Schneider Electric 840 USE 106 0 - Manual

840 USE 106 00 January 2003 9 § 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 o...

Safety Information 10 840 USE 106 00 January 2003 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 ...

840 USE 106 00 January 2003 11 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 Product Related Warnings Schneider Electric assumes no responsi...

About the Book 12 840 USE 106 00 January 2003 User Comments We welcome your comments about this document. You can reach us by e-mail at [email protected]

840 USE 106 00 January 2003 13 1 Overview of Quantum Hot Standby 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, ...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 15 1.1 Control Introduction Purpose This section describes Primary and Standby Control for a Quantum Hot Standby system. What’s in this Section? This section contains the following topics: Topic Page Primary and Standby Control 16 Hardware ...

Overview of Quantum Hot Standby 16 840 USE 106 00 January 2003 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 hardwar...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 17 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 Programmable logic ...

Overview of Quantum Hot Standby 18 840 USE 106 00 January 2003 The CHS 110 Hot Standby Module Topology The following diagram shows the module’s front panel, which consists of: l LED Display l Function Keyswitch l Designation slide switch l Update Button l Fiber optic cable ports CHS 110 Front Panel ...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 19 LED Display The following illustration shows five status indicators on the face of each CHS 110 module. The following table shows the five status indicators. Error messages are discussed in detail in Com Act Error Patterns, p. 209. Indic...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 21 1.2 Operation Modes of Operation HSBY Modes of Operation HSBY has three Modes of Operation: 1. Off Line Mode2. Transfer Mode3. Run Mode These modes are described below. Off Line Mode This mode is used to take a controller out of service ...

Overview of Quantum Hot Standby 22 840 USE 106 00 January 2003 Run Mode When the keyswitch is in this position, the controller is active and is either serving as the Primary controller or is capable of taking over the Primary role, if needed.The keyswitch on both Hot Standby modules should be in the...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 23 1.3 Cabling Introduction Purpose This section describes cabling for CHS 110 Hot Standby modules. What’s in this Section? This section contains the following topics: Topic Page Fiber Optic Cable 24 The CHS 210 Hot Standby Kit 25

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 25 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 m...

Overview of Quantum Hot Standby 26 840 USE 106 00 January 2003 1.4 984 HSBY and IEC HSBY Introduction Purpose This section describes 984 HSBY and IEC HSBY. What’s in this Section? This section contains the following topics: Topic Page 984 HSBY 27 IEC HSBY 28

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 27 984 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" loa...

Overview of Quantum Hot Standby 28 840 USE 106 00 January 2003 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 sys...

Overview of Quantum Hot Standby 840 USE 106 00 January 2003 29 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 ...

Overview of Quantum Hot Standby 30 840 USE 106 00 January 2003 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 ...

840 USE 106 00 January 2003 31 2 Theory of 984 Ladder Logic HSBY Operation At a Glance Purpose This chapter covers the 984 Hot Standby and its theory of operation. What’s in this Chapter? This chapter contains the following topics: Topic Page How a 984 HSBY System Works 32 System Scan Time 33 The St...

Theory of 984 HSBY Operation 32 840 USE 106 00 January 2003 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 kee...

Theory of 984 HSBY Operation 840 USE 106 00 January 2003 33 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...

Theory of 984 HSBY Operation 34 840 USE 106 00 January 2003 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)...

Theory of 984 HSBY Operation 840 USE 106 00 January 2003 35 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. ...

Theory of 984 HSBY Operation 36 840 USE 106 00 January 2003 The State RAM Transfer and Scan Time Reduce Scan Time This section describes manipulating the state RAM transfer to reduce scan time As the simplified block diagram below shows, all 0x references in the state RAM transfer area are transferr...

Theory of 984 HSBY Operation 840 USE 106 00 January 2003 37 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 R...

Theory of 984 HSBY Operation 38 840 USE 106 00 January 2003 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...

Theory of 984 HSBY Operation 40 840 USE 106 00 January 2003 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 Stan...

Theory of 984 HSBY Operation 840 USE 106 00 January 2003 41 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. 0nnnnn 1nnnnn 3nnnnn 4nnnnn Total number of discreteoutputs transferred To...

840 USE 106 00 January 2003 43 3 Theory of IEC HSBY Operation At a Glance Purpose This chapter presents the Theory of Operation for the IEC Hot Standby system. What’s in this Chapter? This chapter contains the following topics: Topic Page IEC Hot Standby Definitions 44 How an IEC HSBY System Works 4...

Theory of IEC HSBY Operation 44 840 USE 106 00 January 2003 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 al...

Theory of IEC HSBY Operation 840 USE 106 00 January 2003 45 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 C...

Theory of IEC HSBY Operation 46 840 USE 106 00 January 2003 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 ke...

Theory of IEC HSBY Operation 840 USE 106 00 January 2003 47 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...

Theory of IEC HSBY Operation 48 840 USE 106 00 January 2003 Transfer diagram The following shows a transfer diagram: Comm Diag IEC Logic Solve Comm Diag IEC Logic Solve IEC Logic Solve Diag 1 Scan State RAM & IECHeap download 128K bytes 128K bytes 128K bytes State RAM & IECHeap download (Ove...

Theory of IEC HSBY Operation 840 USE 106 00 January 2003 49 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. PLC to CHS Data Transfer Rate Calculating the PLC specific data transfer rate in a Hot Standby system le...

Theory of IEC HSBY Operation 50 840 USE 106 00 January 2003 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...

Theory of IEC HSBY Operation 840 USE 106 00 January 2003 51 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...

Theory of IEC HSBY Operation 52 840 USE 106 00 January 2003 All State RAM transferred The following diagram shows the state RAM transfer area. 0nnnnn 1nnnnn 3nnnnn 4nnnnn Where nnnnn is amultiple of 16 Total number of discreteoutputs transferred Total number of discreteinputs transferred Total numbe...

840 USE 106 00 January 2003 55 4 Planning a Quantum Hot Standby System At a Glance Purpose This chapter describes how to plan a Quantum Hot Standby System. What’s in this Chapter? This chapter contains the following topics: Topic Page Guidelines for Planning a Hot Standby System 56 Electrical Safety...

Planning a Quantum Hot Standby System 56 840 USE 106 00 January 2003 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 counterp...

Planning a Quantum Hot Standby System 840 USE 106 00 January 2003 57 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 electr...

Planning a Quantum Hot Standby System 58 840 USE 106 00 January 2003 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 inst...

Planning a Quantum Hot Standby System 840 USE 106 00 January 2003 59 A Single Cable Configuration Diagram of a Single Cable Configuration The following diagram shows a single cable configuration for the Quantum Hot Standby system. Primary PLC Standby PLC Coaxial Cable Fiber Optic Cable RIO Drop #2 R...

Planning a Quantum Hot Standby System 60 840 USE 106 00 January 2003 A Dual Cable Configuration Diagram of a Dual Cable Configuration The following diagram shows a dual cable configuration for the Quantum Hot Standby system. Primary PLC Standby PLC Fiber Optic Cable Coaxial Cable Coaxial Cable Split...

840 USE 106 00 January 2003 61 5 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 ...

Installation 62 840 USE 106 00 January 2003 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. Connect Network The following diagram shows how to conn...

Installation 840 USE 106 00 January 2003 63 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 mod...

Installation 64 840 USE 106 00 January 2003 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...

Installation 66 840 USE 106 00 January 2003 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 mus...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 69 6.1 Configuration Introduction Purpose This section describes Hot Standby configuration. What’s in this Section? This section contains the following topics: Note: To ensure correct operation of the HSBY system, the user must I/O map at l...

Using a Quantum 984 HSBY System 70 840 USE 106 00 January 2003 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 t...

Using a Quantum 984 HSBY System 72 840 USE 106 00 January 2003 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 da...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 73 CHS Instruction Using CHS Instruction Segment 1 may contain the ladder logic for diagnostics and optional Hot Standby functions, such as time-of-day clock updates. Using the CHS Instruction to Control Your Hot Standby System If you choos...

Using a Quantum 984 HSBY System 74 840 USE 106 00 January 2003 6.2 Using the CHS Instruction Block Introduction Purpose This section describes using the CHS Instruction Block. What’s in this Section? This section contains the following topics: Topic Page Using CHS Instruction Block 75 Command Regist...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 75 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...

Using a Quantum 984 HSBY System 76 840 USE 106 00 January 2003 Command Register Command Register The State RAM Transfer Area The command register must be contained within the range of 4x registers in the state RAM transfer area. A fixed block of up to 12K words in state RAM is specified as the trans...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 77 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 respe...

Using a Quantum 984 HSBY System 78 840 USE 106 00 January 2003 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 mon...

Using a Quantum 984 HSBY System 80 840 USE 106 00 January 2003 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 area in the configuration extension screens must be identical to thos...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 81 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 nontransfe...

Using a Quantum 984 HSBY System 82 840 USE 106 00 January 2003 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 ...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 83 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 co...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 85 6.3 Using Configuration Extension Introduction Purpose This section describes using the HSBY Configuration Extension. What’s in this Section? This section contains the following topics: Topic Page Configuration Extension 86 Hot Standby D...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 87 Hot Standby Dialog Hot Standby Dialog in Concept The Hot Standby dialog is shown below, it can be activated through Configure Hot Standby. Concept shown

Using a Quantum 984 HSBY System 88 840 USE 106 00 January 2003 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...

Using a Quantum 984 HSBY System 90 840 USE 106 00 January 2003 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 t...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 91 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 keysw...

Using a Quantum 984 HSBY System 92 840 USE 106 00 January 2003 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 betwee...

Using a Quantum 984 HSBY System 94 840 USE 106 00 January 2003 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 cont...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 95 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. This PLC in OFFLINE mode = 0 1 This PLC running in primar...

Using a Quantum 984 HSBY System 96 840 USE 106 00 January 2003 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 St...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 97 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 ...

Using a Quantum 984 HSBY System 100 840 USE 106 00 January 2003 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...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 101 Additional Data The diagram below illustrates transfer of additional State RAM data. The system transfers additional data in the following order: l All 0x references first l All 1x references second l All 3x references third l All 4x re...

Using a Quantum 984 HSBY System 102 840 USE 106 00 January 2003 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 y...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 103 6.4 Operation Introduction Purpose This section describes Hot Standby operation. What’s in this Section? This section contains the following topics: Topic Page Starting Your Hot Standby System 104 Synchronizing Time-of-Day Clocks 106 Wh...

Using a Quantum 984 HSBY System 104 840 USE 106 00 January 2003 Starting Your Hot Standby System Preconditions 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 ...

Using a Quantum 984 HSBY System 106 840 USE 106 00 January 2003 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 b...

Using a Quantum 984 HSBY System 840 USE 106 00 January 2003 107 The following diagram shows synchronizing time-of-day clocks. 40001 40101 CHS 4 40103 42221 AND 0001 0015 0 ADD 42221 42221 0011 SUB 42222 0002 TODC MBIT 0001 0001 TODC MBIT 0001 40001 = Address of CHS Command Register40101 = First Regi...

Using a Quantum 984 HSBY System 108 840 USE 106 00 January 2003 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 t...

840 USE 106 00 January 2003 109 7 Using a Quantum IEC Hot Standby System At a Glance Purpose This chapter presents operating procedures for the IEC HSBY. What’s in this Chapter? This chapter contains the following sections: Section Topic Page 7.1 Configuration 111 7.2 Hot Standby Dialog 116 7.3 Stat...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 111 7.1 Configuration Introduction Purpose This section describes Quantum IEC Hot Standby configuration. What’s in this Section? This section contains the following topics: Note: To ensure correct operation of the HSBY system, the us...

Using a Quantum IEC Hot Standby System 114 840 USE 106 00 January 2003 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 ...

Using a Quantum IEC Hot Standby System 116 840 USE 106 00 January 2003 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: Topic Page Hot Standby dialog 117 Specifying the Command Regis...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 117 Hot Standby dialog Activation of Hot Standby Dialog The Hot Standby dialog is shown below, it can be activated through Configure Hot Standby. Command Register Command Register: 4x Run Mode Swap Address at Switchover Controller A:...

Using a Quantum IEC Hot Standby System 118 840 USE 106 00 January 2003 Specifying the Command Register Bits in the Hot Standby Command Register The command register controls various parameters of the Hot Standby system. Specify Command Register The command register is specified in the first entry fi...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 119 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 Pr...

Using a Quantum IEC Hot Standby System 120 840 USE 106 00 January 2003 Enable Keyswitch Override Keyswitch Override 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 Control Example For example: Yo...

Using a Quantum IEC Hot Standby System 122 840 USE 106 00 January 2003 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 ru...

Using a Quantum IEC Hot Standby System 124 840 USE 106 00 January 2003 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...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 125 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 th...

Using a Quantum IEC Hot Standby System 126 840 USE 106 00 January 2003 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. The project global data that is updated includes: l All va...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 127 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 compara...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 129 7.3 State RAM Introduction Purpose This section describes Quantum IEC Hot Standby State RAM. What’s in this Section? This section contains the following topics: Topic Page Nontransfer Area of State RAM 130 Hot Standby Status Regi...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 131 The following block diagram shows how the nontransfer area exists with respect to the rest of the state RAM transfer area. Note: The command register must not be placed in the nontransfer area. No more than one block can be defin...

Using a Quantum IEC Hot Standby System 132 840 USE 106 00 January 2003 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 840 USE 106 00 January 2003 133 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 af...

Using a Quantum IEC Hot Standby System 134 840 USE 106 00 January 2003 State RAM Size State RAM Size 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 ...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 135 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 contr...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 137 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 D...

Using a Quantum IEC Hot Standby System 138 840 USE 106 00 January 2003 7.5 Operation Starting Your Hot Standby System Preconditions 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 slid...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 139 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 On the CHS 110...

Using a Quantum IEC Hot Standby System 140 840 USE 106 00 January 2003 7.6 Normal Operation Introduction Purpose This section describes Quantum IEC Hot Standby normal operation. What’s in this Section? This section contains the following topics: Topic Page Memory/Scantime optimization 141 Synchroniz...

Using a Quantum IEC Hot Standby System 142 840 USE 106 00 January 2003 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 3x-register range, the so called IEC HSBY Registers...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 143 A screenshot of the Memory Prediction dialog is shown below. IEC Memory Available:Free: Used: System: Section Code: Section Data: DFB Code:DFB Instance data:EFB Library:Upload information: Diagnostic information: Recommended rese...

Using a Quantum IEC Hot Standby System 840 USE 106 00 January 2003 145 Synchronizing Time of Day Clocks Primary and Secondary controller time-of-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....

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 151 Memory Statistics Memory Statistics The following screen shows memory statistics. 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) C...

Additional Guidelines for IEC Hot Standby 152 840 USE 106 00 January 2003 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 cont...

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 153 Memory Partition Memory Partition The following screen shows a PLC Memory Partition. IEC Applications Optimization Optimization of IEC Hot Standby applications concentrates on two issues: l Very efficient use of state RAM for ...

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 155 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 havin...

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 157 8.3 Efficiency Tips Introduction Purpose This section describes efficiency tips for the IEC Hot Standby. What’s in this Section? This section contains the following topics: Topic Page Use Constants Instead of Equal Literals 15...

Additional Guidelines for IEC Hot Standby 158 840 USE 106 00 January 2003 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 d...

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 159 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 case...

Additional Guidelines for IEC Hot Standby 160 840 USE 106 00 January 2003 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 re...

Additional Guidelines for IEC Hot Standby 840 USE 106 00 January 2003 161 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 interna...

Additional Guidelines for IEC Hot Standby 162 840 USE 106 00 January 2003 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 compl...

840 USE 106 00 January 2003 163 9 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 assignm...

Ethernet Hot Standby Solution 164 840 USE 106 00 January 2003 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 NO...

Ethernet Hot Standby Solution 166 840 USE 106 00 January 2003 Hot Standby Topology Hot Standby Interconnection 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 ...

Ethernet Hot Standby Solution 840 USE 106 00 January 2003 167 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 ...

Ethernet Hot Standby Solution 168 840 USE 106 00 January 2003 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...

Ethernet Hot Standby Solution 840 USE 106 00 January 2003 169 NOE Operating Modes and Hot Standby The NOE Modes The NOE modes are l Primary ModeThe Hot Standby state is primary, and all services are active. l Secondary ModeThe Hot Standby state is standby, and all server services are except DHCP. l ...

Ethernet Hot Standby Solution 170 840 USE 106 00 January 2003 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 Ethern...

Ethernet Hot Standby Solution 840 USE 106 00 January 2003 173 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 show...

Ethernet Hot Standby Solution 174 840 USE 106 00 January 2003 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 n...

840 USE 106 00 January 2003 177 10 Maintenance At a Glance Purpose This chapter discusses maintenance procedures for the HSBY system. What’s in this Chapter? This chapter contains the following sections: Section Topic Page 10.1 Health of a Hot Standby System 179 10.2 Errors 183 10.3 Failures 187 10....

Maintenance 180 840 USE 106 00 January 2003 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 Primar...

Maintenance 840 USE 106 00 January 2003 181 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 t...

Maintenance 182 840 USE 106 00 January 2003 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 d...

Maintenance 840 USE 106 00 January 2003 183 10.2 Errors Introduction Purpose This section will help you determine component failure and causes. What’s in this Section? This section contains the following topics: Topic Page Startup Errors 184 Communications Errors 185 Board Level Errors 186

Maintenance 184 840 USE 106 00 January 2003 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 designa...

Maintenance 840 USE 106 00 January 2003 185 Communications Errors LEDs If the CHS 110 module detects a communications error, the LEDs display the following pattern: LED display for a communications error. Troubleshooting 1. Be sure the fiber optic cables are connected properly and functioning correc...

Maintenance 186 840 USE 106 00 January 2003 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 be...

Maintenance 840 USE 106 00 January 2003 187 10.3 Failures Introduction Purpose This section helps you determine component failure and causes. What’s in this Section? This section contains the following topics: Topic Page Detecting Failures in a Hot Standby System 188 Detecting Failures in the Primar...

Maintenance 840 USE 106 00 January 2003 189 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...

Maintenance 190 840 USE 106 00 January 2003 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 Failure Description Stops All ...

Maintenance 840 USE 106 00 January 2003 191 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 imp...

Maintenance 192 840 USE 106 00 January 2003 10.4 Replacement Introduction Purpose This section describes replacing a Hot Standby module. What’s in this Section? This section contains the following topics: Topic Page Replacing a Hot Standby Module 193 Changing the Program and Performing a Program Upd...

Maintenance 840 USE 106 00 January 2003 193 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 c...

Maintenance 194 840 USE 106 00 January 2003 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. l C...

Maintenance 198 840 USE 106 00 January 2003 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 Eve...

Maintenance 840 USE 106 00 January 2003 199 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 ...

Maintenance 200 840 USE 106 00 January 2003 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 th...

Maintenance 840 USE 106 00 January 2003 201 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. Forcing a Switchover Manually Take the following steps to force a switchover manually. Note: In sys...

840 USE 106 00 January 2003 205 11 Specifications for CHS 110 Hot Standby 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 Conditi...

840 USE 106 00 January 2003 207 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 Appendix? The appendix contains the following chapters: Chapter Chapt...

840 USE 106 00 January 2003 209 A Com Act Error Patterns At a Glance Purpose This Appendix describes error patterns for the HSBY. What’s in this Chapter? This chapter contains the following topics: Topic Page CHS 110 Hot Standby Module Error Patterns 210 CRP Remote I/O Head Processor Error Patterns ...

Com Act Error Patterns 840 USE 106 00 January 2003 211 CRP Remote I/O Head Processor Error Patterns Error Patterns The following table shows error patterns. Number Blinks Code Error Slow (steady) 0000 requested kernel mode 2 6820 hcb frame pattern error 2 6822 head control block diag error 2 6823 mo...

840 USE 106 00 January 2003 213 B Fiber Optic Cable Guide At a Glance Purpose This Appendix describes specifications for the fiber optic cable. What’s in this Chapter? This chapter contains the following topics: Topic Page Fiber Optic Cable 214 Other Tools 216

Fiber Optic Cable Guide 214 840 USE 106 00 January 2003 Fiber Optic Cable Recommen-dations 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 ...

Fiber Optic Cable Guide 840 USE 106 00 January 2003 215 Other Tools Suggested Tools include: Vendor Part Number Description 3M (photodyn e) 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 17XTA-2041 Pow...

Fiber Optic Cable Guide 216 840 USE 106 00 January 2003 Other Tools Other Tools 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 Pho...

840 USE 106 00 January 2003 217 C ProWORX Nxt Configuration 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 transferr...

ProWORX Nxt Configuration 220 840 USE 106 00 January 2003 Command/Status Registers dialog screen Go to the ProWORX Command/Status Registers Dialog Screen. Command/Status Registers Initial Command Register Command Register Status Register Initial Command Register Setting Swap Port Addresses: Controll...

Index 840 USE 106 00 January 2003 225 state RAM transfer area defined, 76 status register, 94switchover automatic, 108swapping addresses, 93 system scan time, 33, 47 T time-of-day clocks synchronizing, 106 timing diagram, 33 transfer buffer, 53 transfer mode, 21transfer process, 32troubleshooting, 1...