Schneider Electric 840 USE 106 0 User Manual

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Quantum Hot Standby

Planning and Installation Guide

840 USE 106 00 Version 4.0

31002766 02

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Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

About the Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Chapter 1 Overview of Quantum Hot Standby . . . . . . . . . . . . . . . . . . . . .13

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Primary and Standby Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hardware Components in a Quantum Hot Standby System. . . . . . . . . . . . . . . . 17

The CHS 110 Hot Standby Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.3 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fiber Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

The CHS 210 Hot Standby Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4 984 HSBY and IEC HSBY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

984 HSBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

IEC HSBY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 2 Theory of 984 Ladder Logic HSBY Operation . . . . . . . . . . . . .31

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

How a 984 HSBY System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

System Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

The State RAM Transfer and Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Default Transfer Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Customizing Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Custom Scans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

State Ram Transfer and Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Layout of completely transferred state RAM in an IEC Hot Standby system. . . . 53

Chapter 4 Planning a Quantum Hot Standby System . . . . . . . . . . . . . . . 55

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Guidelines for Planning a Hot Standby System. . . . . . . . . . . . . . . . . . . . . . . . . . 56

Electrical Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remote I/O Cable Topologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

A Single Cable Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

A Dual Cable Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Chapter 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

How to Install a Hot Standby System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chapter 6 Using a Quantum 984 HSBY System . . . . . . . . . . . . . . . . . . . . 67

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Configuring 984 HSBY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Configuration Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

CHS Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.2 Using the CHS Instruction Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Using CHS Instruction Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Command Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Elements of the Nontransfer Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Zoom screen of CHS Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

The Hot Standby Status Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

The Reverse Transfer Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Reverse Transfer Logic Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6.3 Using Configuration Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Configuration Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Hot Standby Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Bits in the Hot Standby Command Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Keyswitch Override and Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

A Software Control Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Standby on Logic Mismatches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Transfer All State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Hot Standby Status Register for Configuration Extension. . . . . . . . . . . . . . . . . . 95

Advanced Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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Defining the Transfer Area of State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Transferring Additional State RAM Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Scan Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

6.4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Starting Your Hot Standby System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Synchronizing Time-of-Day Clocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

While Your System Is Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Chapter 7 Using a Quantum IEC Hot Standby System . . . . . . . . . . . . .109

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7.1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Loading the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Controlling the Hot Standby System by Configuration Extension . . . . . . . . . . . 114

7.2 Hot Standby Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Hot Standby dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Specifying the Command Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Hot Standby Command Register. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Enable Keyswitch Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Advanced Options Concept 2.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Standby on Logic Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Swapping Addresses at Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

7.3 State RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Nontransfer Area of State RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Hot Standby Status Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Memory Partition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

State RAM Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.4 Section Transfer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Section Transfer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

7.5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Starting Your Hot Standby System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.6 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Memory/Scantime optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Synchronizing Time of Day Clocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

While Your System Is Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Chapter 8 Additional Guidelines for IEC Hot Standby . . . . . . . . . . . . . .147

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

8.1 General Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Memory Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Memory Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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Memory Partition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.2 State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Efficient Use of State RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8.3 Efficiency Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Use Constants Instead of Equal Literals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Use Constants Instead of Open Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Programmed Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Reduce the Use Of Complex Data Structures. . . . . . . . . . . . . . . . . . . . . . . . . . 162

Chapter 9 Ethernet Hot Standby Solution. . . . . . . . . . . . . . . . . . . . . . . . 163

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Overview of Hot Standby Solution for NOEs. . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Hot Standby Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

NOE Configuration and Hot Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

IP Address Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

NOE Operating Modes and Hot Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Address Swap Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Network Effects of Hot Standby Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Chapter 10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

10.1 Health of a Hot Standby System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Verifying Health of a Hot Standby System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Additional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

10.2 Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Startup Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Communications Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Board Level Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

10.3 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Detecting Failures in a Hot Standby System. . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Detecting Failures in the Primary Backplane. . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Detecting Failures in the Standby Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Failure of Fiber Link from Primary Transmit to Standby Receiver. . . . . . . . . . . 191

10.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Replacing a Hot Standby Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Changing the Program and Performing a Program Update. . . . . . . . . . . . . . . . 194

Updating PLC System Executives in a 984 HSBY System . . . . . . . . . . . . . . . . 198

Updating PLC System Executives in an IEC HSBY System . . . . . . . . . . . . . . . 200

10.5 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Forcing a Switchover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

CHS 110 Hot Standby Module Error Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . 210

CRP Remote I/O Head Processor Error Patterns. . . . . . . . . . . . . . . . . . . . . . . 211

Appendix B Fiber Optic Cable Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Fiber Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Other Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Appendix C ProWORX Nxt Configuration. . . . . . . . . . . . . . . . . . . . . . . . . .217

ProWORX Nxt Hot Standby Configuration Extension. . . . . . . . . . . . . . . . . . . . 217

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Page 8

Page 9

Safety Information

Important Information

NOTICE Read these instruction s carefully, an d look at th e equipment to become fami liar with

the device before trying to install, operate, or maintain it. The following special messages may appear th rougho ut this d ocume ntatio n or on the e qui pment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of this symb ol to a Da nger or Warning safety labe l indicates that an electrical hazard exists, which will result in personal injury if the

instructions are not follow ed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death, seri ous injury, or equipmen t da m age.

WARNING

WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death, serious injury , or equipment damage.

CAUTION

CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in injury or equipment d am age.

840 USE 106 00 January 2003 9

Page 10

Safety Information

PLEASE NOTE Electrical equipment should be serviced only by qualified personnel. No responsi-

bility is assumed by Schneid er Elect ric for an y cons equen ces ari sing o ut of the u se of this material. Thi s document is not inte nded as an instructi on manual for untrain ed persons.

840 USE 106 00 January 2003

Page 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

Title of Documentation Reference Number

Quantum Automation Series Hardware Reference Guide 840 USE 100 00

Remote I/O Cable System Planning and Installation Guide 890 USE 101 00

Ladder Logic Block Library User Guide 840 USE 101 00

Modbus Plus Network Planning and Installation Guide 890 USE 100 00

Concept V 2.5 User’s Manual 840 USE 493 00

Concept V 2.5 Installation Instructions 840 USE 492 00

Concept V 2.5 Block Library: IEC 840 USE 494 00

Concept V 2.5 Block Library: LL984 840 USE 496 00

Concept EFB User’s Manual 840 USE 495 00

Product Related Warnings

Schneider Electric assumes no responsibility for any errors that may appear in this document. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or means, electronic or mechanical, including photocopying, without express written permission of the Publisher, Schneider Electric.

840 USE 106 00 January 2003 11

Page 12

About the Book

User Comments We welcome your comments about this document. You can reach us by e-mail at

TECHCOMM@modicon.com

840 USE 106 00 January 2003

Page 13

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, co mp one nts , the Ho t Stan db y m odu le, LEDs and switches, modes of operation, 984 and IEC HSBY, and the application size.

Throughout the rest of this boo k the Qu antum Ho t Standby sy stem is refe rred to as HSBY.

An HSBY system is based on two identically configured programmable logic controllers linked to each other and to the same remo te I/O network. If on e controller fails, the other assumes control of the I/O system.

What’s in this Chapter?

840 USE 106 00 January 2003 13

This chapter contains the following sections:

Section Topic Page

1.1 Control 15

1.2 Operation 21

1.3 Cabling 23

1.4 984 HSBY and IEC HSBY 26

Page 14

Overview of Quantum Hot Standby

840 USE 106 00 January 2003

Page 15

Overview of Quantum Hot Standby

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 Components in a Quantum Hot Standby System 17 The CHS 110 Hot Standby Module 18

840 USE 106 00 January 2003 15

Page 16

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. The Primary controller updates the Standby controller after each scan. The Standby is ready to assume control within one scan if the Primary fails.

Primary and Standby states are switchable. Either controller can be put into the Primary state, but to do this, the ot her must be i n the Standby state. The remote I/O network is always operated by the Primary controller.

Note: A Quantum Hot Standby system supports only remote I/O. It does not support local I/O or distributed I/O (DIO).

Role of the CHS 110 Hot Standby Module

Each controller is paired w ith a 140 C HS 110 00 Hot Standby module. The m odu le monitors its own controller and communicates with the other Hot Standby module. The system monitors itself continuously. If the Primary controller fails, the Hot Standby module switch es control to the Standby, which th en be comes the Primary controller.

If the Standby controller fails, the Primary continues to operate without a backup.

840 USE 106 00 January 2003

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Overview of Quantum Hot Standby

Hardware Components in a Quantum Hot Standby System

Components A Quantum Hot Standby system requires two backplanes, each with at least four

slots. The backplanes must be equipped with identical, compatible Quantum:

Programmable logic controller

Remote I/O head processor

CHS 110 Hot Standby module

Cables (See

Power supply

Other components, (Backplanes, I/O Modules, Splitters, as required)

The following illustration shows the hardware components in a Quantum Hot Standby System.

PS PLC RIO CHS PS PLC RIO CHS

Fiber Optic Cable Guide, p. 213

Primary

Fiber Optic Link

)

Standby

Cable to the RIO Network

Note: The order of the modules in the backplanes must be the same.

840 USE 106 00 January 2003 17

Page 18

Overview of Quantum Hot Standby

The CHS 110 Hot Standby Module

Topology The following diagram shows the module’s front panel, which consists of:

LED Display

Function Keyswitch

Designation slide switch

Update Button

Fiber optic cable ports

CHS 110 Front Panel Controls

The follo wing figure s hows the module’s front panel.

Version Label Model Number Module

Description Color Code

LED Display

Function Keyswitch Designation Slide Switch

Update Button

Transmit Cable Connector

Receive Cable Connector

M0035300

Removable Door

840 USE 106 00 January 2003

Page 19

Overview of Quantum Hot Standby

140 CHS 110 00

HOT STANDBY

Active Ready Fault Run Bal Low Pwr ok Modbus Com Err Modbus! Error A

Com Act Error B Primary Mem Prt Standby

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.

Indicator Color Message

Ready Green If steady, power is being supplied to the module and it has

passed initial internal diagnostic tests. If blinking, module is trying to recover from an interface error.

Com Act Green If steady, CHS 110 modules are communicating. If blinking, an

error has been detected. Primary Green Module is Primary controller. Com Err Red Module is retrying CHS communications or CHS

communications failure has been detected. Standby Amber If steady, module is Standby controller, and is ready to assume

Primary role if needed. If blinking, program update is in

progress.

Error messages are discussed in detail in

Com Act Error Patterns, p. 209

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Page 20

Overview of Quantum Hot Standby

Function Keyswitch

Designation Slide Switch and Update Button

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.

Off

Line

Xfer

Run

Note: For security or convenience, you can disable the function keyswitch with a software override. Once the keyswitch is disabled, you can set the module to run or offline mode with software. This can be especially helpful when the module is not easily accessible.

A slide switch located below and to the right of the keyswitch is used to designate the controller as A or B. One unit must be designated as A and the other as B. Use the Standby Update Button to initiate the Primary to Standby prog ram transfer. You must have the keyswitch in transfer mode.

Note: If the controllers are given identical designations, the system refuses to acknowledge them both. The first unit to power up will be recognized as the Primary controller. It is designated A or B according to its switch position. The second unit remains offline and the ComAct indicator flashes, indicating a startup error.

Note: Once the syst em is running , Primary cont rol may be ex changed betwee n the units regardless of which is designated as A or B.

840 USE 106 00 January 2003

Page 21

1.2 Operation

Modes of Operation

Overview of Quantum Hot Standby

HSBY Modes of Operation

Off Line Mode This mode is used to take a controller out of service without stopping it or

Transfer Mode This mode is used to requ est a progra m update of th e Standby cont roller from the

HSBY has three Modes of Operation:

1. Off Line Mode

2. Transfer Mode

3. Run Mode

These modes are described below.

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.

Primary controller. For a step-by-step description of the procedure refer to

Replacement, p. 192

The Primary controller is able to update the Standby without any interruption in its other functions. If the Primary unit is in Run mode and you hold down the update button on the Standby unit, the Hot Standby modules prepare to copy the full program of the Primary controller to the Standby unit. The program includes the configuration table, I/O map, configuration extensions, segment scheduler, user logic, all .EXE loadables, ASCII messages and the entire state RAM.

To complete the transfer, while continuing to press the update button, turn the key on the Standby to transfer. The Com Act LED extinguishes. Turn the key to the mode you want the Standby to assume after the update, Run or Off Line. The Standby indicator flashes. Release the update button.

The Standby indicator continues to flash during the update and while the Standby unit processes the update. If the unit is set to run mode, the Standby indicator returns to a steady amber. If the unit is set to offline mode, the Standby indicator extinguishes. Remove the key.

840 USE 106 00 January 2003 21

Page 22

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 When the keyswitch is in this position, the controller is active and is either serving

as the Primary controller or is capable of taking over the Primary role, if needed. The keyswitch on both Hot Standby modules should be in the Run position at all times. When the Standby con trol ler is in Run mode and the st andby indica tor is on , it is actively monitoring the status of the system and is ready to take control if the Primary unit fails.

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Page 23

Overview of Quantum Hot Standby

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

840 USE 106 00 January 2003 23

Page 24

Overview of Quantum Hot Standby

Fiber Optic Cable

Cable Connections

The CHS 110 Hot Stan dby module s are c onnected by a fiber op tic cable . The cab le 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 t he Hot Standby syst em does not functi on. The Primary con troller operates without a backup. The Standby unit remains offline.

A 3 meter fiber op tic c ab le is p r ov ide d in the 140 CHS 210 00 Hot Standby kit. One

strand of that cable is marked wit h the manu facturer’s name. This is the onl y way to distinguish the two strands.

This illustration shows CHS 110 Hot Standby modules connected by a fiber optic cable.

Transmit

Receive

Transmit

Receive

840 USE 106 00 January 2003

Page 25

Overview of Quantum Hot Standby

The CHS 210 Hot Standby Kit

Contents of Kit Each 140 CHS 210 00 Hot Standby kit contains the following parts. Part numbers

are listed in parentheses.

Two CHS 110 Hot Standby modules with four fiber cable clasps (140 CHS 110

00)

A 3 meter duplex fiber optic cable (990 XCA 656 09)

Two coaxial splitters together with two tap terminators and four self-term inating F adapters (140 CHS 320 00)

A 3 1/2 in. diskette with the CHS loadable (140 SHS 945 00)

Quantum Hot Standby Planning and Installation Guide, 840 USE 106 00 Version 2

840 USE 106 00 January 2003 25

Page 26

Overview of Quantum Hot Standby

1.4 984 HSBY and IEC HSBY

Introduction

Purpose This section describes 984 HSBY and IEC HSBY.

What’s in this Section?

This section contains the following topics:

Topic Page

984 HSBY 27 IEC HSBY 28

840 USE 106 00 January 2003

Page 27

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 earl ier PLC systems used the "HSBY" l oadable function bloc k. 984 HSBY may also be activated as a configuration extension that allows additional features to be configured. F or detail s refer to

p. 67

Architecture Quantum 984 Hot Standby involves:

Concept Version 2.1 or greater, Modso ft Version 2.3 or greater, Proworx Version

1.5 or greater

All Quantum Controllers

The existing CHS Modules and Execs (CHS 110 00)

Changes to the running application are possible only by download changes to the Primary controller, whereby the Standby goes offline until it gets updated again by using the UPDATE push button (refer to

Using a Quantum 984 HSBY System,

Replacement, p. 192

System Compatibility

840 USE 106 00 January 2003 27

Minimum Module Versions to Support 984 HSBY

Module Version PV / SV

140 CPU x13 0x 2.1 All 140 CPU 424 02 2.1 All 140 CPU x34 1x All All 140 CRP 93x 00 2.1 All 140 NOM 2xx 00 2.1 All

Page 28

Overview of Quantum Hot Standby

IEC HSBY

IEC HSBY Architecture

IEC Hot Standby means: Pro gram m ing an application with the c ho ice 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 contro l are the same, b ut there are some differe nces compa red to the 984 HSBY system.

2. PLC firmware upgrade is allowed without shutting down the system with Concept

2.5 or higher. Earlier versions of Concept require shutting down the sys tem to upgrade PLC firmware.

3. RIO is serviced differently.

4. With Concept 2.5 or higher, it is now possible to download the same appli ca tio n

to Primary and to the Standby controller. The result is that the Hot Standby system will be fully setup (equalized) with identical applications in both controllers. Earlier versions of Concept require you to use the UPDATE bush button (refer to

Using a Quantum IEC Hot Standby Sys tem , p. 109

) on the CHS module in the Standby rack to equalize both controllers. Therefore, the same application including the configuration will be running in both controllers.

5. There’s no CHS function block used in IEC.

840 USE 106 00 January 2003

Page 29

Overview of Quantum Hot Standby

Architecture As shown below, Quantum IEC Hot Standby involves:

Concept Version 2.1 or greater

Two High End Quantum Controllers (CPU 434 12 or CPU 534 14)

The existing CHS Modules and Execs (CHS 110 00). The existing RIO Heads with version 2.0 Execs or greater (CRP 93x).

All five IEC 1131 languages can be used, however 984 Ladder Logic cannot be used.

The follow ing diagram shows the Quantum IEC Hot Standby Architect ure

Quantum IEC Hot Standby Architecture

&RQFHSW9RUKLJKHU

1R/DGGHU/RJLF

4XDQWXP&RQWUROOHUV

&38 &38

([LVWLQJ&+6PRGXOH KDUGZDUHDQG([HFV

([LVWLQJ5HPRWH,2 PRGXOHVDQG([HFV

&(PDUNHG9HUVLRQ RUJUHDWHU

PRIMARY SECONDARY

FIBER OPTIC CHS LINK

REMOTE I/O

0RGEXV3OXV

With Concept 2.1/2.2 , changes to the running application are possible only by download changes to the Primary controller, whereby the Standby controller goes offline until it gets updated again by using the UPDATE push button (refer to

Updating PLC System Executives in an IEC HSBY System, p. 200

). Concept 2.5 supports the Logic Mismatch option on the Hot Standby Configuration Extension which allows the Standby controller to remain online with a different program than the Primary controller.

Note: Unlike Concept 2.1, with Concept 2.2/2.5 it is possible to make changes to the IEC logic offline and downlo ad them as online changes later. I t is not necessary to be connected to the controller at the time of editing the IEC logic.

840 USE 106 00 January 2003 29

Page 30

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, accomp lished by copyi ng the state RAM from the Primary to the Standby, causes differences in te rms of application si ze. In IEC HSBY, a part of the state RAM is used to transport the IEC application data from the Primary to the Standby. Therefore the size of IEC appli catio n data c annot ex ceed the con figured size o f the state RAM itself. The absolute maximum for IEC application data is 128K (64K

words of state RAM). For the size of an IEC application’s executable code there is also a limit of 568K under Concept 2.1/2.2. The IEC application’s executable code limit was increased to 1 Megabyte for Concept 2.5.

Quantum IEC Hot Standby Overview

IEC Language programs only, no 984 Ladder Logic permitted

To bring a Standby on-li ne

Primary and Standby controller executives must be equal.

Primary and Standby IEC Projects must have the same name and the applications must be equal.

On-line changes to the Primary are permitted

With Concept 2.1/2.2, the Standby controller is taken off-line as soon as the first Primary on-line change is made. The Primary program must be transferred to the Standby before it can be brought back on-line.

Concept 2.5 supports Logic Mismatch in the Hot Standby configuration extension. This option allows the Standby controller to remain online with a different program than the primary controller.

Primary controller on-line changes may include

Addition of sections

Addition of DFBs allows pre-qualification of user changes in an office environment

Logic Mismatch

With Concept 2.1/2.2, it is not possible to load a new version of the application on Standby, bring it on-line, and transfer control to make it the new Primary.

Under Concept 2.5, with Logic Mismatch enabled, a new version of the application can be downloaded to the Standby controller and brought online. Control can then be transferred to the Standby controller to make it the new Primary controller.

To upgrade the controller Execs

With Concept 2.1/2.2, the process must be stopped. Then Primary and Standby controllers must be stopped and downloaded individually.

Under Concept 2.5, the controller executives can be upgraded while the process continues to run.

840 USE 106 00 January 2003

Page 31

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 State RAM Transfer and Scan Time 36 Default Transfer Area 38 Customizing Options 40 Custom Scans 41

840 USE 106 00 January 2003 31

Page 32

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 moni tor their own controll er CPU and communica te with each other via fiber link. The Primary contro ller keeps th e Standby info rmed 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.

Stages of State RAM Transfer

State RAM Transfer

A Hot Standby system transfers state RAM data from the Primary to the Standby controller while the Primary co ntrolle r scans and so lves the ladder log ic appli catio n program. There are three steps in this transfer process:

1 Primary controller-to-Primary CHS 110 state RAM transfer. 2 Primary CHS 110-to-Standby CHS 110 state RAM transfer. 3 Standby CHS 110-to-Standby controller state RAM transfer.

The Primary CHS 110 Hot Standby module initiates the state RAM transfer operation. The module requests specified state RAM information from the Primary controller.

At the beginning of ea ch scan, the Primary controller transfer s the current state RAM data to the CHS 110 Hot Standby module.

As soon as the transfer (controller-to-CHS 110) finishes, the Primary controller resumes scanning user logic and servicing I/O. The state RAM data is simultaneously tra ns ferre d from the Prim ary C HS 11 0 mo dul e to th e Standby CHS 110 module over the fiber optic link at a rate of 10 megabaud. In turn, the Standby CHS 110 module transfers the state RAM data to the Standby controller.

Note: Schneider Elect ric defi ne s Sta te RAM as RA M m em ory that is used to hold register and discrete inputs and outputs and internal data storage. State RAM is allocated to the four different reference types: 0xxxx, 1xxxx, 3xxxx, and 4xxxx.

840 USE 106 00 January 2003

Page 33

System Scan Time

Theory of 984 HSBY Operation

Effect on System Scan Time

Primary Rack

PLC

Transfer (over the Q uantum Backplane)

CHS 110

Standby Rack

CHS 110

PLC

When the ladder logic program being executed by the primary controller is longer than the CHS 110-to-CHS 110 transfe r, the transfer does not incre ase total sy stem scan time. However, if the ladder logic program is relatively short, the scan finishes before the CHS 110-t o-CH S 1 10 data transfer and the d ata tra ns fer inc rea ses total system scan time.

The following timing diagram shows how the transfer takes place.

1 Scan

Solve All Segments

PLC-to-CHS 110 State RAM

CHS 110-to-CHS 110 State RAM Transfer (Over Fiber O ptic HSBY Link)

CHS 110-to-PLC State RAM Transfer

Solve Segment 1 Solve Segment 1

1 Scan

The effect on system sc an time of any Hot Standby s ys tem dep en ds v ery mu ch 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 because of the required PLC to CHS data transfer time.

Since the data transfer depends on the PLC type in the system, the following

provides information that allows you to forecast a Hot Standby system‘s scan time:

Calculation of ov era ll scan time for a n orm al Hot Standby baseline co nfi gura tion containing minimum logic as a reference

Calculation of a PLC specific constant that expresses the increase of overall scan time related to an increase of state RAM memory to be transferred

840 USE 106 00 January 2003 33

Page 34

Theory of 984 HSBY Operation

The normal Hot Standby configuration contains:

In the local rack: power supply (CPS), PLC (CPU), RIO Head (CRP 93x), Hot Standby module (CHS)

In one remote IO drop equipped with 8 I/O modules, power supply (CPS) and remote adapter (CRA)

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 tabl e belo w .

CPU - HSBY Baseline Configuration

CPU x13 0x0x: 1536, 1x: 512, 3x: 3000, 4x: 1872

CPU 424 020x: 1536, 1x: 512, 3x: 1212, 4x: 1872

CPU 434 12 / CPU 534 140x: 1536, 1x: 512, 3x: 512, 4x: 1872

Scantime Increase because of HSBY

~ 25 ms 984 Ladder Logic only

~ 40 ms 984 Ladder Logic only

Languages Supported

PLC to CHS Data Transfer Rate

The investigation of the PLC specific data transfer rate in a Hot Standby system leads to th e following results.

CPU x13 0x 1.6 ms / byte CPU 424 02 2.0 ms / byte CPU 434 12 /

CPU 534 14

1.9 ms / byte

State RAM The following table lists the nu mb er of b yt es required for reference st orag e in state

RAM.

Coil (0x) 3 bit Discrete (1x) 3 bit Input Register (3x) 2 bytes Holding Register (4x) 2 bytes plus 2 bit

Based on the data shown in the tables above you ma y forecast the ove rall scan time of a Hot Standby system once you know how much state RAM is going to be transferred and the tim e re qui red for a particular logic ap pli cat io n to be ex ec ute d i n a standalone system.

840 USE 106 00 January 2003

Page 35

Theory of 984 HSBY Operation

Example This example shows th e effect of a co nfiguratio n change fro m baselin e as show n in

the Scan Time Increase Table in

PLC Scan Times, p. 34

A particular HSBY applic ation ha s a standa lone scan time o f 36 ms i n a PLC o f type CPU 424 02. The state RAM to be transferred consists of 3000 coils (0x), 2500 discrete inputs (1x), 2500 input registers (3x) and 8000 holding registers (4x).

The state RAM difference to the reference configuration is shown in the Effects of a Configuration Change from Baseline table below:

0x3000 - 1563 = 1464

1x2500 - 512 = 1988

3x2500 - 1212 = 1288

4x8000 - 1872 = 6128

Total: 17659 bytes = scan time offset = 17659 * 1.6ms ~ 28ms

1464*3/8 =549 Bytes

1988*3/8 = 746 Bytes

1288*2 = 2576 Bytes

6128*2 + (6128*2/8) = 13788 Bytes

This application therefore would have an overall scan time in Hot Standby: 40 ms (reference with CPU 424 02 0x) added by HSBY + 36 ms (standalone scan time) + 28 ms (offset through configuration increase) =104 ms

Note: No matter how long your transfer takes, it does not cause a watchdog timeout.

840 USE 106 00 January 2003 35

Page 36

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 th e Primary a nd Standby controllers. The size of the transfer area

may be as large as the total size of your controller’s state RAM or a portion containing critical I/O reference data types.

As the simplified block diagram below shows, all 0x references in the state RAM transfer area are transferred first, then all 1x references, followed by all the 3x references, and finally all the 4x references:

Total number of discrete outputs transferred

0nnnnn

Total number of discrete inputs transferred

1nnnnn

Total number of register inputs transferred

Where nnnnn is a multiple of 16

3nnnnn

Total number of register outputs transferred

4nnnnn

840 USE 106 00 January 2003

Page 37

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 regis ters in a non-trans fer area, an area contained withi n

the state RAM transfer area but ignored d uring the actual state RAM transfer.

3. Use the HSBY configuration extension to define transfer amounts.

Note: If you are customizing the size of your state RAM transfer area, you must

specify the number of each reference data type (0x, 1x, 3x, and 4x) as either 0 or a multiple of 16. In the case of the 4x registers, there must always be at least 16 registers allotted.

840 USE 106 00 January 2003 37

Page 38

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:

The first 8192 points of 0x output reference data

The first 8192 points of 1x input reference data

A total of 10K registers, of which 1K is allotted for 3x registers and 9K is allotted for 4x registers.

In any case, the number of 4x registers transferred is a multiple of 16 unless all 4x registers have been included. The number of 4x registers may slightly exceed the allotment in order to r each the next highest multiple of 16.

Any state RAM values above the limits shown in the following diagram are not included in the state RAM transfer area and therefore are not shared with the Standby controller. The state RAM values in the range above these limits must not contain the command register or control critical I/O.

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Theory of 984 HSBY Operation

The diagram below shows examples of the data transfer area for different configurations of 3x and 4x regist ers .

Example 1

If you have 3200 3x and 9600 4x registers, then the full allotment of 1000 3x registers will be transferred. The acutual number of 4x registers transferred will be 9008; that is, the full allotment of 9000 registers plus 8 more to reach the next highest multiple of 16.

Transfer Area

Example 2

If you have 3200 3x and 7000 4x registers, then all the 4x registers will be transferred. The full allotment of 1000 3x registers will be transferred, plus an additional 2000 3x registers to bring the total number of registers transferred to 10,000. So a total of 3000 3x registers will be transferred.

Example 3

If you have 700 3x and 9600 4x registers, then all the 3x registers will be transferred. The full allotment of 9000 4x registers will be transferred, plus an additional 300 registers to bring the total to 10,000, plus an additional 12 registers to reach the next highest multiple of 16. In all, 9312 4x registers will be transferred.

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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 u sing a Hot Standby c onfiguration exte nsion (refer to

Guidelines for IEC Hot Standby , p.147

). The configuration extensio n provides three

Additional

alternatives to the default transfer area:

You can define the number of 0x, 1x, 3x, and 4x reference data types that you want transferred in each scan.

You can define a certain amount of reference data types to be transferred on each scan with additional data to be transferred in groups over multiple scans, beginning with 0x registers and proceeding in turn with 1x, 3x, and 4x registers.

You can transfer all the configured reference data types in your system’s state RAM on every scan.

These options allow you to design a transfer area that is as small as 16 4x output registers or large enough to enc ompass all of your controll ers’ state RAM (10K, 32K, or 64K, depending on the type of Quantum controllers you are using in your Hot Standby system).

The reference data of each type (0x, 1x, 3x, and 4x) is placed in the state RAM transfer area, starting at the lowest reference number (000001 for coils, 100001 for discrete inputs, 300001 for register inputs, and 400001 for register outputs). It is accumulated conti guously up to the amo unt of each data ty pe you specify . The total number of each refe rence t ype in the st ate RAM transfe r are a mus t be a multip le of

16. For example, if you indicate that the number of coils in the transfer area is 96, coils

000001... 000096 are tra nsferred from the Primary to th e Standby co ntroller. Any 0 x references beyond 000096 used in state RAM are not transferred.

The additional stat e R AM dat a to be sent over multiple sc ans c an a ls o be of any or all of the four reference data types, and must also be specified in multiples of 16. The additional referen ce data region for eac h data type starts a t the lowest availa ble reference number. For example, if 2048 coils are transferred on every scan (000001... 002048), an d you schedule 1024 ad ditional coils for tra nsfer over multiple scans, references 002049... 003072 are used for the additional transfer data. The additional transfer is hand led by specifyin g the number of scans over wh ich you want to send the additional data. For example, if you specify two scans in which to transfer coils 002049... 003072, then coils 002049... 002560 are sent with coils

000001... 002048 on o ne scan and coil s 002561.. . 003072 are tran sferred with coi ls

000001... 002048 on the next scan.

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Custom Scans

Theory of 984 HSBY Operation

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.

Total number of discrete outputs transferred

0nnnnn

Total number of discrete inputs transferred

1nnnnn

Total number of register inputs transferred

3nnnnn

Total number of register outputs transferred

Critical outputs transferred on every scan

Additional outputs transferred in chunks on multiple scans

Critical inputs transferred on every scan

Additional inputs transferred in chunks on multiple scans

Critical inputs transferred on every scan

Additional inputs transferred in chunks on multiple scans

Critical outputs transferred on every scan

Additional outputs transferred

4nnnnn

840 USE 106 00 January 2003 41

in chunks on multiple scans

Page 42

Theory of 984 HSBY Operation

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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 46 System Scan Time 47 State Ram Transfer and Scan Time 51 Layout of completely transferred state RAM in an IEC Hot Standby system 53

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Theory of IEC HSBY Operation

IEC Hot Standby Definitions

Definitions The following are IEC Hot Standby definitions.

Exec: Quantum controller operating system with integrated IEC language support (IEC runtime system)

Program Data: A continuous memory block containing all program variables, including:

Non-located IEC variables and constants declared in variable editor

Links in FBD and LD sections

Stack (loop) variables in IL and ST

SFC states

Literals

Pointer lists

Internal states of EFBs

DFB Instance Data: Multiple memory blocks containing:

Internal data of each DFB instance

Process diagnostics buffer

Mirror buffer: 1 Byte per configu red 0x/1x ref erence (only Conc ept 2.1 an d older)

Used references list: 1 Bit per configured 0x/1x reference

IEC Heap: One continuous memory block containing:

Program data

DFB instance data

Maximum IEC Heap Size: 128 KByte together with state RAM. If 10K Words (20 KByte) of state RAM are used already for I/O references the max. IEC heap size

would be 128 KByte – 20 KByte = 108 KByte Currently used IEC Heap Size: DFB instance data plus (configured) program data

area size State Table: Also called state RAM, controller refere nces for both real world I/O and

internal referenced (located) variables Project: Concept prog ram fi le containing control le r co nfi gura t io n a nd IEC l ang uag e

control code Application: Downloaded IEC language control code and data

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Theory of IEC HSBY Operation

IEC Heap The m ost importan t new t erms to und erstand i n 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 particul ar application. This can be do ne in the Memory Statistics Dia log while Concept is not connected to the PLC. This dialog can be activated through Online --> Memory Statistics.

Configure size of p rogra m dat a area at the Memo ry Stat ist ics dial og in of fline mod e.

Note: Ch anging the c onfigured size of the program data area results in a complete download of the application, no download changes are possible.

The maximum size of the IEC heap is the maximum amount of memory available for data in any particula r IEC application. What this means in terms of IEC H SBY is shown in the diagram in

All State RAM transferred, p. 52

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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

State RAM Transfer

State RAM Defined

State RAM Transfer Initiated

A Hot Standby system transfers state RAM data from the Primary to the Standby controller while the Primary controller scans and solves the IEC logic application program. There are three steps in the transfer process:

Stage Description

1 Primary controller-to-Primary CHS 110 state RAM transfer. 2 Primary CHS 110-to-Standby CHS 110 state RAM transfer. 3 Standby CHS 110-to-Standby controller state RAM transfer.

Note: Schneider El ect ric defi ne s Sta te R AM as RAM m em ory that is use d to hol d register and discrete inputs and outputs and internal data storage. State RAM is allocated to the four different reference types: 0xxxx, 1xxxx, 3xxxx, and 4xxxx.

The state RAM transfer operation is initiated by the Primary CHS 110 Hot Standby module. The module requests specified state RAM information from the Primary controller.

At the beginning of ea ch scan, the Primary controller transfer s the current state RAM data to the CHS 110 Hot Standby module.

As soon as the controller-to-CHS 110 transfer finishes, the Primary controller resumes scanning user logic and servicing I/O. The state RAM data is simultaneously tra ns ferre d from the Prim ary C HS 11 0 mo dul e to th e Standby CHS 110 module over the fiber optic link at a rate of 10 megabaud. In turn, the Standby CHS 110 module transfers the state RAM data to the Standby controller.

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System Scan Time

Theory of IEC HSBY Operation

Effect on System Scan Time

The effect on system scan time of any Hot Standby system depends on how much state RAM is going t o be transferred from Prim ary to Standby. A Hot Sta ndby system always has a higher scan time than a comparable standalone system.

The following has be en done to provide i nformation th at allows y ou to forecas t a Hot

Standby system’s scan time:

Calculation of ov era ll scan time for a n orm al Hot Standby baseline co nfi gura tion containing minimum logic as a reference

Calculation of a PLC specific constant that expresses the increase of overall scan time related to an increase of memory to be transferred

The normal Hot Standby configuration state RAM contains:

In the local rack: power supply (CPS), PLC (CPU), RIO Head (CRP 93x), Hot Standby module (CHS)

In one remote IO drop equipped with 8 I/O modules, power supply (CPS) and remote adapter (CRA)

Only the logic for the scan time evaluation

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Theory of IEC HSBY Operation

Transfer diagram The following shows a transfer diagram:

Primary Rack

1 Scan

CPU

State RAM & IEC Heap download

128K bytes

CHS

Standby Rack

CHS

Diag Diag DiagCommComm

CPU

Comm DiagIEC Logic Solve Comm DiagIEC Logic Solve IEC Logic Solve Diag

State RAM & IEC Heap download (Over the Fiber Optic HSBY link)

128K bytes

1 Scan

128K bytes

State RAM & IEC Heap download

128K bytes

Note: The size of 128K bytes state RAM memory in the timing diagram being transferred with each scan is not a fixe d valu e. It ex press es the maximu m am ount of data handled by the CHS module during a data transfer. This is a hardware limitation. Therefore , the maximum State RAM li mit ati on fo r the IEC user is 128 K

bytes. Unlike a 984 HSBY system, the Stand by cont roll er doesn’t solve any logic. With the new exec s delivered with Concept 2.5, the Standby Controller solv es logic in Section 1.

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Theory of IEC HSBY Operation

Overall PLC Scan Time

PLC to CHS Data Transfer Rate

The overall scan time for the IEC HSBY supporting PLC type is outlined in the IEC Scan Time Increase Table below.

IEC Scan Time Increase

CPU - HSBY Baseline Configuration Scantime Increase because of HSBY CPU 434 12 / CPU 534 14

0x: 1536, 1x: 512, 3x: 512, 4x: 1872 IEC-HSBY registers (3x): 700

~ 40 ms

Calculating the PLC specific d ata transfe r rate in a Hot Standb y syste m leads to the following result.

CPU 434 12 / 534 14 1.9 ms / byte

State RAM The following table lists the number of bytes required for reference storage

Coil (0x) 3 bits Discrete (1x) 3 bits Input Register (3x) 2 bytes Holding Register (4x) 2 bytes plus 2 bits IEC HSBY Register (3x) 2 bytes

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Theory of IEC HSBY Operation

Example This example shows the eff ect of a c onfiguratio n change fro m baselin e as shown in

the IEC Scan Time Increase Table (See

Overall PLC Scan Time, p. 49

A particular applicati on h as a sta nda lo ne s ca n tim e 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 re gisters (3x), 400 ho lding registers (4x) and 14000 IEC HSBY registers (3x).

The state RA M difference to the ref erence configuration is:

Effects of a Configuration Change from Baseline

0x 200 - 1536 = - 1336 -1336*3/8 = - 501 Bytes

1x 300 - 512 = - 212 - 213*3/8 = - 80 Bytes

3x 150 - 512 = - 362 - 362*2 = - 724 Bytes

4x 400 - 1872 = - 1472 -1472*2 + ( - 1472*2/8)| = - 3312 Bytes

IEC Hot Standby regs 14000(3x) = 14000*2 = 28000 bytes Total = 28000 - 501 - 80 - 724

- 3312 = 23383 bytes Scan time offset = 23383*1.9ms ~ 44ms

This application therefore would have an overall scan time in Hot Standby: 40 ms (reference with CPU 434 12/ 534 14)

+ 25 ms (logic solve) + 44 ms (offset through memory increase) = 109 ms

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State Ram Transfer and Scan Time

Theory of IEC HSBY Operation

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.

In the Quantum HSBY system, IEC HSBY does not allow customizing the transfer area. This means the whole state RAM is transferred in IEC HSBY, except for the nontransfer area, an area contained within the transfer area but ignored during the actual state RAM transfer. Placing registers in the nontransfer area is one way to reduce scan time because the Primary controller to CHS transfer time is shorter. With Concept 2.5, a new function called Section Transfer Control has been added which can be used to reduce scan time. See

Section Transfer Control, p. 135

for

further information on this feature.

Note: No matter how long your transfer takes, it does not cause a watchdog timeout.

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Theory of IEC HSBY Operation

All State RAM transferred

The following diagram shows the state RAM transfer area.

Total number of discrete outputs transferred

0nnnnn

Total number of discrete inputs transferred

1nnnnn

Total number of register inputs transferred

3nnnnn

Total number of register outputs transferred

4nnnnn

Where nnnnn is a multiple of 16

Note: No 3x registers configured for IEC HSBY

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Theory of IEC HSBY Operation

Layout of completely transferred state RAM in an IEC Hot Standby system

Layout of transferred RAM

State RAM

(Compl. xferred)

Total 0x

Total 1xTotal 3x

The diagram below illustrates that a significant piece of the controller’s state RAM is taken as a transfer buffer for co pying the IE C he ap from t he Primary t o the Standby controller. The transfer header is located at the very top of the transfer buffer. The transfer header contains information about the Primary’s exec version, time synchronization information and the IEC application’s version. This information allows the Standby control ler, once it rec eived the trans fer buffer, to decide whether to remain online or go offline. When online, the Standby controller copies the Primary’s IEC heap out of the transfer buffer into its internal memory, which ensures the Standby’s IEC data consistency.

Header

(Exec Vers.,

Timing Info, ..,)

Program Data

Used

Prog. Data Configured

Program Data

Unused

Safety Buffer

for Future

changes/additions

DFB Instance

Data

No. 3x regs

Configured for IEC HSBY

Transfer Buffer for IEC Heap

Total 4x

840 USE 106 00 January 2003 53

Space as big as IEC heap

Free Memory for addtl DFB Instance Data

Page 54

Theory of IEC HSBY Operation

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Page 55

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 Precautions 57 Remote I/O Cable Topologies 58 A Single Cable Configuration 59 A Dual Cable Configuration 60

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Planning a Quantum Hot Standby System

Guidelines for Planning a Hot Standby System

Primary and Standby Controllers

Both the primary and the standby contr oller 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 ins tall them with equal ca re, according to Modi con’s standard planning and installation guidelines. Refer to the

Hardware Reference Guide, Planning and Installation Guide,

840 USE 100 00, and the

890 USE 101 00, for details.

Quantum Automation Series

Remote I/O Cable System

Design your system for safety first, then for economy. Be sure that you understand all the cautions a nd warni ngs in this manua l befo re you begin to ins tall y our sy stem. For the Hot Standby system to function, your component modules must meet the version requirements in

Overview of Quantum Hot Standby, p. 13

You must use identical modules in the primary and standby racks. If you have different models or diffe rent ver sions of the sam e mode l or diff erent fl ash ex ecutive software, the Hot Standby system will not function properly.

Note: The order of the modules in the backplanes must be the same.

While the controllers and RIO heads must be Quantum models, the remote drops may use Quantum, 800 serie s, 500 series or 200 serie s I/O with correspondi ng drop processors.

Positioning The CHS 110 Hot Standby modules are connected by fiber optic cable. A 3 meter

cable is supplied w ith the ki t. However, th e primary an d standby b ackplanes may be placed as much as 1 km apart. If you will be placing the modules more th an 3 m apart, use 62.5/125 micro meter cable with ST-styl e connectors. Ref er to

Cable Guide, p.213

for details.

Fiber Optic

If you intend to place the units more than 3 meters apart, you must consider the effect on the RIO network and any Modbus Plus network.

The controllers are linked to the RIO network by coaxial cable. The longer the distance between the controllers, the higher the grade of trunk cable required to maintain signal integrity. Refer to Chapter 3 of the

Planning and Installati on Guide

, 890 USE 101 00, for details regarding cable grades,

Remote I/O Cable System

distances and signal integrity. If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network , fiber optic repeat ers may be used to boos t the signal. Refer to t he 100 00,

for details on extending a Modbus Plus network.

Modbus Plus Network Pla nning and Installat ion Guide,

840 USE 106 00 January 2003

890 USE

Page 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 electrical cabinets which enclose

the system’s elect ronic components, be sure each cabinet is con nected separately to earth ground and that each backplane is connected to solid ground within its cabinet.

Failure to follow this precaution can result in death, serious inju ry, or equipment damage.

Planning a Quantum Hot Standby System

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Page 58

Planning a Quantum Hot Standby System

Remote I/O Cable Topologies

Cable Connections

In each configuration:

The cables connecting the RIO head processors to the RIO network must be fitted with self-terminating F adapters.

An MA-0186-100 coaxial splitter must be installed between the RIO head processors and the RIO network.

The remote drops must be connecte d to the trunk ca ble via an M A-0185-100 tap and a 97-5750-000 (RG-6) drop cable.

The last tap on a trunk cable must be terminated with a 52-0422-000 trunk terminator. Remote drops must not be connected directly to the trunk cable.

Refer to the

Remote I/O Cable System Planning and Installation Guide,

890 USE 1001 00, for details.

Note: If you a re using a HSBY for data log ging, the RIO heads must be c onfigured and connected with coaxi al ca ble .

If you are using 984, you must configure 2 or more segments.

If you are using IEC, you must configure 2 or more RIO drops.

Note: For ill ustrations of both single c able and dou ble cable c onfigurati ons, please

A Single Cable Configuration, p. 59

see

and

A Dual Cable Configuration, p. 60

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A Single Cable Configuration

Planning a Quantum Hot Standby System

Diagram of a Single Cable Configuration

The following diagram shows a single cable configuration for the Quantum Hot Standby system.

Primary PLC

Self-terminating

F adapter**

#52-0411-000

RIO Drop #2

Drop Cable* (RG-6) #97-5750-000

RIO Drop #4

Coaxial Cable

Trunk

Tap #MA-0185-100

Fiber Optic Cable

Splitter

#MA-0186-100

Trunk Cable (RG-11) #97-5951-000

Tap #MA-0185-100

Drop Cable* (RG-6) #97-5750-000

Standby PLC

Self-terminating F adapter**

#52-0411-000

RIO Drop #3

Last RIO Drop

Tap #MA-0185-100

Drop Cable* (RG-6) #97-5750-000

Trunk Terminator

#52-0422-000

*Premade RG-6 Drop Cable

50’ (14m) AS-MBII-003 140’ (43m) AS-MBII-004

840 USE 106 00 January 2003 59

Tap #MA-0185-100

Drop Cable* (RG-6) #97-5750-000

**140 CHS 320 00 kit includes: 2 Splitters 4 F Adapters 2 Terminators See CHS 210 Hot Standby Kit for entire HSBY kit contents (140 CHS 210 00).

Page 60

Planning a Quantum Hot Standby System

A Dual Cable Configuration

Diagram of a Dual Cable Configuration

The follo wing diagram shows a dual cable configuration for the Quantum Hot Standby system.

Primary PLC

Self-terminating F Adapters** #52-0411-000

RIO Drop #2

RIO Drop #4

Coaxial Cable

Coaxial Cable Splitter #MA-0186-100

Splitter #MA-0186-100

Drop Cable* (RG-6) #97-5750-000

Trunk

Line

Tap

Fiber Optic Cable

(Trunk Cable (RG-11) #97-5951-000)

Trunk

Line

Tap #MA-0185-100

Drop Cable*

(RG-6) #97-5750-000

tandby PL

Self-terminating

F Adapters** #52-0411-000

RIO Drop #3

Drop Cable* (RG-6) #97-5750-000

Trunk Terminator

#52-0422-000

Trunk Terminator

*Premade RG-6 Drop Cable

50’ (14m) AS-MBII-003 140’ (43m) AS-MBII-004

Last RIO Drop

Tap #MA-0185-000

Drop Cable* (RG-6) #97-5750-000

**140 CHS 320 00 kit includes: 2 Splitters 4 F Adapters 2 Terminators See CHS 210 Hot Standby Kit for entire HSBY kit contents (140 CHS 210 00).

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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

Reference Guide Installation Guide

, 840 USE 100 00 or the

, 890 USE 101 00.

Quantum Automation Series Hardware

Remote I/O Cable System Planning and

Installing a Hot Standby System

Install the power supplies, controllers, RIO head processors, hot standby modules and any option modules in the primary and standby backplanes. Be sure:

The modules meet the version requirements listed in

Standby, p. 13

The modules in the prima ry backplane are identical to those in the standby backplane.

Note: The order of the modules in the backplanes must be the same.

The rotary address switches on the back of each controller are set. The controllers may have different addresses. It is strongly recommended that the rotary address switches be set to the same address to eliminate any network address conflicts. The same advice applies to the NOM. For details on setting the switches, see the or the

Quantum Automation Series Ha rdware Refe renc e Guide

Remote I/O Cable System Planning and Installation Guide

Overview of Quantum Hot

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Page 62

Installation

The following diagram illustrates installation of a Hot Standby System.

Setting Designation

The designation s lide swit ch on on e Hot Sta ndby mod ule is set to A an d the oth er is set to B.

Slide Switches

CAUTION HAZARD

Before installing any contro ller in yo ur Hot Stan dby syste m, be sure it s battery has been disconnected for at least five minutes.

Failure to follow this precaution can result in injury or equipment damage.

Note: Be sure your sy ste m m ee ts the p ow er and grounding guidel in es o utl ined in

Appendix D of the Quantum Automation Series Hardware Reference Guide, 840 USE 100 00.

Connect Network The following diagram shows how to connect the network.

Step Action

1 Install a splitter and a self-terminating F adapter between the primary RIO head

processor and the RIO network. 2 Connect the coaxial cable link. 3 Connect the cable between the splitter, another self-terminating F adapter and

the standby RIO head processor

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Installation

Network Connections

Installing Coaxial Cable Link

The following diagram illustrates the network connections.

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 th e protective plastic coverings from the cable ports and the tips of the cable. Snap one of the fibe r cable clasps o nto the cable, carefull y pressing the cab le through the slot so that the wider end of the clasp is closest to the boot. The following diagram shows the installation of a coaxial cable link.

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Installation

Attaching the Fiber Cable Clasp to the Cable

Aligning the Key and Locking Ring

The key to installing the cable is to align the barrel, the locking ring and the connector, as shown in the diagram below.

The table below shows how to align the key and locking ring.

Step Action

1 Turn the locking ring to align an arrow with the key. 2 Then align the key with the keyway. As a result, the locking tab, groove and lock

should also be aligned. 3 Slide the clasp up to the locking ring. 4 Gripping the cable with the clasp, plug the cable into the lower (receive) cable

connector. If it does not connect easily, realign the key with the arrow and try

again.

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Installation

Diagram of Aligning Key and Locking Ring

Attaching the Cable

The diagram below illustrates the alignment of the key and locking ring.

Turn the cable to the right, so that the tab locks securely. You may leave the fiber cable clasp on the cable for future use, but slide it off the boot of the cable to allow the module door to close.

Repeat this process with the remaining strand of cable and the upper (transmit) cable connector.

Note: Remember that each strand of cable must be connected to the upper (transmit) cable connector on one Hot Standby module and the lower (receive) cable connector on the other. If the cable is not properly connected, the modules will not be able to communicate and the Standby will remain offline.

Note: One strand of the ca ble provided i n the CHS 21 0 Hot Standby ki t is marked— for instance, with the manufacturer's name. This is the only way to distinguish the two strands.

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Installation

Adding Hot Standby Capability to an Existing System

Converting to Hot Standby System

To add Hot Standby capability to an existing Quantum system, you must install a second backplane with modules identical to those in the original backplane. Keep the following requirements in mind:

You must remove any local I/O and 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.

You need backplanes with at least four slots. The components in both backplanes must meet the version requirements listed.

You must install a s plitter an d a self-ter minating F adapter be tween the original RIO head processor and the RIO network. A second cable runs from the splitter to the Standby RIO head processor, through a second self-terminating F adapter. In general, you ma y foll ow t he ins t al la tion di rec t io ns in thi s C hap ter. H owev er, as a precaution, you should fi rst stop the controller and di sc onn ec t pow e r t o the sy ste m.

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Using a Quantum 984 HSBY System

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:

Section Topic Page

6.1 Configuration 69

6.2 Using the CHS Instruction Block 74

6.3 Using Configuration Extension 85

6.4 Operation 103

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Using a Quantum 984 HSBY System

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Page 69

6.1 Configuration

Introduction

Purpose This section describes Hot Standby configuration.

Note: To ensure correct ope rati on o f the HSBY syste m, the u ser mu st 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

What’s in this Section?

This section contains the following topics:

Topic Page

Configuring 984 HSBY 70 Configuration Extension 72 CHS Instruction 73

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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 so ftware is included on a di sk ett e in the Hot Standby kit. Once you have loaded the software, you can choose how to proceed. You may control your Hot Standby system through ladder logic or you can use a configuration extension.

The CHS Loadable

Installing the CHS loadable into the 984 Environment

The logic in the CHS loadable is the engine that drive s the Hot Standby ca pability in a Quantum control system. The CHS loadable gives you the ability to:

specify the Hot Standby command reg ister, which is us ed to configure a nd control Hot Standby system parameters

define a Hot Standby status register, which can be used to monitor the real machine status of the system

implement a CHS instruction in ladder logic

Unlike HSBY (a comparable loadable used for Hot Standby configurations in 984 controllers), the CHS instruction does not have to be placed in a ladder logic program. However, the CHS software must be loaded into the Quantum controller in order for a Hot Standby system to be supported.

The following steps are only necessary if the CHS loadable is not already part of your 984 installation. The CHS loadable is provided on a 3 1/2 diskette (140 SHS 945 00) as part of y our 140 CHS 210 0 0 Hot Standby kit. The file is named QCHSVxxx.DAT, where xxx is the three-digit version number of the software.

Step Action

1 Insert the diskette in the disk drive. 2 Either create a new Concept project or open an existing one and have a PLC

selected 3 With the menu command Project Configurator, open the configurator. 4 With Configure Loadables, open the dialog box Loadables. 5 Press the command button Unpack to open the standard Windows dialog box,

Unpack Loadable File. Select the loadable file, click the button OK and it is

inserted into the list box Available.

Modsoft If you are using Modsoft, refer to the

Planning and Installation Guide

, 840 USE 106 00 Version 1, Paragraph 5.1.1.

Modicon Quantum Hot Standby System

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Controlling the Hot Standby System by CHS instruction

If you are upgrading from a 984 H ot Standby system to a Quantu m system, you may port your ladder logic program by first de let ing the HSBY blo ck , the n rel ocatin g the program, and then insert ing a CHS instructio n. This requires the CHS loadable to b e installed into your application.

nnnn nnnn

HSBY CHS

nnnn

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Configuration Extension

Controlling the Hot Standby System by Configuration Extension

Ladder Logic in a Hot Standby System

With the Hot Standby configuration extension screens: You can specify the parameters in the Hot Standby command register and

customize the state RAM data transfer between the Primary and Standby units to help reduce scan time.

If you decide to contro l you r sys tem us ing th e conf igur ation e xtens ion, y ou sti ll ma y want to program a CHS instruction in ladder logic. The CHS instruction allows you to use Zoom screens, w hich allows y ou to access and modify th e command regis ter while the system is running.

Note: If both a configuration extension and the CHS instruction are used, the configuration exte nsi on co ntrols the Hot Standby sy ste m. The only function of th e CHS instruction is to provide Zoom screens. The parameters in the configuration screens are applied by the controlle rs at startup. O nce the con trollers are run ning, the Zoom screens may be us ed to a cces s an d m odi fy the c omm and regi ster. The changes are implemented during runtime, and can be seen in the status register. However, if the Hot Standby system is later stopped and then restarted, the parameters specified in the configuration extension screens go back into effect.

All ladder logic for Hot Standby functions should be in segment 1. Network 1 of segment 1 is reserved exclusively for the CHS instruction block and ladder logic directly associated with it.

program all ladder logic specific to Hot Standby func tions in seg ment 1When th e Hot Standby system is runnin g, the Primary con troller sc ans all segment s, while the Standby controller scans only segment 1 of the configured ladder logic program. This has very important implications with respect to the way you configure system logic:

do not program I/O control logic in segment 1

do not schedule any I/O drops in segment 1

the Standby controller in a Hot Standby system must never execute I/O logic.

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CHS Instruction

Using CHS Instruction

Using a Quantum 984 HSBY System

CAUTION Reschedule Segment Hazard

To help protect against damage to application I/O devices through unexpected system actions, do not reschedule segment 1 via the segment scheduler.

Failure to follow this precaution can result in injury or equipment damage.

Segment 1 may contain the ladder logic for diagnostics and optional Hot Standby functions, such as time-of-day clock updates.

Using the CHS Instruction to Control Your Hot Standby System

If you choose to use the CHS instruction in ladder logic to control the Hot Standby configuration, the instruction must be placed in network 1, segment 1 of the ladder logic program. The top node must be connected directly to the power rail by a horizontal short. No control logic, such as contacts, should be placed between the rail and the input to the to p node . Howev er, oth er logi c may be place d in netw ork 1. Remember, the ladder logic in the Primary and Standby controllers must be identical.

The three nodes in the CHS instruction define the command register, the first register in the nontransfer area, and the length of the nontransfer area.

Execute HSBY

Unconditionally

Enable

Registe

Enable

Nontransfer Area

Command

command register

nontransfer area

CHS

length

HSBY System ACTIVE

PLC cannot communicate

with its CHS module

Configuration extension screens are defining the

HSBY configuration

The bottom output node of the CHS instruction indicates whether the configuration extension screens have been activated and allows the pa rameters in the scree ns to override those in the CHS instruction at startup.

A detailed description of the CHS instruction is provided in the

Library User Guide

Ladder Logic Block

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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 Register 76 Elements of the Nontransfer Area 78 Zoom screen of CHS Instruction 80 The Hot Standby Status Register 81 The Reverse Transfer Registers 82 Reverse Transfer Logic Example 83

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Using CHS Instruction Block

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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 c onf igu r e and cont rol various para me ters of the Hot Standby system.

The command register must be a 4x register in the portio n of the state RAM transfer area that is transferred from the Pri mary to the Standby controlle r on e ve ry s ca n. It also must be outside of the nontransfer area.

Disables keyswitch override = 0

Sets Controller A to OFFLINE mode = 0

Sets Controller B to OFFLINE mode = 0

Sets Controller B to RUN mode=1

Forces standby offline if there is a logic mismatch = 0

Does not force standby offline if there is a logic mismatch = 1

Allows exec upgrade only after application stops = 0

Allows exec upgrade without stopping application = 1

13579111315

2 4 6 8 10 12 14 16

Enables keyswitch override = 1

Sets Controller A to RUN mode = 1

0 = Swaps Modbus port 1 address during switchover 1= Does not swap Modbus port 1 address during switchover

0 = Swaps Modbus port 2 address during switchover

1 = Does not swap Modbus port 2 address during switchover

0 = Swaps Modbus port 3 address during switchover 1 = Does not swap Modbus port 3 address during switchover

CAUTION Hot Standby Command Register Hazard

Take precautions to be sure the re gister you selec t as the Hot Standb y command register is reserved for this purpose and not used for other purposes in ladder logic.

Failure to follow this precaution can result in injury or equipment damage.

The values set for the bits in this register determine the system parameters at startup. The register ca n be access ed while the system is runni ng using a refe rence data editor (RDE) or a Zoom screen on the CHS instruction in ladder logic.

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Command Register

CAUTION Command Register Hazard

If you use the command register to enable the keyswit ch override while the Hot Standby system is running, the Primary controller immediately reads bits 14 and 15 to determine its own state and the state of the Standby. If both bits are set to 0, a switchover occurs and the former Primary CPU goes offline. The new Primary CPU continues to operate.

Failure to follow this precaution can result in injury or equipment damage.

The State RAM Transfer Area

Nontransfer Area Within the State RAM Transfer Area

The command regist er must be contai ned 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 transfer area. It consists of the following:

All the 0x disc rete outp uts in st ate RAM u p to a m aximum of 8192, includi ng their associated histories

All the 1x discrete inputs in state RAM up to a maximum of 8192, including their associated histories

If the total number of registers (3x and 4x combined) implemented in state RAM is 10,000 or less, then all the registers plus the up/down counter history table

If the total number of registers (3x and 4x combined) implemented in state RAM is greater than 10,000, then a total of 10,000 is transferred, in accordance with the previously described formula. See

Default Transfer Area, p. 38

You also must define a nontransfer area in the middle node of the the CHS instruction block. A nontransfer area:

is a tool to reduce scan time

is located entirely w ith in t he range of 4x registers in the state RAM transfer area which are transferred on every scan

consists of a block of four or more 4x registers

allows the user to monitor the status of the Hot Standby syst em (third reg ister of non-transfer area)

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Only 4x reference data can be placed in the nontransfer area. These designated registers are not tra nsferred to the Standby controlle r, thus red ucing scan time. Th e following block diagram shows how the nontransfer area exists with respect to the rest of the state RAM transfer area.

Nontransfer Area Within the State RAM Transfer Area

Total number of register outputs transferred

State RAM Transfer Area

Critical outputs transferred on every scan

Note: The command register must be outside the nontransfer block

Additional outputs transferred in chunks on multiple scans

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Elements of the Nontransfer Area

Nontransfer Area The most important part of the nontransfer area is the Hot Standby status register.

Once the system has been configured and is running, the status register becomes a valuable tool for monitoring the machine states of the two controllers. If you use software to change values in the command register, being able to see the result of those changes in the status register is very helpful.

The nontransfer area is defined in the middle and bottom nodes of the instruction block. The middle node specifies the first register in the nontransfer area. The bottom node specifies the length of the nontransfer area.

Status Register

This PLC in OFFLINE mode = 0 1 This PLC running in primary mode =1 0 This PLC running in standby mode = 1 1

The other PLC in OFFLINE mode = 0 1 The other PLC running in primary mode =1 0 The other PLC running in standby mode = 1 1

PLCs have matching logic = 0 PLCs do not have matching logic = 1

This PLC’s switch set to A = 0 This PLC’s switch set to B = 1

12 34 56 7 8 9 10111213141516

The nontransfer area must be at least four registers long. The first two registers in the nontransfer area are reserved fo r reverse tra nsfer functions. The third re gister in the nontransfer area is the Hot Standby status register.

The fourth register and all other c ontiguous 4x reg isters specified for nontransfe r are ignored when the state RAM values of the Primary controller are transferred to the Standby controller.

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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.

Execute HSBY Unconditionally

Enable

Command Register

Nontransfer Area

CHS

HSBY System ACTIVE

PLC cannot communicate with its CHS module

Configuration extension screens are defining the HSBY

configuration

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Zoom screen of CHS Instruction

Zoom Screen When both a CHS instruction and the H ot Standby configura tion extension are us ed,

the parameters you set for the nontransfer area in the configuration extension screens must be identical to those in the CHS block.

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The Hot Standby Status Register

Using a Quantum 984 HSBY System

Hot Standby Status Register

Bits in the Hot Standby Status Register

The status register is register 40012, the third register in the nontransfer area. The command register, which is defined in the top node, has been placed outside the nontransfer area, as required.

The third register in the nontransfer area is the status register. Use this register to monitor the current machine status of the Primary and Standby controllers.

In the example, the status register is 40012.

This PLC in OFFLINE mode = 0 1 This PLC running in primary mode =1 0 This PLC running in standby mode = 1 1

The other PLC in OFFLINE mode = 0 1 The other PLC running in primary mode =1 0 The other PLC running in standby mode = 1 1

PLCs have matching logic = 0 PLCs do not have have matching logic = 1

This PLC’s switch set to A = 0 This PLC’s switch set to B = 1

12 34 56 7 8 9 10111213141516

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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 Prima ry controlle r. This is op posite from the normal forward state table transfer from the Primary to the Standby.

If you choose not to use the reverse transfer registers, do not connect the CHS bottom input to the rail in your l adder l ogic program , so th e inpu ts to t hese re giste rs are not enabled.

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Reverse Transfer Logic Example

Using a Quantum 984 HSBY System

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.

Network 1 of Segment 1

400005 400100

CHS

Network 2 of Segment 1

400103 000801

BLKM transfers the status of the Hot Standby status register (40103) to internal coils (00801)

BLKM

#001

ST AT sends one register W o rd f rom the standby to a reverse transfer register (400101 in the primary.

000815 (Bit 15)

000816 (Bit 16)

400101 ST AT

#001

(Enables STAT if this PLC is the Standby

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Reverse Transfer Register to

Standby MEMORY PROTECT OFF Lamp

Standby BATTERY FAULT

Reverse Transf er Logic

The logic in network 2 of segment 1 contains a BLKM instruction and a STAT instruction. The Sta ndby ena bles the STAT. Bits 00 0815 a nd 000816 are contro lled by bits 15 and 16 in the Hot Standby status registe r. 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 MEM ORY PROTECT

OFF lamp. Internal coil bit 000716 (sta tus bit 12) control s the STANDBY BATTERY FAULT lamp.

Segment 2

400101

000813 (Bit 13)

000715 (Bit 11)

000716 (Bit 12)

000814 (Bit 14)

000813 (Bit 13)

000705

BLKM #001

BLKM Transfers the Status of Internal Coils

Output Coil

000208

Output Coil

000209

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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 Dialog 87 Bits in the Hot Standby Command Register 88 Keyswitch Override and Run Mode 90 A Software Control Example 91 Standby on Logic Mismatches 92 Transfer All State RAM 94 Hot Standby Status Register for Configuration Extension 95 Advanced Options 96 Defining the Transfer Area of State RAM 97 Transferring Additional State RAM Data 100 Scan Transfers 102

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Configuration Extension

Hot Standby Dialog

The configuration of th e 9 84 H ot Stan dby ca n be done with the Hot Standby dialog and/or with the CHS instruction of the LL984 instruction library.

Concept shown

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Hot Standby Dialog

Using a Quantum 984 HSBY System

Hot Standby Dialog in Concept

The Hot Standby dialog is shown below, it can be activated through Configure Hot Standby.

Concept shown

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Bits in the Hot Standby Command Register

Specifying the Command Register

Command Register

Does not force standby offline if there is a logic mismatch = 1

The command register is used to control various parameters of the Hot Standby system.

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. For example, if you enter 14, the hot Standby command register is 400014.

Disables keyswitch override = 0 Enables keyswitch override = 1

Sets Controller A to OFFLINE mode = 0

Sets Controller A to RUN mode = 1

Sets Controller B to OFFLINE mode = 0

Sets Controller B to RUN mode = 1

Forces standby offline if there is a logic mismatch = 0

Allows exec upgrade only after application stops =0

Allows exec upgrade without stopping application =1

0 = Swaps Modbus port 1 address during switchover 1 = Does not swap Modbus port 1 address during switchover

0 = Swaps Modbus port 2 address during switchover 1 = Does not swap Modbus port 2 address during switchover

0 = Swaps Modbus port 3 address during switchover 1 = Does not swap Modbus port 3 address during switchover

You may enter any number in the range 1... n, where n is the last configured 4x register. However:

The command register mus t be part of the area of state RAM that gets transferred from the Primary to the Standby controller on every scan.

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Therefore, the num ber you specif y for the comman d register mus t be in the r ange of 4x registers you speci fy in the State RA M area i n St ate RA M dia log. If you a re using the 12K option, the command register must be one of the first 9000 4x registers.

The command register must not be within the range of the nontransfer area, which you specify in the nontransfer area of the Hot Standby dialog.

CAUTION Hot Standby Command Register Hazard

Be sure the registe r you selec t as the H ot Standby c ommand regist er is reserved for this purpose and not us ed for other purposes el sewhere in user logic.

Failure to follow this precaution can result in injury or equipment damage.

CAUTION Hot Standby Dialog Hazard

If you intend to use the Hot Standby dialog to configure the command register and the CHS instructi on to modify the command reg ister during runtime, make sure that you specify the same regi ster as the com mand register in Hot S tandby dialo g and the to p node of th e CHS block . If you use different numbers for the command register, the changes that you make via the Zoom screen are not applied to the real Hot Standby command register.

Failure to follow this precaution can result in injury or equipment damage.

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Keyswitch Override and Run Mode

Keyswitch and Run

Keyswitch Override

You may choose to override the keyswitch on the front panel of the CHS 110 modules for security or convenience. If you override the keyswitch, the command register becomes the means for taking the CHS 110 modules on or offline. By default, the keyswitc h override is disabl ed. The Hot Standb y dialog allow s you to enable it.

If you enable the keyswitch override, the Offline/Running operating mode of the controllers at startup is determined by the values you set to bits 14 and 15 of the command register. These bi ts are represented as the Run Mod e for controller A and B (depends on designation slide switch). Remember, that when the keyswitch override is enabled you ca n not initiate a prog ram update (program x fer) at the CHS 110 module in the Standby rack.

As long as the key swi tch o verride is disab led, th e se ttings for th e Ru n Mod e can be ignored.

CAUTION Keyswitch Override Hazard

If you use the Zoom screen or RDE to enable the keyswitch override while the Hot Standby system is running, the Primary controller immediately reads bits 14 and 15 to determine its own state and the state of the Standby.

Failure to follow this precaution can result in injury or equipment damage.

If both bits are set to 0, a switchover occurs and the former Primary CPU goes offline. The new Primary CPU continues to operate.

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A Software Control Example

Using a Quantum 984 HSBY System

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:

Option 1 C hange 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. Download the new configuration.

Option 2 Connect Concept to your Primary controller. Call up the reference data editor

(RDE). Place the Hot Standby command register and the Hot Standby status register in the RDE. The operating mode of controller B is determined by the state of bit 14 of the command register. If controller B is offline, bit 14 is set to

0. To put the controller in RUN mode, change the state of bit 14 to 1. Controller B immediately goes into RUN mode if all other HSBY requirements are healthy.

Option 3 If you have programmed a CHS instruction into the ladder logic: Connect

Concept to your Primary controller. In the editor, place the cursor on the top node of the CHS instruction and invoke the Zoom screen (CTRL+D). Check the Run Mode checkbox for parameter Contoller B in Run Mode and controller B immediately goes into RUN mode.The advantage of options 2 and 3 is that the Hot Standby system does not have to be shut down in order to change its status. If you find the use of the Zoom screen more comfortable than the RDE, consider programming a CHS instruction into ladder logic for purposes such as this.

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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.

The radio buttons provide y ou with the option to overrid e this defau lt. If you change the parameter in this field from Offline to Running, the Standby controller remains online if a logic mismatch is detected between its logic program and that of the Primary controller.

CAUTION Mismatch Hazard

A mismatch in the I/O map or configuration is not allowed under any circumstances.

Failure to follow this precaution can result in injury or equipment damage.

CAUTION Switchover Hazard

If switchover occurs when the radio button is set to Running and there is a logic mi smatch bet ween the two cont rollers , the Standby cont roller will assume Primary responsibilities and will start solving a different logic program from the previous Primary controller.

Failure to follow this precaution can result in injury or equipment damage.

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Swap Address at Switchover

Modbus Plus Port Address Swapping at Switchover

In a Hot Standby system, the Modbus ports on the Primary controller may have MEM addresses in the ran ge of 1 to 119. T his allows an offs et of 128 for compa rable 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 th e default address es for the compar able ports on Sta ndby controller B are 129 and 130. By default, this offset is maintained between port addresses in the event of switchover. For example, if controller B becomes the Primary controller as the result of switchover, its Modbus ports assume the addresses of 1 and 2, and th e comp arable ports on control ler A ass ume ad dresses 129 and 130.

The check boxes allow you to change this default condition on any or all of the Modbus ports on the two controllers in your Hot Standby system.

Modbus ports on the two contro llers in your Hot Standby system. For example: if you deselect the parameter Modbus Port 1, then no offset is maintained at switchover and after switchover the two ports have the sam e address. Thu s if control ler A is the Primary controller and i ts Modbus port 1 address is 1, then th at port address rema ins 1 after a switchover occurs . Likewise, if controller B becomes the Pri mary con troller as a result of switchover, its Modbus port 1 address is also 1.

Note: If you change the selections, the port addresses are not affected until a switchover occurs.

In a Quantum Hot Standby sy stem, the Modbus Plus port addresses on the Stand by controller are offset by 32 from the co mp arab le p orts on the P rim ary con trol ler . For example, if controller A is the Primary controller and its Modbus Plus port has address 1, then the address for th e corresponding p ort on Standby controlle r B is 33. The numerical range for addresses for both ports is 1 through 64. Thus, if the port on the Primary controller has address 50, then the address for the corresponding port on the Standby cannot be 82, so it is 18 (that is, 50 minus 32).

These addresses are automatically swapped at switchover; you do not have the option to change the offset or prevent the addresses from being swapped.

Note: The Quantum Hot Stand by sy ste m sw ap s Mo dbus Plus addresses almost instantaneously at switchover. This means that host devices polling the Quantum controller can be assured tha t they are always talki ng to the Primary control ler and that the network experiences no downtime during switchover.

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Transfer All State RAM

"Transfer All State RAM"

It is not possibl e to d efine a spe cial State RAM or add itiona l St ate RAM ran ge to b e transferred if this check box is activated.

check box

Nontransfer Area The nontransfer area contains the Hot Standby status register, which is used to

monitor the states of both c ont roll ers . It als o contains a pair of registers which may be used for reverse transfer operations. 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 defin e the number of con tiguous reg isters in the no ntransfer block. If you choose to define a nontransfer area, the range of legal values for this entry field is 4 ... n, where n is the number of configu red 4x register s. However, whe n defining the nontransfer area, you must meet these requirements:

The nontransfer area must be located entirely within the area of 4x registers scheduled for transfer on every scan. The transfer area is defined in the State RAM dialog.

The command register (first entry of th e Hot Stand by dialog) mu st be outs ide the nontransfer area.

Note: If you are also programmi ng a CHS instructio n in LL984, the param eters you set for the nontransfer a rea in the Hot Stand by dia log m ust be id entica l to th ose in the CHS block.

Hot Standby Status Register

The third register in t he n ontransfer area is the Hot Standby status regist er. U s e this register to monitor the current machine status of the Primary and Standby controllers.

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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 primary mode = 1 0

This PLC running in standby mode = 1 1

The other PLC in OFFLINE mode = 0 1

The other PLC running in primary mode = 1 0

The other PLC running in standby mode = 1 1

PLCs do not have matching logic = 1

This PLC’s switch sat to A = 0 This PLC’s switch sat to B = 1

An interface error has been detected = 1

Hot standby capab ility has not been activated = 0

PLCs have matching logic = 0

The CHS interface is healthy = 0

Hot standby is active = 1

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Advanced Options

Advanced Options button

When pressing the Advanced O ptions but ton in the Hot Stan dby dialo g, 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 contro llers ste p by step to a new firmw are version without having to shutdown the system. Since this is only necessary in rare situations, it is recommended that you disable this mode by configuration and to enable it by the reference data editor or Zoom screen w hen needed. By default, the c ontrollers must have the same versions of firmware. This means the Standby controller would not go online while having a newer or older firmw are version than the one on the Primary controller.

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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, deacti vate Transfer All State R AM and then use the

Options button.State RA M assoc iated with al l critic al I/O also shou ld be tran sferred in every scan. Additional state RAM can be grouped and transferred over multiple scans.

Concept shown

State RAM

Transfer: User Defined

Number of References to Transfer

Coils (0xxxx):

Discrete Inputs (1xxxx):

Additional State RAM

Transfer Additional State RAM Extra Transfer Time (1-255): 1

Number of References to Transfer

Coils (0xxxx): 0

Discrete Inputs (1xxxx):

0 0

Input Regs (3xxxx):

Output Regs (4xxxx):

Input Regs (3xxxx):

Output Regs (4xxxx):

0 0

OK Cancel Help

If you use the CHS instructio n to configure the Hot Standb y system, you are unable to transfer any more than 12K words, even though the total amount of state RAM could be as much as 64K words. You can limit the number of 4x registers being transferred by selecti ng a block o f regi sters a s part of the nontran sfer area , but you cannot limit the number of 0x, 1x, or 3x registers in the transfer area.

Note: The command register must be located in the area of state RAM which is transferred in every scan.

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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 trans ferred. You also can manage how muc h gets transferred in all sc an s a nd how much gets transferred in pieces over multiple scans.

The parameter you select in the Transfer field of the State RAM determines the flexibility you have in defining your state RAM transfer area. You may choose from two options:

12K

User Defined

Note: The remaining en try field s of the dialog ma y or may not be used depe nding on which one of these two parameters you choose.

Note: No matter which option you choose, remember that the command register must be included in the block of registers transferred on every scan.

12K Option The 12K option mimics the CHS instruction. It gives you a predefined state RAM

transfer area with a predetermined maximum of each reference data type to be transferred. The predefined transfer area consists of the following:

All the 0x disc rete outp uts in st ate RAM u p to a m aximum of 8192, includi ng their associated histories.

All the 1x discrete inputs in state RAM up to a maximum of 8192, including their associated histories.

If the total number of registers (3x and 4x combined) implemented in state RAM is 10 000 or less, then all the registers plus the up/down counter hist ory table.

If the total number of registers (3x and 4x combined) implemented in state RAM is greater than 10 000, then 10 000 registers transfer in accordance with the formula described in

System Scan Time, p.33

If you choose the 12K option, the State RAM and Additional State RAM area become irrelevant. You can not customize the transfer area or transfer additional data in groups over multiple scans. Any entries in these fields are ignored.

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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 Additi onal State RAM check box is activated, it allows you to transfer additional data.

000001 000002 000003

0nnnnn 100001

100002 100003

1nnnnn

300001 300002 300003

3nnnnn

400001 400002 400003 400004 400005 400006

4nnnnn

Outputs transferred on every scan

Remaining outputs not transferred

Inputs transferred on every scan

Remaining inputs not transferred

Inputs transferred on every scan

Remaining inputs not transferred

Outputs transferred on every scan

Remaining outputs not transferred

User Defined State RAM Transfer

Use the State RAM area to defin e the size of the data range . All of the reference data that you specify in this area is tra nsferred from the Prima ry to the Standby co ntroller on every scan (except the defi ne d no ntra ns fer a rea). All reference data items must be 0 or specified in multiples of 16. A minimum of 16 4x registers is required. The maximum amount o f s tate RA M to b e t ransferr ed on every sca n can be a s mu ch as the total amount of available state RAM (10K, 32K, or 64K, depending on the type of Quantum controller).

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Transferring Additional State RAM Data

Additional Data If the Transfer Additional State RAM check box is activated, additional State RAM

could be transferred. In the Additional State RAM area, enter the number of 0x, 1x, 3x, and 4x data

references that you want to be transferred as additional state RAM. All reference data items must be specified in multiples of 16. You must enter a value of 16 or greater for at least one of the four reference data types.

CAUTION Transfer Additional State RAM Hazard

If you choose Transfer Additional State RAM, you must specify additional data to be transferred or the controller will not start.

Failure to follow this precaution can result in injury or equipment damage.

Use the Extra Transfer Time entry field to specify the number of scans over which you want the additional data to be transferred. In general, the system divides the number of reference data eleme nts specifie d in the fifth entry fiel d by the number of scans specified in the sixth entry field. Accordingly, it divides the data into groups that are transferred c ontiguous ly over the speci fied num ber of sca ns. These g roups of data are transferre d with the reg ular s tate RAM data that ha s bee n sc hedule d on every scan.

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Schneider Electric 840 USE 106 0 User Manual

Specifications and Main Features

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User Manual