sto
abcock
ControlWave
Redundancy
Setup Guide
Bri
D5123 – December, 2005
l B
The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.
Bristol Babcock does not guarantee the accuracy, sufficiency or suitability of the software
delivered herewith. The Customer shall inspect and test such software and other materials to
his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for
a particular purpose, concerning the software and other materials delivered herewith.
Bristol is a registered trademark of Bristol Babcock. Other trademarks or copyrighted products
mentioned in this document are for information only, and belong to their respective companies,
or trademark holders.
Copyright (c) 2005, Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of Bristol
Babcock.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result
in damage or injury. The user is urged to keep this book filed in a convenient
location for future reference.
These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or
maintenance. Should problems arise that are not covered sufficiently in the text, the
purchaser is advised to contact Bristol Babcock for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending
upon the application, this could result in possible damage to property or injury to
persons. It is suggested that the purchaser review the need for additional backup
equipment or provide alternate means of protection such as alarm devices, output
limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol Babcock.
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol Babcock for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure
that the materials returned to Bristol Babcock are clean to safe levels, as such levels
are defined and/or determined by applicable federal, state and/or local law
regulations or codes. Such party agrees to indemnify Bristol Babcock and save
Bristol Babcock harmless from any liability or damage which Bristol Babcock may
incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic
instruments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.
Thank you for choosing ControlWave!
We hope you will find ControlWave to be the best solution for your process automation needs.
From the start, Bristol Babcock designed this unit to merge the simplicity and modularity of a
programmable logic controller, with the full communication and programming capabilities of a
remote process controller. The result - the ControlWave-series of Process Automation
Controllers, are true PLC/RTU hybrids, incorporating the best features of both types of devices.
ControlWave features a low-power, modular design, which supports all five IEC 61131-3
programming languages: ladder logic (LD), sequential flow chart (SFC), function block diagram
(FBD), structured text (ST), and instruction list (IL). A full suite of PC-based configuration
wizards and programming tools is provided, as well as a rich library of Bristol Babcock function
blocks that may be used for various process control applications.
Before You Begin
This guide is intended to help you get redundancy 'up-and-running' with a minimal amount of
effort. It does NOT, however, tell you everything you need to know about setting up and
configuring ControlWave hardware and software. We have included references throughout this
book to other places in the documentation set, where you can get more details on a particular
subject.
Throughout your configuration activities, please be aware of the following items:
Shock Hazard! Always follow accepted safety guidelines. As with all electronic devices,
improper installation, grounding, or usage can cause an electrical shock. If you have any doubts
about how to install, ground, and use this product safely, please consult a qualified electrician.
Electrostatic Discharge (ESD) - Sensitive electronic devices such as this can be damaged by
electrostatic discharge. Please follow accepted ESD guidelines.
If You Need Help…
If you're having problems setting up and configuring your ControlWave, please call our
ControlWave Application Support team at (860) 945-2394 or (860) 945-2286 for assistance.
Help is available Monday through Friday 8:00 AM to 4:30 PM Eastern Time, excluding
holidays, and scheduled factory shutdowns.
4
Table of Contents
The Concept of Redundancy........................................................................................................... 9
Redundancy Options Available ..............................................................................................10
Control Redundancy - CPU and Power Supply.............................................................. 10
Local I/O Redundancy.................................................................................................... 13
I/O Expansion Rack Redundancy................................................................................... 14
Setting up Redundancy Hardware ................................................................................................ 17
Major Types of ControlWave Redundancy Hardware ........................................................... 17
ControlWave Redundant Controller............................................................................... 17
Setting Up the ControlWave Redundant Controller......................................... 19
ControlWave Process Automation Controller................................................................ 24
ControlWave I/O Expansion Rack ................................................................................. 25
ControlWave I/O Switcher............................................................................................. 26
Overview of I/O Switcher Hardware Configuration ........................................ 27
Establishing Communications ...................................................................................................... 29
Establishing Communications Using LocalView .................................................................. 29
Establishing Communications Using NetView (ControlWave Already In a Network)......... 31
Setting Flash Parameters............................................................................................................... 32
Before you Begin ................................................................................................................... 33
Signing on to the ControlWave.............................................................................................. 33
Setting Up an Ethernet Port.................................................................................................... 33
Recommended Ranges for IP Addresses ............................................................................... 35
Setting Application Parameters for Redundancy................................................................... 36
Setting other Flash Parameters............................................................................................... 36
Saving the Flash Parameters to the Unit................................................................................ 37
Activating the newly saved parameters.................................................................................. 38
Saving the same parameters to the other unit:........................................................................ 38
Ethernet Connection Redundancy................................................................................................. 39
Testing the Redundant Setup (CPU and Power Supply) .............................................................. 40
Before Testing Redundancy................................................................................................... 40
Using the Sample Redundant Project or Creating Your Own Redundant Project................. 40
Testing the Redundant Setup.................................................................................................. 41
Notes on Redundant Operation..................................................................................................... 46
How do I force a fail-over to the Standby unit via program control?.................................... 46
Forcing I/O Expansion Rack Fail-over via Program Control ................................................ 49
How do I manually force a fail-over to the Standby unit?..................................................... 52
Manually failing over from "A" to "B".................................................................................. 52
Manually failing over from "B" to "A".................................................................................. 52
Return the A/B Enable Key Switch to Automatic Mode....................................................... 53
Specifying a New Primary Unit.............................................................................................. 53
Codes Which Appear on the Standby Unit Display................................................................ 53
Redundancy Status Variables ....................................................................................................... 54
Troubleshooting Redundancy Problems....................................................................................... 59
6
IMPORTANT:
This document is intended to describe the main steps necessary to configuring
ControlWave redundancy. It does NOT include everything you need to know about
configuring a ControlWave controller.
The following is assumed:
• The OpenBSI Network Edition and ControlWave Designer software kits have been
installed on your PC. If this is not the case, please see Chapter 2 of the Open BSI
Utilities Manual (document# D5081) for details on the installation procedure.
• Some familiarity with ControlWave software configuration.
7
8
The Concept of Redundancy
The Concept of Redundancy
Redundancy is a mechanism employed to prevent the loss of control over a process, and to
minimize the loss of data, which can occur, if any single part of a control system should fail.
Redundancy is recommended for plants or processes where a loss of control could result in
damage or injury.
All methods of ControlWave redundancy involve having a duplicate standby unit that is able to
take over in the event there is a failure in the primary unit. The process of transferring control
from the primary to the backup is referred to as fail-over. A fail-over condition typically falls
into one of two categories:
Hardware failures - These could occur from a variety of causes:
• loose cable
• improper configuration, e.g. board not seated properly
• power supply failure (no power for CPU)
• individual board or component breakdown
Software failures - Possible causes include:
• application program running in the CPU 'crashes', as indicated by an 'FF' code on the display
• all tasks are suspended for more than a user-configurable number of milliseconds
• a task watchdog occurs (this option can be user enabled/disabled)
• user-created logic for detection of a particular failure (e.g. local I/O) is activated, triggering a
switchover via a REDUN_SWITCH function block.
• user-created logic for detection of a particular failure in an I/O Expansion Rack, triggering a
switchover via the ERSTAT_x_FAILOVER_O system variable.
When redundancy is used, these sorts of failures trigger a watchdog relay, and cause a fail-over
from the on-line unit that failed to a standby backup unit. The standby unit has been configured
to be an exact duplicate of the on-line unit (except for the A/B switch setting and IP addresses)
so it can now assume full control over the process previously controlled by the failed unit, and
becomes the new on-line unit.
The redundant units that make up the primary and standby pair are referred to as the “A” unit,
and the “B” unit.
ControlWave redundancy only handles a single point of failure i.e. either the “A” set of
CPU/power supply/ or I/O can have a failure, or the “B” set of CPU / power supply or I/O can
have a failure. A failure of the “A” CPU, and the “B” power supply, however, would disable the
entire control system.
9
The Concept of Redundancy
Redundancy Options Available
IMPORTANT
Throughout this manual, we will refer to the redundant units that make up the primary and
standby pair as the “A” unit, and the “B” unit. This term is used whether the units in
question refer to the “A” and “B” units in a ControlWave Redundant Controller, the “A”
and “B” ControlWave Process Automation Controllers, or “A” and “B” ControlWave I/O
Expansion Racks.
The ControlWave family of products offers three distinct types of redundancy. The choice of
which type(s) of redundancy you need is dictated by the needs of your particular application.
Your system may even include a mixture of the different types of redundancy.
Control Redundancy - CPU and Power Supply
Control Redundancy provides protection in the event a single failure occurs in either the
Central Processing Unit (CPU), or the Power Supply (PSSM) of a ControlWave controller.
ControlWave
Redundant
Controller
ControlWave I/O
Expansion Rack
(shared by both
Unit “A” and Unit “B”)
Unit “A”
CPU &
PSSM
W
I
RRTT
1
234
Unit “B”
CPU &
PSSM
W
I
RRTT
1
234
CCRS
10
The Concept of Redundancy
Control redundancy is accomplished using the ControlWave Redundant Controller plus one or
more ControlWave I/O Expansion Racks. I/O Expansion Racks are required because the
ControlWave Redundant Controller does NOT support any local I/O boards.
Alternatively, Control redundancy can be accomplished using two separate ControlWave Process
Automation Controllers in conjunction with a ControlWave I/O Switcher. Because this particular
configuration also allows for Local I/O Redundancy, we will show a picture of it later, in the
‘Local I/O Redundancy’ section.
In either case, whenever the on-line ControlWave CPU receives a download of a new
ControlWave project file (boot project), that project is immediately transmitted to the Standby
ControlWave unit, and stored. This is known as a side-load, and typically occurs through an
Ethernet connection between the “A” and “B” units, which may either be specifically dedicated
for that purpose, or may also be used for Ethernet communications with other devices on the
network. Once the side-load occurs, the boot project is loaded into memory in the Standby but
kept in the 'Stopped' state.
On-line unit receives
download of a new
ControlWave project
file (boot project)
Standby receives a
side-load of the new
On-line CPU
Unit A
boot project from the
On-line unit
Standby CPU
Unit B
The on-line ControlWave CPU is the only unit executing the project, communicating with I/O
boards and controlling the plant or process. The Standby CPU sits idle except for receiving
updates from the on-line unit.
The updates from the on-line unit to the standby unit occur at the end of each task execution
cycle, unless:
• there have been no changes to process I/O output variables -and-
• the minimum update time1 has not expired
1
The minimum update time is a configured value that may be used to limit the amount of traffic b etween the on-line
unit and the standby unit. Every time an update occurs the mini mu m u pd ate ti mer is res t art ed. Unless process I/O
output changes occur, any changes occurring during the time prior to expiration of the configured update timer will
not trigger an update to the standby unit. Instead, they will be held until expiration of the timer, and the end of a
task execution cycle. The timer value is set via the _RDN_MIN_UPD system variable.
11
The Concept of Redundancy
Updates between the on-line unit, and the standby unit, may consist of multiple update messages,
followed by a ‘commit’ message. Until the commit message is received, the update messages are
not applied to the standby. This ensures that if the on-line unit fails before it sends the ‘commit’
message, that a partial update, e.g. incomplete data, is not used. Instead, the standby will discard
the incomplete update data, and start up using the last complete update that ended with a commit
message.
In general, data is only transferred from the on-line unit to the standby unit if it has changed.
Among the types of data transferred are:
• Any changed process I/O output variables
• All variables marked as RETAIN in the user's project
• Any data in the static memory area (begins at address 3.100000)
• Certain function block parameters that are retained
• Changes to certain port configuration information such as on-line baud rate changes, etc.
• Changes to user account definitions (usernames, passwords)
• Any newly generated alarms plus any changed alarm states from alarm function blocks
• Historical data (audit records, archive files)
On-line unit is curren t l y
running the project to
control the process
or plant, receiving data
via I/O boards, etc.
On-line CPU
Unit A
At the end of
each execution
cycle, changes
are copied to
the Standby, to
keep it up-to-date
Standby sits idle, except
for receiving updates from
the on-line unit.
Standby CPU
Unit B
If a failure occurs at the on-line unit, a watchdog relay is triggered, and control is switched to the
Standby CPU. The Standby CPU now becomes the new on-line unit.
12
The Concept of Redundancy
p
o
p
izzle
s
NEW On-line CPU
Unit B
(formerly the Standby unit)
FAILED CPU
Unit A
Unit "A" suffers a component failure. Control is automatically
transferred to the "B" unit. The "B" unit becomes the NEW
on-line unit, and starts up its boot project.
The "B" unit is up-to-date to the point of the last COMPLETE
update received from "A" unit. (Typically, that would have
been the last execution cycle of the "A" unit, prior to its failure.)
Local I/O Redundancy
Local I/O redundancy provides protection in the event a single failure occurs in either the Central
Processing Unit (CPU), Power Supply, or I/O boards in one of two ControlWave Process
Automation Controllers serving together as a redundant pair.
This redundant configuration would require two (2) ControlWave Process Automation
Controllers, plus a ControlWave I/O Switcher.
ControlWave Process
Automation Controller
“Unit B”
ControlWave
I/O Switcher
ControlWave Process
Automation Controller
“Unit A”
Connections to
field inputs/outputs
13
The Concept of Redundancy
With respect to failures of the CPU and power supply, everything would be handled exactly as
described previously in the ‘Control Redundancy - CPU and Power Supply’ section.
Detection of I/O failures, however, is handled differently. The ControlWave series controllers
cannot automatically detect an I/O failure based on data alone. The user must devise logic within
their ControlWave project to determine when a fail-over should occur, and then use a
REDUN_SWITCH function block, in their ControlWave project to trigger the actual fail-over.
When the fail-over occurs, I/O is automatically switched from the on-line unit to the backup
standby unit, which becomes the new on-line unit.
The logic for whether or not a given failure is sufficient reason to force a fail-over to the Standby
unit is based entirely on the user’s own criteria for what constitutes a serious failure. When
activated, this logic serves as a trigger to the REDUN_SWITCH function block, which forces the
fail-over.
Among the items which users might want to consider when making a determination of a local
I/O fail-over could be:
• Comparisons of data from the I/O board in question, with data collected independently from
some separate source.
• Board status codes that can indicate whether or not a board is present, or for analog boards,
whether a conversion operation failed. See the ‘I/O Mapping’ section of the ControlWave
Designer Programmer’s Handbook (document# D5125) for more information on these
codes.
• User-defined timeouts or out-of-range calculations.
• Current status of I/O boards in the standby unit, i.e. is the standby able to take over. This
information is accessible via system variables.
I/O Expansion Rack Redundancy
I/O Expansion Rack redundancy provides protection in the event a single failure occurs in either
of two ControlWave I/O Expansion Racks serving together as a redundant pair.
This redundant configuration would require two (2) ControlWave I/O Expansion Racks, a
ControlWave I/O Switcher, and a Host ControlWave unit, since the I/O Expansion Racks cannot
execute a ControlWave project, they just handle I/O operations.
Typically, the host ControlWave would be a ControlWave Redundant Controller.
14
The Concept of Redundancy
s
Unit “A”
CPU &
PSSM
ControlWave Redundant
Controller provides Control
Redundancy , and also serves
as ‘Host’ to pair of redundant
I/O Expansion Racks.
This type of configuration allows Control Redundancy, via the dual CPUs and power supplies of
the ControlWave Redundant Controller, plus I/O redundancy via the dual ControlWave I/O
Expansion Racks, and ControlWave I/O Switcher.
Alternatively, the host could be a single ControlWave Process Automation Controller, in which
case this segment of the network would have NO CPU or power supply redundancy, but would
have I/O Expansion Rack Redundancy.
Unit “B”
CPU &
PSSM
W
W
I
I
RRTT
RRTT
1
1
234
234
CCRS
ControlWave I/O
Expansion Rack
“Unit B”
ControlWave
I/O Switcher
Connections to
field inputs/outputs
ControlWave I/O
Expansion Rack
“Unit A”
ControlWave I/O
ControlWave Process Automation
Controller serves as ‘Host’ to pair
of redundant I/O Expansion Racks.
There is NO CPU or power supply
redundancy in this configuration.
Expansion Rack
“Unit B”
ControlWave
I/O Switcher
Connections to
field inputs/output
ControlWave I/O
Expansion Rack
“Unit A”
Another possible configuration would be to use a pair of ControlWave Process Automation
Controllers, in conjunction with their own dedicated ControlWave I/O Switcher, as the host. In
general, this type of configuration would only be used in situations where a single ControlWave
Process Automation Controller does not have sufficient local I/O capacity for a given
application, and so additional I/O is needed, via I/O Expansion Racks. This system incorporates
Control Redundancy, plus Local I/O Redundancy, and I/O Expansion Rack Redundancy. In this
particular set up, because there are two separate ControlWave I/O Switchers, the “A” and “B”
units of each one are considered independent of each other, therefore, the control system could
still function even if, for example, the “A” I/O Expansion Rack failed, and the “B” Process
Automation Controller also failed, because the “B” I/O Expansion Rack could be used with the
“A” Process Automation Controller.
15
The Concept of Redundancy
s
No matter which of these configurations you use, detection and handling of I/O failures in the
I/O Expansion Rack is handled by user-defined logic, in the host controller.
The I/O Expansion Racks cannot automatically detect an I/O failure based on data alone. The
user must devise logic within their ControlWave project to determine when a fail-over should
occur. See the ‘Local I/O Redundancy’ section for a list of possible I/O failure criteria.
If the user determines that a fail-over is necessary, it must be triggered by a user write to the failover variable on the ER_STAT board. (NOTE: The ER_STAT board is not an actual physical
I/O board, but a virtual board that maintains data related to the I/O Expansion Rack.) When the
fail-over occurs, I/O is automatically switched from the on-line rack to the backup standby rack,
which becomes the new on-line unit.
The logic for whether or not a given failure is sufficient reason to force a fail-over to the Standby
unit is based entirely on the user’s own criteria for what constitutes a serious failure. When
activated, this logic serves as a trigger to the ER_STAT fail-over variable, which forces the failover.
NOTE: Non-I/O-related hardware failures which trigger the watchdog relay, for example, a
power failure at the on-line I/O Expansion Rack, will also force a fail-over to the standby unit.
ControlWave Process
Automation Controller
“Unit B”
ControlWave
I/O Switcher
Connections to
field inputs/outputs
for LOCAL I/O ONLY
ControlWave Process
Automation Controller
“Unit A”
ControlWave I/O
Expansion Rack
“Unit B”
ControlWave
I/O Switcher
Connections to
field inputs/output
ControlWave I/O
Expansion Rack
“Unit A”
16
Setting up Redundancy Hardware
Setting up Redundancy Hardware
Major Types of ControlWave Redundancy Hardware
There are four (4) major pieces of ControlWave hardware that are useful in various redundant
ControlWave configurations. We will list each type here, and then provide a brief overview how
it works, and how it is set up, or provide references to where setup information is available.
Which types of hardware you use will depend upon which form(s) of redundancy you are
incorporating into your system: Control Redundancy, Local I/O Redundancy, or I/O Expansion
Rack Redundancy. The four types of redundancy hardware are:
• ControlWave Redundant Controller
• ControlWave Process Automation Controller
• ControlWave I/O Expansion Rack
• ControlWave I/O Switcher
ControlWave Redundant Controller
If you have a system which uses Control Redundancy ONLY, you will need a ControlWave
Redundant Controller (See ‘Control Redundancy - CPU and Power Supply’, earlier in this
manual.) The ControlWave Redundant Controller can also be used as the host controller, in a
system using I/O Expansion Rack Redundancy (See ‘I/O Expansion Rack Redundancy’, earlier
in this manual.)
The ControlWave Redundant Controller
consists of a single chassis holding a pair
of ControlWave central processing units
(CPUs) and power supplies, linked
together by a CPU and Communications
Redundancy Switch (CCRS) module.
The ControlWave Redundant Controller
has no local I/O; I/O resides in one or
more ControlWave I/O Expansion
Racks, and is shared between the two
CPUs. Only the on-line CPU
communicates with the I/O).
CPU and
power supply
“A”
CPU and
power supply
“B”
CCRS
17
Setting up Redundancy Hardware
a
Redundant pair of ControlWave CPUs
They share the SAME node name in NetView
but each has a DIFFERENT IP address
ON-LINE
Unit "A"
IP address a.b.c.d
On-line unit is currently
in control of the process
or plant, communicating,
receiving data via I/O
boards, etc.
CCRS
The switch
allows the
automatic
fail-over from
one unit to
the other. It
also can be
used to 'force'
a manual
f
il-over.
STANDBY
Unit "B"
IP Address e.f.g.h
Standby sits idle
as a backup. It
waits to take
over should the
on-line unit fail.
18
Setting up Redundancy Hardware
Setting Up the ControlWave Redundant Controller
This configuration involves unpacking the ControlWaveRED hardware, making proper ground
connections, connecting a communication cable to the PC workstation and setting switches. The
basic steps are outlined, below. For detailed information on a particular step, please consult the
referenced hardware manual.
1. Remove the unit from its carton and install it at its assigned work site. (see Section 2.3.1 of
CI-ControlWaveRED).
2. Install a ground wire between the Chassis Ground Lug and a known good Earth Ground (see
Section 2.3.1.1 of CI-ControlWaveRED).
3. Units are shipped from the factory with CPU switches set for redundant operation, and the
backup battery disabled. If the switch settings have been changed, please set them correctly
according to the following instructions.
Setting CPU Module DIP Switches on each CPU:
For Switch Bank SW1:
Switch
Number
SW1-1 ON This enables the Watchdog circuitry, which is required.
SW1-2 ON This unlocks soft switches, which is required.
SW1-3 ON This forces soft switches to be used, which is required.
SW1-4 See
SW1-5 ON This must be set to ON so that RETAIN memory can be
SW1-6 OFF This enables redundant operation, which is required.
SW1-7 See
SW1-8 ON This enables the boot project, which is required.
Must be
set to:
Notes
notes
Notes:
For firmware versions earlier than 4.2: Had to be set ON to
disable updump. For Version 4.2 or newer: Can be set either
ON (to disable updump), or OFF, to enable updump. Neither
switch position has an effect on the normal operation of the
unit, since updump mode is not activated unless the user
operates the RUN / REMOTE / LOCAL key switch, in a
particular sequence, to trigger the updump.
used.(Required)
This switch must be set either ON or OFF based on whether this
is the "A" CPU (which resides in Chassis slot 2) or the "B" CPU
(which resides in Chassis slot 4):
• SW1-7 must be ON if this is the "A" CPU (in Chassis slot 2)
• SW1-7 must be OFF if this is the "B" CPU (in Chassis slot
4)
19
Setting up Redundancy Hardware
For Switch Bank SW3:
For Switch Bank SW3, all switches should be left in their default position of 'OFF' except for
SW3-4 which must be set to 'ON' to enable the backup battery. This is because units are
shipped from the factory with the backup battery disabled, to reduce the drain on the battery.
To enable the backup battery remove the “A” CPU Module from chassis slot 2, and set
switch SW3-4 to ON, then re-install it in chassis slot 2. Next, remove the “B” CPU Module
from chassis slot 4, and set switch SW3-4 to ON. Then re-install it in chassis slot 4. (see
Section 2.3.3. of CI- ControlWaveRED).
Reset
Switch
Comm.
Port 1 (J2)
Lithium
Battery
3.6V
950mA-hr
½ AA Cell
Comm.
Port 2 (J3)
Ethernet
Port 1 (J4)
Enlarged detail
of CPU switch
banks
(CAPITALIZED entry
indicates ON position)
Bootproject ENABLE / disable
Redundancy DISABLE / enable
static memory RETAIN / initialize
Updump DISABLE / enable
Soft switches USE / ignore
Soft switches write UNLOCK / lock
Watchdog circuit ENABLE/disable
UNIT A / unit B
Port 80
Display
Run/
Remote/
Local
Key Switch
SW1
SW1
SW3
SW3
Leave all SW3
CPU switches
in default 'OFF'
position, except
for #4.
ENABLE/disable battery backup
recovery mode ENABLE/disable
Unused
Unused
(CAPITALIZED entry
indicates ON position)
Most SW1 switches should be 'ON',
but SW1-6 MUST be ‘OFF’ to enable
redundancy, and SW1-7 must be set
'ON' if this is the "A" CPU, or
'OFF' if this is the "B" CPU.
20
Setting up Redundancy Hardware
s
4. Install Watchdog Relay/MOSFET Switch wiring to each PSSM Module (see Section
2.3.4.1.3 of CI-ControlWaveRED).
+12Vdc Bulk Supply #1 Pos. Term.
+12Vdc Bulk Supply #1 Neg. Term.
Chassis Ground
+24Vdc Bulk Supply #1 Pos. Term.
+24Vdc Bulk Supply #1 Neg. Term.
Chassis Ground
5. Connect Bulk DC Power to each of the ControlWaveRED’s PSSM Modules, but don't apply
power at this time (see Section 2.3.4.1 through Section 2.3.4.1.2 of CI-ControlWaveRED).
6. Install the Bezels so that each one covers its associated PSSM and CPU Modules (see
Section 2.3.6 of CI-ControlWaveRED).
7. Connect the special serial communications cable between the four serial communications
ports on CPU Module A and Connector J5 on the front (left) of the CCRS Module. Then
connect the other special serial communications cable between the four serial communication
ports on CPU Module B and connector J6 on the front (right) of the CCRS Module.
Typical Configuration
+VIN
1
+VINF
Shared +12Vdc Power Supply
-VIN
-VINF
CHASSIS
5
+VIN
1
+VINF
Shared +24Vdc Power Supply
-VIN
-VINF
CHASSIS
5
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Setting up Redundancy Hardware
A / B Enabled switch
Run / Remote/ Local
switch
CPU & Power supplyACPU & Power Supply
B
&
= Serial Comm. Port Designation
CPU & Communications
Redundancy Switch (CCRS) Module
12
COM1 COM2
1
6
J1 J2
9
5
COM3 COM4
49
50
J3 J4
J5 J6
1
J7
= Ethernet Comm. Port Designation
8. Connect COMM Port 2 of the CPU & Communications Redundant Switch Module (CCRS)
to one of the communication ports on your PC or laptop. (For more information on
communication ports see Section 2.3.3.2 of CI-ControlWaveRED).
2
• Plug one end of an RS-232 null modem cable
into one of your PC communication ports.
• Plug the other end of the RS-232 null modem cable into Serial Communication Port 2
(COM2) of the ControlWaveRED's CCRS Module.
10. Set the CCRS Module's A/B Enabled key switch to the "A" position.3
11. Set the RUN/REMOTE/LOCAL switch on both CPU A and CPU B to 'LOCAL'.
2
For a wiring diagram of an RS-232 null modem cable, see Figure 2-8 in the CI-ControlWave manual.
3
We have chosen 'A' for purposes of this example, however, you could have chosen 'B', and substituted 'B' in
subsequent steps which mentioned 'A'.
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