Schneider Electric 840 USE 106 0 User Manual

Quantum Hot Standby

Planning and Installation Guide

840 USE 106 00 Version 4.0

31002766 02

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

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

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

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

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

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

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

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

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

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

Overview of Quantum Hot Standby

840 USE 106 00 January 2003

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

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

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

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

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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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.

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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

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.

840 USE 106 00 January 2003

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

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

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

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

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

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

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

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

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