Schneider Electric 840 USE 106 0 User Manual

Quantum Hot Standby

Planning and Installation Guide

840 USE 106 00

Version 4.0

31002766 02

2

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

7

8

Safety Information

§

Important Information

NOTICE	Read these instructions carefully, and look at the equipment to become familiar with
	the device before trying to install, operate, or maintain it. The following special
	messages may appear throughout this documentation or on the equipment to warn
	of potential hazards or to call attention to information that clarifies or simplifies a
	procedure.
	The addition of this symbol to a Danger or Warning safety label indicates
	that an electrical hazard exists, which will result in personal injury if the
	instructions are not followed.
	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, serious injury, or equipment damage.

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 damage.

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 Schneider Electric for any consequences arising out of the use
	of this material. This document is not intended as an instruction manual for untrained
	persons.
	© 2003 Schneider Electric	All Rights Reserved

10	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
	Schneider Electric assumes no responsibility for any errors that may appear in this
Warnings	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 [e-mail]

12	840 USE 106 00 January 2003

Overview of Quantum Hot

Standby	1

At a Glance

Purpose	This chapter presents a brief overview of the Hot Standby system, including a
	description of Primary and Standby control, components, the Hot Standby module,
	LEDs and switches, modes of operation, 984 and IEC HSBY, and the application
	size.
	Throughout the rest of this book the Quantum Hot Standby system is referred to as
	HSBY.
	An HSBY system is based on two identically configured programmable logic
	controllers linked to each other and to the same remote I/O network. If one controller
	fails, the other assumes control of the I/O system.
What’s in this
	This chapter contains the following sections:
Chapter?
	Section	Topic	Page
	1.1	Control	15
	1.2	Operation	21
	1.3	Cabling	23
	1.4	984 HSBY and IEC HSBY	26

840 USE 106 00 January 2003

13

Overview of Quantum Hot Standby

14	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
	This section contains the following topics:

Section?
	Topic	Page
	Primary and Standby Control	16
	Hardware Components in a Quantum Hot Standby System	17
	The CHS 110 Hot Standby Module	18

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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 other must be in 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
	Each controller is paired with a 140 CHS 110 00 Hot Standby module. The module
110 Hot Standby	monitors its own controller and communicates with the other Hot Standby module.
Module	The system monitors itself continuously. If the Primary controller fails, the Hot
	Standby module switches control to the Standby, which then becomes the Primary
	controller.
	If the Standby controller fails, the Primary continues to operate without a backup.

16	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:

lProgrammable logic controller

lRemote I/O head processor

lCHS 110 Hot Standby module

lCables (See Fiber Optic Cable Guide, p. 213)

lPower supply

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

The following illustration shows the hardware components in a Quantum Hot

Standby System.

Primary	Standby
	PS PLC RIO CHS
PS PLC RIO CHS

Fiber Optic Link

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:
	l	LED Display
	l	Function Keyswitch
	l	Designation slide switch
	l	Update Button
	l Fiber optic cable ports
CHS 110 Front
	The following figure shows the module’s front panel.
Panel Controls

Version Label

Model Number Module

Description Color Code

LED Display	Removable Door

Function Keyswitch

Designation Slide Switch

Update Button

Transmit Cable Connector

Receive Cable Connector

M0035300

18	840 USE 106 00 January 2003

		Overview of Quantum Hot Standby
LED Display	The following illustration shows five status indicators on the face of each CHS 110
	module.
	140
	CHS 110 00
	HOT STANDBY
	Active
	Ready	Fault
	Run	Bal Low
	Pwr ok

Modbus Com Err

Modbus! Error A

Com Act Error B

Primary

Mem Prt Standby

The following table shows the five status indicators.

Indicator	Color	Message
Ready	Green	If steady, power is being supplied to the module and it has
		passed initial internal diagnostic tests. 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.

840 USE 106 00 January 2003

19

Overview of Quantum Hot Standby

Function	Beneath the LED display on the face of each CHS 110 control panel is a function
Keyswitch	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.
Designation
	A slide switch located below and to the right of the keyswitch is used to designate
Slide Switch and	the controller as A or B. One unit must be designated as A and the other as B.
Update Button	Use the Standby Update Button to initiate the Primary to Standby program 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 system is running, Primary control may be exchanged between the
	units regardless of which is designated as A or B.

20	840 USE 106 00 January 2003

Overview of Quantum Hot Standby

1.2 Operation

Modes of Operation

HSBY Modes of HSBY has three Modes of Operation:

Operation

1.Off Line Mode

2.Transfer Mode

3.Run Mode

These modes are described below.

Off Line Mode This mode is used to take a controller out of service without stopping it or disconnecting power. If you turn the key on the Primary unit to Off Line, control switches to the Standby. If the Standby controller is taken offline, the Primary continues to operate without a backup.

Transfer Mode This mode is used to request a program update of the Standby controller from the 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 controller is in Run mode and the standby indicator is on,
	it is actively monitoring the status of the system and is ready to take control if the
	Primary unit fails.

22	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
	This section contains the following topics:

Section?
	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	The CHS 110 Hot Standby modules are connected by a fiber optic cable. The cable
Connections	has two identical strands. Each strand transmits a signal in only one direction. For
	this reason, each strand must be connected between the upper (transmit) port on
	one module and the lower (receive) port on the other.
	If the cable is not connected properly, the Hot Standby modules are not able to
	communicate and the Hot Standby system does not function. The Primary controller
	operates without a backup. The Standby unit remains offline.
	A 3 meter fiber optic cable is provided in the 140 CHS 210 00 Hot Standby kit. One
	strand of that cable is marked with the manufacturer’s name. This is the only way to
	distinguish the two strands.
	This illustration shows CHS 110 Hot Standby modules connected by a fiber optic
	cable.

Transmit

Transmit

	Receive		Receive

24	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.

lTwo CHS 110 Hot Standby modules with four fiber cable clasps (140 CHS 110 00)

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

lTwo coaxial splitters together with two tap terminators and four self-terminating F adapters (140 CHS 320 00)

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

lQuantum 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
	This section contains the following topics:

Section?
	Topic	Page
	984 HSBY	27
	IEC HSBY	28

26	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 earlier PLC systems used the "HSBY" loadable function block. 984
	HSBY may also be activated as a configuration extension that allows additional
	features to be configured. For details refer to Using a Quantum 984 HSBY System,
	p. 67.
Architecture
	Quantum 984 Hot Standby involves:
	l Concept Version 2.1 or greater, Modsoft Version 2.3 or greater, Proworx Version
	1.5 or greater
	l All Quantum Controllers
	l 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 Replacement, p. 192).
System	Minimum Module Versions to Support 984 HSBY
Compatibility
	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

840 USE 106 00 January 2003

27

Overview of Quantum Hot Standby

IEC HSBY

IEC HSBY	IEC Hot Standby means: Programming an application with the choice of 5 different
Architecture	IEC compliant languages; FBD, LD, SFC, IL and ST.
	1.	The IEC HSBY system uses the same hardware architectures as 984 HSBY
		system for its basic operations. For example, state RAM data transfer and
		switchover control are the same, but there are some differences compared to the
		984 HSBY system.
	2.	PLC firmware upgrade is allowed without shutting down the system with Concept
		2.5 or higher. Earlier versions of Concept require shutting down the system to
		upgrade PLC firmware.
	3.	RIO is serviced differently.
	4.	With Concept 2.5 or higher, it is now possible to download the same application
		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 System , 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.

28	840 USE 106 00 January 2003

Overview of Quantum Hot Standby

Architecture As shown below, Quantum IEC Hot Standby involves:

lConcept Version 2.1 or greater

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

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

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

The following diagram shows the Quantum IEC Hot Standby Architecture

Quantum IEC Hot Standby Architecture

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‡4XDQWXP &RQWUROOHUV

&38

&38

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‡([LVWLQJ 5HPRWH , 2 PRGXOHV DQG ([HFV

&( PDUNHG 9HUVLRQ

RU JUHDWHU

0RGEXV 3OXV

FIBER OPTIC CHS LINK

I/O

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 download them as online changes later. It 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, accomplished by copying the state RAM from the Primary to the Standby,
	causes differences in terms of application size. In IEC HSBY, a part of the state RAM
	is used to transport the IEC application data from the Primary to the Standby.
	Therefore the size of IEC application data cannot exceed the configured size of 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
	l IEC Language programs only, no 984 Ladder Logic permitted
Standby	l To bring a Standby on-line
Overview	l Primary and Standby controller executives must be equal.
	l Primary and Standby IEC Projects must have the same name and the
	applications must be equal.
	l On-line changes to the Primary are permitted
	l 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.
	l 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.
	l Primary controller on-line changes may include
	l Addition of sections
	l Addition of DFBs allows pre-qualification of user changes in an office
	environment
	l Logic Mismatch
	l 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.

lUnder 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.

lTo upgrade the controller Execs

l With Concept 2.1/2.2, the process must be stopped. Then Primary and

Standby controllers must be stopped and downloaded individually.

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

30	840 USE 106 00 January 2003