Quantum Hot Standby Planning and Installation Guide 31002766 02 840 USE 106 00 Version 4.
Table of Contents Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Chapter 1 1.1 1.2 1.3 1.4 Chapter 2 Overview of Quantum Hot Standby . . . . . . . . . . . . . . . . . . . . . 13 At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 Theory of IEC HSBY Operation. . . . . . . . . . . . . . . . . . . . . . . . . 43 At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 IEC Hot Standby Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 How an IEC HSBY System Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 System Scan Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Chapter 7 7.1 7.2 7.3 7.4 7.5 7.6 Chapter 8 8.1 Defining the Transfer Area of State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Transferring Additional State RAM Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Scan Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 8.3 Chapter 9 Memory Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Efficient Use of State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Efficiency Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Introduction . . . . . .
Chapter 11 Specifications for CHS 110 Hot Standby . . . . . . . . . . . . . . . . 205 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Appendices for Quantum Hot Standby Planning and Installation Guide . . . . . . 207 Appendix A Com Act Error Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 At a Glance . .
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.
Safety Information PLEASE NOTE 10 Electrical equipment should be serviced only by qualified personnel. No responsibility 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.
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.
About the Book User Comments 12 We welcome your comments about this document. You can reach us by e-mail at TECHCOMM@modicon.
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.
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Overview of Quantum Hot Standby 1.1 Control Introduction Purpose This section describes Primary and Standby Control for a Quantum Hot Standby system.
Overview of Quantum Hot Standby Primary and Standby Control Description 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.
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: l l l l l l Programmable logic controller Remote I/O head processor CHS 110 Hot Standby module Cables (See Fiber Optic Cable Guide, p.
Overview of Quantum Hot Standby The CHS 110 Hot Standby Module Topology The following diagram shows the module’s front panel, which consists of: l l l l l CHS 110 Front Panel Controls LED Display Function Keyswitch Designation slide switch Update Button Fiber optic cable ports The following figure shows the module’s front panel.
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 Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus! Error A Com Act Error B Primary Mem Prt Standby 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.
Overview of Quantum Hot Standby Function Keyswitch 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.
Overview of Quantum Hot Standby 1.2 Operation Modes of Operation HSBY Modes of Operation HSBY has three Modes of Operation: 1. Off Line Mode 2. Transfer Mode 3. Run Mode These modes are described below. Off Line Mode 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.
Overview of Quantum Hot Standby Note: If you turn the key on the Primary unit to transfer, the Hot Standby system ignores your action. Run Mode 22 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.
Overview of Quantum Hot Standby 1.3 Cabling Introduction Purpose This section describes cabling for CHS 110 Hot Standby modules.
Overview of Quantum Hot Standby Fiber Optic Cable 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.
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. l Two CHS 110 Hot Standby modules with four fiber cable clasps (140 CHS 110 00) l A 3 meter duplex fiber optic cable (990 XCA 656 09) l Two coaxial splitters together with two tap terminators and four self-terminating F adapters (140 CHS 320 00) l A 3 1/2 in.
Overview of Quantum Hot Standby 1.4 984 HSBY and IEC HSBY Introduction Purpose This section describes 984 HSBY and IEC HSBY.
Overview of Quantum Hot Standby 984 HSBY 984HSBY 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.
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. 2.
Overview of Quantum Hot Standby Architecture As shown below, Quantum IEC Hot Standby involves: l Concept Version 2.1 or greater l Two High End Quantum Controllers (CPU 434 12 or CPU 534 14) l The existing CHS Modules and Execs (CHS 110 00). The existing RIO Heads with version 2.0 Execs or greater (CRP 93x). l All five IEC 1131 languages can be used, however 984 Ladder Logic cannot be used.
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.
Theory of 984 Ladder Logic HSBY Operation 2 At a Glance Purpose This chapter covers the 984 Hot Standby and its theory of operation.
Theory of 984 HSBY Operation How a 984 HSBY System Works 984 Theory 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.
Theory of 984 HSBY Operation System Scan Time Effect on System Scan Time When the ladder logic program being executed by the primary controller is longer than the CHS 110-to-CHS 110 transfer, the transfer does not increase total system scan time. However, if 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.
Theory of 984 HSBY Operation The normal Hot Standby configuration contains: l In the local rack: power supply (CPS), PLC (CPU), RIO Head (CRP 93x), Hot Standby module (CHS) l In one remote IO drop equipped with 8 I/O modules, power supply (CPS) and remote adapter (CRA) l Only the logic for the scan time evaluation PLC Scan Times The scan time increase with different PLCs, after adding HSBY, is outlined in the Scan Time Increase table below.
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).
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.
Theory of 984 HSBY Operation 1. Reduce the reference configuration to minimum requirements (0x, 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.
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: l The first 8192 points of 0x output reference data l The first 8192 points of 1x input reference data l A total of 10K registers, of which 1K is allotted for 3x registers and 9K is allotted for 4x registers.
Theory of 984 HSBY Operation The diagram below shows examples of the data transfer area for different configurations of 3x and 4x registers. 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.
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 Additional Guidelines for IEC Hot Standby , p. 147). The configuration extension provides three alternatives to the default transfer area: l You can define the number of 0x, 1x, 3x, and 4x reference data types that you want transferred in each scan.
Theory of 984 HSBY Operation Custom Scans Setting up Custom Scans The following block diagram shows how the state RAM transfer area might be set up using multiple scans to transfer all the data.
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Theory of IEC HSBY Operation 3 At a Glance Purpose This chapter presents the Theory of Operation for the IEC Hot Standby system.
Theory of IEC HSBY Operation IEC Hot Standby Definitions Definitions The following are IEC Hot Standby definitions.
Theory of IEC HSBY Operation IEC Heap 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. Program Data Area 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.
Theory of IEC HSBY Operation How an IEC HSBY System Works IEC Theory 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.
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.
Theory of IEC HSBY Operation Transfer diagram The following shows a transfer diagram: 1 Scan Primary Rack IEC Logic Solve Comm Diag IEC Logic Solve Comm Diag IEC Logic Solve Diag CPU State RAM & IEC Heap download 128K bytes 128K bytes 128K bytes CHS Standby Rack State RAM & IEC Heap download (Over the Fiber Optic HSBY link) 128K bytes 128K bytes 128K bytes CHS State RAM & IEC Heap download Diag Comm Diag Comm Diag CPU 1 Scan Note: The size of 128K bytes state RAM memory in the timing d
Theory of IEC HSBY Operation Overall PLC Scan Time 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 PLC to CHS Data Transfer Rate 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.
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).
Theory of IEC HSBY Operation State Ram Transfer and Scan Time Reduce Scan Time 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 is as large as the total size of your controller’s state RAM. 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.
Theory of IEC HSBY Operation All State RAM transferred The following diagram shows the state RAM transfer area.
Theory of IEC HSBY Operation Layout of completely transferred state RAM in an IEC Hot Standby system Layout of transferred RAM The diagram below illustrates that a significant piece of the controller’s state RAM is 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.
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Planning a Quantum Hot Standby System 4 At a Glance Purpose This chapter describes how to plan a Quantum Hot Standby System.
Planning a Quantum Hot Standby System Guidelines for Planning a Hot Standby System Primary and Standby Controllers 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.
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.
Planning a Quantum Hot Standby System Remote I/O Cable Topologies Cable Connections In each configuration: l The cables connecting the RIO head processors to the RIO network must be fitted with self-terminating F adapters. l An MA-0186-100 coaxial splitter must be installed between the RIO head processors and the RIO network. l The remote drops must be connected to the trunk cable via an MA-0185-100 tap and a 97-5750-000 (RG-6) drop cable.
Planning a Quantum Hot Standby System A Single Cable Configuration Diagram of a Single Cable Configuration The following diagram shows a single cable configuration for the Quantum Hot Standby system.
Planning a Quantum Hot Standby System A Dual Cable Configuration Diagram of a Dual Cable Configuration The following diagram shows a dual cable configuration for the Quantum Hot Standby system.
Installation 5 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 Standby System l Install the power supplies, controllers, RIO head processors, hot standby modules and any option modules in the primary and standby backplanes.
Installation The following diagram illustrates installation of a Hot Standby System. Setting Designation Slide Switches The designation slide switch on one Hot Standby module is set to A and the other is set to B. 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.
Installation Network Connections The following diagram illustrates the network connections. Installing Coaxial Cable Link Connect the fiber link between the Hot Standby modules, making sure the cable is properly crossed, so that the transmit cable connector of each module is linked to the receive cable connector of the other. Follow these instructions: Remove the protective plastic coverings from the cable ports and the tips of the cable.
Installation Attaching the Fiber Cable Clasp to the Cable The key to installing the cable is to align the barrel, the locking ring and the connector, as shown in the diagram below. Aligning the Key and Locking Ring The table below shows how to align the key and locking ring. 64 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. 3 Slide the clasp up to the locking ring.
Installation Diagram of Aligning Key and Locking Ring The diagram below illustrates the alignment of the key and locking ring. Attaching the Cable Turn the cable to the right, so that the tab locks securely. You may leave the fiber cable clasp on the cable for future use, but slide it off the boot of the cable to allow the module door to close. Repeat this process with the remaining strand of cable and the upper (transmit) cable connector.
Installation Adding Hot Standby Capability to an Existing System To add Hot Standby capability to an existing Quantum system, you must install a second backplane with modules identical to those in the original backplane. Keep the following requirements in mind: You must remove any local I/O and distributed 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.
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 Chapter? This chapter contains the following sections: 840 USE 106 00 January 2003 Section Topic Page 6.1 Configuration 69 6.2 Using the CHS Instruction Block 74 6.3 Using Configuration Extension 6.
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Using a Quantum 984 HSBY System 6.1 Configuration Introduction Purpose This section describes 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 transfered between Primary and Standby CRPs.
Using a Quantum 984 HSBY System Configuring 984 HSBY CHS software 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.
Using a Quantum 984 HSBY System Controlling the Hot Standby System by CHS instruction 840 USE 106 00 January 2003 If you are upgrading from a 984 Hot Standby system to a Quantum system, you may port your ladder logic program by first deleting the HSBY block, then relocating the program, and then inserting a CHS instruction. This requires the CHS loadable to be installed into your application.
Using a Quantum 984 HSBY System Configuration Extension Controlling the Hot Standby System by Configuration Extension 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.
Using a Quantum 984 HSBY System CHS Instruction Using CHS Instruction 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.
Using a Quantum 984 HSBY System 6.2 Using the CHS Instruction Block Introduction Purpose This section describes using the CHS Instruction Block.
Using a Quantum 984 HSBY System Using CHS Instruction Block CHS Instruction Block The command register is defined in the top node of the CHS instruction block. The bits in this register are used to configure and control various parameters of the Hot Standby system. 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.
Using a Quantum 984 HSBY System Command Register Command Register 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.
Using a Quantum 984 HSBY System 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 following block diagram shows how the nontransfer area exists with respect to the rest of the state RAM transfer area.
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.
Using a Quantum 984 HSBY System Example of a Nontransfer Area In the example, the nontransfer area begins at register 40010, as defined in the middle node. The length is 30 registers, as defined in the bottom node. Thus, the last register in the nontransfer area is 40039.
Using a Quantum 984 HSBY System Zoom screen of CHS Instruction Zoom Screen 80 When both a CHS instruction and the Hot Standby configuration extension are used, the parameters you set for the nontransfer area in the configuration extension screens must be identical to those in the CHS block.
Using a Quantum 984 HSBY System The Hot Standby Status Register 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 monitor the current machine status of the Primary and Standby controllers.
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.
Using a Quantum 984 HSBY System Reverse Transfer Logic Example A Reverse Transfer Logic Example The following example shows I/O ladder logic for a Primary controller that monitors two fault lamps and the reverse transfer logic that sends status data from the Standby controller to the Primary. One fault lamp turns ON if the Standby memory protect is OFF; the other lamp turns ON if the memory backup battery fails in the Standby.
Using a Quantum 984 HSBY System Reverse Transfer Logic The logic in network 2 of segment 1 contains a BLKM instruction and a STAT instruction. The Standby enables the STAT. Bits 000815 and 000816 are controlled by bits 15 and 16 in the Hot Standby status register. The STAT instruction sends one status register word to 400101; this word initiates a reverse transfer to the Primary controller. Remote I/O Logic Internal coil bit 000715 (status bit 11) controls the STANDBY MEMORY PROTECT OFF lamp.
Using a Quantum 984 HSBY System 6.3 Using Configuration Extension Introduction Purpose This section describes using the HSBY Configuration Extension.
Using a Quantum 984 HSBY System Configuration Extension Hot Standby Dialog The configuration of the 984 Hot Standby can be done with the Hot Standby dialog and/or with the CHS instruction of the LL984 instruction library.
Using a Quantum 984 HSBY System Hot Standby Dialog Hot Standby Dialog in Concept 840 USE 106 00 January 2003 The Hot Standby dialog is shown below, it can be activated through Configure Hot Standby.
Using a Quantum 984 HSBY System Bits in the Hot Standby Command Register Specifying the Command Register The command register is used to control various parameters of the Hot Standby system. Command Register The command register is specified in the first entry field of the Hot Standby dialog. 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.
Using a Quantum 984 HSBY System l 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. l 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.
Using a Quantum 984 HSBY System Keyswitch Override and Run Mode Keyswitch and Run 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.
Using a Quantum 984 HSBY System A Software Control Example Using Software Control For example: you 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 three ways you can proceed: 840 USE 106 00 January 2003 Option 1 Change the setting on the Hot Standby dialog.
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 logic program, which is updated on every scan by a state RAM data transfer between the two controllers. By default, the Standby controller is set to go offline if a mismatch is detected between its user logic and that of the Primary controller. Switchover cannot occur while the Standby controller is Offline.
Using a Quantum 984 HSBY System Swap Address 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 controller B are 129 and 130.
Using a Quantum 984 HSBY System Transfer All State RAM "Transfer All State RAM" check box It is not possible to define a special State RAM or additional State RAM range to be transferred if this check box is activated. Nontransfer Area 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.
Using a Quantum 984 HSBY System Hot Standby Status Register for Configuration Extension Status Register for Configuration extension Note: Bits 1 and 2 are used only in conjunction with a configuration extension.
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 This lets you upgrade the controllers step by step to a new firmware version without having to shutdown the system.
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.
Using a Quantum 984 HSBY System Hot Standby Dialog 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.
Using a Quantum 984 HSBY System User Defined Option The User Defined option lets you specify the amount of each reference data type 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.
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.
Using a Quantum 984 HSBY System Additional Data The diagram below illustrates transfer of additional State RAM data. 000001 000002 000003 0nnnnn Critical inputs transferred on every scan Additional inputs transferred in chunks on multiple scans Remaining outputs not transferred. 100001 100002 100003 Critical inputs transferred on every scan 1nnnnn Remaining inputs not transferred.
Using a Quantum 984 HSBY System Scan Transfers Data Type 102 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.
Using a Quantum 984 HSBY System 6.4 Operation Introduction Purpose This section describes Hot Standby operation.
Using a Quantum 984 HSBY System Starting Your Hot Standby System Preconditions Note: Start one controller at a time. Be sure... l The controller you are starting first has been fully programmed. l The function keyswitch on the CHS 110 module is in the Run position. l The designation slide switches on CHS 110 modules are in opposite positions. The first controller to power up will automatically become the primary controller, regardless of its designation as A or B.
Using a Quantum 984 HSBY System LED Display Indicators of a Properly Functioning Hot Standby System The following graphic shows LED display indicators of a properly functioning Hot standby system.
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 timeof-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.
Using a Quantum 984 HSBY System The following diagram shows synchronizing time-of-day clocks.
Using a Quantum 984 HSBY System While Your System Is Running Constant Internal Monitoring After your Hot Standby system has been started and is running normally, it will continue to function automatically. It constantly tests itself for faults and is always ready to transfer control from the Primary to the Standby, 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.
Using a Quantum IEC Hot Standby System 7 At a Glance Purpose This chapter presents operating procedures for the IEC HSBY. What’s in this Chapter? This chapter contains the following sections: 840 USE 106 00 January 2003 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.
Using a Quantum IEC Hot Standby System 110 840 USE 106 00 January 2003
Using a Quantum IEC Hot Standby System 7.1 Configuration Introduction Purpose 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.
Using a Quantum IEC Hot Standby System Loading the Software Loading and Concept 2.5 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. Load Software into Controllers 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.
Using a Quantum IEC Hot Standby System Concept Loadables Installation Screen The following diagram shows a Concept loadables installation screen. Loadables Bytes Available: 643210 Bytes Used: 525888 Available: @1S7 @1SE @2I7 @2IE CHS IHSB Installed: V196 V196 V196 V196 V208 V196 Install Remove Unpack Warning: Confirm user loadables are valid for your PLC OK Cancel Edit Help The CHS loadable is now part of the Concept environment and may be installed into a project configuration whenever needed.
Using a Quantum IEC Hot Standby System Controlling the Hot Standby System by Configuration Extension Configuration Extension Use the Hot Standby Concept configuration extension screen as follows: l Specify the parameters in the Hot Standby command register l Define a nontransfer area to help reduce scan time The parameters in the configuration screens are applied by the controllers at startup.
Using a Quantum IEC Hot Standby System Using the Configuration Extensions screen The Configuration Extension offers two check boxes regarding Hot Standby. Since you are using the IEC environment, check the IEC Hot Standby check box. When exiting the Configuration Extension dialog with OK, the CHS Hot Standby 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).
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 Section? This section contains the following topics: 116 Topic Page Hot Standby dialog 117 Specifying the Command Register 118 Hot Standby Command Register 119 Enable Keyswitch Override 120 Advanced Options Concept 2.
Using a Quantum IEC Hot Standby System Hot Standby dialog Activation of Hot Standby Dialog The Hot Standby dialog is shown below, it can be activated through Configure Hot Standby. Concept 2.5 shown Command Register Command Register: 4x Run Mode Swap Address at Switchover Controller A: Offline Controller B: Offline Modbus Port 1 Modbus Port 2 Modbus Port 3 Standby On Logic Mismatch Enable Keyswitch Override Offline Running Advanced Options...
Using a Quantum IEC Hot Standby System Specifying the Command Register Bits in the Hot Standby Command Register The command register controls various parameters of the Hot Standby system.
Using a Quantum IEC Hot Standby System Hot Standby Command Register Range You may enter any number in the range 1 ... n, where n is the last configured 4x register. However: l 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. l 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.
Using a Quantum IEC Hot Standby System Enable Keyswitch Override Keyswitch Override 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.
Using a Quantum IEC Hot Standby System Options for Software Control Example Option 1 Stage Description Comment 1 Change the setting on the Hot Standby dialog. To do this, you must shut down the 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).
Using a Quantum IEC Hot Standby System Advanced Options Concept 2.5 Advanced Options button When selecting 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. Advanced Options WARNING!! Selecting “Without Stopping” overrides all safety checking between Primary and Hot Standby controllers.
Using a Quantum IEC Hot Standby System IEC HSBY System Executive Upgrade Procedure 840 USE 106 00 January 2003 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 1 Action 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. 2 Disconnect from the Primary controller.
Using a Quantum IEC Hot Standby System Standby on Logic Mismatch Overview 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.
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: l Internal states of Elementary Function Blocks (EFBs) used in the section (Timers, Counters, PID, etc.
Using a Quantum IEC Hot Standby System Updating Project Global Data With a logic mismatch, project global data will be updated with every scan. Global data that do not exist on both controllers is not updated.
Using a Quantum IEC Hot Standby System Swapping Addresses at Switchover Modbus Port Swap Address 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.
Using a Quantum IEC Hot Standby System 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. IP Address Swapping at Switchover The Quantum network option module NOE 771 (Ethernet TCP/IP) supports address swapping at switchover when used in a Hot Standby system.
Using a Quantum IEC Hot Standby System 7.3 State RAM Introduction Purpose This section describes Quantum IEC Hot Standby State RAM.
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.
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 0nnnnn 1nnnnn 3nnnnn Actual transferred registers Nontransfer area is excluded from state RAM transfer Total number of configured 4x registers Actual transferred registers 4nnnnn Note: The command register must not be placed in the nontransfer area. No more than one block can be defined as the nontransfer area.
Using a Quantum IEC Hot Standby System Hot Standby Status Register Hot Standby Status Register 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.
Using a Quantum IEC Hot Standby System Memory Partition IEC HSBY Registers The number of IEC HSBY Registers (size of transfer buffer) is set to the maximum 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 0x, 1x, 3x, 4x and the remaining maximum for IEC HSBY Registers (3x).
Using a Quantum IEC Hot Standby System State RAM Size State RAM Size 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.
Using a Quantum IEC Hot Standby System 7.4 Section Transfer Control Section Transfer Control Section Transfer Control Description A 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.
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: l internal states of EFBs used in the section l 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.
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.
Using a Quantum IEC Hot Standby System 7.5 Operation Starting Your Hot Standby System Preconditions Note: Start one controller at a time. Be sure l the controller you are starting first has been fully programmed; l the function keyswitch on the CHS 110 module is in the Run position; l the designation slide switches on CHS 110 modules are in opposite positions. Starting the System The first controller to power up, automatically becomes the Primary controller, regardless of its designation as A or B.
Using a Quantum IEC Hot Standby System Start Standby The following table shows the steps to starting Standby. Step Action 1 Start the Standby controller. 2 Check the LED display. If the system is functioning normally, the display should be as follows: l l l 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.
Using a Quantum IEC Hot Standby System 7.6 Normal Operation Introduction Purpose This section describes Quantum IEC Hot Standby normal operation.
Using a Quantum IEC Hot Standby System Memory/Scantime optimization IEC State RAM Map An illustration of the IEC State RAM Map. State RAM (compl. xferred) prog. data configured Program data used Safety buffer for future changes/ additions No. 3x regs configured for IEC HSBY 840 USE 106 00 January 2003 Space as big as IEC heap Transfer buffer for IEC heap Program data unused Total 4x Total 3x Total 1x Total 0x Header (Exec vers., timing info,...) DFB instance data free memory for addtl.
Using a Quantum IEC Hot Standby System IEC application data To maintain consistency of the IEC application’s data between the Primary and Standby controllers the IEC heap is transferred through a reserved area in the 3xregister range, the so called IEC HSBY Registers. The size of this reserved area is assigned in the PLC Memory Partition dialog (refer to Additional Guidelines for IEC Hot Standby , p. 147).
Using a Quantum IEC Hot Standby System A screenshot of the Memory Prediction dialog is shown below. Memory Prediction IEC Memory Available: Free: Used: System: Section Code: Section Data: DFB Code: DFB Instance data: EFB Library: Upload information: 100.0 % ---- % 1024 Byte ---- Byte 1088 Byte 0.2 % ---- % 0.2 % ---- Byte 6380 Byte 7768 Byte 0 Byte ---- % 1.2 % 1.4 % 0.0 % 0 Byte 0.0 % 4096 Byte 0.8 % 0 Byte 0.0 % LL 984 Memory Available: Used for code: 63198 Byte 0 Byte 100.0 % 0.
Using a Quantum IEC Hot Standby System Memory Statistics 144 Memory Statistics HSBY (online) used for downsizing the number of 3x-Registers for IEC Hot Standby data.
Using a Quantum IEC Hot Standby System Synchronizing Time of Day Clocks Primary and Secondary controller timeof-day clocks 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.
Using a Quantum IEC Hot Standby System While Your System Is Running Constant Internal Monitoring After your Hot Standby system has been started and is 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. Regular Data Transfers While the system is running, the module automatically transfers all state RAM to the Standby unit at the end of each scan.
Additional Guidelines for IEC Hot Standby 8 At a Glance Purpose 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. What’s in this Chapter? This chapter contains the following sections: 840 USE 106 00 January 2003 Section Topic Page 8.1 General Application Requirements 149 8.2 State RAM 155 8.
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Additional Guidelines for IEC Hot Standby 8.1 General Application Requirements Introduction Purpose This section describes general application requirements for an IEC Hot Standby system.
Additional Guidelines for IEC Hot Standby Memory Savings Memory Savings The reasons that memory savings are important to IEC Hot Standby are: l 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). l 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.
Additional Guidelines for IEC Hot Standby Memory Statistics Memory Statistics The following screen shows memory statistics.
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.
Additional Guidelines for IEC Hot Standby Memory Partition Memory Partition The following screen shows a PLC Memory Partition.
Additional Guidelines for IEC Hot Standby IEC Applications Optimization, Continued 1. There are 64K words of state RAM as a maximum for IEC HSBY Registers in an IEC Hot Standby application. Using as little state RAM as possible for other 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.
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.
Additional Guidelines for IEC Hot Standby Configured State RAM Registers, Continued 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 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.
Additional Guidelines for IEC Hot Standby 8.3 Efficiency Tips Introduction Purpose This section describes efficiency tips for the IEC Hot Standby.
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.
Additional Guidelines for IEC Hot Standby Use Constants Instead of Open Inputs Programmed Logic The number of unused pins should be reduced to the absolute minimum, so as to 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. Therefore the logic should look like the diagram below.
Additional Guidelines for IEC Hot Standby Programmed Logic, Continued The only problem with logic programmed like that is, for every open pin there is as 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.
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.
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.
Ethernet Hot Standby Solution 9 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.
Ethernet Hot Standby Solution Overview of Hot Standby Solution for NOEs Please Note 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". Description of the Hot Standby Solution The Hot Standby solution provides bumpless transfer of I/O using remote I/O.
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 NOE Module Functionality The NOE 771 family provides different Ethernet services. Some services are enabled or disabled in a Hot Standby system.
Ethernet Hot Standby Solution Hot Standby Topology The following diagram shows a Hot Standby system the relationship between the 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. Fiber Optic C H S R I O Drop C P U R I O Drop N O E C H S T Connector C P U Cable N O E Ethernet Switch Hot Standby Interconnection Note: The following three items are important. 1. The two systems must be identical. 2.
Ethernet Hot Standby Solution NOE Configuration and Hot Standby TCP/IP Configuration When an NOE goes into service the first time, the NOE attempts to get its IP Address 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.
Ethernet Hot Standby Solution IP Address Assignment Configuring the NOE 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.
Ethernet Hot Standby Solution NOE Operating Modes and Hot Standby The NOE Modes The NOE modes are l Primary Mode The Hot Standby state is primary, and all services are active. l Secondary Mode The Hot Standby state is standby, and all server services are except DHCP. l Standalone Mode Occurs when NOE is in a non redundant system, or if the CHS module is not present or is not healthy. l Offline Mode CPU is stopped. CHS module is in Offline mode.
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 ...
Ethernet Hot Standby Solution Power-Up and Ethernet Services 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 shows how the status of an NOE service is affected by the Hot Standby state.
Ethernet Hot Standby Solution Step 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 Additional Switchover Information Action Simultaneously, Secondary NOE listens for all server connections and reestablishes those connections. The following list provides additional information about the NOE’s IP addressing process resulting from a Hot Standby switchover.
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.
Ethernet Hot Standby Solution Network Effects of Hot Standby Solution Overview 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 l l l l l Browsers Remote and Local clients I/O Scanning service Global Data service FTP/TFTP server The following are factors you may encounter while using the Hot Standby solution.
Ethernet Hot Standby Solution I/O Scanning Service 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.
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Maintenance 10 At a Glance Purpose This chapter discusses maintenance procedures for the HSBY system. What’s in this Chapter? This chapter contains the following sections: 840 USE 106 00 January 2003 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.
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Maintenance 10.1 Health of a Hot Standby System Introduction Purpose This section describes checking the health of a Hot Standby System.
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.
Maintenance Additional Checks Checking on a Redundant Power Supply 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. Responding to and Recognizing Errors When a CHS 110 Hot Standby module experiences an error, it takes its controller offline.
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.
Maintenance 10.2 Errors Introduction Purpose This section will help you determine component failure and causes.
Maintenance Startup Errors LED Display for a Startup Error When the Hot Standby system detects a mismatch between the Primary and Standby controllers, it reports a startup error. The mismatch may be in the configuration, 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.
Maintenance Communications Errors LEDs If the CHS 110 module detects a communications error, the LEDs display the following pattern: LED display for a communications error. 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 Troubleshooting 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.
Maintenance Board Level Errors PROM, RAM, UART Board level errors include PROM checksum, RAM data, RAM address and UART errors. If the Hot Standby module detects one of these errors, it displays the following pattern: LED Display for a Board Level Error The diagram below shows a LED Dislplay for a Board Level Error.
Maintenance 10.3 Failures Introduction Purpose This section helps you determine component failure and causes.
Maintenance Detecting Failures in a Hot Standby System Main Components of the Primary Backplane If one of the main components of the Primary backplane fails, control shifts to the Standby. If a component fails in the Standby backplane, the Standby goes offline. Likewise, if the fiber cable link between the Hot Standby modules fails, the Standby goes offline. This section helps you determine which component failed. When you have replaced that component, you must cycle power, with one exception.
Maintenance Detecting Failures in the Primary Backplane Troubleshooting Components To determine which component failed, compare the status of the controller, Hot Standby module and RIO head to the chart below: Controller CHS 110 RIO Head Failure Type Description Stops All LEDs off except READY OR COM ACT displays error pattern All LEDs off except READY READY on and COM ACT blinks four times The Interface error patterns are described in Com Act Error Patterns, p.
Maintenance Detecting Failures in the Standby Backplane Troubleshooting Components To determine which component failed, compare the status of the controller, Hot Standby module and RIO head to the chart below. Controller CHS 110 RIO Head Stops All LEDs off except READY OR COM ACT displays error pattern All LEDS off except Controller READY OR READY on and COM ACT blinks once a second The Interface error patterns are described in Com Act Error Patterns, p.
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.
Maintenance 10.4 Replacement Introduction Purpose This section describes replacing a Hot Standby module.
Maintenance Replacing a Hot Standby Module Hot Swap and the Hot Standby System 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.
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: l Change program means: a complete program change.
Maintenance 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. Before You Begin: 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.
Maintenance Updating Standby Procedure The following table demonstrates how to update the Standby procedure. Step Action 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.
Maintenance Step 4 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 Off Line Xfer Off Line Xfer Run Run Slide switches must be set in opposite positions. Update Button 840 USE 106 00 January 2003 5 Release the update button. Result The Primary controller begins copying its full program to the Standby.
Maintenance Updating PLC System Executives in a 984 HSBY System Updating PLC System Executives Bit 12 in the Hot Standby command register can be set to 1 to facilitate an executive upgrade while one of the controllers in the Hot Standby system continues to operate CAUTION Overriding the Safety Checking Protection Hazard Setting bit 12 to 1 overrides the safety checking protections between the Primary and Standby controllers in your Hot Standby system.
Maintenance Steps to Upgrade PLC executives while Hot Standby is running 840 USE 106 00 January 2003 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 1. 2 Disconnect from the PLC and start the Firmware Loader Utility. 3 Perform a firmware download to the standby controller.
Maintenance Updating PLC System Executives in an IEC HSBY System Updating PLC System Executives 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. 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.
Maintenance 10.5 Testing Forcing a Switchover Testing a Hot Standby Switchover To test your Hot Standby system, you may force a switchover manually or through software. Note: In systems with scan times of 200 ms or greater and more than 15 RIO drops, it is recommended that the drop holdup time be increased to 1.5 seconds to ensure that communication with remote drops is maintained during switchover.
Maintenance Step 5 Action Confirm that the keyswitch on both Hot Standby modules has not been overridden by software. After Taking the Primary Controller Offline Primary 202 Standby 6 Turn the key on the Primary Hot Standby module to Off Line. Result: Standby should now be functioning as the Primary controller. 7 Check to see that all LED indicators are normal and all application devices are functioning properly.
Maintenance Step 8 840 USE 106 00 January 2003 Action Return the key on the original Primary unit to the Run position. The Standby indicator should come on.
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.
Specifications for CHS 110 Hot Standby 11 Specifications Specifications for CHS 110 Hot Standby Electrical Electrostatic Discharge (IEC 801-2) 8 kV air/ 4 kV contact RFI Immunity (IEC 801-3) 27 - 1000 MHz, 10 V/m Bus Current Required (Typical) 700 mA Operating Conditions Temperature 0 to 60° C Humidity 0 to 95% Rh noncondensing @ 60C Altitude 15,000 ft. (4500 m) Vibration 10 - 57 Hz @ 0.075 mm d.a.
Specifications for CHS 110 Hot Standby 206 840 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.
Appendices 208 840 USE 106 00 January 2003
Com Act Error Patterns A At a Glance Purpose This Appendix describes error patterns for the HSBY.
Com Act Error Patterns CHS 110 Hot Standby Module Error Patterns CHS 110 Error Patterns 210 The following table shows the number of times the Com Act indicator blinks for each type of error and the codes possible for that group (all codes are in hex).
Com Act Error Patterns CRP Remote I/O Head Processor Error Patterns Error Patterns The following table shows error patterns.
Com Act Error Patterns 212 Number Blinks Code Error 8 8002 flash prog / erase error 8 8003 unexpected executive return 840 USE 106 00 January 2003
Fiber Optic Cable Guide B At a Glance Purpose This Appendix describes specifications for the fiber optic cable.
Fiber Optic Cable Guide Fiber Optic Cable Recommendations 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 3.5dB 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.
Fiber Optic Cable Guide Other Tools Suggested Tools include: Vendor 840 USE 106 00 January 2003 Part Number Description 3M 9XT (photodyn e) Optical Source Driver (hand-held, requires light source) 3M (Photody ne) 1700-0850-T Optical Light Source (850 nm, ST connectors, for 9XT) 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
Fiber Optic Cable Guide Other Tools Other Tools 216 Suggested tools include Vendor Part Number Description 3M (Photody ne) 9XT Optical Source Driver (hand-held, requires light source) 3M (Photody ne) 1700-0850-T Optical Light Source (850 nm, ST connectors, for 9XT) 3M Photodyn e 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
ProWORX Nxt Configuration C ProWORX Nxt Hot Standby Configuration Extension Description 840 USE 106 00 January 2003 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.
ProWORX Nxt Configuration Configuration Extensions Dialog Screen Go to the ProWORX Configuration Extensions Dialog Screen.
ProWORX Nxt Configuration Field and functions The following table describes the functions of the fields of the dialog 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.
ProWORX Nxt Configuration Command/ Status Registers dialog screen Go to the ProWORX Command/Status Registers Dialog Screen.
ProWORX Nxt Configuration Field and functions 840 USE 106 00 January 2003 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.
ProWORX Nxt Configuration 222 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: l Yes – PLC has to be stopped l 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).
B AC Index Numerics 984 HSBY, 27, 67 A advanced options, 96 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 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 networ
Index H N 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 nontransfer area of state RAM command register must not be placed in the nontransfer area, 76 placing registers, 128 I reduce scan time, 36 redundant power supply, 181 reference data edi
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
