Schneider Electric Modicon Quantum User Manual

Modicon Quantum

Hot Standby with Unity

User Manual

UNY USE 107 10 V20E

September 2004

2

Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Part I Introducing the Modicon Quantum Hot Standby with

Unity System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

Chapter 1 Modicon Quantum Hot Standby with Unity Overview. . . . . . . 15

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

Overview of the Modicon Quantum Hot Standby with Unity System. . . . . . . . . . 16

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Modicon Quantum Hot Standby with Unity System Overview. . . . . . . . . . . . . . . 19

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components. . . . . 21

Operating the Modicon Quantum Hot Standby with Unity 140 CPU 671 60

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED

Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 2 Modicon Quantum Hot Standby with Unity Compatibility,

Differences, and Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Compatibility with Installed Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Understanding System Words and System Bits . . . . . . . . . . . . . . . . . . . . . . . . . 41

Understanding Multitasking Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Local I/O and Distributed I/O Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Understanding Other Module Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Understanding USB Link Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Understanding Application Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3

4

Chapter 3 Using IEC Logic and Modicon Quantum Hot Standby with

Unity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Modicon Quantum Hot Standby with Unity and IEC Logic. . . . . . . . . . . . . . . . . . 48

Understanding the Modicon Quantum Hot Standby with

Unity State RAM Transfer Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Understanding System Scan Time in Modicon Quantum Hot Standby with

Unity Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Transferring Application Data in a Modicon Quantum Hot Standby with

Unity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Part II Setting up and Maintaining a Modicon Quantum Hot

Standby with Unity System. . . . . . . . . . . . . . . . . . . . . . . . 55

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

Chapter 4 Setting up, Installing, and Cabling a Modicon Quantum

Hot Standby with Unity System . . . . . . . . . . . . . . . . . . . . . . . . 57

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Setting Up the Modicon Quantum Hot Standby with Unity System . . . . . . . . . . . 58

Mapping the Backplane Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Connecting Two Modicon Quantum Hot Standby with Unity

HE CPU 671 60s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Connecting the Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Testing the Modicon Quantum Hot Standby with Unity System . . . . . . . . . . . . . 66

Chapter 5 Configuring a Modicon Quantum Hot Standby with

Unity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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

5.1

Configuring a System with the Unity Pro Tabs and Dialogs . . . . . . . . . . . . . . . . 70

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Introducing Unity Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Accessing the Base Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Using the Summary Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Using the Overview Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Using the Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Using the Modbus Port Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Using the Animation Tab and PLC Screen Dialogs . . . . . . . . . . . . . . . . . . . . . . . 81

Using the Hot Standby Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Configuring the PCMCIA Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Configuring the Modbus Plus Communication Type . . . . . . . . . . . . . . . . . . . . . . 87

Setting the Invalidate Keypad Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Swapping Network Addresses at Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.2

Configuring a NOE with Unity Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Overview of Modicon Quantum Hot Standby with Unity Solution for

NOEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

NOE Operating Modes and Modicon Quantum Hot Standby with Unity . . . . . . . 98

IP Address Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Address Swap Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Network Effects of Modicon Quantum Hot Standby with Unity Solution . . . . . . 105

5.3

Configuring Registers with Unity Pro. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Understanding the Non-Transfer Area, Transferring State RAM,

and Reverse Transfer Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Understanding the Unity Command Register . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Understanding the Unity Status Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Transferring User Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Using Initialized Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Synchronizing Time-of-Day Clocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Chapter 6 Maintaining a Modicon Quantum Hot Standby with

Unity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Verifying the Health of a Modicon Quantum Hot Standby with

Unity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with

Unity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Detecting Primary Controller, Copro, and RIO Head Failures. . . . . . . . . . . . . . 123

Detecting Standby Controller, Copro, and RIO Head Failures . . . . . . . . . . . . . 125

Detecting High-Speed Data Link (HDSL) Failures . . . . . . . . . . . . . . . . . . . . . . 126

Detecting Remote I/O (RIO) Link Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Checking for Identical Application Programs—Checksum . . . . . . . . . . . . . . . . 131

Replacing a Faulty Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Troubleshooting the Primary Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Troubleshooting the Standby Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Part III Understanding the Modicon Quantum Hot Standby with

Unity System Special Features . . . . . . . . . . . . . . . . . . . 135

At a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Chapter 7 Enabling EXEC Upgrade with Unity Pro . . . . . . . . . . . . . . . . . 137

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade . . . . . 138

Executing the EXEC Upgrade Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Chapter 8 Handling Logic Mismatch with Unity Pro . . . . . . . . . . . . . . . .141

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch . . . 142

5

6

Understanding Switchover Behavior during Logic Mismatch. . . . . . . . . . . . . . . 146

Online or Offline Modifications and Logic Mismatch . . . . . . . . . . . . . . . . . . . . . 148

Online Modifications to an Application Program in the Standby and

Logic Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Online Modifications to an Application Program in the Primary and

Logic Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Offline Modification of an Application Program and Logic Mismatch. . . . . . . . . 151

Switchover Methods and Logic Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Application Program Transfer Method and Logic Mismatch . . . . . . . . . . . . . . . 155

Recommendations for Using Logic Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Chapter 9 Transferring an Application Program with Unity Pro . . . . . . 159

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Overview of Application Program Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Executing the Application Program Transfer Procedure Using the

Command Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Automatic Application Program Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Executing the Application Program Transfer Procedure Using the Keypad . . . 164

Chapter 10 Using the Modicon Quantum Hot Standby with

Unity EFBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Description: HSBY_RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Description: HSBY_ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Description: HSBY_WR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Description: REV_XFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Appendices for Quantum Hot Standby Planning and Installation Guide . . . . . . 181

Appendix A Modicon Quantum Hot Standby with Unity

Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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

Fiber Optic Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with

Unity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

CRP Remote I/O Head Processor Error Patterns . . . . . . . . . . . . . . . . . . . . . . . 187

TextIDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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.

7

Safety Information

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

© 2004 Schneider Electric. All Rights Reserved.

8

About the Book

At a Glance

Document Scope This guide describes the Modicon Quantum Hot Standby with Unity system consisting of the Unity Pro software, the Modicon Quantum Hot Standby with Unity

140 CPU 671 60, power supplies, and remote I/O (RIO).

This guide describes how to build a Modicon Quantum Hot Standby with Unity system. Users of legacy Quantum Hot Standby systems should note that significant differences exist between Unity and legacy systems, and where important, this guide identifies those differences.

Note: Software Requirements

Required to use a Quantum Modicon Hot Standby with Unity system: z z z

Unity Pro 2.0 or higher

CRA firmware: Release 1.25 or higher

CRP firmware: Release 1.14 or higher

Note: Who should use this document?

Anyone who uses a Hot Standby system or needs fault-tolerant availability through redundancy in an automation system.

You should have knowledge of programmable logic controllers (PLCs). Familiarity with automation controls is expected.

You should possess a working knowledge of the Unity Pro software. Familiarity with Concept, ProWORX, or Modsoft will help.

9

About the Book

Validity Note

Note: Terminology

This guide uses the following terminology.

z z application program = a project or logic program controller = a Unity Programmable Logic Controller (PLC), module, which contains both

1.

a CPU z z

2.

a Copro

CPU = (Central Processing Unit) a microprocessor in the controller, which processes the application program copro = a microprocessor in the controller, which communicates between two z z z controllers modify = to edit or to change an application program module = any unit either a controller, NOE, RIO, CRP, CRA, DDI, AVO scan = program cycle

Because Modicon Quantum Hot Standby with Unity systems deliver fault-tolerant availability through redundancy, use a Modicon Quantum Hot Standby with Unity system when downtime cannot be tolerated. Redundancy means that two backplanes are configured identically. A Modicon Quantum Hot Standby with Unity system must have identical configurations: z z identical 140 CPU 671 60s which contain both a CPU and a Copro identical versions of the EXEC z z identical power supplies identical RIO Heads z z identical cabling and cabling systems identical I/O drops z identical sequential placement on the backplane

The data and illustrations found in this book are not binding. We reserve the right to modify our products in line with our policy of continuous product development. The information in this document is subject to change without notice and should not be construed as a commitment by Schneider Electric.

10

About the Book

Related

Documents

Title of Documentation

Quantum with Unity Pro Hardware Reference Manual

Quantum with Unity Pro Discrete and Analog I/O Reference

Manual

Quantum with Unity Pro Experts and Communication Reference

Manual

Quantum Automation Series Hardware Reference Manual

Modbus Plus Network I/O Servicing Guide, Version 2.0

Remote I/O Cable System Planning and Installation Guide,

Version 3.0

Modbus Plus Network Planning and Installation Guide,

Version 4.0

Reference Number

Electronic Documentation

CD: UNYUSE909CDM

Electronic Documentation

CD: UNYUSE909CDM

Electronic Documentation

CD: UNYUSE909CDM

840USE10000

840USE10400

890USE10100

890USE10000

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 by any means, electronic or mechanical, including photocopying, without express written permission of

Schneider Electric.

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to ensure compliance with documented system data, only the manufacturer should perform repairs to components.

When controllers are used for applications with technical safety requirements, please follow the relevant instructions.

Failure to use Schneider Electric software or approved software with our hardware products may result in improper operating results.

Failure to observe this product related warning can result in injury or equipment damage.

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

11

About the Book

12

Introducing the Modicon Quantum

Hot Standby with Unity System

I

At a Glance

Purpose

What's in this

Part?

This part introduces the Modicon Quantum Hot Standby with Unity system. The content describes the hardware available, the compatibility of Modicon Quantum

Hot Standby with Unity system with legacy systems, and using IEC logic and Unity.

This part contains the following chapters:

Chapter

1

2

3

Chapter Name

Modicon Quantum Hot Standby with Unity Overview

Modicon Quantum Hot Standby with Unity Compatibility,

Differences, and Restrictions

Using IEC Logic and Modicon Quantum Hot Standby with Unity

Page

15

39

47

13

Introducing Modicon Quantum Hot Standby with Unity

14

Modicon Quantum Hot Standby with Unity Overview

1

Introduction

Overview

What's in this

Chapter?

In this chapter you will find a brief overview of the Modicon Quantum Hot Standby with Unity system, the module, and the indicators.

This chapter contains the following topics:

Topic

Overview of the Modicon Quantum Hot Standby with Unity System

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module Overview

Modicon Quantum Hot Standby with Unity System Overview

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components

Operating the Modicon Quantum Hot Standby with Unity 140 CPU 671 60

Keypad

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED

Indicators

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens

Page

16

18

19

21

23

25

27

15

Overview Modicon Quantum Hot Standby with Unity

Overview of the Modicon Quantum Hot Standby with Unity System

Purpose of a Hot

Standby System

Use a Modicon Quantum Hot Standby with Unity system when downtime cannot be tolerated. Hot standby systems deliver high availability through redundancy. A hot standby system consists of two identical configurations.

z Modicon Quantum 140 CPU 671 60 z Modicon Quantum Power Supply Module

Modicon Quantum RIO Head z z Modicon Optional Modules (NOE, NOM)

One of the 140 CPU 67160’s acts as the Primary controller, and the other acts as the Standby controller. The Primary controller runs the application program and operates the remote I/O.

Identical

Configurations

Primary and

Standby

Controllers

Two backplanes are configured with identical hardware and software.

One of the programmable logic controllers (PLCs) functions as the Primary controller and the other as a Standby controller, and either controller can be put in the Primary state, but the other must be in the Standby state or offline.

The Primary controller executes the application program, controls the remote I/O, and updates the Standby controller after every scan (program cycle). If the Primary controller fails, the Standby controller takes control within one scan. To determine if the Primary controller failed, note controller’s status displayed in the HE CPU LCD screen and the RIO Head’s status displayed by the RIO Head’s LEDs. (See

Troubleshooting the Primary, p. 133 )

The Standby controller does not execute the full application program but only the first section, and the Standby controller does not control the remote I/O but checks out the availability of the Modicon Quantum Hot Standby with Unity equipment.

Switchover

Capability

Either of the two controllers may function as the Primary controller and the other as the Standby controller.

Primary and Standby states are switchable.

Therefore, if one of the two controllers is functioning as the Primary controller, the other must be in Standby mode. Otherwise, the second controller is in the default mode, which is offline.

The remote I/O is always controlled by the Primary controller.

16

Monitoring the

System

Power Cycle

Overview Modicon Quantum Hot Standby with Unity

The Primary and the Standby controllers communicate with each other constantly to monitor the functionality of the system.

z If the Primary controller fails, the state of the controllers is switched.

The Standby controller becomes the Primary, executes the application program, z and controls the remote I/O.

If the Standby controller fails, the Primary controller continues to run without redundancy and acts as a stand alone system.

On power cycle, the controller that has the lowest MAC address will become the

Primary. The second system automatically becomes the Standby.

Handling I/O

Note: The Modicon Quantum Hot Standby with Unity system supports I/O connected to a Remote I/O network and Ethernet I/O scanning.

Handling Local

I/O

Software

Requirements

Local I/O is not supported in a Modicon Quantum Hot Standby with Unity system environment. However, local I/O can be configured and run but will not have any corresponding backup.

Required to use a Quantum Modicon Hot Standby with Unity system: z z z

Unity Pro 2.0 or higher

CRA firmware: Release 1.25 or higher

CRP firmware: Release 1.14 or higher

Configuring

Modbus Plus

(MB+) Addresses

Note: Configure MB+ address first time

1.

Default MB+ address = 1 (new 140 CPU 671 60 from factory)

2.

Change MB+ address at first configuration (on both controllers)

Schneider Electric recommends: do not change MB+ address after first configuration because unintended operation may result.)

(See

Configuring a System with the Unity Pro Tabs and Dialogs, p. 70 )

17

Overview Modicon Quantum Hot Standby with Unity

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Module Overview

Illustration

18

The following figure shows the Modicon Quantum Hot Standby (with Unity)

140 CPU 671 60 module and its components. Its HSBY fiber optic communications port differentiates this High End CPU module from the 140 CPU 651 60.

140

CPU 671 60

1

2

3

12

13

RESTAR

ESC MO ENT

Mem. Extract Rdy

6

7

4

5

COM

ST

8

9

10

11

Mac Address

1 Model number, module description, color code

2 Lens cover (open)

3 LCD Display (here covered by lens cover)

4 Key switch

5 Keypad (with 2 red LED indicators)

6 Modbus port (RS-232) (RS-485)

7 USB port

8 Modbus Plus port

9 PCMCIA slots A and B (Type II, Type III)

10 LED indicators (yellow) for Ethernet communication

11 HSBY fiber optic communications port

12 Restart button

13 Battery (user installed)

Note: Unity Quantum High End CPUs are equipped with two receptacles (A and

B) in which to install PCMCIA cards. PCMCIA is a standard type of memory card.

Overview Modicon Quantum Hot Standby with Unity

Modicon Quantum Hot Standby with Unity System Overview

System

Components

The following graphic shows the components required for a Modicon Quantum Hot

Standby with Unity system.

5

1

3 6 10 5

2

3 6 10

9A

4

A B

7

9

7A

8

A B

7C

8

7B

1 Primary PLC

2 Standby PLC

3 Modicon Quantum Hot Standby with Unity controller with integrated coprocessor

4 Fiber Optic Cable to connect to both controllers

5 Modicon Quantum power supply module: Install power supply in first slot for better rack layout.

6 Modicon Quantum RIO head

7 Coaxial cable with splitters (7A) (MA-0186-100), trunk terminators (7B) (52-0422-000), and tap (7C) (MA-0185-100) for connecting the RIO heads (6) with the RIO drops (8). The dashed connections represent a redundant connection in the RIO network, which is not required for the Modicon Quantum Hot Standby with Unity system.

8 Modicon Quantum RIO drop

9 Unity Pro computer connected to both controllers via Modbus or Modbus Plus (9A)

10 Optional modules (NOMs, NOEs) if required

19

Overview Modicon Quantum Hot Standby with Unity

Software

Requirements

Please note z z

CRA modules must have V1.25 or higher of the firmware

The Unity Hot Standby system is NOT compatible with previous versions of CRA modules.

CRP modules must have V1.14 or higher of the firmware

The Unity Hot Standby system is NOT compatible with previous versions of CRP modules.

20

Overview Modicon Quantum Hot Standby with Unity

Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Components

Lens Cover

LCD Display

Protects and provides access to z Key Switch z z

Battery

Reset Button

Open the lens cover by sliding upwards.

Has a 2 lines by 16 characters LCD display with a backlight (dims) and adjustable contrast.

The backlight turns on when z keypad driver detects a key press z z z key switch state is changed error message is displayed on the LCD

The backlight dims if no key switch or keypad activity z

Backlight dims in 5 seconds.

error message is generated

Backlight remains on until the error is corrected and the error message stops.

2 Lines by 16 characters LCD

21

Overview Modicon Quantum Hot Standby with Unity

Key Switch Use the key switch as a security feature and memory protection switch.

The key switch has two positions: locked and unlocked.

Key position unlocked

PLC operation z z all system menu operations are able to be invoked and all changeable module parameters are able to be modified by the operator via the LCD and keypad memory protection is OFF locked z z no system menu operations are able to be invoked and all module parameters are read only memory protection is ON

Switching the key switch position from locked to unlocked or vice versa will turn on the LCD's backlight.

Keypad The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 keypad consists of five keys that are mapped to a hardware address.

5-key keypad with 2 LEDs

1

ESC MOD ENTER

Reset Button

2

1 5 keys

2 2 LEDs

Use the keys on the keypad to access the Modicon Quantum Hot Standby with Unity set of system menus, which enable you to z perform PLC operations for example: Start PLC, Stop PLC z display module parameters for example, communications parameters

Forces a cold start of the PLC.

22

Overview Modicon Quantum Hot Standby with Unity

Operating the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 Keypad

Using the Keys Functionality

Key

ESC

Function

To cancel an entry, or suspend or stop an action in progress

To display the preceding screens successively (step up the menu tree)

To confirm a selection or an entry

ENTER

To set a field on the display into modify mode

MOD

LED: on

LED: flashing

LED: off

LED on

LED flashing

LED off z z key active

To scroll through menu options

To scroll through modify mode field options key active z Field in modify mode has options to scroll through key inactive z No menu options, no field options z z key active

To move around in a screen, field to field

To go to the sub-menu key active z To move around in a field that is in modify mode, digit to digit z z z key inactive

No sub-menu for menu option

No moving around in a screen

No moving around in a field

23

Overview Modicon Quantum Hot Standby with Unity

Adjusting the

Contrast

The contrast is adjustable from the keypad when the Default screen is displayed as follows:

Step

1

2

Action

Press the MOD key:

MOD

To adjust the contrast darker press:

3 To adjust the contrast lighter press:

Using the

Backlight

4 To confirm the setting press:

ENTER

Pressing a key will turn on the LCD backlight (if it was off). When the user presses the ESC key and the LCD backlight was off, the LCD backlight will turn on and the

Default Screen will stay as the displayed screen.

If at any time the executive detects an error in the CPU it will display an error message to the LCD and the LCD's backlight will turn on until the error condition disappears

24

Overview Modicon Quantum Hot Standby with Unity

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LED

Indicators

Overview The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 offers two indicators:

1.

LCD display screen

(See Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens, p. 27 )

The default display screen serves as a controller status screen. (See

Understanding the Default Screen, p. 29 )

2.

LED Indicators

(See

Interpreting the LED Indicators, p. 26

)

Position of indicators on Modicon Quantum Hot Standby with Unity 140 CPU 671 60

140

CPU 671 60

HOT STANDBY CONTROLLER

1

RESTART

ESC

Mem. Extract Rdy

MOD ENTER

COM

2

STS

COM

STS

Mac Address

00:00:##:##:##:##

1 LCD Display (lens cover closed)

2 LED Indicators

25

Overview Modicon Quantum Hot Standby with Unity

Interpreting the

LED Indicators

The LEDs provide information

CPU 671 60 (HSBY)

LEDs

COM

Color Description

Yellow Controlled by the

Coprocessor

1

hardware

Indicates

Communication activity between Primary and

Standby controllers

STS Yellow Controlled by the

Coprocessor

1

firmware

Status of Copro z Blinking z system is redundant and data are exchanged from the Primary to Standby z controller

Steady on z z z system is NOT redundant

Copro booting from power-on to end of self-tests

Steady off z

Copro auto tests failed

Note: No activity returns the LEDs to the default.

1 The Modicon Quantum Hot Standby with Unity HE CPU uses an embedded coprocessor

(Copro) to provide a dedicated communications link, which transfers data between the

Primary and Standby controllers.

26

Overview Modicon Quantum Hot Standby with Unity

Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens

Overview

1

The controller’s LCD displays messages. These messages indicate the controller’s status. There ae four levels of menus and submenus. All menus are accessed using the keypad on the front of the controller.

For detailed information about the menus and submenus see: z

Using the PLC Operations Menus and Submenus, p. 30

z

Using the Communications Menus and Submenus, p. 33

Using the System Info Menus and Submenus, p. 36

z z

Using the LCD Settings Menus and Submenus, p. 37

Structure: LCD display menus and submenus

Mode State Bat L port

2

Quantum

PLC Operations =>

3

Quantum

Communications =>

Quantum

System Info =>

Quantum

LCD Settings =>

4

1 Default Screen

2 System Menus

3 Sub Menus

4 Sub Screens

27

Overview Modicon Quantum Hot Standby with Unity

Accessing the

Screens

Use the keys on the keypad to access the system menus and submenus.

Step

1

Action

To access the screens, ensure that the key switch is in the unlocked position .

2 To step down to a lower menu, operate one of the following keys:

ENTER

3 To return to the previous menu, press:

ESC

28

Understanding the Default

Screen

Overview Modicon Quantum Hot Standby with Unity

Default screen displays the following information

Mode State Bat L port PCM

The default screen is read only.

Default

Screen

Displays

Default

Fields Available

State

Options

Available

RUN

BatL

Port USB

Modbus

Plus

Modbus

PCM

STOP

No Conf

MB+ mb+

232

485

1

2

Description

Application program is running

RUN Primary

RUN Standby

RUN Offline

Application program is NOT running

STOP Offline

CPU has no application program z z

Indicates health of battery

Steady = Battery is low

No message = Battery is OK

Indicates that port has activity

Indicates Modbus Plus activity

No activity

Serial port activity for RS-232

Serial port activity for RS-485

Indicates the card in slot 1 is being accessed

The status displayed indicates the health z z of the battery

Steady = Battery is OK

No message = Batery is low z z

Blinks, when the card in slot 2 is being accessed

The status displayed indicates the health of the battery

Steady = Battery is OK

No message = Batery is low

29

Overview Modicon Quantum Hot Standby with Unity

Using the PLC

Operations

Menus and

Submenus

Structure: PLC Operations menu and submenus

Quantum

PLC Operations =>

PLC Operations

Start PLC =>

PLC Operations

Stop PLC =>

PLC Operations

Init PLC =>

PLC Operations

Hot Standby =>

Press <ENTER> to confirm Start =>

Press <ENTER> to confirm Stop =>

Press <ENTER> to confirm Init =>

Hot Standby

State: State

Hot Standby

Mode: Mode

Hot Standby

Order: OOOOOO

Hot Standby

Transfer =>

Hot Standby

Diag: =>

Press <ENTER> to confirm Transfer =>

Hot Standby diag: halt

Hot Standby diag: rio fails

Hot Standby diag: hsby fails

Hot Standby diag: stop

Hot Standby diag: off keypad

Hot Standby diag: off %sw60

Hot Standby diag: takeover

Hot Standby diag: run

Hot Standby diag: plug&run

Hot Standby diag: power up

30

Overview Modicon Quantum Hot Standby with Unity

Submenu: PLC Operations: Start, Stop, Init

Start, Stop,

Init Screens

Display

Start PLC

Stop PLC

Init PLC

Fields Available Description

Press <ENTER> to confirm Start Pressing <ENTER> starts the controller

Press <ENTER> to confirm Stop Pressing <ENTER> stops the controller

Press <ENTER> to confirm Init Pressing <ENTER> initializes the controller

Submenu: PLC Operations: Hot Standby

Hot Standby

Screen

Displays

Hot Standby

State:

Hot Standby

Mode:

Hot Standby

Order:

Fields

Available

State

(read only)

Mode modifiable only if z key switch is in the unlocked z position

Invalidate

Keypad is not selected

OOOOOO

(read only)

Options Available Description

PRIMARY

STANDBY

Off Line

RUN

Controller serves as Primary

Controller serves as Standby

Controller is offline steady Controller is active and is either serving as the Primary or is capable of taking over the Primary role if needed blinking Controller is waiting for configuration

A

B

OFFLINE steady z Controller is taken out of service without stopping it or disconnecting it from power z If the controller is the Primary when the Mode state is changed to OFFLINE, control switches to the Standby z z

If the Standby is taken OFFLINE, the Primary continues to operate without a backup

OFFLINE mode does not manage the Remot I/O (RIO). (Only

Primary state manageds the RIO) blinking Controller is waiting for configuration

Hot Standby Power Order

The order comes from the MAC address. The controller with the lowest MAC address is A.

31

Overview Modicon Quantum Hot Standby with Unity

Hot Standby

Screen

Displays

Hot Standby

Transfer:

Hot Standby

Diag

Fields

Available

Mode modifiable only if z z

Options Available Description key switch is in the unlocked position

Invalidate Keypad is not selected

Order of diagnostic screens varies with the operation; therefore your order may be different from the list here.

Halt

RIO fails

HSBY fails

Stop

Off keypad

Off %sw60

Take over

Run

Plug & Run

Power up

Pressing the <ENTER> key confirms the Transfer. The transfer initiates the request for an application program update from the Primary controller.

Pressing any other key cancels the

Transfer request and returns the Hot

Standby Transfer menu option screen to the display.

User’s task in halt mode

Error reported by RIO head

Error reported by optical link

Stop command ordered

Offline command entered on keypad

Offline command set in command register

Standby switched to Primary mode

Run command ordered

Standby plugged and started

User powered up controller

32

Overview Modicon Quantum Hot Standby with Unity

Using the

Communications

Menus and

Submenus

Structure: Communications menu and submenus structure

Quantum

PLC Communications =>

Communications

TCP/IP Ethernet =>

Communications

Modbus Plus =>

Communications

Serial Port =>

TCP/IP Ethernet

IP Address =>

TCP/IP Ethernet

Subnet Mask =>

TCP/IP Ethernet

IP Gateway =>

TCP/IP Ethernet

MAC Address =>

MB+ Address: ##

Modbus Plus State

Mode Protocol: Adr

Rate,Par,DB,SB

=>

IP Address:

###.###.###.###

Subnet Mask:

###.###.###.###

IP Gateway:

###.###.###.###

MAC Address:

##.##.##.##.##.##

Serial Port

RS-Mode: RS-232

Serial Port

Protocol: Modbus

Serial Port

Unit Address: 1

Serial Port

Baudrate: 9600

Serial Port

Parity: Even

Serial Port

Databits: RTU - 8

Serial Port

RS-Mode: RS-232

Serial Port

Stopbits: 1

33

Overview Modicon Quantum Hot Standby with Unity

Submenu: PLC Communications: TCP/IP Ethernet

TCP/IP Ethernet

Screen Displays

TCP/IP Ethernet

IP Address 1,2

TCP/IP Ethernet

Subnet Mask

1

TCP/IP Ethernet

IP Gateway

1

TCP/IP Ethernet

MAC Address

Fields Available

###.###.###.###

(not modifiable)

###.###.###.###

(not modifiable)

###.###.###.###

(not modifiable)

##.##.##.##.##.##

(read only)

Options Available decimal numbers

Description displays IP address decimal numbers decimal numbers displays Subnet

Mask address displays Ethernet IP

Gateway address hexadecimal numbers displays MAC

(Medium Access

Control) address

Submenu: PLC Communications: Modbus Plus

Modbus Plus

Screen Displays

Modbus Plus

Address

Fields Available

##

(modifiable only if the key switch is in the unlocked position)

Modbus Plus State

Options Available

1-64

Monitor Link

Normal Link

Sole Station

Duplicate address

No Token

Description to enter a valid

Modbus Plus address

Modbus Plus State

34

Overview Modicon Quantum Hot Standby with Unity

Submenu: PLC Communications: Serial Port

Seriial Port

Screen Displays

Serial Port

Fields Available* Options Available Description

Mode

Protocol

Adr

232

485

ASCII

RTU

1 - 247 for Modbus switchover

Primary 1-119

Standby 129 - 247

RS mode

Protocols available

Unit address

Rate

Par

50, 75, 110, 134.5, 150,

300, 600, 1200, 1800,

2400, 3600. 4800, 7200,

9600, 19200 bits/s

NONE

ODD

Baud rate

Parity

DB

EVEN

7,8 Databits: if Protocol is Modbus then RTU-8 or ASCII-7

SB 1,2 Stopbits

* If the key switch is in the unlocked position, all fields are modifiable.

35

Overview Modicon Quantum Hot Standby with Unity

Using the

System Info

Menus and

Submenus

Structure: System Info menus and submenus

Quantum

System Info =>

System Info

Stop Code =>

System Info

Firmware Info =>

System Info

Hardware Info =>

Stop Code: ####

Description

OS Ldr Rev: ##.##

Exec Rev: ##.##

HW Rev: Rev

SN: ########

Submenu: PLC Communications: System Info

System Info

Screen Displays

Stop Code

Firmware Info

Hardware Info

Fields

Available*

Option

Available

Description

####

Description

##.##

##.##

Rev shows the machine stop code shows the description to the machine stop code shows the number of OS Loader Revision shows the number of Exec Revision

########

* All fields are read only.

shows the number of Hardware Revision shows the serial number of Hardware

36

Using the LCD

Settings Menus and Submenus

Overview Modicon Quantum Hot Standby with Unity

Structure: LCD Settings menus and submenus

Quantum

LCD Settings =>

LCD Settings

LCD Contrast:

LCD Settings

LCD Light:

### time

0% is black

100% is green

On

Off

1 Min

5 Min

10 Min

15 Min

Submenu: LCD Settings: LCD Contrast

LCD Screen

Contrast Screen

Displays

LCD Contrast:

Fields

Available

####

Description

A lower percent is darker. A higher percent is brighter.

z z

Use the arrow keys to adjust the setting.

Up arrow increases percent

Down arrow decreases percent

Submenu: LCD Settings: LCD Light

Screen Displays Fields Available Description

LCD Light: On

Off

LCD light remains on permanently or until changed

LCD light remains off permanently or until changed

1 Min

5 Min

10 Min

LCD light remains on for one minute

LCD light remains on for five minutes

LCD light remains on for ten minutes

15 Min LCD light remains on for fifteen minutes

37

Overview Modicon Quantum Hot Standby with Unity

38

Modicon Quantum Hot Standby with Unity Compatibility,

Differences, and Restrictions

2

Introduction

Overview

What's in this

Chapter?

In this chapter you will find an overview of compatibilities within a system that has already been installed, differences from Legacy Hot Standby systems, and restrictions for the Modicon Quantum Hot Standby with Unity system.

This chapter contains the following topics:

Topic

Compatibility with Installed Systems

Understanding System Words and System Bits

Understanding Multitasking Restrictions

Local I/O and Distributed I/O Restrictions

Understanding Other Module Restrictions

Understanding USB Link Restrictions

Understanding Application Restrictions

Page

40

41

42

43

44

45

46

39

Compatibility, Differences, Restrictions

Compatibility with Installed Systems

Modicon

Quantum Legacy

Systems

If you install a Unity Pro executive, you have to replace the Legacy CPU (16 and 32 bit) and the CHS option module with a Modicon Quantum Hot Standby with Unity

140 CPU 671 60. Otherwise, Modicon Quantum Hot Standby with Unity will not be available.

Note: EXISTING FIBER CONNECTIONS

Fiber connections used on the CHS module will NOT work with the Modicon

Quantum Hot Standby with Unity 140 CPU 671 60.

Note: CHANGING FROM LEGACY

To install a Modicon Quantum Hot Standby with Unity 140 CPU 671 60 controller in the backplane requires two sequential slots.

Legacy systems required two slots in the backplane, but the two slots did not need to be sequential.

Copro and

Remote I/O Head

Instead of a Modicon Quantum Hot Standby Option Module (140 CHS 110 00), an embedded coprocessor (Copro) provides a dedicated communications link transferring data between the Primary and Standby controllers. This dedicated link cannot be used for any other communications.

S908 Remote I/O Head Option Modules (140 CRP 93 x00) are required in the system for communicating with the remote I/O drops and exchanging status between the Primary and Standby controllers.

40

Compatibility, Differences, Restrictions

Understanding System Words and System Bits

Overview

System Word

%SW60

In conforming with IEC standards, Unity uses global objects called system bits and system words. Users of legacy Schneider Electric products may be familiar with registers (984LL notation). Regardless of notation, the behavior remains the same.

System Word %SW60 can be used to read from and to write to the Modicon

Quantum Hot Standby with Unity Command Register.

Note: %SW60 is described using the IEC convention.

System Word

%SW61

System Word

%SW62 and

%SW63

System Word %SW61 can be used to read the contents of the Modicon Quantum

Hot Standby with Unity Status Register.

Note: %SW61 is described using the IEC convention.

System Words %SW62 and %SW63 are reverse registers reserved for the Reverse

Transfer process. Both reverse registers can be written to the application program

(first section) of the Standby controller and are transferred at each scan to the

Primary controller.

41

Compatibility, Differences, Restrictions

Understanding Multitasking Restrictions

General

MAST

Asynchronous

Events

In a Modicon Quantum Hot Standby with Unity system, the Standby controller is kept ready to assume the role of the Primary controller by having the same application loaded (in the Standby) and by receiving from the Primary—once per scan—a copy of the Primary's data. During the scan, there is a tight synchronization between the

Primary and Standby.

Schneider Electric recommends using only MAST to transfer data during a scan.

Tasks are handled singly and sequentially. Using MAST is consistent with current

Modicon Quantum Hot Standby systems because multi-tasking is not provided, and data transfer will be synchronized with MAST.

Using a Modicon Quantum Hot Standby with Unity system in a multitasking environment may cause data to change between scans. Because in a multi-tasking system, events may occur asynchronously to the normal scan. Those events may happen at a faster rate, the same rate, or at a slower rate. The result is that data modified by these events can be changed during a transfer.

FAST and AUX

Note: FAST and AUX can be used.

Ensure that you both analyze your system needs and account for problems that may arise if you use FAST or AUX.

42

Compatibility, Differences, Restrictions

Local I/O and Distributed I/O Restrictions

General Note the two following restrictions: z Although local I/O and distributed I/O (DIO) can be used in a Modicon Quantum

Hot Standby with Unity system, they are not considered as part of the redundant system.

z When either local I/O and/or distributed I/O (DIO) are used in a Hot Standby system, each controller in the configured Hot Standby system controls ONLY its own local I/O and/or DIO respectively.

43

Compatibility, Differences, Restrictions

Understanding Other Module Restrictions

General The Modicon Quantum Hot Standby with Unity, V2.0 does not support the following modules.

Model

140 NOE 771 00

140 NOE 771 10

140 NOE 311 00

140 NOE 351 00

140 CHS 110 00

140 NOA 611 10

140 NOA 622 00

140 NOL 911 10

140 CRP 811 00

140 HLI 340 00

Support Provided

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

Module NOT supported in Unity V2.0

44

Compatibility, Differences, Restrictions

Understanding USB Link Restrictions

No Hot Standby

Switchover through the USB

Link

USB link switchover is not available in a Modicon Quantum Hot Standby with Unity system because the USB link is connected to only one CPU, allowing Unity Pro to communicate only to this local controller.

Therefore, USB cannot be used for transparent access to the Primary controller.

45

Compatibility, Differences, Restrictions

Understanding Application Restrictions

Timer Events and

I/O Errors

Timer events are NOT synchronized in Modicon Quantum Hot Standby with Unity applications. Schneider Electric recommends not using timer events.

Note: NOT EXCHANGING I/O ERRORS

If timer events are used, I/O errors are not exchanged between Primary and

Standby.

46

Using IEC Logic and Modicon

Quantum Hot Standby with Unity

3

Introduction

Overview

What's in this

Chapter?

This chapter provides information about using IEC Logic with a Modicon Quantum

Hot Standby with Unity system.

This chapter contains the following topics:

Topic

Modicon Quantum Hot Standby with Unity and IEC Logic

Understanding the Modicon Quantum Hot Standby with Unity State RAM

Transfer Process

Understanding System Scan Time in Modicon Quantum Hot Standby with

Unity Systems

Transferring Application Data in a Modicon Quantum Hot Standby with Unity

System

Page

48

49

50

54

47

IEC Logic

Modicon Quantum Hot Standby with Unity and IEC Logic

Overview

Data Transfer and User Data

A Modicon Quantum Hot Standby with Unity system requires two backplanes configured with identical hardware, software, and firmware. One of the controllers

(PLC) functions as the Primary controller and the other as a Standby controller.

z The Primary updates the Standby after every scan.

z The Primary and Standby communicate constantly monitoring the health of the system.

z If the Primary fails, the Standby takes control within one scan.

In a Modicon Quantum Hot Standby with Unity system, data is transferred from

Primary to Standby after every scan.

The following data transfers after every scan: z Located Variables (State RAM 128 Kb) z z all Unlocated variables up to 512 Kb

All instances of the DFB and EFB type z z

SFC variable area

System Bits and Words

Note: Forced Bits at Transfer

At each scan, all forced bits are transferred from the Primary to the Standby.

State RAM

Definition

State RAM is the memory range, which is used for z z word-orientated input and output components (for example, analog modules) bit oriented input and output components (for example, digital modules) z binary and word variables for the application program

State RAM is assigned the four reference types: %IW, %QW, %I and %Q.

48

Understanding the Modicon Quantum Hot Standby with Unity State RAM

Transfer Process

IEC Logic

Hot Standby

Transfer

Diagram

The following illustrates the transfer of data from the Primary to the Standby Copro:

Scan n

Primary PLC

CPU

Copro

IEC Logic Solve Comm Diag IEC Logic Solve

User Data

State RAM: Located + Unlocated Data

(max. 128 + max. 512 kByte)

640K bytes

640K bytes

Comm Diag IEC Logic Solve Diag

640K bytes

Standby PLC

User Data

State RAM: Located + Unlocated Data

(max. 128 + max. 512 kByte)

Copro

640K bytes

Diag

640K bytes

User Data

State RAM: Located + Unlocated Data

Comm Diag

CPU

640K bytes

Comm Diag

Scan n-1

49

IEC Logic

Understanding System Scan Time in Modicon Quantum Hot Standby with Unity

Systems

Effect on System

Scan Time

The scan time of any Modicon Quantum Hot Standby with Unity system depends on the amount of data transferred.

Because data must be transferred from Primary to Standby, any Modicon Quantum

Hot Standby with Unity system always has a higher scan time than a comparable standalone system.

Note: CHANGING FROM LEGACY

In legacy systems, the CPU performed both z application program (project) processing z communication transfer

In a Modicon Quantum Hot Standby with Unity system, in parallel z z

CPU performs application program processing

Copro performs communication transfer

Result: Greatly reduced transfer time with Unity

50

Performance

Considerations

IEC Logic

A Modicon Quantum Hot Standby with Unity system increases the length of a MAST scan, creating system overhead.

Note: System Overhead

System overhead is the time required to copy the application data to the communication link layer.

The network scan (communication between Primary and Standby copros)

1.

exchanges data between both controllers

2.

runs in parallel with the application program

A Hot Standby system

Input

HSBY

Input

HSBY

5 ms per 100 Kb of Overhead

First

Section

Logic

Data

(Copro)

Data

(Copro)

30 ms per 100 Kb

Output

Primary Standby

Output

Most of time, the MAST scan hides the network scan.

51

IEC Logic

Examples

Standalone scan time: 80 ms

100 KB data to exchange

Input

HSBY

Scan time in a HSBY system: 85 ms

100 KB data exchanged

Result

Primary

5 ms per 100 Kb of overhead

Data

Transfer

30 ms

No impact on scan time data exchange (30 < 80 ms)

Logic

Exec

However, when processing some application programs, additional system overhead may occur.

Example #1 z Standalone application scan time: 80 ms z Data (state RAM + unlocated variables): 100 Kb

Output

Example #2 z

Standalone application scan time: 80 ms z Data (state RAM + unlocated variables): 300 Kb

52

IEC Logic

Standalone scan time: 80 ms

300 KB data to exchange

Input

HSBY

Scan time with HSBY: 105 ms

300 KB data exchanged

Result

Primary

15 ms per 100 Kb of overhead

90 ms

HSBY impact on scan time = 25ms

= 15 ms + (90 - 80 ms)

= 25 ms

Logic

Exec Data

Transfer

Output

53

IEC Logic

Transferring Application Data in a Modicon Quantum Hot Standby with

Unity System

Changing from

Legacy

Modicon

Quantum Hot

Standby with

Unity

Memory

Consumption

Current Modicon Quantum controllers that use the Concept software have an application data transfer limit of approximately 128 Kb. This limit includes located data (in state RAM) and unlocated data. To transfer the unlocated data, the system must use a part of the 3x area in the state RAM. Schneider Electric chose this method to be compatible with the existing CHS option module (140 CHS 110 00).

Thus, a trade-off is necessary: the more unlocated data, the less state RAM and vice versa.

In the Modicon Quantum Hot Standby with Unity 140 CPU 671 60, the CHS option module is no longer used. Both the controller and Hot Standby functions are in the same unit. Thus, there is no need to force unlocated data through the 3x area. Not forcing means that all of the state RAM can be used as state RAM (up to 128 Kb).

In addition to the state RAM, you may have a maximum of 512 Kb of unlocated data.

The amount of data to be transferred is automatically adjusted by the system.

For Information on the size of the memory consumption, select PLC → Memory

Consumption .

54

Setting up and Maintaining a

Modicon Quantum Hot Standby with Unity System

II

At a Glance

Purpose

What's in this

Part?

This part describes three important processes in using a Modicon Quantum Hot

Standby with Unity system.

z setting up, installing, and cabling a Modicon Quantum Hot Standby with Unity system z z configuring a Modicon Quantum Hot Standby with Unity system using the Unity

Pro software maintaining a Modicon Quantum Hot Standby with Unity system once installed

This part contains the following chapters:

Chapter

4

5

6

Chapter Name

Setting up, Installing, and Cabling a Modicon Quantum Hot

Standby with Unity System

Configuring a Modicon Quantum Hot Standby with Unity

System

Maintaining a Modicon Quantum Hot Standby with Unity

System

Page

57

69

119

55

Maintaining Modicon Quantum Hot Standby with Unity

56

Setting up, Installing, and Cabling a Modicon Quantum Hot Standby with Unity System

4

Introduction

Overview

What's in this

Chapter?

This chapter provides an overview of setting up, installing, and cabling a Modicon

Quantum Hot Standby with Unity system.

This chapter contains the following topics:

Topic

Setting Up the Modicon Quantum Hot Standby with Unity System

Mapping the Backplane Extension

Connecting Two Modicon Quantum Hot Standby with Unity HE CPU 671 60s

Connecting the Remote I/O

Testing the Modicon Quantum Hot Standby with Unity System

Page

58

60

62

63

66

57

Installation and Cabling

Setting Up the Modicon Quantum Hot Standby with Unity System

Overview

Mapping the

Backplane

Extensions

Schneider Electric is a leader in offering fault-tolerant, redundant systems, Hot

Standby. Setting up a Modicon Quantum Hot Standby with Unity system involves a number of processes, summarized in the following paragraphs here and explained in detail elsewhere.

A Modicon Quantum Hot Standby with Unity requires two backplanes with at least four slots.

You must map the two backplanes in an identical manner: z same Modicon Quantum Hot Standby with Unity HE CPU with integrated coprocessor (Copro) z z z z same firmware same revision level same Modicon Quantum power supply module same Modicon Quantum RIO Head

And, if other modules are used, for example local I/Os, NOMs, NOEs, those modules must be identical.

Connecting Two

High End CPUs

Connect the two Modicon Quantum Hot Standby with Unity High End CPUs with a fiber optic cable as described in Connecting Two Modicon Quantum Hot Standby

with Unity HE CPU 671 60s, p. 62

.

Establishing the

Primary and

Standby

Controllers

The system determines that one of the two Modicon Quantum Hot Standby with

Unity HE CPUs will be the Primary controller and the second controller as the

Standby.

The Keypad may provide status information. Therefore, to view the status, use the

Modicon Quantum Hot Standby with Unity HE CPU’s keypad by selecting Quantum

PLC Operations => → PLC Operations Hot Standby => → Hot Standby Order .

See Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens, p. 27

.

Connecting the

Remote I/O

Configuring in

Unity Pro

Connect the Modicon Quantum RIO Heads with each other and with the RIO drops as described in

Connecting the Remote I/O, p. 63 .

Using Unity Pro, configure a network that is appropriate for the installed backplanes and the cabling.

Configure the Hot Standby Register for the Modicon Quantum Hot Standby with

Unity HE CPU in Unity Pro as described in

Accessing the Base Configuration, p. 73 .

58

Installation and Cabling

Transferring and

Sending the

Program from

Primary to

Standby

Transfer the program from your PC to High End CPU using the Unity Pro command

PLC → Transfer program to PLC .

See

Overview of Application Program Transfer, p. 160 .

Send your program from the Primary to the Standby using the Primary’s keypad.

Select Quantum PLC Operations => → PLC Operations Hot Standby => → Hot

Standby Transfer => → Press <ENTER> to confirm Transfer => .

See Using the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 LCD

Display Screens, p. 27 .

Note: A program can be sent only from the Primary controller to the Standby controller.

59

Installation and Cabling

Mapping the Backplane Extension

Requiring

Identical

Backplanes

Two backplanes must be configured with identical hardware, software, and firmware in identical order. Then, both controllers may function either as a Primary controller or as a Standby controller.

Note: INSTALLING CONTROLLERS

Schneider Electric recommends referring to Schneider Electric planning and installation guidelines. You will find more information in the Quantum Automation

Series Hardware Reference Guide 840 USE 100 00 and in Remote I/O Cable

System Planning and Installation Guide 840 USE 101 00 .

Noting the

Module Version

The Primary and Standby must belong to the Modicon Quantum Hot Standby with

Unity product family.

The Modicon Quantum RIO drops can be from Schneider Electric’s 800 series of modules.

60

Installation and Cabling

Installing

Components and

Modules

A Modicon Quantum Hot Standby with Unity system requires two backplanes with at least four slots.

The backplanes (1, 2) must be identically equipped with: z Modicon Quantum Hot Standby with Unity 140 CPU 671 60 with integrated z coprocessor (Copro) (3)

Modicon Quantum power supply module (4) z z

Modicon Quantum RIO Head (5)

Other modules for example, Modicon Quantum NOMs, NOEs (6)

Note: The sequence of the modules on the backplane is not predefined, but the sequence of the modules on the backplanes of the Primary and the Standby must be identical. Otherwise, a Modicon Quantum Hot Standby with Unity system does not exist.

The following graphic shows a possible scheme for components and their connectors.

1 2

4 3 5 6 4 3 5 6

A B

7

A B

8A

9 8

1 Primary controller backplane

2 Standby controller backplane

3 Modicon Quantum Hot Standby with Unity 140 CPU 671 60 with integrated coprocessor

(Copro)

4 Modicon Quantum power supply module: Install power supply in first slot for better rack layout.

5 Modicon Quantum RIO head

6 Other modules, for example Modicon Quantum NOMs, NOEs

7 Fiber Optic Cable to connect to both Modicon Quantum Hot Standby with Unity 140 CPU

671 60s.

8 Coaxial cable with splitters (8A) for connecting the RIO heads (5) with the RIO drops in the network. The dashed connection represents a redundant connection in the RIO network, which is not required for the Modicon Quantum Hot Standby with Unity system.

9 Connection to the Unity Pro computer via Modbus or Modbus Plus

61

Installation and Cabling

Connecting Two Modicon Quantum Hot Standby with Unity HE CPU 671 60s

Handling Cable

Connections

If the cable is not connected properly, the Modicon Quantum Hot Standby with Unity

HE CPU 671 60s cannot communicate, and the Hot Standby system will not function. Therefore, the Primary operates without a backup, and the Standby remains offline.

Fiber optic cables are sold separately.

Model

490NOR0003

490NOR0005

490NOR0015

Description

3 m MTRJ/ MTRJ

5 m MTRJ/ MTRJ

15 m MTRJ/ MTRJ

Controllers connected by a crossed fiber optic cable.

COM

STS

COM

STS

Mac Address

00:00:##:##:##:##

Mac Address

00:00:##:##:##:##

Note: REDUCING FAILED COMPONENTS

Hubs and switches are not allowed as part of the fiber optic link.

Therefore, the fiber connection between Primary and Standby must be a direct cable connection, which reduces the components that could fail in the redundant system.

Connecting Two

Backplanes

However, the Primary and Standby backplanes may be placed as much as 2 km apart. If you will be placing the modules more than 15 m apart, use 62.5/125 micrometer cable with MTRJ type connectors. Refer to Modicon Quantum Hot

Standby with Unity Additional Information, p. 183

for details.

62

Installation and Cabling

Connecting the Remote I/O

Connecting

Cables to

Remote I/O

In each configuration: z The cables connecting the RIO head processors to the RIO network have to be z fitted with self-terminating F adapters.

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

The remote drops have to be connected to the trunk cable via an MA-0185-100 z tap and a drop cable.

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

An optional 60-0545-000 Ground Block at the head will provide earth ground connection when the cable and RIO processor are disconnected. Ground blocks may also be used at other ground points along the trunk cable, as required.

Refer to the Remote I/O Cable System Planning and Installation Guide, 890 USE

101 00 for details.

Note: CABLING REQUIREMENTS z If you are using a Modicon Quantum Hot Standby with Unity system for data logging, the RIO heads have to be configured and connected with coaxial cable, and you have to configure one (1) or more RIO drops.

63

Installation and Cabling

The following diagram shows the hardware required for the Remote I/O cabling.

1 2

3 3

A B A B

6

5

7

4

8

4

9

1 Primary controller

2 Standby controller

3 Modicon Quantum RIO head

4 Modicon Quantum RIO drop

5 Coaxial cable (components shown with dashed lines are not mandatory)

6 Self-terminating F adapter

7 Splitter (MA-0186-100)

8 Tap (MA-0185-100)

9 Trunk Terminator (52-0422-000)

64

Installation and Cabling

Connecting over

Long Distances

If you intend to place the units more than 3 meters apart, you have to 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 the Remote I/O Cable System Planning and Installation Guide, 890 USE

101 00 for details regarding cable grades, distances, and signal integrity.

If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network, fiber optic repeaters may be used to boost the signal.

Refer to the Modbus Plus Network Planning and Installation Guide, UNY USE 10410

V10E for details on extending a Modbus Plus network.

65

Installation and Cabling

Testing the Modicon Quantum Hot Standby with Unity System

Testing Methods

(First Time)

Follow these steps to conduct tests to observe z Hot Standby start-up z z automatic Application Program Transfer switchover of control from Primary to Standby

These tests are not necessary but helpful. If your backplanes are horizontally parallel and within 1 meter (3 feet) apart, the transfer process is easier to observe.

Hot Standby

Start-up and

Application

Program

Transfer

Follow these steps.

Step

1

2

3

4

5

6

7

8

Action

Configure two backplanes with identical hardware and firmware in identical order.

Connect to a Remote I/O (RIO) drop. Establishing the Primary and Standby

Controllers, p. 58

Note: Ensure that the fiber optic cable is connected between the controllers.

Start Unity Pro software and configure the local rack and the Remote I/O drop as per your physical configuration.

After completing Step 3, execute the Build Project command, and save your application program.

Power up and connect to one controller.

Note: The front panel keypad will display No Conf .

Download your application program and RUN the controller.

Note: The controller will become RUN Primary.

Power up the other controller.

Note: Application Program Transfer will occur automatically. The "other" controller will become RUN Standby.

Ensure the Primary and Standby controllers are in RUN Primary and RUN

Standby mode.

66

Preparing to

Switchover

Installation and Cabling

After completing the preceding steps, your Modicon Quantum Hot Standby with

Unity system is ready to perform a switchover. Perform the switchover using either: z z

Hot Standby submenu on the front panel keypad

Command Register, system bit %SW60.1 or %SW60.2

Note: Observing the Switchover

If you would like to observe a switchover effect on the I/O modules, configure the

Remote I/O (RIO) drop with a discrete output module during your initial start-up.

Before performing a switchover, connect to the Primary and force the output bits in the module. Perform the switchover and take note of the bumpless switchover effect on the forced bits.

Switchover Test

Using Front

Panel Keypad

To force a switchover using the front panel keypad, do the following:

Step

1

2

3

4

5

6

Action

Access the front panel keypad of the Primary controller.

Go to PLC Operation menu.

Go to Hot Standby submenu.

Go to Hot Standby mode

Modify Run to Offline.

Note: Ensure that Standby switched to Primary.

Modify offline to run.

Note: Ensure that the LCD displays Run Standby .

67

Installation and Cabling

Switchover Test

Using Command

Register

Follow these steps.

Step

1

2

3

4

5

6

7

8

Action

Connect to the Primary.

Observe whether the controller order on the Primary is A or B.

Note: Observe using either of the following methods: z Front panel keypad of the Primary

PLC Operation | Hot Standby | Hot Standby Order z Unity Pro status dialog

Refer to the bottom of the Unity Pro window when connected online

Access the Command Register system bit z %SW60.1

(If the connected Primary order is A.) z %SW60.2

(If the connected Primary order is B.)

Set bit to 0.

Note: Ensure that the Standby switched to Primary

Connect to the new Primary.

Access the Command Register system bit. Choose the same bit selected in Step

3.

Set bit to 1.

Note: Ensure Standby displays RUN Standby.

Ensure the Primary and Standby controllers are in RUN Primary and RUN

Standby mode.

68

Configuring a Modicon Quantum

Hot Standby with Unity System

5

Introduction

Overview

What's in this

Chapter?

This chapter describes configuring the Modicon Quantum Hot Standby with Unity

140 CPU 671 60 module.

This chapter contains the following sections:

Section

5.1

5.2

5.3

Topic

Configuring a System with the Unity Pro Tabs and Dialogs

Configuring a NOE with Unity Pro

Configuring Registers with Unity Pro

Page

70

95

108

69

Configuring a Modicon Quantum Hot Standby with Unity System

5.1

Configuring a System with the Unity Pro Tabs and

Dialogs

At a Glance

Purpose

What's in this

Section?

Use the Unity Pro editor dialog tabs to

1.

select options for configuring the Modicon Quantum Hot Standby with Unity 140

CPU 671 60

2.

obtain system status information

This material describes how you can z z z

Accessing the Base Configuration, p. 73 , including Modbus Ports and HSBY

Configuring with Unity Pro, p. 86

Configuring with Unity Pro, p. 87

This section contains the following topics:

Topic

Introducing Unity Pro

Accessing the Base Configuration

Using the Summary Tab

Using the Overview Tab

Using the Configuration Tab

Using the Modbus Port Tab

Using the Animation Tab and PLC Screen Dialogs

Using the Hot Standby Tab

Configuring the PCMCIA Cards

Configuring the Modbus Plus Communication Type

Setting the Invalidate Keypad Option

Swapping Network Addresses at Switchover

Page

71

73

74

75

76

79

81

85

86

87

88

90

70

Configuring a Modicon Quantum Hot Standby with Unity System

Introducing Unity Pro

Overview Unity Pro software is a fully Windows compatible application. Unity Pro supports only the IEC method of configuration with some simplifications: z Removes the legacy requirement to reserve the 3xxxx area for transferring unlocated variables z

(Unlocated variables are transferred with the State RAM).

Uses system words for the command and status registers, which are removed from the State Ram.

No Loadables

Needed

Command

Register

Changes from

Concept

Note: CHANGING FROM LEGACY

The current Modicon Quantum Hot Standby loadable (CHS) is no longer needed.

For Unity Pro Modicon Quantum Hot Standby with Unity systems, the control functionality will be embedded in the executive.

For legacy Modicon Quantum Hot Standby systems (Modsoft, Concept, or

ProWORX), the CHS module owns the control functionality.

The Command Register defines the basic operational parameters of a Modicon

Quantum Hot Standby with Unity solution. The command register’s functionality is described in

Understanding the Unity Command Register, p. 110 .

z z z z z

Command and Status Registers are no longer stored in the State RAM.

Command and Status Registers are accessible in the system words %SW60 and

%SW61.

Reverse Transfer registers are no longer stored in the State RAM.

System automatically allocates system words %SW62 and %SW63 as Reverse

Transfer words.

Reverse Transfer words are no longer part of the Non-Transfer Area of the 4xxxx registers.

71

Configuring a Modicon Quantum Hot Standby with Unity System

Changes from

LL984 z z

Note: CHANGING FROM LEGACY

There is no longer a Non-Transfer Area for the 0xxx, 1xxx, and 3xxx registers.

Transferring over multiple scans is no longer available.

In current Modicon Quantum Hot Standby Systems using the CHS option module, additional state RAM could be transferred over multiple scans. Not transferring over multiple scans minimizes the impact of state RAM transfers.

In the Unity Pro Modicon Quantum Hot Standby with Unity 140 CPU 671 60, transfer speeds will be much faster, and the amount of state RAM used for transfers will be smaller since unlocated data will be used instead.

Opening the

Editor Dialog

After starting Unity Pro, go to the Local Bus in the Structural View of the Project

Browser.,

Step Action

1 Open the Local configuration editor either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open

A graphical representation of the local bus appears in the configuration editor.

2 Select the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 module and right-click.

The context menu appears.

3 Select Open Module.

4 The editor appears. The Summary tab is the default.

Unity Pro Hot

Standby Editor

Dialog

The editor with the Hot Standby tab selected

NA

CPU

1.2 : 140 CPU 671 60

P266 CPU Hot-Standby, 1Mb Program + PCMCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

Sum...

Confi...

M

B Modb...

Anima...

Hot St...

Run Mode

Controller A

Controller B

Online

Online

Standby On Logic Mismatch

Offline

Online

State RAM

Non-Transfer Area

Start: %MW 0

Invalidate Keypad

Yes

Swap Address At Switchover

Modbus Port 1

Modbus Port 2

Modbus Port 3

Length: 0

I/O objects

72

Configuring a Modicon Quantum Hot Standby with Unity System

Accessing the Base Configuration

Accessing with

Unity Pro

After starting Unity Pro, go to the Local Bus in the Structural View of the Project

Browser.

Step Action

1 Open the Local Bus configuration editor either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open.

A graphical representation of the local bus appears in the configuration editor.

2 Select the Modicon Quantum Hot Standby with Unity HE CPU module and right-click.

The context menu appears.

Bus:

Local Bus

1 140 CPU 671 60 01.00

1

CPS

111

00

2

CPU

671

60

CPU

671

60

ACI

030

00

4 5 6 7 8 9 10

1

Cut

Copy

Paste

Delete Module

Open Module

Move Module

Replace Processor...

Power Supply and IO Budget...

3 Select Open Module.

The editor appears. The Summary tab is default.

4 Choose one of these tabs: z z

Summary (See

Using the Summary Tab, p. 74 )

Overview (See

Using the Overview Tab, p. 75 )

z Configuration (See

Using the Configuration Tab, p. 76 )

Modbus Port (See

Using the Modbus Port Tab, p. 79 )

z z z

Animation (See

Using the Animation Tab and PLC Screen Dialogs, p. 81

Hot Standby (See

Using the Hot Standby Tab, p. 85

)

)

73

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Summary Tab

Viewing Use the Summary tab of the Unity Pro editor to determine if Peer Cop and Hot

Standby are enabled.

NA

CPU

1.2 : 140 CPU 671 60

P266 CPU Hot-Standby, 1 Mb Program + PCNCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

Sum...

Confi...

M

B Modb...

Anima...

Hot St...

I/O objects

CPU Name/Model

Peer Cop:

Hot Standby:

Quantum CPU

Enabled

Enabled

Describing Summary tab:

Item Option Value Description

CPU Name/Model: Quantum CPU N/A

Peer Cop: Disabled

Read Only

Enabled Read Only

Peer Cop="Enabled" if the function is valid in the Modbus Plus menu

Hot Standby: Enabled Enabled Read Only

74

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Overview Tab

Viewing The read only Overview tab of the editor displays detailed information about the module’s specifications.

NA

CPU

1.2 : 140 CPU 671 60

P266 CPU Hot-Standby, 1 Mb Program + PCMCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

CPU

671

60

ACI

030

00

Sum...

Confi...

M

B Modb...

Anima...

Hot St...

P266 CPU MB MB+ USB ETHERNET HSBY 1024K IEC AND PCMCIA

SPECIFICATIONS

Model

Description

General Specifications

Communications ports

I/O objects

140-CPU-671-60

P266 CPU MB MB

Bus Current required

Max. number of NOM, NOK, CRP 811 and

MMS modules supported (any combination)

Key switch

Processor

-

1 Modbus (RS-232

1 Modbus Plus (R

1 USB

1 Ethernet (used

6

Yes

75

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Configuration Tab

Viewing Change values using the Configuration tab of the editor.

NA

CPU

1.2 : 140 CPU 671 60

P226 CPU Hot-Standby, 1 Mb Program + PCMCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

Sum...

Operating Mode On Cold Start

Automatic start in Run

%MWi Reset

Confi...

M

B Modb...

Memory Card

A: TSX MCP C 002M

Usage: Data Storage

Size

Application Size

1,024

2,048

B: TSX MRP F 008M

Usage: Data Storage

Size 8,192

KBytes

KBytes

KBytes

Anima...

State RAM

Mem usage

Hot St...

%M

%I

0x

256

1x

256

I/O objects

4%

%MW

%IW

4x

1024

3x

1024

Viewer

76

Describing

Configuring a Modicon Quantum Hot Standby with Unity System

Configuration tab:

Item

Operating Mode

On Cold Start

Memory Cards

State RAM

Option

Automatic start in Run

Value Description x

%MWi Reset on cold start x

Determines the operating condition during Cold Start

A:

B:

N/A

N/A

Displays the configuration in the

PCMCIA Slots

Mem usage

%M-0x

%MW-4x

%I-1x

%IW-3x

1.

2.

2.

2.

2.

A bar displays percent of memory used.

Size of the different memory areas

Note: The values for %IW and %MW have to be divisible by 8.

Viewer N/A Opens the State RAM Viewer tab, which displays the allocation of used memory. (See the illustration following.)

1. The value (expressed as a percentage and displayed on the scale) depends on the memory usage of the Hot Standby configuration.

2. Enter the appropriate values. All values depend on Hot Standby configuration.

77

Configuring a Modicon Quantum Hot Standby with Unity System

Using the State

RAM Viewer

The State RAM Viewer dialog

State Ram Viewer

1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1

0

100

200

300

400

500

600

700

800

900

1000

1100

Legend

Modules

Language

Variables

Modules Variables

Address Information

Address %M 0

Module Address

Language

Go To

Memory Area

%M (0x) %I (1x) %IW (3x) %MW (4x)

78

Each cell in the grid represents an address location and displays the entity stored in that location. The contents of the grid may be changed by selecting options in either of two filters:

1.

Memory used grid options

Select one—or all—of the three options (using the check box) and one to three bar graphs appear.

z

Modules

Indicates the topological address used in the modules. Address appears as a z bar graph in the grid.

Language

Indicates the topological address used in the program. Address appears as a bar graph in the grid.

z

Variables

Indicates the topological address used in the variables. Address appears as a bar graph.

2.

Memory Area options

Using this option, you designate a state RAM address. Select one of four reference types.

z z z z

%M

%I

%IW

%MW

Your choice appears in the Address field of the Address Information area.

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Modbus Port Tab

Viewing You may change Modbus communication options using the Modbus Port tab of the

Unity Pro editor:

NA

CPU

1.2 : 140 CPU 671 60

P266 CPU Hot-Standby, 1Mb Program + PCMCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

Sum...

Confi...

M

B Modb...

Anima...

Hot St...

Bridge Mode

I/O objects

Modbus Port

Baud

1

2

3

9600

9600

9600

Data

Bits

Stop Bits

8 1

Parity

Even

Delay (ms) Address Head Slot

10 1

Mode

0 RTU

8 1

8 1

Even

Even

10

10

1

1

0 RTU

0 RTU

Protocol

RS232

RS232

RS232

Note: FINDING MODBUS ADDRESS

If you need the Modbus address of the controller, go to the 140 CPU 671 60 module and find the address using the keypad. (See Understanding the Default Screen,

p. 29 )

79

Configuring a Modicon Quantum Hot Standby with Unity System

Describing Modbus Port tab:

Item Option

Modbus Port Baud

Data Bits

Stop Bits

Parity

Delay (ms)

Address

Head Slot

Mode

Protocol

Value

9600

50-19200 kBit/s

8

1 or 2

EVEN

ODD

NONE

1 ms

1 -247 for Modbus switchover

1 - 119 (Primary)

129 - 247 (Standby)

0

RTU

ASCII

RS232

RS485

Description

Data must be specified for every link.

80

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Animation Tab and PLC Screen Dialogs

Accessing the

PLC Screen

Dialogs

To access the Task, Realtime clock, and Information tabs of the Unity Pro Animation tab,

Step

1

2

Action

Select the Animation tab.

The PLC screen tab appears automatically.

Note: The dialogs illustrated here are depicted in offline mode. When Unity Pro is connected to a PLC, the information displayed in these tabs changes.

Viewing the Task

Tab

Unity Pro Task tab dialog:

PLC Screen

Task

Events

Activate or

Disable all

State:

Number:

Last Stop

Realtime clock

Start/reStart

Warm restart

Cold start i Information

Output Fallback

Applied Outputs

Output Fallback

81

Configuring a Modicon Quantum Hot Standby with Unity System

Describing the

Task Tab

Description of the Task tab:

Item

Events

Option

State:

Value xxx

Start/reStart

Number: xxx

Activate or Disable all Click button

Warm Start

Cold Start

Click button

Click button

Output fallback Applied Outputs

Output Fallback

Last Stop Read only z z z

N/A

N/A

Day

DD/MM/YY

Time

Description

Status information of events available Online

N/A

Button to control the events

To initialize Warm Start

To initialize Cold Start

Not used in Modicon Quantum

Hot Standby with Unity system

Indicates the day, date, time, and cause of the last controller stop

Viewing the

Realtime Clock

Tab

Unity Pro Realtime clock tab dialog: i PLCScreen

Task

PLC Date and Time

Tuesday, 01. January 2002

12:00:00 AM

PC Date and Time

Thursday, 25. September 2003

2:38:05 PM

1 2

Update :

PC -> PLC

Error PLC Data

Realtime clock

User Date and Time

September, 2003

Sun Mon Tue Wed Thu Fri Sat

31 1 2 3 4 5 6

7 8 9 10 11 12 13

14 15 16 17 18 19 20

21 22 23 24 25 26 27

28 29 30 1

5 6 7 8

2

9

3 4

10 11

Today: 9/25/2003 i Information

Date:

25/09/2203

Time:

2:36:42 AM

Update :

User -> PLC

82

Describing the

Realtime Clock

Tab

Configuring a Modicon Quantum Hot Standby with Unity System

Description of the Realtime clock tab:

Item

PLC Date and Time

Option

Read only

Description

Indicates the current PLC date and time

PC Date and Time Update PC->PLC Updates the PLC with the PC system time

User Date and Time Update User->PLC Updates the PLC with the time set by the user

Viewing the

Information Tab

Unity Pro Information tab dialog:

P L

C S

PLC Screen

Task

SYSTEM INFORMATION

PLC

IDENTIFICATION

MEMORY

APPLICATION

IDENTIFICATION

OPTION

HOTSTANDBY

Realtime clock i Information

83

Configuring a Modicon Quantum Hot Standby with Unity System

Describing the

Information Tab

Description of the Information tab:

Item

System

Information

Option

PLC / Identification

Value

PLC Range

Hardware ID

Processor Name

Processor Version

Network address

PLC / Memory

Application / Identification

Application / Option

Hot Standby

Name

Creation Product

Date

Modification Product

Date

Version

Signature

Empty Terminal Support

Upload Information

Comments

Animation Table

Global Protection

Section Protection

Application Diagnostic

Forced Bits

Bit Number

Status Register

PLC Mode

Other PLC Mode

PLCs matching Logic

PLC switch

Copro Health

Hot Standby Capability

Description

Only Online available

84

Configuring a Modicon Quantum Hot Standby with Unity System

Using the Hot Standby Tab

Viewing the Hot

Standby Tab

Configure Hot Standby values in the Hot Standby tab of the Unity Pro editor:

NA

CPU

1.2 : 140 CPU 671 60

P266 CPU Hot-Standby, 1Mb Program + PCMCIA, Ethernet-HSBY Fiber optic, USB, MB, MB+

Over...

Sum...

Run Mode

Controller A

Controller B

Online

Online

Standby On Logic Mismatch

Offline

Online

State RAM

Non-Transfer Area

Start: %M 1

Confi...

M

B Modb...

Anima...

Invalidate Keypad

Yes

Length: 0

Hot St...

Swap Address At Switchover

Modbus Port 1

Modbus Port 2

Modbus Port 3

I/O objects

Describing the

Hot Standby Tab

Description of the Hot Standby tab:

Item

Run Mode

Invalidate Keypad

Option

Controller A

Controller B

Disable

Enable

Value

Offline/Online

Offline/Online

Yes is NOT selected

Yes is selected

(Check mark displays)

Description

Indicates which controller is offline and which controller is online

When selected, you prevent keypad changes to the Hot

Standby submenu.

Standby On Logic

Mismatch

Swap Address At

Switchover

State RAM: Non-

Transfer Area

Offline

Online -

Default

Offline button selected

Modbus Port 1 x

Start: %MW

Length:

1.

1.

If mismatch is detected,

Standby goes Offline

If button is selected and mismatch is detected, Standby remains Standby

When selected, enables

Modbus switchover to occur.

%MW is not transferred.

Specify the range of the length.

1. Enter the appropriate values. All values depend on Hot Standby configuration.

85

Configuring a Modicon Quantum Hot Standby with Unity System

Configuring the PCMCIA Cards

Configuring with

Unity Pro

Allocating memory to the memory card

Step Action

1 If not opened, open the Local Bus configuration editor.

2 Go to the local bus in the Structural View of the Project Browser.

3 Open the local bus either by double-clicking on the Local Bus or by selecting the

Local Bus and executing right-click Open.

A graphical representation of the local bus appears.

4 Point to and select either PC CardA (1 slot) or PC CardB (2 slot).

1

CPS

111

00

2

CPU

671

60

CPU

671

60

ACI

030

00

4 5 6 7 8 9 10 11 12 13 14

1

2

1 Memory configuration of the PCMCIA card 1

2 Memory configuration of the PCMCIA card 2

5 Double-click or right-click either PCMCIA card.

The New/Replace Submodule dialog appears.

New/Replace Submodule

PartNumber

ATA FLASH DISK

TSX MDP F 032M

FLASH EPROM

SRAM

TSX MRP F 0128P

TSX MRP F 0256P

TSX MRP C 001M

TSX MRP C 002M

TSX MRP C 003M

TSX MRP C 007M

TSX MRP C 768K

SRAM Data or Files

TSX MRP F 002M

TSX MRP F 004M

TSX MRP F 008M

Description

ATA FLASH DISK

ATA PCMCIA, Files 32768kb

FLASH EPROM

SRAM

SRAM PCMCIA, Prog 192kb

SRAM PCMCIA, Prog 384kb

SRAM PCMCIA, Prog 1024kb, Data 1600kb

SRAM PCMCIA, Prog 2048kb, Data 1856kb

SRAM PCMCIA, Prog 3072kb, Data 2880kb

SRAM PCMCIA, Prog 7168kb, Data 6976kb

SRAM PCMCIA, Prog 768kb, Data 576kb

SRAM Data or Files

SRAM PCMCIA, Data or Files 2048kb

SRAM PCMCIA, Data or Files 4096kb

SRAM PCMCIA, Data or Files 8192kb

6 Add or replace the desired memory.

OK

Cancel

86

Configuring a Modicon Quantum Hot Standby with Unity System

Configuring the Modbus Plus Communication Type

Configuring with

Unity Pro

Configuring the Modbus Plus communication type

Step Action

1 If not opened, open the Local Bus configuration editor.

2 Go to the local bus in the Structural View of the Project Browser.

3 Open the Local Bus editor either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open.

A graphical representation of the local bus appears.

4 Point to the Modbus Plus port, No. 3.

1

CPS

111

00

2

CPU

671

60

CPU

671

60

ACI

030

00

4 5 6 7 8 9 10 11 12 13 14

3

5 Double-click or right-click on the Modbus Plus port.

The Submodule dialog appears. The General tab is default.

1.2 : MBP

MBP

Overview General

Communication Type

DIO Bus

Peer Cop

I/O objects

Please choose a link:

No Link

6 Select one or both Communication Type: z z

DIO bus

Peer Cop

87

Configuring a Modicon Quantum Hot Standby with Unity System

Setting the Invalidate Keypad Option

Overview

Methods for

Selecting the

Invalidate

Keypad Option

The keypad is located on the front panel of the Modicon Quantum Hot Standby with

Unity 140 CPU 671 60 module.

Setting the Invalidate Keypad option can disable the Hot Standby submenu ( PLC

Operations | Hot Standby ). (See

Accessing the Screens, p. 28

) When the

Invalidate Keypad option is selected, the Hot Standby submenu is read only.

You may choose to prevent access to the Hot Standby control through the keypad z to avoid the possibility of accidental (or malicious) state changing z for security or convenience

There are two methods for selecting/enabling this option:

Method Used

Hot Standby tab

Description

Select the Invalidate Keypad option in the Hot Standby tab using the

Unity Pro software. (See

Using the Hot Standby Tab, p. 85 )

Selecting the Invalidate Keypad option requires that the application program be downloaded to the CPU.

Command Register Set the system bit, %SW60.0 to 1.

Selecting the system bit %SW60.0 must be performed online in the

Primary controller.

Note: By setting the Invalidate Keypad option, the Run/Stop PLC control option on the PLC Operation menu is NOT disabled.

88

Disabling

Options

Configuring a Modicon Quantum Hot Standby with Unity System

Two Hot Standby options/controls are disabled using the front panel keypad z Changing the HSBY mode (Run/Offline) z Application program transfer to/from Standby

Note: CHANGING FROM LEGACY

In the legacy Quantum Hot Standby system, setting command register bit 16 affects both the mode (offline or run) of controllers A and B and affects the state of bit 14 and bit 15 z z

Bit 16 set to 0 z disables (overrides) Command Register bit 14 and bit 15 state z enables key switch state

Bit 16 set to 1 z z enables Command Register bit 14 and bit 15 state disables key switch state

In Unity, z the state/condition of system bit %SW60.0 ONLY disables/enables the Hot

Standby submenu option in the front panel keypad.

z z setting system bit %SW60.0 does NOT affect the state of system bits %SW60.1 and %SW60.2

regardless of the setting for system bit %SW60.0, system bits %SW60.1 and

%SW60.2 control the mode (offline or run) of controllers A and B. (See Setting

the Bits in the Command Register, p. 110 )

89

Configuring a Modicon Quantum Hot Standby with Unity System

Swapping Network Addresses at Switchover

Overview

Handling

Modbus

Addresses at

Switchover

The following material describes handling network addresses at Switchover. A

Modicon Quantum Hot Standby with Unity system can communicate data over different network protocols: z Modbus z z

Modbus Plus

TCP/IP

In a Modicon Quantum Hot Standby with Unity system, the Modbus port addresses are: z Primary: 1-119 z Standby: Offset +128

Maximum address: 247 z

Range 1-247

The Modbus port addresses can be changed using one of two methods: z z

Communication menu in the front panel keypad

Modbus Port tab in the Unity Pro editor

Changing addresses:

Using the Communication menu in the Front Panel Keypad

Change address on either

Primary

1.

Access the front panel keypad of the

Primary.

2.

Go to Communication menu

3.

Go to Serial Port submenu

4.

Select address

5.

Change address

6.

Perform application program transfer

7.

Verify Standby Modbus address is +128.

Standby

1.

Access the front panel keypad of the

Standby.

2.

Go to Communication menu

3.

Go to Serial Port submenu

4.

Select address

5.

Change address

6.

Perform switchover

7.

Ensure Standby switched to Primary

8.

Perform application program transfer

9.

Verify Standby Modbus address is +128

Using the Modbus Port Tab in Unity Pro Editor

To change address, download application program. (See Offline Modification of an

Application Program and Logic Mismatch,

p. 151 )

Note: If the Modbus address is changed in the Primary using the front panel keypad, ensure that application program transfer is made to enable the corresponding Modbus switchover in the Standby.

90

Configuring a Modicon Quantum Hot Standby with Unity System

Note: CHANGING FROM LEGACY

In a Modicon Quantum Hot Standby with Unity system only one port is available for

Modbus.

By default address swap at switchover is maintained between the Primary and

Standby Modbus ports. This default condition can be changed using the following two methods: z Using Hot Standby menu in the Unity Pro editor

This choice requires the application program to be downloaded.

Using the Command Register system bit %SW60.8

z

This choice MUST be performed online in the Primary.

Selecting/deselecting address swap at Switchover

Using Hot Standby Menu in Editor

1.

Open Hot Standby menu in Unity Pro

2.

Go to Swap Address at Switchover area

3.

Deselect Modbus Port 1

4.

Verify modifications

5.

Download application program to controller. (See Offline Modification of an

Application Program and Logic Mismatch,

p. 151 )

6.

Perform switchover

7.

Ensure Standby switch to Primary

8.

Perform application program transfer

Using the Command Register system bit

%SW60.8

1.

Connect to Primary

2.

Access the Command Register System bit %SW60.8

3.

Set bit to 1

Default is 0

Swap Modbus

Addresses at

Switchover

If controller A is the Primary controller and its Modbus port has an address of 1, then the default addresses for the comparable port on controller B, the Standby, is 129, which is 1 plus the offset of 128.

If controller B becomes the Primary controller as the result of a switchover, its

Modbus port assumes the address of 1, and the comparable port on controller A assumes the address of 129.

No Swap Modbus

Addresses at

Switchover

If controller A is the Primary controller and its Modbus port 1 address is 1, then that port address remains at 1 after the switchover occurs. Likewise, if controller B becomes the Primary controller as a result of a switchover, its Modbus port 1 address is remains at 1.

91

Configuring a Modicon Quantum Hot Standby with Unity System

Important

Information

Note: Important Information

1.

If you change the options, the port addresses are not affected until a switchover occurs.

2.

If NOM modules are used in the configuration, the offset of the Modbus address is +/-32 following the Modbus Plus address switchover.

Handling

Modbus Plus

Addresses at

Switchover

92

In a Modicon Quantum Hot Standby with Unity system, the Modbus Plus port addresses on the Standby controller are offset +/-32 from the comparable ports on the Primary controller.

Modbus Plus address swap behavior at switchover

Default Behavior at Switchover z z

Controller A = Primary

MB+ address = 1

Controller B = Standby

MB+ address = 33 (1 +32)

(+32 = Offset)

Switchover occurs.

z z

Controller A = new Standby

MB+ address = 33 (1 +32)

Controller B = new Primary

MB+ address = 1

Note: Numerical address of both ports (A and B) range: 1 - 64.

If Primary address = 50, corresponding Standby = 18 (50 - 32)

The Modbus Plus address of the controllers can be changed using the front panel keypad: Communication | Modbus Plus | Modify Address

Modbus Plus address swap behavior when addressed is changed

Forced Behavior at Switchover z z

Controller A = Primary

MB+ address = 1

Controller B = Standby

MB+ address = 33 (1 +32)

(+32 = Offset)

Change address of Primary = 5.

z z

Controller A = Primary

MB+ address = 5

Controller B = Standby

MB+ address = 33

Perform Application Program Transfer.

Configuring a Modicon Quantum Hot Standby with Unity System

Forced Behavior at Switchover z z

Controller A = Primary

MB+ address = 5

Controller B = Standby

MB+ address = 37 (5 +32)

Force switchover.

z z

Controller A = new Standby

MB+ address = 37 (5 +32)

Controller B = new Primary

MB+ address = 5

If he Modbus Plus address is modified, perform an Application Program Transfer. (See

Transferring an Application Program with Unity Pro, p. 159 ) Failure to perform a transfer

creates a different offset address in the Standby.

Note: SWAPPING ADDRESSES

At switchover, the Modicon Quantum Hot Standby with Unity system and NOMs swap Modbus Plus addresses almost instantaneously (within one or two milliseconds). This almost instantaneous switchover means that host devices which are polling the controller should be talking to the Primary controller and that the network should have minimal network interruption during switchover.

Note: EXEC UPGRADE USING OSLOADER

When using Modbus Plus communication and OSLoader, only address 1 is valid.

(See

Executing the EXEC Upgrade Procedure, p. 139 )

93

Configuring a Modicon Quantum Hot Standby with Unity System

Handling TCP/IP

Addresses at

Switchover

When used in a Modicon Quantum Hot Standby with Unity system, the Modicon

Quantum Ethernet TCP/IP network option modules NOE 771 01 and 11 support address swapping at switchover. The swapping of IP addresses behaves much like the address swap of the Modbus Plus ports, except that the offset is 1 instead of 32.

At switchover, the modules exchange their IP addresses. NOE 771 address swapping occurs automatically and can not be controlled by options selected in any of the tabs of the editor or controlled by turning ON/OFF any of the bits in the command register.

All standard rules apply to IP addressing with the additional restriction that the IP address cannot be greater than 253 or the broadcast address minus 2. Also, no other device should be assigned the configured IP +1 address.

Note: NOE 771 01 and 11 ADDRESS SWAP z NOE 771 01 and 11 are the only Ethernet option modules that support the IP address swap in Modicon Quantum Hot Standby with Unity system V2.0. z z

NOE 77101 and 11 modules must be configured in the same slot of the Primary and Standby backplanes.

NOE 771 01, 11 requires minimum firmware revision 2.0 or higher.

94

5.2

At a Glance

Purpose

Configuring a Modicon Quantum Hot Standby with Unity System

Configuring a NOE with Unity Pro

What's in this

Section?

This material describes configuring a NOE, a Quantum Ethernet module, using Unity

Pro. For a complete description of all models of the NOE, see the Quantum NOE

771 xx Ethernet Modules User Guide, 840 USE 116 00 .

This section contains the following topics:

Topic

Overview of Modicon Quantum Hot Standby with Unity Solution for NOEs

NOE Operating Modes and Modicon Quantum Hot Standby with Unity

IP Address Assignment

Address Swap Times

Network Effects of Modicon Quantum Hot Standby with Unity Solution

Page

96

98

102

104

105

95

Configuring a Modicon Quantum Hot Standby with Unity System

Overview of Modicon Quantum Hot Standby with Unity Solution for NOEs

Please Note The Modicon Quantum Hot Standby with Unity system supports up to six NOE 771

Ethernet adapters on bus controllers.

Description of the Hot Standby

Solution

The NOE Hot Standby allows automatic IP Address swap. Both controllers are configured identically. One controller is the Primary NOE; the other controller, the

Secondary NOE. In case of a failure, the controllers switchover and the system recovers.

The NOEs coordinate the swapping of IP addresses. After closing both the client and the server connections, each NOE sends a swap UDP message to its peer

NOE. The sending NOE then waits a specified timeout (500 ms) for the peer swap of UDP messages. Either after receiving the messages or after a timeout, the NOE changes its IP address.

Note: NOEs must communicate with each other in order to swap IP Addresses.

Schneider Electric recommends that you connect the primary and Secondary

NOEs to the same switch because z z

Communication failures between the NOEs increases the time to swap

Connecting two NOEs to the same switch, minimizes the probability of a communication failure

Note: Schneider Electric recommends that a switch (not a hub) is used to connect the NOEs to each other or to the network. Schneider Electric offers switches; please contact a local sales office for more information.

The NOE waits for either a change in the controller’s Hot Standby state or the swap of UDP messages. Then the NOE performs one of two Hot Standby actions.

If the NOE:

1.

Detects that the new Hot Standby state is either primary or standby:

The NOE changes the IP address

2.

Receives a swap UDP message:

The NOE transmits a Swap UDP message and swaps the IP address

All client/server services (I/O Scanner, Global Data, Messaging, FTP, SNMP, and

HTTP) continue to run after the switchover from the old to the new Primary NOE.

Note: Failure of an NOE module is not a condition for the primary system to leave the primary state.

96

Configuring a Modicon Quantum Hot Standby with Unity System

Hot Standby and

NOE Module

Functionality

The NOE 771 family provides different Ethernet services. Some services are enabled or disabled in a Modicon Quantum Hot Standby with Unity system. The following table shows which services are enabled and disabled.

Service

I/O Scanning

Global Data

Modbus Messaging

FTP/TFTP

SNMP

HTTP Server

DHCP

NOE 771 x1

Enabled

Enabled

Enabled

Enabled

Enabled

Enabled

Disabled

Note: Only the 140 NOE 771 01 or 140 NOE 771 11 (TCP/IP Ethernet Modules) support a Modicon Quantum Hot Standby with Unity V2.0 system.

97

Configuring a Modicon Quantum Hot Standby with Unity System

NOE Operating Modes and Modicon Quantum Hot Standby with Unity

The NOE Modes The NOE modes are z Primary Mode z

The Hot Standby state is primary, and all client/server services are active.

Secondary Mode

The Hot Standby state is standby, and all server services are active except

DHCP.

z Standalone Mode

Occurs when NOE is in a nonredundant system, or if the HE CPU module is not present or is not healthy.

Offline Mode z

CPU is stopped.

CPU module is in Offline mode.

The Modicon Quantum Hot Standby with Unity and the NOE operating modes are synchronized by the conditions described in the following table.

HE CPU Module Status

Present and Healthy

Present and Healthy

Present and Healthy

Present and Healthy

Not present or unhealthy

HSBY State

Primary

Standby

Offline

Unassigned

N/A

NOE Operating Mode

Primary

Secondary

Offline

Standalone

Standalone

Any one of four events will affect the NOE operating mode. These four events occur when the NOE is powered-up, when an NOE executes a Hot Standby switchover, when an NOE goes to offline mode, or when a new application is downloaded to the

NOE.

98

Configuring a Modicon Quantum Hot Standby with Unity System

Power-Up and IP

Address

Assignment

An NOE obtains its IP Address assignment at power-up as follows:

If the HSBY state is ...

Unassigned

Primary

Secondary

Unassigned to Offline

Then the IP Address assigned is ...

Configured IP Address

Configured IP Address

Configured IP Address + 1

See the Offline Mode at Power-up Sequence table following

If two NOEs power-up simultaneously, a "resolution algorithm" determines the

Primary NOE, and after determining the Primary NOE, the "resolution algorithm" assigns the configured IP Address to the Primary NOE and then assigns the configured IP Address + 1 to the Secondary NOE.

Offline Mode at Power-up Sequence table:

Offline Mode at Power-up Sequence

Both controller A and controller B power-up a the same time

Result

Controller A powers-up before controller B z IP Address of controller A is configured IP

Address z IP Address of controller B is the configured

IP Address + 1

The resolution algorithm will assign controller A the configured IP address and will assign controller B the configured IP address + 1.

The NOE performs a "duplicate IP" test by issuing an ARP request to the configured

IP Address. If a response is received within 3 seconds, the IP Address remains at the Default IP and blinks a diagnostic code.

If no IP configuration exists, the NOE remains in standalone mode, and the IP

Address must be obtained from either a BOOTP server or from a MAC address.

99

Configuring a Modicon Quantum Hot Standby with Unity System

Power-Up and

Ethernet

Services

The following table shows how the status of an NOE service is affected by the

Modicon Quantum Hot Standby with Unity HSBY state.

HSBY State Status of NOE Services

Client Services Client/

Server

Services

I/O Scanner Global Data Modbus

Messaging

Unassigned Run

Primary Run

Secondary

Offline

Stop

Stop

Run

Run

Stop

Stop

Run

Run

Run

Run

Server Services

FTP

Run

Run

Run

Run

SNMP

Run

Run

Run

Run

HTTP

Run

Run

Run

Run

100

Hot Standby

Switchover

Configuring a Modicon Quantum Hot Standby with Unity System

The following steps describe how NOEs coordinate the Hot Standby switchover.

Step

1

2

3

4

5

6

7

8

9

10

Action

NOE A (installed in a HSBY rack) detects that its local controller changed from

Primary to Offline.

NOE A changes its HSBY state from Primary to Offline with the same Ethernet services running, starts its watch-dog timer (with 500 ms timeout setting), and expects from its peer NOE a UDP request to swap the IP Address.

NOE B (installed in peer HSBY rack) detects that its local controller changed state from Secondary to Primary.

NOE B stops all Ethernet services, sends a UDP request to its peer NOE (NOE

A) for the synchronization of the IP Address swap, starts its watch-dog timer

(with 500 ms timeout setting), and then waits for an UDP response from its peer

NOE.

Once NOE A receives the UDP request from NOE B (or after its watch-dog timer times out), it stops all Ethernet services, sends a UDP response to NOE B (no

UDP response is sent to NOE B for watch-dog timeout case), swaps IP Address as Secondary, and starts Secondary services.

As soon as NOE B receives the UDP response from NOE A (or after its watchdog timer times out), it swaps IP Addresses and starts Ethernet services as

Primary.

After NOE A senses that its local controller changes state from Offline to

Standby, it changes to Secondary accordingly.

The Secondary NOE now becomes the Primary NOE.

Primary NOE opens all client connections and listens for all server connections and re-establishes those connections.

Simultaneously, Secondary NOE listens for all server connections and reestablishes those connections.

Going to Offline When either the CPU stops or the Hot Standby state goes to offline mode, two events occur:

1.

NOE mode goes to Offline

2.

NOE uses the IP Address of the present configuration

IP Address Assignment and Going Offline

HSBY State

Primary to Offline

Standby to Offline

IP Address Assigned Is ...

Configured IP Address, if other controller does not go to

Primary

Configured IP Address + 1

101

Configuring a Modicon Quantum Hot Standby with Unity System

IP Address Assignment

Configuring the

NOE

The NOE can be configured to work in conjunction with the Modicon Quantum Hot

Standby with Unity controller. Since the Primary and Secondary controllers must have an identical configuration, the configured IP Addresses will be the same. The

NOE’s IP Address is either the configured IP Address or the configured IP Address

+1. The IP Address is determined by the current local Hot Standby state.

In the Offline state, the IP Address is determined by whether or not the other controller is in transition to the Primary state.

Note: For a Modicon Quantum Hot Standby with Unity system, the two IP

Addresses will be consecutive.

The following table shows the IP Address assignments.

Hot Standby State

Primary

Standby

Transition from Primary to Offline

Transition from Standby to Offline

IP Address

Configured IP Address

Configured IP Address + 1

Configured IP Address, if peer controller does not go to Primary

Configured IP Address + 1

Note: Offline - Results depend on whether or not the other controller is detected as in transition into the primary state. If Current IP is the configured IP Address, then change the IP Address to the configured IP Address + 1.

IP Address

Restriction

Note: Configuring NOE

Do not use either broadcast IP Address or broadcast IP Address - 2 to configure a

NOE.

102

IP Address

Transparency

Configuring a Modicon Quantum Hot Standby with Unity System

For continued Ethernet communication, the new Primary NOE must have the same

IP Address as the former Primary NOE. The IP Address in the Secondary NOE (an

NOE in the secondary state) is IP Address + 1.

The NOEs integrated into the Modicon Quantum Hot Standby with Unity configuration coordinate this swapping IP Address with the management of Ethernet services used.

Note: Do not use the address IP + 1. For a Modicon Quantum Hot Standby with

Unity system, do not use consecutive addresses of the configured IP Address. If you configure the last IP Address (255), NOE returns diagnostic code "Bad IP configuration".

103

Configuring a Modicon Quantum Hot Standby with Unity System

Address Swap Times

Description The following table details what the "time for an Address swap" comprises, such as the time to close connections, time to swap IP addresses, or time to establish connections.

The following table shows the swap time for each of the Ethernet services.

Service

Swap IP Addresses

I/O Scanning

Global Data

Client Messaging

Server Messaging

FTP/TFTP Server

SNMP

HTTP Server

Typical Swap Time

6 ms

Maximum Swap Time

500 ms

1 initial cycle of I/O Scanning 500 ms + 1 initial cycle of I/O scanning

500 ms + 1 CPU scan For swap times, please see the 840USE11600, Quantum

NOE 771 xx Ethernet

Modules User Guide

1 CPU scan

1 CPU scan + the time of the client reestablishment connection

The time of the client reestablishment connection

1 CPU scan

The time of the client reestablishment connection

500 ms + 1 CPU scan

500 ms + the time of the client reestablishment connection

500 ms + the time of the client reestablishment connection

500 ms + 1 CPU scan

500 ms + the time of the client reestablishment connection

104

Configuring a Modicon Quantum Hot Standby with Unity System

Network Effects of Modicon Quantum Hot Standby with Unity Solution

Overview The Modicon Quantum Hot Standby with Unity solution is a powerful feature of

NOEs, a feature that increases the reliability of your installation. Hot Standby uses a network, and using the Hot Standby feature over a network can affect the behavior of z z z z

Browsers

Remote and Local clients

I/O Scanning service

Global Data service z FTP/TFTP server

The following are factors you may encounter while using the Modicon Quantum Hot

Standby with Unity solution.

Browsers

Remote Clients

Local Clients

Note: In Modicon Quantum Hot Standby with Unity configuration the NOE’s I/O scanner is enabled.

If a browser requests a page and during the process of downloading that page an IP

Address swap occurs, the browser will either hang or time out. Click the Refresh or

Reload button.

Hot Standby swaps affect remote clients.

An NOE will reset under the following conditions: z Remote Connection Request during Hot Standby Swap

If a remote client establishes a TCP/IP connection during a Hot Standby swap, z the server closes the connection using a TCP/IP reset.

Hot Standby Swap during Remote Connection Request

If a remote client makes a connection request and a Hot Standby swap occurs during the connection request, the sever rejects the TCP/IP connection by z sending a reset.

Outstanding Requests

If there is an outstanding request, the NOE will not respond to the request, but the NOE will reset the connection.

The NOE will do a Modbus logout if any connection has logged in.

During a swap, the NOE will reset all client connections using a TCP/IP reset.

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Configuring a Modicon Quantum Hot Standby with Unity System

I/O Scanning

Service

The I/O Scanning provides the repetitive exchange of data with remote TCP/IP nodes I/O devices. While the PLC is running the Primary NOE sends Modbus Read/

Write, read or write request to remote I/O devices, and transfer data to and from the

PLC memory. In the secondary controller, the I/O scanning service is stopped.

When the Hot Standby swap occurs, the Primary NOE closes all connections with I/

O devices by sending a TCP/IP reset. The I/O scanning service in this NOE is standby.

After the swap, the new Primary NOE re-establishes the connection with each I/O devices. It restarts the repetitive exchange of data with these re-connections.

The NOE 771 01 and 11 provides the I/O scanning feature. Configure using either z z

Unity Pro software

Internal I/O Scanner Web page

Using either method, the configuration and transfer of data between network addresses can be done without using the MSTR/IEC function block.

Note: I/O SCANNING AND SWITCHOVER WITH CRITICAL APPLICATIONS

Account for the following Ethernet I/O scanning considerations during a switchover.

z z

If MSTR/IEC function block is used for TCP/IP, only some of the Op Code will be used. Therefore, the block will not complete its transaction and returns error code 0x8000.

While the NOE is in the process of performing the transaction, a new MSTR/IEC z function block may become active.

The output states of the scanned I/Os will follow the state defined in the last value option configured in the I/O scanning table of the NOE module (in Unity

Pro software).

These two states are either

1.

set to 0

2.

Hold last

With the above considerations, Schneider Electric recommends using switchover with Ethernet I/O scanning for less critical applications.

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Configuring a Modicon Quantum Hot Standby with Unity System

Global Data

(Publish/

Subscribe)

Service

The Hot Standby NOE is one station within a distribution group. Distribution groups exchange application variables. Exchanging application variables allows the system to coordinate all the stations in the distribution group. Every station publishes local application variable in a distribution group for all other stations and can subscribe to remote application variables independent of the location of the producer.

The communication port has only one multicast address.

In this network service, the Modicon Quantum Hot Standby with Unity controllers are viewed like only one station. The Primary NOE publishes the Hot Standby application variables and receives the subscription variables. The Secondary NOE global data service is in a stopped state.

When the Hot Standby swap occurs, the Primary NOE stops the Global Data service. The NOE does not publish the local variable during a swap. And after the swap, the new Primary NOE starts to publish application variables and to receive the subscription variables.

FTP/TFTP Server The File Transfer Protocol/Trivial File Transfer Protocol (FTP/TFTP) server is available as soon as the module receives an IP address. Any FTP/TFTP client can logon to the module. Access requires the correct user name and password. Modicon

Quantum Hot Standby with Unity allows only one active FTP/TFTP client session per NOE module.

When the Hot Standby swap occurs, the Primary and Secondary NOEs close the

FTP/TFTP connection. If a user sends an FTP/TFTP request during the swap, the communication is closed.

Whenever you re-open communication, you must re-enter a user name and a password.

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Configuring a Modicon Quantum Hot Standby with Unity System

5.3

Configuring Registers with Unity Pro

At a Glance

Purpose

What's in this

Section?

This material describes configuring a Modicon Quantum Hot Standby with Unity system by selecting options that affect the registers. You may want to use this method if your system has specific configuration needs.

This section contains the following topics:

Topic

Understanding the Non-Transfer Area, Transferring State RAM, and Reverse

Transfer Words

Understanding the Unity Command Register

Understanding the Unity Status Register

Transferring User Data

Using Initialized Data

Synchronizing Time-of-Day Clocks

Page

109

110

113

115

116

117

108

Configuring a Modicon Quantum Hot Standby with Unity System

Understanding the Non-Transfer Area, Transferring State RAM, and Reverse

Transfer Words

Designating a

Non-Transfer

Area

Using the Hot Standby tab of the editor dialog, you may designate a block of %MW words as a Non-Transfer area.

Step

1

2

3

Action

Ensure that the Hot Standby tab is selected.

If you want to review the process for starting Unity Pro and opening the editor dialog, please see

Accessing the Base Configuration, p. 73 .

Enter the starting address in the system word field, %MW.

The field is located in the Non-Transfer Area of the Hot Standby tab.

Enter the number of contiguous registers in the Length: field.

The field is located in the Non-Transfer Area of the Hot Standby tab.

Non-Transfer

Area of State

RAM

Transferring

Data to the

Primary

The designated registers will be ignored when state RAM values are transferred from the Primary controller to the Standby. Placing registers in the Non-Transfer

Area is one way to reduce scan time.

Note: With the new hardware design of the Modicon Quantum Hot Standby with

Unity 140 CPU 671 60s, the scan time optimization provided by the Non-Transfer area may be very low.

A pair of system words,%SW62 and %SW63, are dedicated to transfer data from the

Standby controller to the Primary.

These system words can be used by the application program (in the first section) to register diagnostic information.

The data coming from the Standby are transferred at each scan and are available to the Primary.

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Configuring a Modicon Quantum Hot Standby with Unity System

Understanding the Unity Command Register

Setting the Bits in the Command

Register

The Command Register defines the operating parameters of a Hot Standby application for both the Primary and Standby and is located at system word %SW60.

At each scan, the Command Register is replicated and transfers data from the

Primary to the Standby. Transfer occurs only from Primary to Standby. Any changes made to the Command Register on the Standby will have no effect because the values transferred from the Primary overwrite the values in the Standby.

The following illustration identifies the operating options provided by the Command

Register.

Disables LCD Invalidate Keypad = 0

Enables LCD Invalidate Keypad = 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

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

MSB

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

LSB

0 = No application program transfer

1 = Application program transfer requested

0 = Swaps Modbus port 1 address during switchover

1 = Does not swap Modbus port 1 address on switchover

System Word

%SW60.0

Invalidate Keypad is an option that allows a controller to accept or refuse commands from the Hot Standby submenu in the front panel keypad.

z %SW60.0 = 1

Invalidate Keypad enabled.

z

The Modicon Quantum Hot Standby with Unity system refuses all changes from the Hot Standby submenu in the front panel keypad.

%SW60.0 = 0

Invalidate Keypad disabled.

The Modicon Quantum Hot Standby with Unity system accepts all changes from the Hot Standby submenu in the front panel keypad.

(See

Setting the Invalidate Keypad Option, p. 88 )

110

System Word

%SW60.1

System Word

%SW60.2

System Word

%SW60.3

System Word

%SW60.4

Configuring a Modicon Quantum Hot Standby with Unity System

Controller A OFFLINE/RUN mode z %SW60.1 = 1 z

Controller A goes to Run mode

%SW60.1 = 0

Controller A goes to Offline mode

Controller B OFFLINE/RUN mode z %SW60.2 = 1 z

Controller B goes to Run mode

%SW60.2 = 0

Controller B goes to Offline mode

Logic mismatch z %SW60.3 = 0

If a logic mismatch is detected, Standby forced to Offline mode.

%SW60.3 = 1 z

Standby operates normally even if a mismatch occurs.

(See

Handling Logic Mismatch with Unity Pro, p. 141

)

EXEC upgrade z %SW60.4 = 1

Allows the executive to be upgraded on the Standby and the Primary continues z to control the process.

%SW60.4 = 0

Allows the executive to be upgraded and to stop the Primary’s control of the process.

Upgrading allows z a Hot Standby system to operate with different versions of the OS running on the z

Primary and Standby upgrades without shutting down the process

To perform the executive upgrade, the Standby must be stopped. When started again, the Standby operates as a valid Standby. (See Enabling EXEC Upgrade with

Unity Pro, p. 137 )

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Configuring a Modicon Quantum Hot Standby with Unity System

System Word

%SW60.5

Commands Standby to initiate an application transfer.

z z

%SW60.5 = 1 means Standby requests an application program transfer from

Primary

%SW60.5 = 0 is default and no transfer occurs

Note: %SW60.5 is a Monitor Bit

%SW60.5 monitors an action. Once the action occurs, %SW60.5 returns to the default, which is zero (0).

System Word

%SW60.8

Swap Modbus port z %SW60.8 = 1

Swaps Modbus addresses on port 1when a switchover occurs.

Note: In a Modicon Quantum Hot Standby with Unity system only Modbus port 1 is available for use.

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Configuring a Modicon Quantum Hot Standby with Unity System

Understanding the Unity Status Register

Bits in the Hot

Standby Status

Register

The Hot Standby Status Register is a readable register located at system word

%SW61 and is used to monitor the current machine status of the Primary and

Standby.

Both the Primary and the Standby/Offline have their own copy of the Status register.

The Status register is not transferred from Primary to Standby. Each PLC must maintain its local Status Register based on the regular communication between the two controllers.

The following illustration identifies the operating options provided by the 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

Other PLC in OFFLINE mode = 0 1

Other PLC running in primary mode =1 0

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

MSB 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 LSB

0 = Unlocated Variables being transferred Primary to Standby

1 = Unlocated Variables not being transferred Primary to Standby

0 = The hot standby has not been activated

1 = The hot standby is active

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Configuring a Modicon Quantum Hot Standby with Unity System

System Words

%SW61.0 to

%SW61.3

System Word

%SW61.4

System Word

%SW61.5

These four bits display the states of the local and remote Hot Standby controllers.

Status of local PLC z z

%SW61.1 = 0 and %SW61.0 = 1means local PLC is in OFFLINE mode

%SW61.1 = 1 and %SW61.0 = 0 means local PLC is running in Primary mode z %SW61.1 = 1 and %SW61.0 = 1 means local; PLC is running in Standby mode

Status of remote PLC z z z

%SW61.3 = 0 and %SW61.2 = 1means remote PLC is in OFFLINE mode

%SW61.3 = 1 and %SW61.2 = 0 means remote PLC is running in Primary mode

%SW61.3 = 1 and %SW61.2 = 1 means remote PLC is running in Standby mode

%SW61.4 is set = 1 whenever a logic mismatch is detected between the Primary and Standby controllers.

%SW61.4 depends on %SW60.3 (Command Register) set = 1.

%SW61.5 identifies the Order reported by the Copro at start time.

The order depends on the range of the MAC addresses.

z z

If the A/B designation is A, then bit 5 will be set = 0.

If the A/B designation is B, then bit 5 will be set = 1.

Note: On controller LCD displays z z

A

B

System Word

%SW61.14

System Word

%SW61.15

If %SW61.14 is set = 1, the setting indicates that a logic mismatch has been detected, which prevents Unlocated Variables to be transferred from the Primary to

Standby.

If %SW 61.15 is set = 1, the setting indicates that the Copro device is set up correctly and working.

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Configuring a Modicon Quantum Hot Standby with Unity System

Transferring User Data

General

Variables,

Instances, Bits,

Words

At end of scan in a redundant system the Primary must send its data to the Standby in order to keep in ready to assume the role of Primary if the need arises.

The user data that will be transferred includes: z z

Located variables (in state RAM)

All unlocated variables z z

All instances of DFB and EFB data

SFC states z System Bits and Words

115

Configuring a Modicon Quantum Hot Standby with Unity System

Using Initialized Data

Loading at Coldstart Time

The Modicon Quantum Hot Standby with Unity 140 CPU 671 60 supports initialized data.

Initialized data allows you to specify initial values for the data that are to be loaded at cold-start time. Declare the variables before a cold start.

Updating Online In addition to declaring values before a cold start, you can update the initial values online.

Updating the initial values online creates a mismatch situation in a redundant system.

Handling

Problems at

Switchover

Updating the initial values online presents a problem: if a switchover occurs to the non-updated PLC, then you execute a cold-start, the older initial values will be used.

Note: WINDOW OF TIME

Pay attention to the fact that there is a window of time during which a mismatch can occur. Mismatches may cause inconsistent operations.

Solving

Mismatch

Problems

However, logic mismatches cause the same problems. Thus, value mismatches will be treated in the same way as logic mismatches. Value mismatches give the same indications and the same update requirements.

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Configuring a Modicon Quantum Hot Standby with Unity System

Synchronizing Time-of-Day Clocks

Setting the Timeof-Day Clocks in the Primary and

Standby

Controllers

In a Modicon Quantum Hot Standby with Unity system, the Primary and Standby controllers have their own Time-of-Day clocks, which are not implicitly synchronized.

If the clocks are not synchronized, then at switchover, the Time-of-Day would change by the difference between the two clocks. Non synchronization of the clocks could cause problems if you are controlling a time critical application.

117

Configuring a Modicon Quantum Hot Standby with Unity System

118

Maintaining a Modicon Quantum

Hot Standby with Unity System

6

Introduction

Overview

What's in this

Chapter?

This chapter provides information about maintaining a Modicon Quantum Hot

Standby with Unity system.

This chapter contains the following topics:

Topic

Verifying the Health of a Modicon Quantum Hot Standby with Unity System

Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with

Unity System

Detecting Primary Controller, Copro, and RIO Head Failures

Detecting Standby Controller, Copro, and RIO Head Failures

Detecting High-Speed Data Link (HDSL) Failures

Detecting Remote I/O (RIO) Link Failures

Checking for Identical Application Programs—Checksum

Replacing a Faulty Module

Troubleshooting the Primary Controller

Troubleshooting the Standby Controller

Page

120

121

131

132

133

134

123

125

126

129

119

Maintaining a Modicon Quantum Hot Standby with Unity System

Verifying the Health of a Modicon Quantum Hot Standby with Unity System

Generating and

Sending Health

Messages

Performing

Automatic

Confidence

Tests

Conducting

Startup Tests

The Modicon Quantum Hot Standby with Unity modules exchange a health message approximately every 10 ms.

If the Primary has an error, the Standby is notified and assumes the Primary role.

If the Standby has an error, the Primary continues to operate as a standalone.The

RIO head processors periodically verify communication with one another.

The Primary sends a health message to the Standby either

1.

every 10 milliseconds when no other data is being sent on the high speed Copro link

2.

every 5 milliseconds if no communication is required with any drop on RIO link.

If the Standby never receives any message on either link, the Standby will try to determine the cause of the failure and assumes control if necessary.

If the Primary does not receive a valid response from the Standby, the Primary will operate as if there was no back up available as if the Primary were a standalone.

The system automatically performs two kinds of confidence tests on the Modicon

Quantum Hot Standby with Unity Copro: z z

Startup tests

Run time tests

Startup confidence testing on the Modicon Quantum Hot Standby with Unity Copro attempt to detect hardware errors in the module before the application is allowed to run.

If the module fails any of its tests, it will remain offline and will not communicate with the other Modicon Quantum Hot Standby with Unity module.

Conducting Run

Time Tests

Run time tests are performed whenever the Copro is in the operational state. Run time tests are executed in small slices to prevent delays in scan time.

If the module fails any of its tests, the module remains offline and will not communicate with the other module.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Detecting and Diagnosing Failures in a Modicon Quantum Hot Standby with

Unity System

Important

Information

Please note.

If...

Component of Primary fails

Component of Standby fails

Fiber optic cable link fails

Then ...

Control shifts to Standby

Standby goes offline

Standby goes offline

Understanding

Health Messages

The Primary sends a health message to the Standby every 10 milliseconds.

If ...

No communication is required with any drop on RIO link

All systems OK

Then Primary Sends Health Message ...

every 5 milliseconds every scan

Exceptions

If ...

Standby never receives any message on either link

Primary does not receive a valid response from the Standby

Then ...

1.

Standby determines cause of failure

2.

Standby assumes control

Primary operates as if

1.

no back up available

2.

Primary were a standalone

Standalone = 1) no working Copro 2) no Hot

Standby Functionality

Finding

Diagnostic

Information with

Unity Pro

Errors and switchovers are logged in the diagnostic buffer. To view the log,

Step

1

Action

Select Tools → Diagnostic Viewer from the main menu.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Finding More

Information in this Manual

Refer to the following sections

Type of failure

Primary controller

Primary Copro

Primary RIO head

Standby controller

Standby Copro

Standby RIO head

High speed data link failures

Remote I/O link

Application program checksum failures

Refer to section

Detecting Primary Controller, Copro, and

RIO Head Failures, p. 123

Detecting Standby Controller, Copro, and

RIO Head Failures, p. 125

Detecting High-Speed Data Link (HDSL)

Failures, p. 126

Detecting Remote I/O (RIO) Link Failures,

p. 129

Checking for Identical Application

Programs—Checksum, p. 131

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Maintaining a Modicon Quantum Hot Standby with Unity System

Detecting Primary Controller, Copro, and RIO Head Failures

Understanding

CPU to Copro

Communication

Facts

1

2

3

4

On every scan, CPU communicates with Copro.

Main CPU executes the Hot Standby control at the start of the scan, the main CPU asks the Copro to service its requests.

CPU reports any errors detected.

If Primary Copro fails, Primary Controller operates as a standalone.

Standalone = 1) no working Copro 2) no Hot Standby functionality

Failure Detection between Two

Controllers

If an error occurs in either one of two controllers,

Situation

Controller with error

Controller without error

Response

Reports error to other controller by sending a message through either

1.

high speed Copro transfer link

2.

RIO link

Detects error from a timeout which occurs because of no activity on link

Note: Primary maintains continuous activity on link, which ensures Standby can detect an error as soon as possible.

Failure Detection within

One CPU —

Hard Errors

Facts

1

2

RAM failure is a hard error.

Copro detects hard errors.

Detecting failures:

If ...

Hard error occurs

Then ...

1.

Copro sends a take control command to the Standby

2.

Primary Copro stops because of an interface error

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Maintaining a Modicon Quantum Hot Standby with Unity System

Failure Detection in Either Copro

Detecting failures

If ...

Primary Copro reports any error

Primary Copro does not respond within

5 milliseconds

Primary Copro sends a take control command to the other Copro

Standby copro experiences an error

Then ...

1.

Primary controller acknowledges the error

2.

Primary controller attempts to transfer control to the other controller by sending a take control command to the Standby through the

RIO link

1.

Primary controller acknowledges the error

2.

Primary controller attempts to transfer control to the other controller by sending a take control command to the Standby through the

RIO link

1.

Primary Copro relinquishes control

2.

Primary Copro does not expect any response

1.

Standby controller reports the error by sending a No Standby message

2.

Standby controller goes offline

Failure Detection by an RIO Head

Table with two columns

If ... RIO Head

Responds

Then ... Primary Controller

Releases control and the Standby station becomes a Standalone.

Standalone = 1) no working Copro 2) no Hot Standby functionality

Does NOT respond Continues to scan the I/O.

Understanding

RIO Head Failure

If the RIO Head fails,

3

4

1

2

5

Main CPU times out when it fails to communicate with the RIO Head.

Main CPU stops.

Main CPU reports RIO failure to log.

Main CPU reports RIO failure error to the Copro.

Copro goes offline.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Detecting Standby Controller, Copro, and RIO Head Failures

Standby CPU

Failure

When Standby CPU fails,

Stage

1

2

3

Description

The Standby CPU reports errors to the Standby Copro.

The Standby Copro sends a No Standby message to the Primary Copro.

The Standby CPU and the standby copro go offline.

Standby Copro

Failure

When Standby Copro fails,

Stage

1

2

3

4

Description

When the Primary CPU communicates with the Standby, the Standby Copro reports its error to the Primary.

The Primary requests the Copro to go offline.

The Standby Copro will also report its error to the Primary Copro by sending a

No Standby message.

Standby goes offline.

Standby RIO

Head Failure

When the Remote IO Head fails,

Step

1

2

3

4

Description

The CPU stops and reports a RIO failure.

The CPU reports the error to the Copro

The Copro sends a No Standby command to the Primary.

The Standby goes offline.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Detecting High-Speed Data Link (HDSL) Failures

Important

Information

Facts

1

2

3

High-speed data link connects the two Copros.

Using the high-speed data link, the Primary controller communicates with the

Standby every 10 milliseconds.

Primary sends either

1.

data message

2.

health message

Note: If both the Primary and Standby do not hear from each other, either station can detect a high speed data link failure.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Standby Detects a Failure

At first,

Step Action

1 Standby does not hear from the

Primary on the high-speed data link

Result

1.

Standby requests the Primary CPU to monitor the RIO link

2.

Primary CPU sends a request to the RIO

Head

When the RIO Head receives the request,

If ...

RIO Head finds the

RIO link not active

RIO Head finds the

RIO link is active

Then ...

1.

RIO Head assumes that the Primary must be down

2.

Standby assumes control

Message received from Primary CPU must be either

1.

health message

Messages are sent every 5 milliseconds from Primary RIO Head to

Standby RIO Head.

2.

I/O transaction data message

Messages are sent from the Primary RIO Head to the I/O drops at the request of the controller.

Facts about the I/O

1

2

3

If the message is an I/O transaction, the RIO Head

1.

concludes the failure occurred on the high-speed data link

2.

informs the Primary controller to go to offline

If you never configure an I/O drop, the failure on the high-speed data link could cause the Standby to assume control since the Standby RIO head will never receive any I/O transaction message.

After any CPU fails,

1.

RIO Head will not perform drop communication

2.

RIO Head sends only health messages

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Maintaining a Modicon Quantum Hot Standby with Unity System

Standby

Assumes

Control

The Standby becomes Primary

Step

1

2

3

4

Action Result

After the Primary controller goes offline, A health message from the Standby controller is the only message received by the Standby RIO Head.

Standby controller listens to the highspeed data link for one scan.

If Standby controller hears nothing, Standby knows that the failure must be on both the Primary Copro and Primary

CPU.

Standby assumes control.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Detecting Remote I/O (RIO) Link Failures

Important

Information

Facts

1

2

3

4

Remote I/O (RIO) Link connects the two RIO Heads.

Primary RIO Head performs a health check on the RIO link by sending health messages.

Primary RIO Head sends a health message every 5 milliseconds.

Unlike the health communication check performed on the Copro link, the Primary

Copro does not wait for a response from the Standby Copro. Instead the Primary

Copro expects a reply every second. Expecting a reply every second minimizes the impact on the Primary's performance.

Standby

Controller and

Messages

How the Standby handles messages depends on:

If Standby ...

Never Responds to any message

Never Receives a message from the Primary

Then ...

Primary assumes that the

Standby RIO Head failed.

Standby assumes failure may be in the RIO link.

Action

Standby continues to control the drops.

Standby cannot assume control.

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Maintaining a Modicon Quantum Hot Standby with Unity System

Standby

Monitors RIO and

Copro Links

To start the process,

Step Action

1 Standby RIO Head sends a request to the Primary RIO

Head.

2 Standby requests that the Main

CPU monitor the Copro link.

Result

Confirm whether Primary RIO

1.

Head failed or

2.

link failed

Main CPU passes this request to Copro either as a

1.

monitor RIO request

2.

Copro link request

To complete the process, the Standby determines

If ...

Copro link is down and the

Primary is down

Copro link is up

Then ...

Standby assumes control

Standby Copro sends a message to the Primary Copro and

1.

Primary Copro passes this request to the Primary CPU

2.

Primary checks the Primary RIO link

Understanding

Communication

Status to the

Drops

Depending on the status, the Primary RIO Head continues either to operate as the

Primary or goes offline.

If communication to drops is

Healthy

Then Action

Not healthy

RIO link failure must be on Standby side.

1.

The station continues to operate as the

Primary

2.

Standby RIO Head shows the link error pattern on the LEDs

RIO link failure is on

Primary side.

1.

The Primary RIO Head displays a link error

2.

Standby assumes control

130

Maintaining a Modicon Quantum Hot Standby with Unity System

Checking for Identical Application Programs—Checksum

Important

Information

Please note

Fact

A Hot Standby system requires that both stations must have the same application program.

Result

This requirement prevents the Standby from executing a different application program if transfer of control occurs.

Note: OVERRIDING SAME APPLICATION PROGRAM REQUIREMENT

To override the requirement that both controllers have the same application program, ensure that the Command Register’s %SW60.3 is set = 1. (See System

Word %SW60.3, p. 111 )

Standby Checks for Mismatches

Checking for identical application programs

Step

1

2

3

Action

At each scan, the application program's instruction, checksum

(CKSM), is transferred from the

Primary to the Standby along with any other necessary data.

Standby determines if mismatch occurs.

Result

The Standby validates the new checksum (CKSM) against its existing checksum (CKSM).

1.

Mismatch: Standby goes Offline

2.

No mismatch: system operates normally

The controller returns to Online and is the Standby as soon as the application programs are identical.

131

Maintaining a Modicon Quantum Hot Standby with Unity System

Replacing a Faulty Module

Important You may replace a faulty module while a system is running.

Ensure that the module being replaced:

1.

installs into the Standby backplane

2.

resides in the same position in both backplanes

3.

is same type of module

Same type of module means NOE replaces NOE, CRP replaces CRP.

Note: IMPORTANT INFORMATION

1.

Perform a switchover if replacing a Primary.

2.

Do NOT remove a Primary controller under power supply (Hot Swap).

132

Maintaining a Modicon Quantum Hot Standby with Unity System

Troubleshooting the Primary Controller

Troubleshooting the Primary

To determine which component failed, note controller’s status displayed in the HE

CPU LCD screen and the RIO Head’s status displayed by the RIO Head’ LEDs.

Controller Status RIO Head Status

Stop All LEDs off except

READY on and Com

Act blinks four times

Offline All LEDs off except

READY on

Stop

Failure Type Description

Controller An Interface error occurred.

Fiber Optic connection between both controllers

RIO Head

A Com Act error occurred.

A Com Act error occurred.

Stop

All LEDs off except

READY on and Com

Act displays error pattern

READY on and Com

Act blinks four times

RIO Cable

Failure at

Primary End

In a dual cable system, if only one cable fails, the Error A or

Error B indicator on the RIO

Head lights instead of stopping the system, and the system continues to operate. When the RIO cable fails at the

Primary end, input data may be reset to 0 for one scan because the communication failure to the drop occurs before the broken link is detected.

133

Maintaining a Modicon Quantum Hot Standby with Unity System

Troubleshooting the Standby Controller

Troubleshooting the Standby

To determine which component failed, note controller’s status displayed in the HE

CPU LCD screen and the RIO Head’s status displayed by the RIO Head’s LEDs.

RIO Head Status Failure Type Description Controller

Status

Stop

Offline

Stop

Stop

Offline

All LEDS off except

READY on or READY on and Com Act blinks once a second

READY on and Com

Act stops blinking

Com Act displays error pattern

Controller

Fiber Optic connection between both controllers

RIO Head

READY on and Com

Act blinks four times

An Interface error occurred.

A Com Act error occurred.

RIO Cable Failure at

Standby end

After you have replaced the module and cycled power, to ensure that the controllers have identical application programs, you must perform an application program update.

In a dual cable system, the RIO

Head gives no indication if only one cable has failed.

Com Act stops blinking Fiber Link failures: z from Standby

Transmit to z

Primary Receive from Primary

Transmit to

Standby Receive

134

Understanding the Modicon

Quantum Hot Standby with Unity

System Special Features

III

At a Glance

Purpose

What's in this

Part?

This part describes the special features of a Modicon Quantum Hot Standby with

Unity system.

z z z enabling an EXEC upgrade handling logic mismatch transferring application programs

This part contains the following chapters:

Chapter

7

8

9

10

Chapter Name

Enabling EXEC Upgrade with Unity Pro

Handling Logic Mismatch with Unity Pro

Transferring an Application Program with Unity Pro

Using the Modicon Quantum Hot Standby with Unity EFBs

Page

137

141

159

167

135

Understanding Modicon Quantum Hot Standby with Unity Special Features

136

Enabling EXEC Upgrade with

Unity Pro

7

Introduction

Overview

What's in this

Chapter?

In this chapter you will find information regarding the EXEC upgrade method for a

Modicon Quantum Hot Standby with Unity system. Upgrading allows you to update the EXEC for the standby controller while the process is still controlled by the primary controller.

This chapter contains the following topics:

Topic

Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade

Executing the EXEC Upgrade Procedure

Page

138

139

137

Enabling EXEC Upgrade

Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade

Upgrading while

Process is

Running

The Executive Upgrade feature allows upgrading the EXEC of the Standby controller while the Primary controller continues to control the process. However, during the upgrade, the system can no longer be considered redundant. That is, there is no Standby available to assume control if the Primary should fail before the

Standby upgrade is complete.

Upgrading EXEC without Stopping

Under normal operating conditions, both controllers in a redundant system must have the same versions of firmware.

In fact, there are checks by the controllers to detect if there is a mismatch in firmware.

Normally, when a mismatch exists, performing a switchover would not be possible because the Standby controller would not be allowed to go online.

However, to allow an EXEC Upgrade without stopping the application, overriding is possible by setting the Command Register system bit %SW60.4. Details of the

Modicon Quantum Hot Standby with Unity command register can be found in

Understanding the Unity Command Register, p. 110 .

Note: Enabling EXEC upgrade without stopping the application overrides the process of checking whether the Primary and Standby are configured identically.

Disable the upgrade without stopping bit as soon as the EXEC upgrade is finished.

Note: IMPORTANT INFORMATION

EXEC upgrade is possible only with compatible firmware.

138

Enabling EXEC Upgrade

Executing the EXEC Upgrade Procedure

General

Using Modbus

RTU

Perform an EXEC upgrade using the installed OSLoader tool. Use one of two communication methods available in the OSLoader: z z

Modbus RTU

Modbus Plus

Follow these steps.

Step

1

2

3

6

7

4

5

10

11

13

14

15

8

9

12

Action

Connect to the Primary.

Access the Command Register system bit %SW60.4; set bit to 1.

Disconnect the fiber optic cable on both controllers.

Open the OSLoader tool.

Select the Modbus communication option.

Stop the Standby.

Connect to the Standby using Modbus.

Note: Use the Standby’s Modbus address.

Download the OS to the Standby.

After completing the OS download, perform application program transfer to the

Standby.

Reconnect the fiber optic cables.

Put in RUN mode.

Note: Ensure Primary and Standby are in RUN Primary and RUN Standby mode.

Perform a switchover.

Note: Ensure Standby becomes Primary.

Repeat Steps 4 through 9 on the new Standby.

Connect to the new Primary.

Access Command Register system bit %SW60.4; set bit to 0).

Important If you upgrade using Modbus Plus, only address 1 is allowed for downloading.

Otherwise, there is no communication.

Ensure that no device in the Modbus Plus network is using the address ‘1’. (See

Handling Modbus Plus Addresses at Switchover, p. 92

)

139

Enabling EXEC Upgrade

Using Modbus

Plus

Follow these steps.

Step

1

2

3

4

9

10

7

8

5

6

11

12

13

14

15

16

Action

Connect to the Primary.

Access the Command Register system bit %SW60.4; set bit to 1.

Note: Before stopping the Standby, note the Modbus Plus address.

Stop the Standby.

Disconnect the fiber optic cable from both controllers.

Note: Primary operates without a Standby.

Switch off power, and switch on power to the Standby.

If not set to 1, change the Modbus Plus address of the Standby to 1.

Open the OSLoader tool.

Connect the Standby using Modbus Plus.

Note: Use the Standby’s Modbus Plus address.

Download the OS to the Standby.

Download application program to the Standby.

Note: Ensure that you download a valid application program.

Ensure that the Modbus Plus address is the same as the address noted in Step

3.

Reconnect fiber optic cable to both controllers.

Note: Primary operates with a Standby.

Put in RUN mode.

Ensure Primary and Standby are in RUN Primary and RUN Standby mode.

Perform switchover.

Note: Ensure Standby becomes Primary.

Repeats Steps 3 through 12 to the new Standby.

Ensure Primary and Standby are in RUN Primary and RUN Standby mode.

Connect to the new Primary, and access the Command Register system bit

%SW60.4; set to 0.

Compatibility

Issues

To upgrade a Modicon Quantum Hot Standby with Unity EXEC without shutting down the process, the current application program must be executable by the new

EXEC.

Observe this requirement when installing minor revisions targeted for bug fixes or minor enhancements.

When a major function enhancement needs to be made, maintaining this compatibility may not be possible.

In this case, to perform an EXEC upgrade requires a system shut down.

140

Handling Logic Mismatch with

Unity Pro

8

Introduction

Overview

What's in this

Chapter?

This chapter provides information about using the Logic Mismatch feature available in Unity Pro.

This chapter contains the following topics:

Topic

Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch

Understanding Switchover Behavior during Logic Mismatch

Online or Offline Modifications and Logic Mismatch

Online Modifications to an Application Program in the Standby and Logic

Mismatch

Online Modifications to an Application Program in the Primary and Logic

Mismatch

Offline Modification of an Application Program and Logic Mismatch

Switchover Methods and Logic Mismatch

Application Program Transfer Method and Logic Mismatch

Recommendations for Using Logic Mismatch

Page

142

146

148

149

150

151

153

155

156

141

Logic Mismatch

Understanding Modicon Quantum Hot Standby with Unity Logic Mismatch

Needing

Identical

Application

Programs

In a fault-tolerant redundant system and under normal operating conditions, both controllers must load the identical application program (also called a logic program).

The application program is updated every scan by transferring data from the Primary to the Standby. Both controllers conduct tests to detect if a mismatch exists between the application programs.

The following conditions cause a mismatch in the application program: a difference between: z programs z z animation tables comments (on variables)

Note: Animation Tables and Comments

Both animation tables and comments (on variables) may be excluded from the mismatch by not including in the upload information.

z z

Exclude by selecting Tools | Project Settings | Build tabs (default).

In the Upload Information area, select without .

Not including requires downloading application program

When a mismatch exists, a switchover is not possible, and the Standby controller would NOT go online. However, there are situations when you may want to allow a mismatch between the application programs. To enable this condition, use the

Modicon Quantum Hot Standby with Unity Logic Mismatch feature.

Note: Switchover can NOT occur while the Standby controller is offline.

Defining Logic

Mismatch

Logic Mismatch is a Modicon Quantum Hot Standby with Unity feature that allows a mismatch between the application programs of the Primary and Standby controllers.

Use the Logic Mismatch feature to modify an application program without stopping the process.

Using the Build

Project Function

Note: Build Project vs. Rebuild All Project

1.

Use the Build Project function to perform a logic mismatch with Unity Pro.

Schneider Electric recommends do not use Rebuild All Project to create a logic mismatch because the Rebuild All Project function creates a completely new project even if nothing has been changed in the application.

142

Causing a

Mismatch

Allowing a

Mismatch

Creating a

Mismatch

Logic Mismatch

Note: CHANGING FROM LEGACY

Legacy Hot Standby systems reserved areas of the State RAM for user data, which was transferred from the Primary to the Standby during scans. Because of the transfer process, legacy Hot Standby systems could support different application programs in the two controllers. One application program resided in one controller, and a different application program resided in the other controller.

In the legacy system, the user could program the logic (now called application program) and decide where to store the data. With this method of programming, the memory is known as static data memory layout and is necessary to have different user data accessing the same variables.

In the Modicon Quantum Hot Standby with Unity system, all memory is allocated by a memory manager, which automatically transfers the logical memory to a physical memory location.

This dynamic data memory layout is the heart of the programming flexibility and platform independence that Unity Pro provides, but on a Modicon Quantum Hot

Standby with Unity system with different user logic, dynamic data memory layout makes a cyclical data update very difficult. Therefore, mismatches occur.

In a Modicon Quantum Hot Standby with Unity system, Logic Mismatch allows the following without stopping the application program process.

z modify (edit) online an application program in the Standby while the Primary controls the process

(See Online Modifications to an Application Program in the Standby and Logic z z

Mismatch, p. 149 )

modify online an application program in the Primary while the Primary controls the process

(See Online Modifications to an Application Program in the Primary and Logic

Mismatch, p. 150 )

download an offline-modified application program to the Standby and perform a switchover to run the modified application program

(See

Offline Modification of an Application Program and Logic Mismatch, p. 151 )

Use one of two methods to create a Logic Mismatch condition:

1.

select Standby on Logic Mismatch ; select online

(Hot Standby Tab in the Unity Pro dialog)

This action requires the application program to be downloaded to the controller.

2.

set to 1 the Command Register system bit %SW60.3

This action MUST be performed online in the Primary controller.

143

Logic Mismatch

Transferring

User Data during a Mismatch

The table following shows which user data is transferred when a mismatch occurs

Data Type Transferred on Logic Mismatch

Located variables (State RAM) Yes

Unlocated global variables

DFB & EFB instance data

Yes unless variables exist ONLY in modified controller

Yes unless data exist ONLY in modified controller

SFC variable area

System Bits and Words

Yes unless associated-SFC section is modified

Yes

Using Care with

Logic Mismatch

WARNING

I/O MAP HAZARD; CONFIGURATION HAZARD

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

z z

Ensure that both I/O maps are identical.

Ensure that both configurations are identical.

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

Selecting the Standby On Logic Mismatch option, allows you to override this default condition (Standby going offline).

If you change the parameter in this field from Offline to Running, the Standby remains online if a logic mismatch is detected between the application program of the Standby and the application program of the Primary.

Updating Section

Data in an

Application

Program

All data of a section will be fully updated during every scan if the data in the Standby is equal to the counterpart data on the Primary. Section data will not be updated if it is not equal to its counterpart on the Primary.

If the sections are equal on the Primary and the Standby, the section data that is updated is: z Internal states of Elementary Function Blocks (EFBs) used in the section

For example, Timers, Counters, PID z All Derived Function Block (DFB)-Instance data blocks of each DFB instantiated in the section including nested DFBs.

144

Logic Mismatch

Updating Global

Data in an

Application

Program

With the Logic Mismatch enabled, application program global data will be updated with every scan. Global data that does not exist on both controllers is not updated.

The application program’s updated global data includes both:

1.

All declared variables in the Variable-Editor.

2.

All section and transition variables.

The process of updating the application program global data in a Hot Standby system affects: z z z

Declared variables

All declared variable will be updated on every scan as long as they are declared on both controllers.

Updating Standby

If a complete application program transfer is done to the controller that did not receive the modified changes, then both controllers will have equal application programs, and the Standby controller is fully updated.

Deleted and redeclared variables

If, due to a modification, a global variable has been deleted first, and then redeclared , this variable would be treated as a NEW variable, even if the same name is used. The update procedure must be followed to bring the controllers to an equalized state.

Note: GLOBAL DATA VARIABLES

The system reserves space for these variables whether they are used in the controller’s application program or not.

Unused variables consume space and require time to be transferred from the

Primary to the Standby. Therefore, in the Primary’s application program, Schneider

Electric does not recommend using variables that are defined but not used.

145

Logic Mismatch

Understanding Switchover Behavior during Logic Mismatch

Modifying the

Application

Variables

If a switchover occurs during logic mismatch, the new Primary will execute its own application program with the data received from the other controller.

Depending on the modification, different behaviors occur:

Modification

Only code changed (same variables).

Variables added to the initial Primary

Variables deleted from the initial Primary

Variables added to the initial Standby

Variables deleted from the initial Standby

Effect

All the variables exchanged between the controllers are equal.

Variables are not used by the new Primary.

New Primary executes application program using the latest values for these variables.

New Primary executes application program using initial values for these variables.

New Primary will not use these variables

146

Logic Mismatch

Modifying an

SFC Section with

Unity Pro

The SFC code-generation process does not generate direct executable code but generates a set of data used by the SFC interpreter in the controller’s OS to compute the next state.

As with Concept, Unity Pro z z does not maintain the equality between the two application programs when a modification of a SFC section occurs does execute an SFC section by restarting the controller from its initial state after a switchover

When a SFC section is modified in the Primary, its data are not transferred to the

Standby. When a transfer of logic occurs from the Primary to the Standby, the first section of the logic is diagnostic information.

Note: SFC Programming Language

Schneider Electric recommends not using the SFC programming language.

WARNING

SWITCHOVER HAZARD

If switchover occurs when the Run mode is selected and there is a logic mismatch between the two controllers, the Standby assumes Primary responsibilities and starts solving a different application program from the previous Primary.

z After completing modifications, perform application program transfer to ensure controllers contain the same application and remove logic mismatch.

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

147

Logic Mismatch

Online or Offline Modifications and Logic Mismatch

Modifying

Application

Programs

Normally, once a fault-tolerant redundant system is configured, programmed, and controlling its process, the system is not shut down—not even for periodic maintenance. However, there may be situations when you may need to make modifications to the application program and continue to control the process.

The logic mismatch feature allows you to modify application programs online or offline while controlling the process.

WARNING

IMMEDIATE CONTROL OF PROCESS

Once a new application program is switched to the Standby, the

Standby takes control of the process.

z Ensure that you understand the

1.

operation of your process

2.

modifications made z Monitor all modifications to the application program

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

148

Logic Mismatch

Online Modifications to an Application Program in the Standby and

Logic Mismatch

Executing the

Procedure

To make online modifications to an application program (logic program or project) in the Standby controller, follow these steps.

Step

1

2

5

6

3

4

7

8

9

10

11

Action

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Connect to the Primary controller and access the Command Register system bit

%SW60.3.

Set to 1 the Command Register system bit %SW60.3

Connect to the Standby controller.

Modify online the application program.

After completing the modifications, perform Build Project .

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Perform a switchover. (See

Switchover Methods and Logic Mismatch, p. 153 )

Note: Standby will change to Primary.

Perform application transfer to Standby. Application Program Transfer Method

and Logic Mismatch, p. 155

Connect to the new Primary controller and access the Command Register system bit%SW60.3.

Set to 0 the Command Register system bit %SW60.3

Note: Command Register is returned to 0 from 1.

Important

Reference

(See

Recommendations for Using Logic Mismatch, p. 156

)

149

Logic Mismatch

Online Modifications to an Application Program in the Primary and Logic

Mismatch

Executing the

Procedure

To make online modifications to an application program (logic program or project) in the Primary controller, follow these steps.

Step

1

2

5

6

3

4

7

8

9

Action

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Connect to the Primary controller and access the Command Register system bit

%SW60.3.

Set to 1 the Command Register system bit %SW60.3

Modify online the application program.

After completing the modifications, perform Build Project .

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Perform an application transfer to the Standby. Application Program Transfer

Method and Logic Mismatch, p. 155

Connect to the new Primary controller and access the Command Register system bit %SW60.3.

Set to 0 the Command Register system bit %SW60.3

Note: Command Register is returned to 0 from 1.

Important

Reference

(See

Recommendations for Using Logic Mismatch, p. 156 )

150

Logic Mismatch

Offline Modification of an Application Program and Logic Mismatch

Executing the

Procedure

To make offline modifications to an application program in either controller, follow these steps.

Step

1

2

3

4

5

6

7

8

9

10

11

12

Action

Modify offline the application program.

After completing the modifications, perform Build Project and save.

Note: Do NOT use the Rebuild All Project option because using Rebuild

All Project will cause the Standby to go offline when the application program is downloaded.

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Connect to the Primary controller and access the Command Register system bit

%SW60.3.

Set to 1 the Command Register system bit %SW60.3

Open the modified program and connect to the Standby controller.

Download the program and select RUN.

Note: Check your controller’s state and ensure state is Run | Standby .

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

Perform a switchover. (See

Switchover Methods and Logic Mismatch, p. 153 )

Note: Ensure Standby switched to Primary.

Perform application transfer to Standby. Application Program Transfer Method

and Logic Mismatch, p. 155

Connect to the new Primary controller and access the Command Register system bit %SW60.3.

Set to 0 the Command Register system bit %SW60.3

Note: Command Register is returned to 0 from 1.

Important

Reference

(See

Recommendations for Using Logic Mismatch, p. 156

)

151

Logic Mismatch

Important

WARNING

IMMEDIATE CONTROL OF PROCESS

Once a new application program is switched to the Standby, the

Standby takes control of the process.

z Ensure that you understand the

1.

operation of your process z

2.

modifications made

Monitor all modifications to the application program

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

152

Switchover Methods and Logic Mismatch

General

Switchover

Using Front

Panel Keypad

Switchover can be performed using one of two methods: z Hot Standby submenu on the front panel keypad z Command Register either system bit %SW60.1 or %SW60.2

To force a switchover using the front panel keypad, do the following:

Step

1

2

3

4

5

6

Action

Access the front panel keypad of the Primary controller.

Go to PLC Operation menu.

Go to Hot Standby submenu.

Go to Hot Standby mode

Modify Run to Offline.

Note: Ensure that Standby switched to Primary.

Modify offline to run.

Note: Ensure that the LCD displays Run Standby .

Logic Mismatch

Important for

Command

Register

Switchover

To perform the switchover using Command Register system bit %SW60.1 or

%SW60.2, ensure that following are considered: z application program is saved twice. Each save uses a different file name.

z file 1

Saved before modification z file 2

Saved after modification z order of the controller is [(A) or (B)]; use one of two methods: z

Hot Standby submenu on the front panel keypad ( PLC Operation | Hot z

Standby | Hot Standby Order ).

Unity Pro status dialog (refer to the bottom of the Unity Pro window when connected online)

153

Logic Mismatch

Switchover

Using Command

Register System

Bit %SW60.1 or

%SW60.2

To force a switchover by setting the bits in the Command Register, do the following:

Step

1

2

3

4

5

8

9

6

7

10

Action

Open file 1.

Connect to the Primary.

Ensure the controller order of the Primary is A or B.

Access z Command Register system bit %SW60.1

If the connected controller order is A.

z Command Register system bit %SW60.2

If the connected controller order is B.

Set bit to 0.

Note: Ensure that the Standby switched to Primary.

Open file 2.

Connect to the new Primary controller.

Access the Command Register system bit used in Step 4.

Set bit to 1.

Note: Ensure Standby controller is now online.

Ensure both Primary and Standby controllers are in Run Primary and Run

Standby mode.

154

Logic Mismatch

Application Program Transfer Method and Logic Mismatch

General

Application

Program

Transfer Using

Front Panel

Keypad

Application Program Transfer can be performed using one of two methods: z Hot Standby submenu on the front panel keypad z Command Register system bit %SW60.5

To transfer an application program (logic program or project) to either the Primary or Standby controller using the front panel keypad, do the following>

Step

1

2

3

4

Action

Access the front panel keypad of any controller (Primary or Standby)

Go to PLC Operations menu

Go to Hot Standby submenu

Go to Hot Standby transfer and press ENTER to confirm the transfer.

Note: Ensure transfer to Standby occurs.

Application

Program

Transfer Using

Command

Register System

Bit %SW60.5

To transfer an application program (logic program or project) to either the Primary or Standby controller using Command Register system bit %SW60.5, do the following.

Step

1

2

3

Action

Connect to the Primary controller.

Access Command Register system bit %SW60.5.

Set bit to 1.

Note: The process of setting the bit toggles the bit from 0 to 1 and back to 0.

155

Logic Mismatch

Recommendations for Using Logic Mismatch

General

Upload

Information

Management

Feature—

General

When using the Logic Mismatch feature, Schneider Electric recommends noting that the following are affected z z

Upload Information Management

Online modifications to the Standby z z

Application Program Transfer

Setting the Command Register system bit %SW60.3

During online modifications, your system detects that the application-program information in the controller differs from the application-program information in the computer. Because this information will be used later when an upload is performed, the system requires you to update this information and constantly presents a confirmation dialog. To avoid constant display of the dialog, use the Upload

Information Management feature.

Using the Upload

Information

Management

Feature

Before doing any modifications and at the initial start up of your system, do the following:

Step

1

2

3

4

5

Action

From the menu, select Tools | Option .

In the Options window, select the General tab (default).

Select Automatic in the Upload Information Management area.

Press OK to close the window.

Save the program and download to the controller.

Handling Online

Modifications to the Standby

For major modifications to the application program on the Standby, ensure the

Standby is in offline mode.

Two benefits result from this action: z Run process continues z Primary does NOT perform a switchover during modification of the Standby

Note: SWITCHOVER DURING MODIFICATION

If the Standby is online during modifcations, there is a possibilty of switchover occuring. If a switchover occurs, the Standby becomes Primary, and the process may run with incomplete modifications.

156

Performing

Application

Program

Transfer

Logic Mismatch

When performing an application program transfer, you want to avoid the possibility of having two different application programs running in the Primary and Standby.

Step

1

Action

Perform Application program transfers after completing online modifications with

Logic Mismatch.

Resetting

Command

Register System

Bit %SW60.3

When resetting the Command Register system bit %SW60.3 to 0, you want to avoid the possibility of having two different application programs running in the Primary and Standby.

Step

1

2

3

Action

Connect to Primary.

Access the Command Register system bit %SW60.3.

Reset bit to 0.

157

Logic Mismatch

158

Transferring an Application

Program with Unity Pro

9

Introduction

Overview

What's in this

Chapter?

This chapter provides information about the Application Program Transfer feature that enables you to configure the Standby controller from the Primary controller.

This chapter contains the following topics:

Topic

Overview of Application Program Transfer

Executing the Application Program Transfer Procedure Using the Command

Register

Automatic Application Program Transfer

Executing the Application Program Transfer Procedure Using the Keypad

Page

160

162

163

164

159

Application Program Transfer

Overview of Application Program Transfer

Overview

Methods of

Transferring

Programs

Validating

Transfer

Understanding

Transfer Time

The Application Program Transfer feature provides you with the ability to configure the Standby from the Primary controller.

Use this feature when you reprogram the Primary controller or replace the Standby controller because the process copies the full application program of the Primary to the Standby. This feature not only saves time but ensures that the controllers have identical configurations.

The system transfers the application program over the dedicated Modicon Quantum

Hot Standby with Unity communications link. In a redundant system, this link connects the two Copros.

Application transfer is always from the Primary to the Standby. There are three methods of transferring application programs: z z

Hot Standby submenu on the front panel keypad

Command Register system bit %SW60.5

z Automatic transfer (Occurs when you start a Hot Standby system for the first time.) Therefore, the Primary automatically transfers the application program to the Standby. (See

Automatic Application Program Transfer, p. 163

)

The Standby validates the transferred application program. After validating, the

Standby starts automatically.

Application Program Transfer time depends on the size of the application program, the larger the program, the longer the time. Application Program Transfer takes a few seconds.

Note: During application program transfer, the system can no longer be considered redundant.

If the Primary should fail before the Standby is ready to assume the role of Primary, there is no Standby available.

Updating from the Primary

An application program update may only be performed from the Primary to the

Standby.

Note: UPDATING STANDBYS

The Standby controller cannot update the Primary.

160

Application Program Transfer

Understanding

Transfer Size

Limits

Note: CHANGING FROM LEGACY

Legacy Modicon Quantum controllers running Concept have an Application

Program Transfer limit of 1 megabyte.

In the Modicon Quantum Hot Standby with Unity 140 CPU 671 60 transfer size depends on the configuration. For example, using a card bridge you may transfer up to 7 Mb.

Therefore, transfer the complete application program regardless of the size. This transfer takes place over multiple scans, thus will be broken up into multiple transfer packets.

161

Application Program Transfer

Executing the Application Program Transfer Procedure Using the Command

Register

Overview To transfer, use the command register in the Unity Pro software tools. The Primary copies the complete application program and data to the Standby.

Transferring the

Application

Program Using

Command

Register System

Bit %SW60.5

To transfer an application program (logic program or project) to either the Primary or Standby controller using Command Register system bit %SW60/5, do the following.

Step

1

2

3

Action

Connect to the Primary controller.

Access Command Register system bit %SW60.5.

Set bit to 1.

Note: The process of setting the bit toggles the bit from 0 to 1 and back to 0.

162

Application Program Transfer

Automatic Application Program Transfer

Overview New in a Modicon Quantum Hot Standby system with Unity is automatic application program transfer.

As soon as a Primary controller detects a blank controller, the Primary transfers the program to the blank controller, which becomes the Standby. After application program transfer both controllers have identical application programs.

This new feature works well when two controllers are at a maximum of 2 Km apart.

Note: Same Configuration

The controllers need to have the same configuration (with the same PCMCIA cards or without cards).

163

Application Program Transfer

Executing the Application Program Transfer Procedure Using the Keypad

Overview

Using the

Keypad

For specifics on setting Modicon Quantum Hot Standby with Unity state, mode, order, and transfer from the keypad, see Configuring a Modicon Quantum Hot

Standby with Unity System, p. 69

.

To transfer, use the front panel keypad on the controller unit (Primary or Standby).

The Primary copies the complete application program and data to the Standby.

Note: CHANGING FROM LEGACY

In legacy Quantum Hot Standby systems, an application program transfer could be performed ONLY on the Standby controller.

The Standby requested from the Primary an application transfer. The process was performed on the CHS module and required setting the key in the Xfer key position while pushing the update button.

In Modicon Quantum Hot Standby with Unity, an application transfer is performed either z using the command register z

An application program transfer can be performed at any time.

automatically z

Transfer occurs first time Primary finds an empty Standby using the keypad

Use either the Primary or Standby.

Transferring the

Application

Program

The following table shows the Application Program Transfer Procedure.

Step

1

2

3

4

5

Action

Ensure the Primary Controller is in RUN PRIMARY mode.

Result: The LCD on the PLC will display the mode as RUN PRIMARY.

Check that both

1.

Invalidate Keypad option is NOT selected

2.

the key switch is unlocked

Go to the submenu Hot Standby | Transfer.

Push Enter to execute the application program transfer from the Primary to the

Standby.

Note: The Hot Standby | Transfer command can be performed either in the

Primary or Standby controller, BUT only the Standby controller will be updated.

164

Identical

Configurations and Application

Programs

Application Program Transfer

After the transfer, the Primary and Standby have identical configurations and application programs.

In the event of a failure in the Primary and depending on the mode selected for the

Standby (Run or Offline), the Standby may or may not be ready to assume the role of Primary.

165

Application Program Transfer

166

Using the Modicon Quantum Hot

Standby with Unity EFBs

10

Introduction

Overview

What's in this

Chapter?

This chapter describes the Modicon Quantum Hot Standby with Unity elementary function blocks (EFBs) z z

HSBY_RD

HSBY_ST z z

HSBY_WR

REV_XFER

This chapter contains the following topics:

Topic

Description: HSBY_RD

Description: HSBY_ST

Description: HSBY_WR

Description: REV_XFER

Page

168

171

174

177

167

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Description: HSBY_RD

Function description

Representation in FBD

This EFB allows you to use the Hot Standby function. It searches (together with other EFBs in the Hot Standby family) the configuration of the respective

Quantum PLC for the required components. These components always refer to hardware that is actually connected.

Therefore the correct behavior of this EFB on the simulators cannot be guaranteed.

The HSBY_RD EFB independently checks if a Hot Standby configuration exists.

( %SW60 ). If a configuration is present the contents of the command register are given and the HSBY output is set to "1". If there is no Hot Standby configuration present the HSBY_ConfigurationFound output is set to "0".

EN and ENO can be configured as additional parameters.

Representation:

HSBY_RD_Instance

HSBY_RD

HSBY

INV_KEY

PCA_RUN

PCB_RUN

SBY_OFF

EXC_UPD

SWP_MB1

SWP_MB2

SWP_MB3

HSBY_ConfigurationFound

InvalidateKeypad

PLC_A_Running

PLC_B_Running

StandbyOff

ExecUpdate

SwapAddressModbusPort1

168

Representation in LD

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Representation:

HSBY_RD_Instance

HSBY_RD

EN ENO

HSBY

INV_KEY

PCA_RUN

PCB_RUN

SBY_OFF

EXC_UPD

SWP_MB1

SWP_MB2

SWP_MB3

HSBY_ConfigurationFound

InvalidateKeypad

PLC_A_Running

PLC_B_Running

StandbyOff

ExecUpdate

SwapAddressModbusPort1

Representation in IL

Representation in ST

Representation:

CAL HSBY_RD_Instance (HSBY=>HSBY_ConfigurationFound,

INV_KEY=>InvalidateKeypad, PCA_RUN=>PLC_A_Running,

PCB_RUN=>PLC_B_Running, SBY_OFF=>StandbyOff,

EXC_UPD=>ExecUpdate, SWP_MB1=>SwapAddressModbusPort1)

Representation:

HSBY_RD_Instance (HSBY=>HSBY_ConfigurationFound,

INV_KEY=>InvalidateKeypad, PCA_RUN=>PLC_A_Running,

PCB_RUN=>PLC_B_Running, SBY_OFF=>StandbyOff,

EXC_UPD=>ExecUpdate,

SWP_MB1=>SwapAddressModbusPort1);

169

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Parameter description

Description of the output parameters:

Parameter Data type Meaning

HSBY BOOL "1" = Hot Standby configuration found

INV_KEY

PCA_RUN

BOOL

BOOL

"1" = The submenu for the Hot Standby PLC button is disabled.

"1" = The PLC with the Hot Standby CPU

1.

function is "A" on local rack

2.

Command Register is selected RUN

PCB_RUN

SBY_OFF

BOOL

BOOL

"0" = The PLC with the Hot Standby CPU

1.

function is "A" on local rack

2.

Command Register is selected OFFLINE

"1" = The PLC with the Hot Standby CPU

1.

function is "B" on local rack

2.

Command Register is selected RUN

"0" = The PLC with the Hot Standby CPU

1.

function is "B" on local rack

2.

Command Register is selected OFFLINE

"1" = The standby PLC switches to the offline mode as soon as both PLCs receive a different program.

EXC_UPD

SWP_MB1

SWP_MB2

SWP_MB3

BOOL

BOOL

BOOL

BOOL

"1" = Exec-(Operating system-)Update in the Standby-PLC is possible with the primary PLC still running.

(After Exec-Update the standby PLC changes back to the online mode.)

If a switchover has occurred,

"1" = No Swap address of Modbus ports 1.

"0" = Swap address of Modbus ports 1.

Not used. Reserved

Not used. Reserved

170

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Description: HSBY_ST

Function description

Representation in FBD

This EFB allows you to use the Hot Standby function. It searches (together with other procedures in the Hot Standby family) the configuration of the respective

Quantum PLC for the required components. These components always refer to hardware that is actually connected.

Therefore the correct behavior of this EFB on the simulators cannot be guaranteed.

The EFB is used to read the IEC Hot Standby status register ( %SW61 ). If there is no

Hot Standby configuration present the HSBY output is set to "0".

EN and ENO can be configured as additional parameters.

Representation:

HSBY_ST_Instance

HSBY_ST

HSBY

THIS_OFF

THIS_PRY

THIS_SBY

REMT_OFF

REMT_PRY

REMT_SBY

LOGIC_OK

THIS_ISA

THIS_ISB

HSBY_ConfigurationFound

PLC_Offline

Primary_PLC

Standby_PLC

Remote_PLC_Offline

PrimaryRemote_PLC

StandbyRemote_PLC

IdenticalPrograms

HSBY_ModuleSwitchA

HSBY_ModuleSwitchB

171

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Representation in LD

Representation:

HSBY_ST_Instance

HSBY_ST

EN ENO

HSBY

THIS_OFF

THIS_PRY

THIS_SBY

REMT_OFF

REMT_PRY

REMT_SBY

LOGIC_OK

THIS_ISA

THIS_ISB

HSBY_ConfigurationFound

PLC_Offline

Primary_PLC

Standby_PLC

Remote_PLC_Offline

PrimaryRemote_PLC

StandbyRemote_PLC

IdenticalPrograms

HSBY_ModuleSwitchA

HSBY_ModuleSwitchB

Representation in IL

Representation:

CAL HSBY_ST_Instance (HSBY=>HSBY_ConfigurationFound,

THIS_OFF=>PLC_Offline, THIS_PRY=>Primary_PLC,

THIS_SBY=>Standby_PLC,

REMT_OFF=>Remote_PLC_Offline,

REMT_PRY=>PrimaryRemote_PLC,

REMT_SBY=>StandbyRemote_PLC,

LOGIC_OK=>IdenticalPrograms,

THIS_ISA=>HSBY_ModuleSwitchA,

THIS_ISB=>HSBY_ModuleSwitchB)

172

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Representation in ST

Parameter description

Representation:

HSBY_ST_Instance (HSBY=>HSBY_ConfigurationFound,

THIS_OFF=>PLC_Offline, THIS_PRY=>Primary_PLC,

THIS_SBY=>Standby_PLC,

REMT_OFF=>Remote_PLC_Offline,

REMT_PRY=>PrimaryRemote_PLC,

REMT_SBY=>StandbyRemote_PLC,

LOGIC_OK=>IdenticalPrograms,

THIS_ISA=>HSBY_ModuleSwitchA,

THIS_ISB=>HSBY_ModuleSwitchB);

Description of output parameters:

Parameter Data type Meaning

HSBY BOOL "1" = Hot Standby configuration found

THIS_OFF

THIS_PRY

BOOL

BOOL

"1" = This PLC is offline

"1" = This PLC is the primary PLC

THIS_SBY

REMT_OFF

REMT_PRY

REMT_SBY

BOOL

BOOL

BOOL

BOOL

"1" = This PLC is the standby PLC

"1" = The other (remote) PLC is offline

"1" = The other PLC is the primary PLC

"1" = The other PLC is the standby PLC

LOGIC_OK

THIS_ISA

THIS_ISB

BOOL

BOOL

BOOL

"1" = The programs for both PLCs are identical and Logic

Mismatch is active.

"1" = This PLC chose the CPU with the lower IP address between both Hot Standby CPUs. This is the Hot Standby CPU "A".

"1" = This PLC chose the CPU with the higher IP address between both Hot Standby CPUs. This is the Hot Standby CPU "B".

173

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Description: HSBY_WR

Function description

Representation in FBD

This EFB allows you to use the Hot Standby function. It searches (together with other EFBs in the Hot Standby family) the configuration of the respective

Quantum PLC for the required components. These components always refer to hardware that is actually connected.

Therefore the correct behavior of this EFB on the simulators cannot be guaranteed.

The EFB HSBY_WR is used to set different Hot Standby Modes permitted for Hot

Standby. Setting the respective modes means a change in the Hot Standby command register ( %SW60 ), which is carried out automatically by the function block.

If there is no Hot Standby configuration, the HSBY_ConfigurationFound output is set to "0", otherwise it is set to "1".

Note: This function only affects the primary CPU.

EN and ENO can be configured as additional parameters.

Representation:

InvalidateKeypad

PLC_A_Running

PLC_B_Running

SwapAddressModbusPort1

HSBY_WR_Instance

HSBY_WR

INV_KEY

PCA_RUN

PCB_RUN

SWP_MB1

SWP_MB2

SWP_MB3

HSBY HSBY_ConfigurationFound

174

Representation in LD

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Representation:

InvalidateKeypad

PLC_A_Running

PLC_B_Running

SwapAddressModbusPort1

HSBY_WR_Instance

HSBY_WR

EN ENO

HSBY INV_KEY

PCA_RUN

PCB_RUN

SWP_MB1

SWP_MB2

SWP_MB3

HSBY_ConfigurationFound

Representation in IL

Representation in ST

Representation:

CAL HSBY_WR_Instance (INV_KEY:=InvalidateKeypad,

PCA_RUN:=PLC_A_Running, PCB_RUN:=PLC_B_Running,

SWP_MB1:=SwapAddressModbusPort1,

HSBY=>HSBY_ConfigurationFound)

Representation:

HSBY_WR_Instance (INV_KEY:=InvalidateKeypad,

PCA_RUN:=PLC_A_Running, PCB_RUN:=PLC_B_Running,

SWP_MB1:=SwapAddressModbusPort1,

HSBY=>HSBY_ConfigurationFound);

175

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Parameter description

Description of the input parameters:

Parameter Data type Meaning

INV_KEY BOOL In the submenu for the Hot Standby PLC button

"1" = Changes are disabled.

"0" = Changes are allowed.

PCA_RUN

PCB_RUN

BOOL

BOOL

"1 -> 0" = The Hot Standby CPU with function "A" on the local rack is forced into OFFLINE mode.

"0 -> 1" = The Hot Standby CPU with function "A" is forced into

RUN mode if its own button mode is in RUN mode.

"1 -> 0" = The Hot Standby CPU with function "B" on the local rack is forced into OFFLINE mode.

"0 -> 1" = The Hot Standby CPU with the function "B" is forced into

RUN mode if its own button mode is in RUN mode.

SWP MB1

SWP_MB2

SWP MB3

BOOL

BOOL

BOOL z z

"0" and a switchover has occurred: The Modbus address on port 1 of the NEW primary PLC changes.

new primary PLC address = old primary address new standby PLC address = old address + 128.

"1" and a switchover has occurred: The Modbus address at Port 1 z z of the NEW primary PLC changes.

new primary PLC address = old primary address new standby PLC address = old primary address

Not used. Reserved

Not used. Reserved

Description of the output parameters:

Parameter

HSBY

Data type

BOOL

Meaning

"1" = Hot Standby configuration found.

176

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Description: REV_XFER

Function description

Appearance in

FBD

This EFB allows you to use the Hot Standby function. It searches (together with other EFBs in the Hot Standby family) the configuration of the respective

Quantum PLC for the required components. These components always refer to hardware that is actually connected.

Therefore the correct behavior of this EFB on the simulators cannot be guaranteed.

The EFB REV_XFER provides the option of transferring two 16 bit words from the standby PLC to the primary PLC. The two registers transferred by this procedure are

%SW62 and %SW63 .

REV_XFER must be called up absolutely in the first section of the project executed.

The parameter addresses TO_REV1 and TO_REV2 must be in the non-transfer area to prevent an overwriting by the Primary PLC.

Note: In the old (Concept) Hot Standby System these two registers (Reverse

Transfer Registers) are the first addresses in the non-transfer area.

As additional parameters, EN and ENO are projected.

Appearance:

Standby_PLC_FirstReg

Standby_PLC_SecondReg

REV_XFER_Instance

REV_XFER

TO_REV1

TO_REV2

HSBY

PRY

SBY

FR_REV1

FR_REV2

HSBY_ConfFlag

Primary_PLC_Flag

Standby_PLC_Flag

FirstRevTransReg

SecondRevTransReg

177

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Appearance in

LD

Appearance:

Standby_PLC_FirstReg

Standby_PLC_SecondReg

REV_XFER_Instance

REV_XFER

EN

TO_REV1

TO_REV2

ENO

HSBY_ConfFlag

HSBY

PRY

Primary_PLC_Flag

Standby_PLC_Flag

SBY

FR_REV1

FR_REV2

FirstRevTransReg

SecondRevTransReg

Appearance in IL Appearance :

CAL REV_XFER_Instance (TO_REV1:=Standby_PLC_FirstReg,

TO_REV2:=Standby_PLC_SecondReg, HSBY=>HSBY_ConfFlag,

PRY=>Primary_PLC_Flag, SBY=>Standby_PLC_Flag,

FR_REV1=>FirstRevTransReg,

FR_REV2=>SecondtRevTransReg)

Appearance in

ST

Appearance:

REV_XFER_Instance (TO_REV1:=Standby_PLC_FirstReg,

TO_REV2:=Standby_PLC_SecondReg, HSBY=>HSBY_ConfFlag,

PRY=>Primary_PLC_Flag, SBY=>Standby_PLC_Flag,

FR_REV1=>FirstRevTransReg,

FR_REV2=>SecondtRevTransReg);

178

Parameter description

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

Description of input parameters:

Parameter Data type Description

TO_REV1 INT Describes the first reverse transfer register if this PLC is the standby PLC.

TO_REV2 INT Describes the second reverse transfer register if this PLC is the standby PLC.

Description of the output parameters:

Parameter Data type Meaning

HSBY BOOL 1= Hot Standby configuration

PRY

SBY

FR_REV1

FR_REV2

BOOL

BOOL

INT

INT

1 = This PLC is the primary PLC.

1 = This PLC is the standby PLC.

Content of first reverse transfer register ( %SW62 ). Output only if

HSBY is "1".

Content of second reverse transfer register ( %SW63 ). Output only if

HSBY is "1".

179

Using Modicon Quantum Hot Standby with Unity HSBY EFBs

180

Appendices

Appendices for Quantum Hot Standby Planning and Installation Guide

At a Glance

What's in this

Appendix?

The appendices for the Quantum Hot Standby Planning and Installation Guide are included here.

The appendix contains the following chapters:

Chapter

A

Chapter Name

Modicon Quantum Hot Standby with Unity Additional Information

Page

183

181

Appendices

182

Modicon Quantum Hot Standby with Unity Additional Information

A

Introduction

Overview

What's in this

Chapter?

This chapter describes the necessary cables, design specifications, error codes.

This chapter contains the following topics:

Topic

Fiber Optic Cable

140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with Unity

CRP Remote I/O Head Processor Error Patterns

TextIDs

Page

184

185

187

189

183

Additional Information

Fiber Optic Cable

Schneider

Electric

Recommends

Recommendations

1

2

3

4

Use up to 2 km of 62.5/125 µ m graded index, duplex, multimode glass fiber for all applications because of the relatively low loss of signal and signal distortion.

Note: Most 62.5/125 µ m cables are rated at 3.5 dB loss per km.

Use a 3 mm diameter cable for your Modicon Quantum Hot Standby with Unity system.

Note: The fiber cable clasps used to maneuver the cable into the ports are designed to be used with 3 mm cable.

Select the cable that meets the demands of your application.

Wherever possible, use a multiconductor cable since the cable is inexpensive and provides a backup in case the cable is cut in the process of pulling.

Cables Available From Schneider Electric

Part Number

490 NOR 000 03

490 NOR 000 05

490 NOR 000 15

Maximum Length

3 meters

5 meters

15 meters

184

Additional Information

140 CPU 671 60 Specifications for Modicon Quantum Hot Standby with Unity

Module

Specifications

Component

Communication ports

Bus current required

Max. number of NOM, NOE, CRP 811 and

MMS modules supported (any combination)

Key switch

Keypad

Yes

Yes

Description

1 Modbus (RS-232/RS-485)

1 Modbus Plus (RS-485)

1 USB

1 Ethernet (used as HSBY port)

1800 mA

6

Processor

Feature

Model

Clock speed

Coprocessor

Watchdog timer

Description

Pentium

266 MHz

Yes, Built-in Ethernet

250 ms S/W adjustable

Memory

Reference

Capacity

RAM

768 kbytes

128 kbytes

64 kwords

8.192 kbytes

Discrete (bits)

Registers (words)

Description memory for on board program and unlocated data, extensible to 7,168 Mb by PCMCIA max memory for configuration memory for located data (state RAM)

PCMCIA extension for data storage

64 k (any combination)

64 k max.

185

Additional Information

Remote I/O

Max. I/O words/drop

Max. number of remote drops

64 in / 64 out*

31

* This information can be a mix of discrete or register I/O. For each word of configured I/O, one of the I/O words must be subtracted from the total available.

Battery and

Clock

Battery type

Service life

Shelf life

Battery load current @ power-off

TOD clock

3 V Lithium

1200 mAh

10 years with 0.5% loss of capacity/year typical: 14 µ A max. 420 µ A

+/-8.0 s/day @ 0 ... 60 ° C

Diagnostic

Power-up

Run Time

RAM

RAM address

Executive Checksum

User Logic Check

Processor

RAM

RAM address

Executive Checksum

User Logic Check

186

Additional Information

CRP Remote I/O Head Processor Error Patterns

Error Patterns The following table displays both z number of times the Com Act indicator blinks for each type of error z possible codes for each type of blink

187

Additional Information

5

6

7

All codes are in hex.

Number of blinks on

Com Act Indicator

Slow (steady)

2

3

4

8

Code in hex

684B

684C

6729

6616

6617

6619

681A

681C

6503

6402

6300

6301

8001

8002

8003

6840

6841

6842

6843

6844

6845

0000

6820

6822

6823

682A

682B

682C

6846

6847

6849

684A

Error requested kernel mode hcb frame pattern error head control block diag error mod personality diag error fatal start IO error bad read IO pers request bad execute diag request

ASCII input xfer state

ASCII output xfer state

IO input comm state

IO output comm state

ASCII abort comm state

ASCII pause comm state

ASCII input comm state

ASCII output comm state building 10 byte packet building 12 byte packet building 16 byte packet illegal IO drop number

984 interface bus ack stuck high coax cable initialization error coax cable dma xfer error coax cable dumped data error coax cable DRQ line hung coax cable DRQ hung

RAM address test error

RAM data test error

PROM checksum error (exec not loaded)

PROM checksum error kernel PROM checksum error flash prog / erase error unexpected executive return

188

Additional Information

TextIDs

TextIDs TextIds define the warning messages written in the diagnostic buffer.

TextIDs switching from Primary to Offline

TextID

13001

13002

13003

13004

13005

13006

13007

Warning message

System halt

Remote IO failure

ETH device failure

ETH communication problem

Stop PLC command

Offline keypad switch

Offline Command register request

TextIDs switching from Standby to Offline

TextID

13008

13009

13010

13011

13012

13013

13014

Warning message

System halt

Remote IO failure

ETH device failure

ETH communication problem

Stop PLC command

Offline keypad switch

Offline Command register request

TextIDs switching from Standby to Primary

TextID

13015

13016

Warning message

Control command over ETH

Control command over RIO

TextIDs switching from Offline to Primary/Standby

TextID

13017

13018

Warning message

Switch from Offline to Primary

Switch from Offline to Standby BY

189

Additional Information

190

Glossary

!

%I

%IW

%KW

%M

%MW

%Q

%QW

According to the IEC standard, %I indicates a discrete input-type language object.

According to the IEC standard, %IW indicates an analog input -type language object.

According to the IEC standard, %KW indicates a constant word-type language object.

According to the IEC standard, %M indicates a memory bit-type language object.

According to the IEC standard, %MW indicates a memory word-type language object.

According to the IEC standard, %Q indicates a discrete output-type language object.

According to the IEC standard, %QW indicates an analog output-type language object.

A

ADDR_TYPE

ANL_IN

This predefined type is used as output for ADDR function. This type is ARRAY[0..5]

OF Int. You can find it in the libset, in the same family than the EFs which use it.

ANL_IN is the abbreviation of Analog Input data type and is used when processing analog values. The %IW adresses for the configured analog input module, which were specified in the I/O component list, are automatically assigned data types and should therefore only be occupied with Unlocated Variables.

191

Glossary

ANL_OUT

ANY

192

ANL_OUT is the abbreviation of Analog Output data type and is used when processing analog values. The %MW adresses for the configured analog input module, which were specified in the I/O component list, are automatically assigned data types and should therefore only be occupied with Unlocated Variables.

There is a hierarchy between the different types of data. In the DFB, it is sometimes possible to declare which variables can contain several types of values. Here, we use ANY_xxx types.

The following diagram shows the hierarchically-ordered structure:

ANY

ANY_ELEMENTARY

ANY_MAGNITUDE_OR_BIT

ANY_MAGNITUDE

ANY_NUM

ANY_REAL

REAL

ANY_INT

DINT, INT, UDINT, UINT

TIME

ANY_BIT

DWORD, WORD, BYTE, BOOL

ANY_STRING

STRING

ANY_DATE

DATE_AND_TIME, DATE, TIME_OF_DAY

EBOOL

ANY_DERIVED

ANY_ARRAY

ANY_ARRAY_ANY_EDT

ANY_ARRAY_ANY_MAGNITUDE

ANY_ARRAY_ANY_NUM

ANY_ARRAY_ANY_REAL

ANY_ARRAY_REAL

ANY_ARRAY_ANY_INT

ANY_ARRAY_DINT

ANY_ARRAY_INT

ANY_ARRAY_UDINT

ANNY_ARRAY_UINT

ANY_ARRAY_TIME

ANY_ARRAY_ANY_BIT

ANY_ARRAY_DWORD

ANY_ARRAY_WORD

ANY_ARRAY_BYTE

ANY_ARRAY_BOOL

ANY_ARRAY_ANY_STRING

ANY_ARRAY_STRING

ANY_ARRAY_ANY_DATE

ANY_ARRAY_DATE_AND_TIME

ANY_ARRAY_DATE

ANY_ARRAY_TIME_OF_DAY

ANY_ARRAY_EBOOL

ANY_ARRAY_ANY_DDT

ANY_STRUCTURE

ANY_DDT

ANY_IODDT

ANY_FFB

ANY_EFB

ANY_DFB

ARRAY

Glossary

An ARRAY is a table of elements of the same type.

The syntax is as follows: ARRAY [<terminals>] OF <Type>

Example:

ARRAY [1..2] OF BOOL is a one-dimensional table made up of two BOOL -type elements.

ARRAY [1..10, 1..20] OF INT is a two-dimensional table made up of 10x20

INT -type elements.

B

Base 10 literals

Base 16 Literals

Base 2 Literals

Base 8 Literals

A literal value in base 10 is used to represent a decimal integer value. This value can be preceded by the signs "+" and "-". If the character "_" is employed in this literal value, it is not significant.

Example:

-12 , 0 , 123_456 , +986

An literal value in base 16 is used to represent an integer in hexadecimal. The base is determined by the number "16" and the sign "#". The signs "+" and "-" are not allowed. For greater clarity when reading, you can use the sign "_" between bits.

Example:

16#F_F or 16#FF (in decimal 255)

16#F_F or 16#FF (in decimal 224)

A literal value in base 2 is used to represent a binary integer. The base is determined by the number "2" and the sign "#". The signs "+" and "-" are not allowed. For greater clarity when reading, you can use the sign "_" between bits.

Example:

2#1111_1111 or 2#11111111 (in decimal 255)

2#1110_0000 or 2#11100000 (in decimal 224)

A literal value in base 8 is used to represent an octal integer. The base is determined by the number "8" and the sign "#". The signs "+" and "-" are not allowed. For greater clarity when reading, you can use the sign "_" between bits.

Example:

8#3_77 or 8#377 (in decimal 255)

8#34_0 or 8#340 (in decimal 224)

193

Glossary

BCD

BOOL

BYTE

BCD is the abbreviation of Binary Coded Decimal format

BCD is used to represent decimal numbers between 0 and 9 using a group of four bits (half-byte).

In this format, the four bits used to code the decimal numbers have a range of unused combinations.

Example of BCD coding: z the number 2450 z is coded: 0010 0100 0101 0000

BOOL is the abbreviation of Boolean type. This is the elementary data item in computing. A BOOL type variable has a value of either: 0 ( FALSE ) or 1 ( TRUE ).

A BOOL type word extract bit, for example: %MW10.4

.

When 8 bits are put together, this is callad a BYTE . A BYTE is either entered in binary, or in base 8.

The BYTE type is coded in an 8 bit format, which, in hexadecimal, ranges from

16#00 to 16#FF

D

DATE

DATE_AND_

TIME

The DATE type coded in BCD in 32 bit format contains the following information: z the year coded in a 16-bit field, z z the month coded in an 8-bit field, the day coded in an 8-bit field.

The DATE type is entered as follows: D# <Year> <Month> <Day>

This table shows the lower/upper limits in each field:

Field

Year

Limits Comment

[1990,2099] Year

Month [01,12]

Day [01,31]

The left 0 is always displayed, but can be omitted at the time of entry

For the months 01\03\05\07\08\10\12

[01,30]

[01,29]

[01,28]

For the months 04\06\09\11

For the month 02 (leap years)

For the month 02 (non leap years) see DT

194

DBCD

DDT

DFB

DINT

Glossary

Representation of a Double BCD-format double integer.

The Binary Coded Decimal (BCD) format is used to represent decimal numbers between 0 and 9 using a group of four bits.

In this format, the four bits used to code the decimal numbers have a range of unused combinations.

Example of DBCD coding: z the number 78993016 z is coded: 0111 1000 1001 1001 0011 0000 0001 0110

DDT is the abbreviation of Derived Data Type.

A derived data type is a set of elements of the same type ( ARRAY ) or of various types

(structure)

DFB is the abbrevation of Derived Function Block.

DFB types are function blocks that can be programmed by the user ST, IL, LD or

FBD.

By using DFB types in an application, it is possible to: z z z z simplify the design and input of the program, increase the legibility of the program, facilitate the debugging of the program, reduce the volume of the generated code.

DINT is the abbrevation of Double Integer format (coded on 32 bits).

The lower and upper limits are as follows: -(2 to the power of 31) to (2 to the power of 31) - 1.

Example:

-2147483648 , 2147483647 , 16#FFFFFFFF .

195

Glossary

DT DT is the abbreviation of Date and Time.

The DT type coded in BCD in 64 bit format contains the following information: z The year coded in a 16-bit field, z z the month coded in an 8-bit field, the day coded in an 8-bit field, z z the hour coded in a 8-bit field, the minutes coded in an 8-bit field, z the seconds coded in an 8-bit field.

Note: The 8 least significant bits are unused.

The DT type is entered as follows:

DT# <Year> <Month> <Day> <Hour> : <Minutes> : <Seconds>

This table shows the lower/upper limits in each field:

Field

Year

Limits Comment

[1990,2099] Year

Month [01,12]

Day [01,31]

The left 0 is always displayed, but can be omitted at the time of entry

For the months 01\03\05\07\08\10\12

Hour

[01,30]

[01,29]

[01,28]

[00,23]

Minute [00,59]

Second [00,59]

For the months 04\06\09\11

For the month 02 (leap years)

For the month 02 (non leap years)

The left 0 is always displayed, but can be omitted at the time of entry

The left 0 is always displayed, but can be omitted at the time of entry

The left 0 is always displayed, but can be omitted at the time of entry

196

DWORD

Glossary

DWORD is the abbreviation of Double Word.

The DWORD type is coded in 32 bit format.

This table shows the lower/upper limits of the bases which can be used:

Base

Hexadecimal

Octal

Binary

Lower limit

16#0

8#0

2#0

Upper limit

16#FFFFFFFF

8#37777777777

2#11111111111111111111111111111111

Representation examples:

Data content

00000000000010101101110011011110

00000000000000010000000000000000

00000000000010101011110011011110

Representation in one of the bases

16#ADCDE

8#200000

2#10101011110011011110

E

EBOOL

EF

EBOOL is the abbrevation of Extended Boolean type. It can be used to manage rising or falling edges, as well as forcing.

An EBOOL type variable takes up one byte of memory.

Is the abbreviation of Elementary Function.

This is a block which is used in a program, and which performs a predefined software function.

A function has no internal status information. Multiple invocations of the same function using the same input parameters always supply the same output values.

Details of the graphic form of the function invocation can be found in the "[Functional block (instance)] ". In contrast to the invocation of the function blocks, function invocations only have a single unnamed output, whose name is the same as the function. In FBD each invocation is denoted by a unique [number] via the graphic block, this number is automatically generated and can not be altered.

You position and set up these functions in your program in order to carry out your application.

You can also develop other functions using the SDKC development kit.

197

Glossary

EFB

Elementary

Function

EN

ENO

Is the abbreviation for Elementary Function Block.

This is a block which is used in a program, and which performs a predefined software function.

EFBs have internal statuses and parameters. Even where the inputs are identical, the output values may be different. For example, a counter has an output which indicates that the preselection value has been reached. This output is set to 1 when the current value is equal to the preselection value.

see EF

EN means EN able, this is an optional block input. When EN is activated, an ENO output is automatically drafted.

If EN = 0, the block is not activated, its internal program is not executed and ENO ist set to 0.

If EN = 1, the internal program of the block is executed, and ENO is set to 1 by the system. If an error occurs, ENO is set to 0.

ENO means E rror NO tification, this is the output associated to the optional input EN .

If ENO is set to 0 (caused by EN =0 or in case of an execution error), z the outputs of function blocks remain in the status they were in for the last correct z executed scanning cycle and the output(s) of functions and procedures are set to "0".

F

FBD

FFB

Function

Function Block

Diagram

FBD is the abbreviation of Function Block Diagram.

FBD is a graphic programming language that operates as a logic diagram. In addition to the simple logic blocks ( AND , OR , etc.), each function or function block of the program is represented using this graphic form. For each block, the inputs are located to the left and the outputs to the right. The outputs of the blocks can be linked to the inputs of other blocks to form complex expressions.

Collective term for EF (Elementary Function), EFB (Elementary Function Block) and

DFB (Derived Function block) see EF see FBD

198

Glossary

G

GRAY Gray or "reflected binary" code is used to code a numerical value being developed into a chain of binary configurations that can be differentiated by the change in status of one and only one bit.

This code can be used, for example, to avoid the following random event: in pure binary, the change of the value 0111 to 1000 can produce random numbers between

0 and 1000, as the bits do not change value altogether simultaneously.

Equivalence between decimal, BCD and Gray:

Decimal 0

BCD

1 2 3 4 5 6 7 8 9

0000 0001 0010 0011 0100 0101 0110 0111 1000 1001

Gray 0000 0001 0011 0010 0110 0111 0101 0100 1100 1101

I

IEC 61131-3

IL

INF

International standard: Programmable Logic Controls

Part 3: Programming languages.

IL is the abbreviation of Instruction List.

This language is a series of basic instructions.

This language is very close to the assembly language used to program processors.

Each instruction is composed of an instruction code and an operand.

Used to indicate that a number overruns the allowed limits.

For a number of Integers, the value ranges (shown in gray) are as follows:

-INF

-3.402824e+38 -1.1754944e-38 0.0

1.1754944e-38

INF

3.402824e+38

When a calculation result is: z z less than -3.402824e+38, the symbol -INF (for -infinite) is displayed, greater than +3.402824e+38, the symbol INF (for +infinite) is displayed.

199

Glossary

INT

Integer Literals

IODDT

INT is the abbreviation of single integer format (coded on 16 bits).

The lower and upper limits are as follows: -(2 to the power of 15) to (2 to the power of 15) - 1.

Example:

-32768 , 32767 , 2#1111110001001001 , 16#9FA4 .

Integer literal are used to enter integer values in the decimal system. The values can have a preceding sign (+/-). Individual underlines (_ ) between numbers are not significant.

Example:

-12 , 0 , 123_456 , +986

IODDT is the abbreviation of Input/Output Derived Data Type.

The term IODDT designates a structured data type representing a module or a channel of a PLC module. Each application expert module possesses its own

IODDTs.

K

Keyword A keyword is a unique combination of characters used as a syntactical programming language element (See annex B definition of the IEC standard 61131-3. All the key words used in Unity Pro and of this standard are listed in annex C of the IEC standard 61131-3. These keywords cannot be used as identifiers in your program

(names of variables, sections, DFB types, etc.)).

LD

L

Located variables

LD is the abbreviation of Ladder Diagram.

LD is a programming language, representing the instructions to be carried out in the form of graphic diagrams very close to a schematic electrical diagram (contacts, coils, etc.).

A located variable is a variable for which it is possible to know its position in the PLC memory. For example, the variable Water_pressure , is associated with %MW102 .

Water_pressure is said to be localized.

200

Glossary

M

Multiple Token Operating mode of an SFC. In multitoken mode, the SFC may possess several active steps at the same time.

N

Naming conventions

(Identifier)

NAN

An identifier is a sequence of letters, numbers and underlines beginning with a letter or underline (e.g. name of a function block type, an instance, a variable or a section).

Letters from national character sets (e.g: ö,ü, é, õ) can be used except in project and

DFB names. Underlines are significant in identifiers; e.g. A_BCD and AB_CD are interpreted as different identifiers. Multiple leading underlines and consecutive underlines are invalid.

Identifiers cannot contain spaces. Not case sensitive; e.g. ABCD and abcd are interpreted as the same identifier.

According to IEC 61131-3 leading digits are not allowed in identifiers. Nevertheless, you can use them if you activate in dialog Tools → Project settings in tab

Language extensions the ceck box Leading digits .

Identifiers cannot be keywords.

Used to indicate that a result of an operation is not a number (NAN = Not A Number).

Example: calculating the square root of a negative number.

Note: The IEC 559 standard defines two classes of NAN: quiet NAN ( QNAN ) and signaling NaN ( SNaN ) QNAN is a NAN with the most significant fraction bit set and a

SNAN is a NAN with the most significant fraction bit clear (Bit number 22). QNAN s are allowed to propagate through most arithmetic operations without signaling an exception. SNAN generally signal an invalid-operation exception whenever they appear as operands in arithmetic operations (See %SW17 and %S18).

201

Glossary

Network There are two meanings for Network.

z In LD:

A network is a set of interconnected graphic elements. The scope of a network z is local to the program organization unit (section) in which the network is located.

With communication expert modules:

A network is a group of stations which communicate among one another. The term network is also used to define a group of interconnected graphic elements.

This group forms then a part of a program which may be composed of a group of networks.

P

Procedure Procedures are functions view technically. The only difference to elementary functions is that procedures can take up more than one output and they support data type VAR_IN_OUT . To the eye, procedures are no different than elementary functions.

Procedures are a supplement to IEC 61131-3.

202

Glossary

R

REAL Real type is a coded type in 32 bits.

The ranges of possible values are illustrated in gray in the following diagram:

-INF

-3.402824e+38 -1.1754944e-38 0.0

1.1754944e-38

INF

3.402824e+38

When a calculation result is: z between -1.175494e-38 and 1.175494e-38 it is considerd as a DEN , z z z less than -3.402824e+38, the symbol -INF (for - infinite) is displayed, greater than +3.402824e+38, the symbol INF (for +infinite) is displayed, undefined (square root of a negative number), the symbol NAN or NAN is displayed.

Note: The IEC 559 standard defines two classes of NAN: quiet NAN ( QNAN ) and signaling NaN ( SNaN ) QNAN is a NAN with the most significant fraction bit set and a

SNAN is a NAN with the most significant fraction bit clear (Bit number 22). QNAN s are allowed to propagate through most arithmetic operations without signaling an exception. SNAN generally signal an invalid-operation exception whenever they appear as operands in arithmetic operations (See %SW17 and %S18).

Note: when an operand is a DEN (Denormalized number) the result is not significant.

Real Literals

Real Literals with

Exponent

An literal real value is a number expressed in one or more decimals.

Example:

-12.0

, 0.0

, +0.456

, 3.14159_26

An Literal decimal value can be expressed using standard scientific notation. The representation is as follows: mantissa + exponential.

Example:

-1.34E-12 or -1.34e-12

1.0E+6 or 1.0e+6

1.234E6

or 1.234e6

203

Glossary

S

SFC

Single Token

ST

STRING

SFC is the abbreviation of Sequential Function Chart.

SFC enables the operation of a sequential automation device to be represented graphically and in a structured manner. This graphic description of the sequential behavior of an automation device, and the various situations which result from it, is performed using simple graphic symbols.

Operating mode of an SFC chart for which only a single step can be active at any one time.

ST is the abbreviation of Structured Text language.

Structured Text language is an elaborated language close to computer programming languages. It enables you to structure series of instructions.

A variable of the type STRING is an ASCII standard character string. A character string has a maximum length of 65534 characters.

T

TIME

Time literals

TIME_OF_DAY

The type TIME expresses a duration in milliseconds. Coded in 32 bits, this type makes it possible to obtain periods from 0 to 2

32

-1 milliseconds.

The units of type TIME are the following: the days ( d ), the hours ( h ), the minutes ( m ), the seconds ( s ) and the milliseconds ( ms ). A literal value of the type TIME is represented by a combination of previous types preceded by T# , t# , TIME# or time# .

Examples: T#25h15m , t#14.7S

, TIME#5d10h23m45s3ms

The units of type TIME are the following: the days ( d ), the hours ( h ), the minutes ( m ), the seconds ( s ) and the milliseconds ( ms ). A literal value of the type TIME is represented by a combination of previous types preceded by T# , t# , TIME# or time# .

Examples: T#25h15m , t#14.7S

, TIME#5d10h23m45s3ms see TOD

204

TOD

Glossary

TOD is the abbreviation of Time of Day.

The TOD type coded in BCD in 32 bit format contains the following information: z the hour coded in a 8-bit field, z z the minutes coded in an 8-bit field, the seconds coded in an 8-bit field.

Token

TOPO_ADDR_TY

PE

Note: The 8 least significant bits are unused.

The Time of Day type is entered as follows: TOD# <Hour> : <Minutes> : <Seconds>

This table shows the lower/upper limits in each field:

Field

Hour

Minute

Second

Limits

[00,23]

[00,59]

[00,59]

Comment

The left 0 is always displayed, but can be omitted at the time of entry

The left 0 is always displayed, but can be omitted at the time of entry

The left 0 is always displayed, but can be omitted at the time of entry

Example: TOD#23:59:45 .

An active step of an SFC is known as a token.

This predefined type is used as output for READ_TOPO_ADDR function. This type is an ARRAY[0..4] OF Int. You can find it in the libset, in the same family than the

EFs which use it.

U

UDINT

UINT

UDINT is the abbreviation of Unsigned Double Integer format (coded on 32 bits) unsigned. The lower and upper limits are as follows: 0 to (2 to the power of 32) - 1.

Example:

0 , 4294967295 , 2#11111111111111111111111111111111 , 8#37777777777 ,

16#FFFFFFFF .

UINT is the abbreviation of Unsigned integer format (coded on 16 bits). The lower and upper limits are as follows: 0 to (2 to the power of 16) - 1.

Example:

0 , 65535 , 2#1111111111111111 , 8#177777 , 16#FFFF .

205

Glossary

Unlocated variable

An unlocated variable is a variable for which it is impossible to know its position in the PLC memory. A variable which have no address assigned is said to be unlocated.

V

Variable Memory entity of the type BOOL , WORD , DWORD , etc., whose contents can be modified by the program during execution.

W

WORD The WORD type is coded in 16 bit format and is used to carry out processing on bit strings.

This table shows the lower/upper limits of the bases which can be used:

Base

Hexadecimal

Octal

Binary

Lower limit

16#0

8#0

2#0

Upper limit

16#FFFF

8#177777

2#1111111111111111

Representation examples

Data content

0000000011010011

1010101010101010

0000000011010011

Representation in one of the bases

16#D3

8#125252

2#11010011

206

Index

Symbols

%I, 48, 78

%IW, 48, 78

%M, 78

%MW, 48, 78

%Q, 48

%SW60, 41, 71, 110, 156

%SW61, 41, 71, 114

%SW62, 41, 71

%SW63, 41, 71

Numerics

16 bit compatibility, 40

32 bit compatibility, 40

984 Ladder Logic, 72

A

adapters

self-terminating F, 63

addresses

IP, 94, 96

MAC, 94, 114

Modbus, 90

Modbus Plus, 92, 139

swapping, 94, 96

application programs, 112, 131, 157, 160

A C

B

backlights, 21, 24

backplanes

configuring, 73

connecting, 62

identical, 16, 19, 58

mapping, 58, 60

base configurations, 19, 73

blinking indicators, 26, 133, 134, 187

Build Project, 142

buttons

ENTER, 23

ESC, 23

MOD, 23

reset, 22

right, 23 up, 23

C

cables

coaxial, 63

connecting, 62

diagrams, 64

fiber optic, 62, 184

topologies, 63

checksums

transferring, 131 validating, 131

CKSM, 131

clasps

fiber optic, 184

207

Index clocks

real time, 83

time-of-day, 117

coaxial splitters, 63

cold starts, 77, 82, 116

Com Act errors, 133, 134, 188

command registers, 131, 157

diagrams, 110

commands

Copro link, 130 monitor RIO, 130

No Standby, 125

take control, 124

communication types, 87

communications

healthy, 130 not healthy, 130

compatibility

16 bit, 40

32 bit, 40

components

Unity systems, 61

configurations

identical, 144

contrast adjustments, 24

controller failures, 134

Copro link commands, 130

Copro link requests, 130

Copros, 40

CRAs

software requirements, 20

CRPs

software requirements, 20

D

data editor, 85

data logging, 63

data messages, 126

data transfers, 48, 50, 54

data types, 144

DFBs, 144

diagnostics

Hot Standby, 32

Unity Pro, 121

208 diagrams

command registers, 110

Hot Standby systems, 19

MAST scans, 51

remote I/O networks, 64

state RAM, 49

status registers, 113

transfer, 49

drops

remote I/O, 63

E

EFBs, 144, 167

ENTER buttons, 23, 28

error logs, 121

error patterns, 188

errors

checksum, 187

Com Act, 133, 134, 187

detecting, 123 hard, 123

I/O, 46, 187

interface, 133, 134

ESC buttons, 23, 28

events, 82

EXEC upgrades, 111, 138

F

failures

controllers, 134

detecting, 123, 124

dual cables, 133, 134 fiber links, 62, 134

high-speed data links (HSDL), 126

RIO cables, 133, 134

types, 122

fiber optic cables, 62

G

Global Data, 145

green indicators, 26

H

hard errors, 123

health messages, 120, 121, 126

healthy communications, 130

hubs, 62

I

I/O errors, 46

I/O maps, 144

I/O transactions, 127

identical programs, 142

indicators

blinking, 26, 133, 134

green, 26

LED, 25

red, 26

status, 133, 134

steady, 133

steady off, 26 steady on, 26

interface errors, 133, 134

Invalidate Keypad, 88

K

key switches, 22, 28

keypads, 22, 23, 88

L

LCDs

backlights, 24

communications screens, 33

default screens, 29

displays, 21, 25, 27

LCD settings screens, 37

PLC operations screens, 30

system info screens, 36

LED indicators, 25

lens covers, 21

limits

transfer size, 161

located variables, 48

locked key switch, 22

logic mismatches, 114, 142, 146

logs

errors, 121

M

MAST scans, 51

menus

communications, 33

default, 29

LCD display screens, 27

LCD settings, 37

PLC operations, 30

system, 36

messages

health, 120, 121, 126, 129

No Standby, 125

warning, 189

mismatches

checksums (CKSM), 131

logic, 114

MOD buttons, 23

Modbus, 90

Modbus Plus, 87, 90, 92, 139

Modbus ports, 80

Modbus RTU, 139

modes

Hot Standby, 31

OFFLINE, 111, 114

RUN, 111

modifications, 146, 156 offline, 151, 156 online, 149, 150, 156

modules

replacing, 132

monitor RIO commands, 130 monitor RIO requests, 130

multiple transfer packets, 161

multitasking restrictions, 42

N

No Standby commands, 125

No Standby messages, 125

NOE, 16, 58, 94, 98, 105, 185

NOM, 16, 58

Index

209

Index

NOR, 62

not healthy communications, 130

O

offsets, 90 network addresses, 90

order

Hot Standby, 31

OSLoader, 139

overhead, system, 51

P

packets

multiple transfers, 161

PCMCIA cards, 86

Peer Cop, 74

PLC operations screens, 30

Primary controllers

time-of-day clocks, 117

programs

application, 131

identical, 131, 142

transferring, 160, 164

R

Rebuild All Project, 142

red indicators, 26

reference types, 48, 78

registers, 41, 71

command, 110, 131

reverse, 41

status, 113

remote I/O networks, 65

reports, 121

requests

Copro link, 130 monitor RIO, 130

reset buttons, 22

restrictions

DIO, 43 local I/O, 43

multitasking, 42

USB links, 45

210

reverse registers, 41, 71

right buttons, 23, 28

RIO, 63

heads, 127, 129

links, 127, 129

S

S908 modules, 40

scan times, 49, 50, 110, 120, 121, 123, 124,

126, 131, 144

sections

data, 144

SFC, 48, 147

updating, 144

setup methods

Hot Standby System, 58

SFC sections, 147

specifications, 185

splitters

coaxial, 63

standalones, 121, 123, 124

Standby controllers

time-of-day clocks, 117

state RAM, 48, 49, 71, 78, 143

states

Hot Standby, 31

static data memory layout, 143

status registers, 113

steady indicators, 29

steady off indicators, 26 steady on indicators, 26

submenus

default screen, 29

Hot Standby, 31

Init, 31

LCD contrast, 37

LCD display screens, 27

LCD Light, 37

Modbus Plus, 34

PLC operations screens, 30

serial port, 35

Start, 31

Stop, 31

System Info, 36

TCP/IP Ethernet, 34

switches, 62

switchovers, 90, 112, 121

USB, 45

system bits, 41, 110, 114

system information, 83

system words, 41, 110, 114

T

tabs

Animation, 81

Configuration, 76

Hot Standby, 85

Information, 83

Modbus Port, 79

Overview, 75

Realtime clock, 82

Summary, 74

Task, 81

take control commands, 123

TCP/IP, 90

tests

confidence, 120

Hot Standby systems, 66

of the Copro, 120 run time, 120

start-up, 66

startup, 120

switchover, 68

textids, 189

time-of-day clocks, 117

timer events, 46

times, 82

address swaps, 104

transfer, 50, 160

transferring programs, 160

transfer-size limits, 161

trunk terminators, 63

U

unlocated variables, 48, 71, 111, 114

unlocked key switch, 22

up buttons, 23, 28

updating

offline, 116

Primarys, 160

Standbys, 160

upgrades, 138

Upload Information Management, 156

user data, 143, 144

Index

V

values

initial, 116

variables, 145 declared, 145

located, 48, 144

redeclared, 145 section, 145 transition, 145

unlocated, 48, 71, 111, 114, 144

W

warm starts, 82

warnings

Configuration Hazard, 144

I/O Map Hazard, 144

Immediate Control of Process, 148, 152

Switchover Hazard, 147

211

Index

212