_B BIT1 bool C BIT2 bool_FALSE gt BIT3 bool_FALSE BIT4 bool_FALSE BITS bool_FALSE BITE bool_FALSE gt BIT bool FALSE gt BITS boo
160. uding their associated histories e All the 1x discrete inputs in state RAM up to a maximum of 8192 including their associated histories e f the total number of registers 3x and 4x combined implemented in state RAM is 10 000 or less then all the registers plus the up down counter history table e f the total number of registers 8x and 4x combined implemented in state RAM is greater than 10 000 then 10 000 registers transfer in accordance with the formula described in System Scan Time p 33 If you choose the 12K option the State RAM and Additional State RAM area become irrelevant You can not customize the transfer area or transfer additional data in groups over multiple scans Any entries in these fields are ignored 98 840 USE 106 00 January 2003 Using a Quantum 984 HSBY System User Defined The User Defined option lets you specify the amount of each reference data type Option that you want to be transferred on each scan If the Transfer Additional State RAM check box is activated it allows you to transfer additional data me Outputs transferred on every scan 000003 H Y e Remaining outputs Onnnnn y not transferred ry 1 Hd Inputs transferred on every scan 100003 e e Remaining inputs innnnn y nottransferred ry d Inputs transferred 300003 on every scan Remaining inputs 3nnnnn not transferred Y ry 400001 400002 400003 Outputs transferred 400004 on every scan 4000
161. umber of 4x registers being transferred by selecting a block of registers as part of the nontransfer area but you cannot limit the number of Ox 1x or 3x registers in the transfer area Note The command register must be located in the area of state RAM which is transferred in every scan 840 USE 106 00 January 2003 97 Using a Quantum 984 HSBY System Hot Standby Dialog 12K Option Using the Hot Standby dialog you have a great deal more flexibility in determining how much or how little State RAM gets transferred You also can manage how much gets transferred in all scans and how much gets transferred in pieces over multiple scans The parameter you select in the Transfer field of the State RAM determines the flexibility you have in defining your state RAM transfer area You may choose from two options e 12K e User Defined Note The remaining entry fields of the dialog may or may not be used depending on which one of these two parameters you choose Note No matter which option you choose remember that the command register must be included in the block of registers transferred on every scan The 12K option mimics the CHS instruction It gives you a predefined state RAM transfer area with a predetermined maximum of each reference data type to be transferred The predefined transfer area consists of the following e All the 0x discrete outputs in state RAM up to a maximum of 8192 incl
162. use of state RAM references should concentrate on I O purposes only and not on storing some application data just to make it accessible for a SCADA System The better way would be to use any kind of application related data which includes everything except I O points pure IEC variables non located variables The connection to the SCADA system can then be accomplished more easily with an OPC OLE for Process Control server that accesses certain application data by name and not by location This method of SCADA connection is very flexible and reliable and saves state RAM which is good for IEC Hot Standby applications There is one thing that can reduce the IEC application data consumption better than anything else Program only what s really necessary to control a particular process When learning about IEC compliant programming and the different EFBs in the different libraries concentrate on which EFBs not to use This will help you reduce the size of an application to the necessary minimum 156 840 USE 106 00 January 2003 Additional Guidelines for IEC Hot Standby 8 3 Efficiency Tips Introduction Purpose This section describes efficiency tips for the IEC Hot Standby What s in this This section contains the following topics Section Topic Page Use Constants Instead of Equal Literals 158 Use Constants Instead of Open Inputs 159 Programmed Logic 161 Reduce the Use Of Complex Data Structures
163. wing block diagram shows how the nontransfer area exists with respect to the rest of the state RAM transfer area State RAM Transfer Area 000004 ODDO OUDCHYS TODCRHI TODO 100003 3000 SOS 300003 m m j ET ERR AT Critical outputs transferred 4pOnee abona i boul S ADODO4 ote The command register Total number et 400005 must be outside the register outputs 400006 nontransfer block transferred Additional outputs transferred in chunks on multiple scans 840 USE 106 00 January 2003 77 Using a Quantum 984 HSBY System Elements of the Nontransfer Area Nontransfer Area The most important part of the nontransfer area is the Hot Standby status register Once the system has been configured and is running the status register becomes a valuable tool for monitoring the machine states of the two controllers If you use software to change values in the command register being able to see the result of those changes in the status register is very helpful The nontransfer area is defined in the middle and bottom nodes of the instruction block The middle node specifies the first register in the nontransfer area The bottom node specifies the length of the nontransfer area Status Register This PLC in OFFLINE mode 0 1 This PLC running in primary mode 1 0 This PLC running in standby mode 1 1 The other PLC in OFFLINE mode 0 1 The other PLC running in primary mode 1 0 The other PLC running
164. xial cable Splitter Cabletoth e RIO network Installing Coaxial Connect the fiber link between the Hot Standby modules making sure the cable is Cable Link properly crossed so that the transmit cable connector of each module is linked to the receive cable connector of the other Follow these instructions Remove the protective plastic coverings from the cable ports and the tips of the cable Snap one of the fiber cable clasps onto the cable carefully pressing the cable through the slot so that the wider end of the clasp is closest to the boot The following diagram shows the installation of a coaxial cable link la Clasp Boc F bar 840 USE 106 00 January 2003 63 Installation Attaching the Fiber Cable Clasp to the Cable Aligning the Key The key to installing the cable is to align the barrel the locking ring and the connector as shown in the diagram below Arrow Lock Barr al Grae Locking Hing The table below shows how to align the key and locking ring and Locking Ring Step Action 1 Turn the locking ring to align an arrow with the key 2 Then align the key with the keyway As a result the locking tab groove and lock should also be aligned Slide the clasp up to the locking ring 4 Gripping the cable with the clasp plug the cable into the lower receive cable connector If it does not connect easily realign the key with the arrow and try aga
165. y 2003 Ethernet Hot Standby Solution NOE Configuration and Hot Standby TCP IP When an NOE goes into service the first time the NOE attempts to get its IP Address Configuration from a BOOTP server If no BOOTP server is available the NOE derives its IP Address from its MAC address Connecting to a BOOTP server or deriving the IP Address from a MAC address allows you a connection to the NOE that enables you to download a project to the PLC All standard rules apply to IP addressing with the additional restriction that the IP address cannot be greater than 253 or broadcast address minus 2 Also no other device can be assigned the configured IP 1 address 840 USE 106 00 January 2003 167 Ethernet Hot Standby Solution IP Address Assignment Configuring the NOE IP Address Transparency The NOE can be configured to work in conjunction with the Hot Standby controller Since the Primary and Secondary controllers must have an identical configuration the configured IP Addresses will be the same The NOE s IP Address is either the configured IP Address or the configured IP Address 1 The IP Address is determined by the current local Hot Standby state In the Offline state the IP Address is determined by whether or not the other controller is in transition to the Primary state Note For a Hot Standby system the two IP Addresses will be consecutive The following table shows the IP Address assignments
166. y to standby occurs The 2 options for this field are Yes address changes on switchover e No address does not change on switchover Controller A Mode Use to specify the operating mode for the PLC at startup when the keyswitch override is enabled There are 2 options for this field e Offline e Run Controller B Mode Use to specify the operating mode for the PLC at startup when the keyswitch override is enabled There are 2 options for this field e Offline e Run Standby Mode on logic mismatch Use to specify Standby PLC s state if a mismatch is detected between its logic program and the Primary PLCs logic program The 2 state options are e Yes Online Standby with logic mismatch No Offline with logic mismatch 840 USE 106 00 January 2003 221 ProWORX Nxt Configuration Field Function Executive Upgrade Switch Use to specify if the PLC has to be stopped to download new executive to PLC The 2 options are e Yes PLC has to be stopped No PLC does not have to be stopped Keyswitch Override Use to specify if the keyswitch on CHS 110 modules is disabled command register controls online offline state of PLCs The 2 options are e Disabled keyswitch controls online offline state e Enabled control register controls online offline state 222 840 USE 106 00 January 2003 Index Numerics 984 HSBY 27 6
167. ys has a higher scan time than a comparable standalone system because of the required PLC to CHS data transfer time Since the data transfer depends on the PLC type in the system the following provides information that allows you to forecast a Hot Standby system s scan time e Calculation of overall scan time for a normal Hot Standby baseline configuration containing minimum logic as a reference e Calculation of a PLC specific constant that expresses the increase of overall scan time related to an increase of state RAM memory to be transferred 840 USE 106 00 January 2003 33 Theory of 984 HSBY Operation PLC Scan Times PLC to CHS Data Transfer Rate The normal Hot Standby configuration contains e In the local rack power supply CPS PLC CPU RIO Head CRP 93x Hot Standby module CHS e In one remote IO drop equipped with 8 I O modules power supply CPS and remote adapter CRA e Only the logic for the scan time evaluation The scan time increase with different PLCs after adding HSBY is outlined in the Scan Time Increase table below CPU HSBY Baseline Scantime Increase Languages Supported Configuration because of HSBY CPU x13 0x0x 1536 1x 512 3x 25 ms 984 Ladder Logic only 3000 4x 1872 CPU 424 020x 1536 1x 512 3x 40 ms 984 Ladder Logic only 1212 4x 1872 CPU 434 12 CPU 534 140x 40 ms 984 Ladder Logic only 1536 1x 512 3x 512 4x 1872 The invest
168. ystem LED Display Indicators of a Properly Functioning Hot Standby System The following graphic shows LED display indicators of a properly functioning Hot standby system Primary Backplane Standby Backplane 140 CHS 110 00 HOT STANDBY Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A Com Act Error B Primary Mem Prt Standby 140 CHS 110 00 HOT STANDBY Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A Com Act Error B Primary Mem Prt Standby RIO Head HOT STANDBY Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A Com Act Error B Primary Mem Prt Standb RIO Head HOT STANDBY Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus Error A 840 USE 106 00 January 2003 105 Using a Quantum 984 HSBY System Synchronizing Time of Day Clocks Clock Synchronization In a Hot Standby system the Primary and Standby controllers have their own time of day clocks They are not synchronized At switchover the time of day changes by the difference between the two clocks This could cause problems if you are controlling a time critical application To solve this problem program the Standby controller to reset its clock from the state table provided by the Primary controller If you are controlling your system via configuration extension screens put the logic for time synchronization first Otherwise put the logic for time sy
169. ystem and make the necessary change in the dialog then power up the system again Download the new configuration Option 2 Connect Concept to your Primary controller Call up the reference data editor RDE Place the Hot Standby command register and the Hot Standby status register in the RDE The operating mode of controller B is determined by the state of bit 14 of the command register If controller B is offline bit 14 is set to 0 To put the controller in RUN mode change the state of bit 14 to 1 Controller B immediately goes into RUN mode if all other HSBY requirements are healthy Option 3 If you have programmed a CHS instruction into the ladder logic Connect Concept to your Primary controller In the editor place the cursor on the top node of the CHS instruction and invoke the Zoom screen CTRL D Check the Run Mode checkbox for parameter Contoller B in Run Mode and controller B immediately goes into RUN mode The advantage of options 2 and 3 is that the Hot Standby system does not have to be shut down in order to change its status If you find the use of the Zoom screen more comfortable than the RDE consider programming a CHS instruction into ladder logic for purposes such as this 840 USE 106 00 January 2003 91 Using a Quantum 984 HSBY System Standby on Logic Mismatches Logic Program To function properly the Primary and the Standby controller in a Hot Standby system must be solving an identical lo

Schneider Electric Stroller 840 USE 106 0 User's Manual

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