Schneider Electric Backup240, principle and functionalities User Guide

PDF

Document

Somm blc debut page

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Contents

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Chapter

1 Introduction

1.1 General

1.2 Operational depednability concept

1.3 Positioning of the BACKUP 240 solution

2 Presentation of BACKUP 240

2.1 Principles of the solution

2.2 Functionalities available

2.2-1 Overview of the functionalities

2.2-2 Functionalities of the redundant PLCs

2.2-3 Management of a private program

2.3 Duration of a switch-over

2.4 Hardware required

2.4-1 Composition of the BACKUP 240 package

2.4-2 Minimum hardware requirement

2.4-3 FIPIO compatibility

3 Installation of the solution

3.1 Procedure

3.2 Hardware installation 74

3.3 Installation of BACKUP 240

3.3.1 Loading of files

3.3.2 Installation of the software in the case of a new application 82

3.3.3 Installation of the software in the case of an existing application 84

Page

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Contents

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4 Chapter

3.4 Parametering the PLCs

3.4-1 Configuration of modules predundant PLCs

3.4-2 Parametering of the CW constants

3.4-3 Parametering the use of private racks

3.5 Entry of the user application

3.5-1 Limitations

3.5-2 Programming rules

3.5-3 Definition of the data base

3.5-4 Software/user application interface

User interface

4.1 Diagnostic words in the redundant PLCs

4.2 Diagnostic LEDs on the TSX DST module (redundant PLC)

4.3 Diagnostic LEDs on the TSX DET module (redundant PLC)

4.4 Signification of the LEDs on the TSX LES 240 modules

5 Use of the system

5.1 System start-up

5.2 Stopping the system

5.3 Switch-over

5.3-1 Switch-over following a fault

5.3-2 User-requested switch-over

5.4 Behavior following a network fault 99

5.5 System maintenance

5.5-1 Reinsertion of a PLC following repair

5.5-2 Reinsertion of the TSX LES 240 modules after exchange

5.5-3 Exiting the fallback state programmed by the user

100

101

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Page

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Contents

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Chapter

6 Appendixes

6.1 Installation of a new version of the software

6.2 Converting a BACKUP 240 application without FIPIO into an application with FIPIO

6.3 Performance

6.4 PMS2 regulation application

Page

103

104

106

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Introduction

1.1 General

BACKUP 240 is software/hardware package carrying out the tasks required for the operation of a passive CPU redundancy solution. This solution manages the rackmounted modules (in which case it is based on logical switching of the I/O bus) and the equipment on FIPIO..

Example of configuration :

MAPWAY/ETHWAY or FIPWAY network

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1.2 Operational dependability context

Dependability combines a number of concepts:

In the broad sense, dependability is the science of the failures and breakdowns.

In the strict sense, operational dependability is the collective term used to describe "the availability performance and its influencing factors: reliability performance, maintainability performance and maintenance support performance".*

* IEC 50 (191) Standard

Availability characterizes the ability of a system or a device to assure its function (or task, or service) in given conditions, at a given point in time or for a given period, assuming that the necessary means are provided.

In the area of automation systems, safety is also included as this characterizes the ability of a device to present no risk to personnel, equipment or the environment (no accidents).

Dependability of automation systems

Ability to assure a specified duty during a life cycle

Safety

Ability of an

entity to present no danger to personnel, equipment or the environment

Availability

Ability of an entity to be in an operational condition, at a given instant in time, or over a given period

Reliability

Ability of an

entity to assure a duty for a given duration

Maintainability

Ability of an entity to be maintained in or restored to an operational state in a given duration

Maintenance support

Ability of an

organization to supply the means required for maintenance

Finding a solution to a problem of dependability in the field of the automatic control involves selecting and implementing the type of architecture meeting the overall need.

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Introduction 1

1.3 Positioning of the BACKUP 240 solution

The BACKUP 240 solution is suitable for all automation systems making use of centralized data processing and requiring a high level of availability.

Notable examples are systems monitoring an installation in continuous service, reporting incidents to a control station, transmitting commands to different points on a large installation.

Examples:

Centralized technical management of a public works project (tunnel, airport, etc.),

Control of a water treatment and distribution center,

Automated control of electrical systems,

Control of a continuous process.

The goal is to guarantee the continuity of the central functions of the automatic control system, even in the event of a failure of one of its components.

The failure of an I/O interface module is tolerated, as is the breakdown of a sensor or an actuator. Such defects must if possible be detected and reported to the control station.

As regards the modules forming part of the central functions (processor, its power supply, its rack, its interface with the I/O racks, the module providing dialog with the control station), any failure of these modules must be tolerated to assure the continuity of the task of the automatic control system.

For this reason, BACKUP 240 provides a redundancy solution known as "hot stand-by" of the main rack of the TSX/PMX 7 programmable controller (PLC), the input/output interfaces being shared by means of logical switching.

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Presentation of BACKUP 240

2.1 Principles of the solution

The BACKUP 240 solution is based on the principle of the logical switching of the inputs/ outputs of the CPU of the main PLC to that of a back-up PLC in the event of a failure of the main PLC.

Functionally, the switch-over depends on the redundancy of the whole of the I/O bus for the rack-mounted modules and on the change of the bus arbitrator for FIPIO. Only one of the PLCs has access to the I/Os, the other being passive.

On failure of the main PLC, the back-up PLC intercepts the inputs/outputs and, after a re-learning sequence referred to as the "teach-in" phase, takes control of the process.

This teach-in phase is necessary in order that the switch-over can occur without

"faltering" of the outputs being transmitted to the process. It is made possible by a continuous exchange of the application context between the main PLC and the backup PLC .

Note:

The main PLC controlling the shared I/Os is also referred to as the active PLC. The backup PLC is known as the passive PLC.

2.2 Functionalities available

2.2-1 Overview of the functionalities

Main PLC

Back-up PLC

Supervision of inputs/outputs

Management of a p r i v a t e program

Sharing of a data base representative of the state of the active PLC

Communication with external entities

Supervision of:

. the state of the dual PLC

. the I/O link

Management of PLC switching

Management of a p r i v a t e program

Supervision of inputs/outputs

Sharing of a data base representative of the state of the active PLC

Communication with external entities

Supervision of:

. the state of the dual PLC

. the I/O link

Management of PLC switching

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2.2-2 Functionalities of the redundant PLCs

All the functionalities are implemented on the two redundant PLCs, which provides for identical, crossed behavior of these two entities.

1. System surveillance

The purpose of this function is :

• supervision of the host PLC: supervision of the base rack (processor, discrete I/O, communication coupler) and the execution of the PL7-3 program.

• supervision of the dual PLC: this is performed in part by means of hard-wired digital

I/O information (watchdog status, active/passive status, status of its connection to the shared I/Os and to the communication network).

• supervision of the shared I/Os: status of the connection to the extension racks for both

PLCs and status of the modules of the active PLC only.

• supervision of equipment on FIPIO (on the active PLC only).

2. Management of the active/passive mode of the CPU

CPU redundancy is based on a "main/back-up" principle. The "main" PLC is in active mode, controlling the I/Os. The "back-up" PLC is in passive mode; it does not have access to the I/Os and does not execute the application program.

This function enables:

• determination of the active and passive PLCs: a PLC in STOP state or having failed is always passive. If both PLCs are operational, only one of them must be active. In the event of failure of the active PLC, it becomes passive and its dual PLC becomes active. In the case of manual switching the states of the two PLCs are switched.

• management of changes of state: the passive PLC becomes active after a conclusive

"teach-in" phase. If its data base is inconsistent, it does not take control of the process.

The process adopts a fallback position configured by the user.

3. Sharing of a data base reflecting the state of the active PLC

In order for the back-up PLC (passive) to take control of the process smoothly during switch-over, it must at all times have complete knowledge of the state of the active PLC

(value of outputs, active steps, internal data). For this purpose the two PLCs share a data base containing all this information. The active PLC updates this data base and transmits the changes to the back-up PLC which in turn updates its version of the data base. An update of data that have changed is made every cycle. In addition, the whole data base is transferred periodically.

The transfer of the data base is made via an ETHWAY, MAPWAY or FIPWAY network.

The software is designed to manage two networks (a main network and a back-up) with automatic switching, if required, between the two.

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Presentation of BACKUP 240 2

In the case of use of I/O on FIPIO, redundancy of the inter-PLC communication network is possible with 87 and107 processors; with a 67 processor, only one inter-PLC communication network can be used.

4. Signalling

A data area containing the following information is made available to a programming terminal (FTX 507 or FTX 417), a supervisor or another PLC:

• state of the PLC,

• state of the dual PLC,

• state of the communication between the redundant PLCs.

5. Fallback function

When back-up PLC must take control of the process, but considers its data base to be inconsistent, the switch-over takes place but the user program is no longer executed.

A fallback sub-program (defined by the user) is executed.

This fallback sub-program enables the outputs to be set to a predetermined state and, if required, to start special processing. It is possible to exit deliberately from fallback mode and continue execution of the normal program.

2.2-3 Management of a private program

It is possible to manage non-shared I/Os in each PLC.

These can be installed in racks known as private racks. Racks 0/1 and 2/3 are designed to be private racks; it is possible via the parameters to declare one or more extension racks (from rack 4/5) as private racks.

The program managing these private racks is executed permanently in each PLC whatever its status (active or passive).

The main/backup function does not apply to these private racks.

The program and the configuration of private racks can be different on each of the two

PLCs.

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2.3 Duration of a switch-over

1. Rack-mounted modules

The time required for switch-over and taking of control of the process (access to the

I/Os) is 2 to 3 MAST cycles, the minimum being 200 ms.

2. Remote modules

Recognition of the FIPIO network by a CPU requires a set of checks whose duration depends on the type and number of equipment units configured. This time can range from about 1 second for a network with digital equipment only to several seconds if analog TBXs are in use.

2.4 Hardware required

2.4-1 Composition of the BACKUP 240 package

BACKUP 240 comprises 2 packages :

• TXT L BKP 240 V2M: basic package containing two 3"1/2 diskettes, this documentation and a user license.

One diskette (TXT LF FB SUR V2) contains a safety OFB (TWIN) used by the program to manage the redundancy; the other diskette (TXT LF RED 240 V2) contains the

PL7-3 REDUND 240 software for a configuration with rack modules only.

• TXT L BKP FIP V1: this package includes only one diskette (TXT LF RED FIP V1) which contains the PL7-3 REDUND FIP software for a configuration with equipement

on FIPIO and rack modules.

Therefore, if equipment on FIPIO must be managed, it is necessary to install this

program in place of the one provided in the basic package (the diskette TXT LF

RED 240 V2 is not used in this case).

The software is installed using the MINI X-TEL or X-TEL software workshop (versionV5 or later).

As regards hardware, TSX/PMX Model 40 processors (version V5.3 or later) must be used in the architecture. In addition, the link with the shared racks must obligatorily be of "long distance" electrical type using TSX LES 240 remote rackmaster modules.

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2.4-2 Minimum hardware requirement

Presentation of BACKUP 240 2

Base rack

Function Type of equip t TE reference

Rack power supply Power supply mod.TSX SUP xx

Management of redundancy/ execution of appl.

program

Series 7, model 40 V5

Version

≥

5.3

TSX P (or TPMX)

67 425/455 to107

425/455 (**)

Qty

Remoting of bus to long-distance extensions

"Long-distance" TSX LES 120 electrical remote adaptor module

Transmission Digital output of status information module to dual PLC

Reception of status Digital input information from dual PLC module

TSX DST8 xy xy depending on type of power supply

TSX DET8 xy (xy xy depending on type of power supply)

Communication between redundant PLCs

Extension rack Rack power supply

Remoting of bus from base rack /

Bus sharing

Communication TSX MAP107 4 coupler or TSX ETH107 or FIPWAY link integrated in the CPU

Power supply mo. TSX SUP xx

"Long-distance" electrical remote rackmaster module for redundant configuration

TSX LES 240

1/rack

2/rack

* the quantities indicated correspond to the whole architecture

(**) only TSX P (TPMX) 67 455 to 107 455 for managing FIPIO equipment.

Remark 1: The software is installed using the X-TEL software workshop (V5) under OS/2 version 1.3 or later.

Remark 2: See section 3.2 for the choice of base rack input and output modules.

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Hardware architecture

MAPWAY/ETHWAY or FIPWAY network

TSX 7

Model 40 V5.3

TSX LES 75

TSX LES 70

TSX LES 120

TSX LES 805

TSX CB xxx

TSX LES 240

Remote modules

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Presentation of BACKUP 240 2

2.4-3 FIPIO compatibility

• The wiring diagram given for FIPIO is only indicative.

Many other connection possibilites can be used (the two CPUs are considered to be two equipments).

• Check the possibility of parametering the fallback to hold the digital outputs of the

TBXs.

• The following are not handled on FIPIO :

- CCX 17

- NUM.

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Installation of the solution

3.1 Procedure

Hardware installation of the configuration:

- install the modules,

- connect the redundant PLCs,

- configure the communication couplers

(see § 3.2)

Installation of the BACKUP 240 program

files from the diskettes (see § 3.3-1)

Yes No

New application?

Integration of the software

in the station (see §3.3-2)

Input of the application

(see §3.5)

Adaptation of the user application according to the rules (see § 3.5)

Integration of the software

in the station (see §3.3-3)

Parametering of the redundant

PLCs (see §3.4 and §3.5-4)

Operation

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3.2 Hardware installation

Locations of the modules:

• In each base rack, the positions of the TSX DET 8xy and TSX DST 8xy modules are imposed:

TSX DET 8xy : Slot 2

TSX DST 8xy : Slot 3

Note: slots 0 and 1 are reserved for the TSX LES 120 remote adapter module

• In the shared extension racks, the two TSX LES 240 remote rackmaster modules occupy slots M and 0.

• In the private extension racks, fit a TSX LES 240 module in slot M.

FIPIO network

• The two CPUs must have station numbers 0 and 1 respectively.

• The network number must be different from 0.

• Make sure you set the same network number on both CPUs.

Numbering of the racks

• The shared racks are 4/5 to E/F,

• The private extension racks, if any, must be numbered starting at 4/5.

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Examples of wiring of the private racks

Installation of the solution 3

TSX LES 805

Private 4/5

Private 6/7

Private 4/5

Shared 8/9

A B

TSX LES 805

H Private 4/5 Private 4/5

Shared 8/9

Private 6/7

Shared A/B

Remark:

The availablity of the private racks can be increased by connecting them to a second LES

120 board in the main rack.

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Installation of the solution 3

Power supplies

The power supplies of the "main" and "back-up" PLCs must be independent to prevent a common failure mode.

Selection of input/output boards

The BACKUP 240 solution requires the use of 5 channels of an output board and 7 channels of an input board on each redundant PLC.

In a situation where no constraint exists as regards the choice of these boards, we recommend the use of 8 channel boards powered at the same voltage as each of the redundant PLCs. This enables the use of the power supply of each PLC to supply its own watchddog.

If this is not the case, check the voltage compatibility of the outputs and input boards.

The watchddog contact must then be supplied at this same voltage.

In both cases, an independent-channel input board is preferable. For reference, we give below the reference and supply voltage of suitable 8 channel boards:

Power supply

24 V DC

48 V DC

110 V AC

24 V AC

42-48 V AC

220-240 V AC

Ref. Input board

TSX DET 8 12

TSX DET 8 13

TSX DET 8 24

TSX DET 8 02

TSX DET 8 03

TSX DET 8 05

Ref. Output board

TSX DST 8 35

TSX DST 8 17

TSX DST 8 04

TSX DST 8 05

TSX DST 8 35

TSX DST 8 05

TSX DST 8 35

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Wiring of the inputs-outputs and the RAL contact ("watchdog")

The TSX DET 8xy and TSX DST 8xy modules of the main racks provide for information exchange between the two PLCs.

The TSX DET module 8xy must be in slot 2 and the TSX DST 8xy in slot 3.

In addition, one of the channels of each input board is used for wiring a push-button for manual switch-over of the system. The same "closing-type" push-button is fitted on both

PLCs.

The TSX DET 8xy module of a PLC must therefore be wired as follows: channel 0: channel 0 of the TSX DST 8xy module of the dual PLC channel 1: channel 1 of the TSX DST 8xy module of the dual PLC channel 2: RAL contact of the power supply of the main rack of the dual PLC channel 4: channel 4 of the TSX DST 8xy module of the dual PLC channel 5: channel 5 of the TSX DST 8xy module of the dual PLC channel 6: channel 6 of the TSX DST 8xy module of the dual PLC channel 7: + external power supply of the DET 8xy and DST 8xy modules

TSX DET 8xy TSX DST 8xy

Power

CPU

RAL

DST

8xy

Power

CPU

RAL

DET

8xy

Channel 0

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 0

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

+

External power supply

The two other TSX DET 8xy and TSX DST 8xx modules are wired in exactly the same manner.

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Installation of the solution 3

Addressing of the "redundancy" network

The system is designed to use one or two networks (one main, one back-up).

In the case of use of I/O on FIPIO, redundancy of the communication network is possible with 87 and 107 processors; with a 67 processor, only one network can be used.

Among the communication couplers present, those assigned to inter-PLC communication must be declared in the words managed by the software (see section 3.3-4).

Remarks:

• If two networks are in use, the station numbers of the two network couplers of each

PLC must be identical.

• The numbers of the networks must be different from 0.

Connection of the extension racks

• The wiring of the main rack/ extension racks (with TSX LES 240 remote rackmaster module) is identical to that of the TSX LES 200 module (use of the TSX LES 805 or

810 taps, end-of-line adaptation, etc.); the remoting characteristics are the same.

Important

Each line termination must be adapted in the TSX LES 805/810 taps by fitting a 150 ohm resistor between the Red and Green terminals (see the service instruction with the TSX LES 240 module).

• Direct extension racks, as in all architectures, must be of TSX RKE/RKS type, i.e. with a simplified backpanel bus.

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3.3 Installation of BACKUP 240

3.3-1 Loading the files

Prerequisites:

Operations are carried out with the X-TEL (V5) software workshop under OS/2 (version

1.3 or later):

• The user project must have been developed.

• The station for which redundancy is required must have been developed (as a single model).

Remark:

In the case of a new application, only the station should be created (name and type). Do not enter PL7-3 or XTEL-CONF, except in the case of existing applications.

Installation of the BACKUP 240 solution on the hard disk

• Open a full-screen OS/2 window

• Install the files of the SAFETY OFB diskette:

Place the diskette in disk drive A:

Choose logical unit A:

Type the command INSTALL, then press ENTER

Follow the instructions displayed

• Install the files of the BACKUP 240 software (REDUND 240 if there are only rack

modules, otherwise REDUND FIP):

Place the diskette in disk drive A:

Choose logical unit A:

Type the command INSTALL, then press ENTER

• Reply to the questions displayed by the system:

Choose the language (F for French, E for English)

The installation procedure for the REDUND 240 (or REDUND FIP) module of the

BACKUP 240 solution has started. This software was written by AEG Schneider

Automation.

It is the V2.0 version of BACKUP 240 for series 7 V5.3 PLCs.

You must know: the names of the station, project, destination application disk

(the station must already be created).

Do you want to continue? (Y/N)

The program comprises a PL7-3 macro-module to be integrated in the user program.

Do you want to install the macro module ? (Y/N)

The macro-module will be copied into the directories associated with the X-TEL station in which your PL7-3 program will be developed.

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Installation of the solution 3

The 3 following questions will enable you to give details of this X-TEL station:

Enter the name of the disk used (C or D)

Enter the name of the X-TEL project

Enter the name of the X-TEL station

Do you confirm these names ?(Y/N)

The solution imposes the use of one or more X-WAY networks (MAPWAY,

ETHWAY or FIPWAY type) for inter-PLC communication.

Is the FIPWAY network used for inter-PLC communication? (Y/N)

Remark: The declaration of the FIPWAY (even as a back-up network) reduces the length of messages sent to the back-up PLC by a half (see the documentation on the use of communication couplers).

The following questions will enable you to indicate the types of language planned or used in the PL7-3 application program:

Does the application program include a Grafcet function chart? (Y/N)

If your application includes the Grafcet function chart you must reply to the 2 following questions:

Is the preliminary field of the MAST task written in Litteral or Ladder language? (LIT/LAD)

Is the posterior field of the MAST task written in Litteral or Ladder language? (LIT/LAD)

If you do not use the Grafcet function chart for your application:

Is the main of the MAST task written in Litteral or Ladder language? (LIT/

LAD)

Do you confirm this information ? (Y/N)

Is this a new application ? (Y/N)

- Reply "YES" if it is a new application

- Reply "NO" if the application already exists

The message "Transfer of the sources files from the installation diskette successful" indicates that the copy procedure has been completed.

If the message "0 files copied" appears, the installation is unsuccessful (name of project or terminal incorrect).

You can now recover the REDUND macro-module from your X-TEL station.

PROCEDURE COMPLETE: you can remove the diskette and exit the OS/2 window.

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3.3-2 Installation of the software in the case of a new application

• Open the PL7-3 window of the station

• Check the configuration

In the OPERATING MODE (Key F2) menu select option 1 CONFIGURATION.

In the configuration menu select option 0 APPLICATION. Modify this configuration according to your user application (e.g. if you use the Grafcet function chart )

APPLICATION CONFIGURATION

0 APPLICATION DATE :

1 APPLICATION NAME:

2 APPLICATION VERSION :

3 MASTER TASK

4 GRAFCET

15/06/1995

BACKUP240 V2.0

SYST LIT LAD GRAFCET

V5.0 V5.0 V5.0

NUMBER SR : 15

(Y/N) :

5 PERIODIC TASKS

6 INTERRUPT TASK

(Y/N) : Y

(Y/N) :

7 COLD START: RUN AUTO (Y/N) : RESET Wi (Y/N) :

• In the main screen of window PL7-3, after validation of the configuration (if it has been modified):

Key CR, then VALID (Key F9), then YES (Key F9)

RECONFIGURATION DIAGNOSIS (0), then RECONFIGURATION (1)

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Installation of the solution 3

Installation of the software modules in the station to be made redundant

• In the main screen of the PL7-3 window, execute the RETRIEVE command:

Key F9

Deselect the line APPLICATION (.BIN): command UNSELECT (Key F2)

Select the line READ XTEL-MOD/PL7-PMS2: Key SOURCE F9, position on this line, then execute command SELECT (Key F2).

Press ENTER to start reading and wait for integration of all the modules.

Selection

RETRIEVE

Recoveries to be made

APPLICATION (.BIN)

Files

PL7_3

Mode

★

READ CONSTANTS (.CST)

READ XTEL-MOD/PL7-PMS2

PL7_3 AUTO

AUTO

UNSELECT MODE SEL.CUR.

• Return to the main screen of the PL7-3 window

Key clear

• Save the application in PL7-3.BIN

Key Store

RETRIEVE APPLI

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3.3-3 Installation of the software in the case of an existing application

In this case it is necessary to:

• Adapt the PL7-3 program following the rules described in section 3.5.

• Update in XTEL-CONF the configuration of the boards on the station to be made redundant:

- DET 8 xy module in slot 2 and configured as a MAST task,

- DST 8 xy module in slot 3 and configured as a MAST task.

• Application:

- configure the various options according to needs.

• Bits, words and function blocks:

- configure timer T0 as follows: PRST = 100, TB = 10ms,

- configure text blocks 0 to 3 as indicated in the following table:

NB MNEMONIC

0 ................

1 ................

................

NETWORK TYPE ADDR BUFFER

NET SYS IND CW40

NET TXT IND CW0

NET

TXT

IND

CW10

CW20

RECEPT A

H'0000'

T M L C

H'0736'

- Declare a number of words Wi (this depends on the application) and in all cases a number

≥

4700

• Optional function blocks:

- Install OFB "TWIN" (safety family), declare a number = 1.

- If REDUND FIP is used, install the OFB "TWINF" (safety family); declare a number

= 1.

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Installation of the solution 3

Install the new modules on the station ot be made redundant

• In the main screen of the PL7-3 window, execute the RETRIEVE command:

Key F9

Deselect the line APPLICATION (.BIN): command UNSELECT (Key F2)

Select the line READ XTEL-MOD/PL7-PMS2: Key SOURCE F9, position on this lline, then execute command SELECT (Key F2).

Press Enter to start reading; wait for the modules to be installed.

Selection

RETRIEVE

Recoveries to be made

APPLICATION (.BIN)

Files

PL7-3

Mode

★

READ CONSTANTS (.CST)

READ XTEL-MOD/PL7-PMS2

PL7-3 AUTO

AUTO

UNSELECT MODE SEL.CUR.

RETRIEVE SOURCE

• Return to the main screen of window PL7-3

Key clear

• Save the application in PL7-3.BIN

Key Store

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3.4 Parametering the PLCs

3.4-1 Configuration of modules for redundant PLCs

• Configurer using XTEL-CONF the I/O modules of the station to be made redundant

Remarks:

- the DET 8xy module managed by the software must be in slot 2 and configured as a MAST task

- the DST 8xy module managed by the software must be in slot 3 and configured as a MAST task

• Do not place a module in slot 0 of the extension racks; this slot is reserved for the second TSX LES 240. module.

• For the remote I/Os on FIPIO, do not place equipment at connection point 1; this is reserved for the second CPU.

H 3.4-2 Parametering of the CW constants

• Constant words CW50, CW51, CW52 and CW53 must be given by the user to define the assignment of network couplers in the inter-PLC dialog.

The word CW50 is assigned to the first coupler physically present (starting from the

CPU board); the word CW51 is assigned to the second coupler, and so on.

FIPWAY is considered to be the last network.

The word CWi of each coupler will contain:

- 0 if the coupler is not used for inter-PLC dialog,

- 1 if the coupler is that of the main network,

- 2 if the coupler is that of the back-up network.

Example:

The configuration includes, starting from the CPU board:

1 MAPWAY coupler,

1 ETHWAY coupler, and the FIPWAY coupler.

FIPWAY is the main network,

MAPWAY is the back-up network.

therefore: CW50 = 2

CW51 = 0

CW52 = 1

CW53 = 0.

• The constant word CW55 is used to define the size of the database; its defaut value is 2000, which is also the maximum size, the minimum value being 10.

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Installation of the solution 3

• The constant word CW54 is used to define the number of MAST cycles between successive transmissions of the entire data base to the back-up PLC; its default value is 3000; this can be modified by the user.

The periodic transfer of the whole database is a security feature providing permanent protection against erroneous entries from third-party equipment. However, since this transfer penalizes variables that change frequently, it is recommended to set the periodicity to more than one minute.

• The constant word CW19 contains an identification code for the redundant PLCs; its default value is H’B201' ;

If several BACKUP 240 configurations use the same inter-PLC network, then each configuration must have a different identification code. Only the least significant byte can be modified.

Example :

On the 1st redundant configuration:

CW19 = H'B201'

On the 2nd redundant configuration:

CW19 = H'B202'

• The constant word CW56 is used to define the re-starting of the polling of the user program after switch-over:

CW56 = 0 : re-start polling as soon as shared racks are recovered

CW56 = 1 : re-start polling as soon as shared racks and the remote digital I/Os on FIPIO are recovered

CW56 = 2 : re-start polling as soon as shared racks are recovered and all FIPIO connection points returned (digital and analog I/Os).

Remarque

CW56 is not used by the REDUND 240 software (version without I/O on FIPIO).

3.4-3 Parametering the use of private racks

It is possible to manage I/Os in private racks in each of the redundant PLCs (see

§ 2.2-3).

If private racks other than 0/1 and 2/3 are required, their number must be declared in the constant BAC-PRIV of the OFB TWIN.

To do this, in the "OFB constants" screen of the OFB TWIN, modify the value of BAC-PRIV

(0 by default) to the number of private racks required in the PLC.

• If 1 private rack is declared, this is obligatorily the rack 4/5; the shared racks start at

6/7,

• If 2 private racks are declared, these are obligatorily racks 4/5 and 6/7; the shared racks start at 8/9, etc.

The constant BAC-PRIV is read during program loading.

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3.5 Entry of the user application

3.5-1 Limitations:

• Do not use the subprograms SR0 to SR14 of the MAST task

• Do not use (never overwrite these variables, except for the data base: W2610 to W4598)

- constant words CW0->CW59

- words W0->W4699

- bits B0->B99

- timer T0

- text blocks TXT0 to TXT3 : the text block TXT0 is used by the program every 3 cycles in each processor and on each inter-PLC network (main and back-up).

Blocks TXT1 to TXT3 are used only on the main network (or on the backup network if the main one is out of service), at most once per cycle.

- system bits SY8, SY32 to SY39 (except those associated with private racks) and SY116

- activity times of the GRAFCET steps

- the following labels:

L1 to L210 and L900 to L999 of MAIN for an application without

GRAFCET

L1 to L210, L900 to L999 of PRL and L900 to L999 of POST for an application with GRAFCET

• If you use the FIPWAY network for the inter-PLC dialog, parameter a MAST task longer than 100 ms.

• In other cases, the period of the MAST task must be longer than 50 ms.

• For an application with remote I/Os on FIPIO, the period of the MAST task must be longer than 100 ms.

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Installation of the solution 3

3.5-2 Programming rules

• Respect the limits defined above (software resources).

• MAIN, PRL and POST define several fields:

- fields reserved for the program that must not be modified

- fields to be input by the user:

. learning field,

. unlearning field,

. "program executed permanently" field,

. initialization field,

. "program executed by the active PLC" field.

Comments delimit each of these fields.

These fields are described in the pages which follow.

• The application program concerning the shared modules must be input in the

"program executed by the active PLC" field.

• The field referred to as the "initialization field" is used for the initializations of the application executed on the active PLC (for example, positioning of the Grafcet function). It is executed once only the first time the PLC enters RUN state (if it is active).

• The analog output modules in racks must be configured to be held when the CPU is in STOP state, in order to assure a "smooth" switch-over.

• The remote digital and analog outputs must be configured to be held when a switchover occurs (check that the digital TBXs used allow this).

• For the rack modules, before sending the configuration of the couplers (analog, for example), make sure that operation has not already been performed. This test is essential in order not to re-configure the boards and cause interference following a switch-over.

• The handling of the interrupt task and the detection of the rising edge of input bits or the dating of events can be perturbed during a switch-over (notably the loss of these bits). So it is essential to make sure that the process can tolerate such a situation.

• For the modules dialoging with text blocks (SCM type), note that it is possible to lose information during a switch-over. In addition, it is necessary to initilize these text blocks (RESET TXT) in the unlearning field in order not to leave them in an error state in the back-up PLC (e.g. an exchange in progress at the instant of the switch-over).

• If FAST, IT and/or Auxiliairy tasks are used, these can be stopped in the back-up PLC.

This is provided for in the software: just enter the unlearning field. These tasks are started from the user program.

• The use of a PCM coupler in the shared racks does not require any special programming.

During operation, the coupler is re-initialized during a cold start-up (after loading the program). Consequently, on the back-up PLC the initialization of the PCM takes place during the first switch-over.

• For a regulation application, see appendix 6.4.

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Private racks

• In order that the program handling the private I/Os is executed in the corresponding

PLC whatever its state (active or passive), it is necessary to complete fields reserved for this purpose ("program executed permanently" field in MAIN, PRL et POST).

• During switching from active to passive state (which takes two MAST cycles and at least 200 ms) the outputs of the private racks are held.

• During switching from passive to active, the outputs will remain held until the user program re-starts polling the shared I/Os (the time depends on the re-starting mode defined by CW56).

• However the outputs remain accessible during switching by using the explicit addressing mode (WRITE BIT, WRITE REG).

• When a fault occurs on the CPU, the behavior of the private I/Os is determined by the state of the system bits SY34 (rack 4/5) to SY39 (rack E/F).

3.5-3 Definition of the data base

The data base is used to transfer the context of the main PLC to the back-up PLC, which then enables a switch-over without "faltering".

• The words W2600 to W4599 are reserved for the data base, but only words W2610

to W4599 are usable for data exchanges (W2600 to W2609 are reserved by the program).

• The size of the data base can be defined by a parameter (CW55), the default size being 2000. If another size is defined the data base occupies words W2600 to (W2600

+ CW55 - 1).

Example : for a size of 500 words, data base from W2600 to W3099, usable words from W2610 to W3099.

• The size of the data base does not affect the performance of the data exchanges

(updates of the back-up PLC), except in the case of the periodic transfer of the entire data base.

• The time required for update data exchanges is proportional to the number of variables

(data base words) that have changed during each PLC cycle. In the appendix, the maximum update time of a variable in the back-up PLC is defined as a function of:

- the number of variables changing each cycle,

- the cycle time,

- the type of inter-PLC network.

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Installation of the solution 3

• The content of the data base must be defined by the user; the following data are required:

- values of the digital and analog outputs,

- command registers of the analog couplers,

- status of the GRAFCET steps and macro-steps,

- values of the timers and counters,

- words, bits and OFB elements representative of the process.

3.5-4 Software/user application interface

The following fields must be completed by the user:

- unlearning field: management of the change from main to back-up PLC

- SR12 : transfer of data to the database

- SR13 : transfer of the database to the data

- SR14 : fallback subprogram

- teach-in field: management of the change from back-up to main PLC.

1) Unlearning field (in PRL or MAIN)

In this field input:

• the instructions required to stop the FAST, IT and AUX tasks (if they are used) when the PLC becomes the back-up PLC.

Example: RESET CTRL i

• stopping or forcing of the Grafcet

Example: SET SY22

2) Subprogram SR12

Update the database using the data of the application executed in the main PLC:

Input the following instructions (according to needs):

Digital ouputs:.................................... Oxy,0[16] ->Wz / ROxy, 0[16] ->Wz

Analog outputs : ................................ OWx,y ->Wz

Grafcet. steps: ................................... X0[y]->Wz

Grafcet. macro steps: ........................ X2,1[y]->Wz

Timers: .............................................. Ti,V -> Wz

Monostables: ..................................... Mi,V -> Wz ; Mi,R -> Wz,F

OFB, Miscellaneous: ......................... Wi -> Wz

Internal words: ................................... Wi -> Wz

Internal bits: ....................................... Bi[16] -> Wz where 2610

≤

[2600 + max. database size. (CW55) - 1]

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3) Subprogram SR13

Update of the application data using the database data

Input the following instructions (according to needs):

Digital outputs: ......... Wz -> Oxy,0[16] / Wz -> ROxy, 0[16]

Analogi outputs: ....... Wz -> OWx,y

Timers: .................... IF [Wz>0].[Wz<Ti,P] THEN Ti,P -> W1;

Wz -> Ti,P;PRESET Ti; START Ti;W1 -> Ti,P

Monostables : .......... IF Wz,F THEN Mi,P->W1;RESET Wz,F;

Wz->Mi,P;START Mi;W1->Mi,P

Internal words: ......... Wz -> Wi

Internal bits: ............. Wz -> Bi[16] where 2610

≤

[2600 + max. database size (CW55) - 1]

4) Subprogram SR14

This subprogram is executed in the event of switching to a PLC whose database is inconsistent..

If need be, input in this subprogram the actions corresponding to the fallback of the process.

Remarks in the case of fallback:

1) If this subprogram is not given, the outputs are held.

2) This subprogram is executed indefinitely in the place of the rest of the program.

If the user wishes to exit this subprogram and re-start normal operation, he must input the following instruction at the end of SR14:

IF (user condition)

THEN SET W8,1;

(see § 5.5-3)

3) If th user wishes to suspend the GRAFCET, he must set the system bit SY22 to 1 in SR14.

4) The program concerning the private I/Os is always executed.

5) Learning field

If your application uses the Grafcet function, its repositioning must be configured in the event of switch-over. This configuration is defined in this field (in PRL) from the label L6 in the following format:

!L6

If [w2950=0] Then JUMP L7

If W2950,0 Then SET X0

If W2950,1 Then SET X1

!L7

If [W2951=0] Then JUMP L8

In this example, the internal words W2950 and W2951 contain the states of the graph steps coming from the dual PLC, one bit of the word corresponding to one step (see SR12).

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4.1 Diagnostic words in the redundant PLCs

W4 ,x : Signification if bit x =1

0 : Base not connected to the shared extensions (in racks)

1 : CPU active

2-5 : Non-significative

6 : Data base not updated

7 : Non-significative

8 : System unable to switch

9 : Fault on network 1

A : Fault on network 2

B : Network 1 active

C : Network 2 active

D : No network available

E : Transmission fault

F : Reception fault

W5 ,x : Signification if bit x =1

0: I/O fault of the user configuration

1: Master task overrun

2: Index overflow or arithmetic error

3: Error on TWIN OFB

4: Digital input board redundancy fault

5: Digital output board redundancy fault

6: Fault on rack 4

7: Fault on rack 6

8: Fault on rack 8

9: Fault on rack A

A: Fault on rack C

B: Fault on rack E

C: Fault on communication coupler 1

D: Fault on communication coupler 2

E: Fault on redundant digital input module of dual PLC

F: Fault on redundant digital output module of dual PLC

User interface

W6 Valid only in REDUND FIP

,x : Signification if bit x =1

0 : Remote digital I/Os active

1 : All FIPIO connection points are recognized

2-4 : Non-significative

5 : FIPIO station number incorrect (for the CPU)

6 : FIPIO physical fault

7 : Error on TWINF OFB

8 : Valure of CW56 incorrect

9-F : Non-significative

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W7 ,x : Signification if bit x =1

0 : Configuration of network n

incorrect

1 : Configuration of station n

incorrect

2 : PLC in safety fallback position

3 : Correct identification of the dual PLC

4 : Dual PLC in RUN state

5 : Database of dual PLC badly connected to the shared extensions (in racks)

6 : Dual CPU active

7 : Database of the dual PLC not updated

8 : Inconsistent RUN state in the dual PLC

9 : Inconsistent active state in the dual PLC

A : Inconsistency in the state of the connection to the shared extensions of the

dual PLC

B : Non-significative

C : Inconsistent RUN state in the local PLC

D : Inconsistent active state in the local PLC

E : Inconsistency in the state of the connection to the shared extensions of the

local PLC

F : Database size incorrect

W8 Command word

0 : External switching request

1 : Request for exit from the fallback state

2-F : Non-significative

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User interface 4

4.2 Diagnostic LEDs on the TSX DST module (redundant PLC)

LED 0 - 4: Connection to the shared I/Os in racks (on = OK)

LED 1 & 5: CPU active (LED on) or passive (LED off)

LED 2: On = PLC in safety fallback position

LED 3: On = System unable to switch

LED 6: On = data base updated

4.3 Diagnostic LEDs on the TSX DET module (redundant PLC)

Same specifications as TSX DST, except:

LED 2: RAL of the DUAL

LED 7: Presence of external power supply on modules TSX DET and TSX DST

4.4 Signification of the LEDs on the TSX LES 240 modules

1. On the I/O bus of the active CPU: the meanings of the LEDs of the TSX LES 240 module is identical to those of a TSX LES 200:

• PLC in RUN state and no I/O fault: RUN LED is on and I/O LED is off

• PLC in RUN state and I/O fault: RUN LED is on and I/O LED is on

• If the two LEDs of the TSX LES 240 are off when the PLC is in RUN state, this means there is a fault on the TSX LES 240 module or a connection problem somewhere on the I/O bus

2. On the I/O bus of the passive CPU:

• PLC in RUN state and with or without I/O fault: RUN LED is off and I/O LED is on

• If the two LEDs of the TSX LES 240 are off, then either there is a fault on this module or there is a connection problem somewhere on the I/O bus.

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Use of the system

5.1 System start-up

The operations described in the following sequence are carried out using the X-TEL software workshop, connected to the PLCs via a network or terminal port.

• Start situation:

The applications of the two PLCs have been loaded. The PLCs are powered up and in STOP state.

• Start sequence:

1. On the PLC destined to start in "main PLC" mode (active PLC):

Set the PLC to RUN state.

Carry out the following checks:

TSX LES 240 modules connected to this PLC are in RUN state and their

I/O LED is off

Tests of normal operation of the software:

W4,0 = 0 and LED 0 of the TSX DST 8xx module on: Base connected to the shared extensions

W4,1 = 1 and LED 1 of the TSX DST 8xx module on: CPU active

W4,2 = 0 and LED 5 of the TSX DST 8xx module on: Able to control the process

W4,6 = 0 and LED 6 of the TSX DST 8XX module on: data base is upto-date

W7,0 = 0 and W7,1 = 0: network couplers correctly recognized.

Tests of normal operation of user application software, if required.

2. On the PLC destined to start up in "back-up PLC" mode (passive PLC):

Set the PLC to RUN state.

Carry out the following checks:

On the shared extension racks, the TSX LES 240 modules connected to this

PLC have their RUN LED off and their I/O LED on.

Check that the two redundant PLCs are correctly identified:

W7,3 = 1; W7,4 = 1 on both PLCs

Check that the back-up PLC is able to switch:

(wait about 30 seconds after the back-up PLC goes into RUN state before carrying out this check.)

W4,6 = 0: data base updated

W4,8 = 0: system able to switch

On the TSX DST 8xx module of this PLC, the LEDs should be as follows:

LED 0 and 4 on

LED 1 and 5 off

LED 6 on

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3. Perform a manual switch-over to check that the system works correctly: check that the two PLCs have inverted their roles (inversion of information, bits and

LEDs).

4. Repeat operation 3 in order to return the PLCs to their initial roles (this operation is not essential).

Remark:

It is preferable to check the correct operation of the application on a single-PLC configuration. To do this, switch off the back-up PLC or set it to STOP.

5.2 Stopping the system

Proceed as follows:

1. Stop the back-up PLC;

2. Stop the main PLC.

5.3 Switch-over

5.3-1 Switch-over following a fault

• A switch-over from the main to the back-up PLC occurs in the following cases:

- fault on the power supply module of the main rack,

- CPU fault,

- change to STOP state of the CPU,

- loss of connection to the shared I/Os in racks: connection problem, fault on the LES

120 or LES 240,

- fault on the DST 8xy output board or the DET 8xy input board of the main rack.

Remarks:

1. Loss of the shared I/O modules (in racks or remote) does not cause a switch-over.

2. If the database of the back-up PLC is not up-to-date at the time of a switch-over, the process goes into the programmed fallback state (defined in SR14).

3. The redundant system sets the outputs to their parametered fallback states when a switch-over is requested to a back-up PLC whose CPU is out of service, in STOP state or switched off.

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Use of the system 5

5.3-2 User-requested switch-over

A switch-over can be triggered via a supervisor or a terminal communicating with the

main PLC, by setting the bit W8,0 to 1.

This bit is reset to 0 by the program after execution of the command.

The switch-over will be effective if the back-up PLC is in RUN state (RAL contact closed).

Guarantee of correct switch-over

The back-up PLC is capable of taking over control of the process provided its data base is up-to-date, it is connected to the rack I/Os and the inter-PLC dialog is operative.

Bit W4,8 provides the indication of these conditions (W4,8 = 0 if OK).

To avoid accidental switch-overs (i.e. a request for switching to a PLC unable to control the process), it is possible to make the setting of bit W8,0 to 1 dependent on W4,8.

If a switch-over is requested via a push-button connected to an input on a shared rack, the falling edge of this signal must be used.

5.4 Behavior following a network fault

If the PLCs are linked by a single network, a fault in this network has no immediate effect on the behavior of the system. On the other hand, if a switch-over occurs the process will take the fallback position programmed by the user (since the data base is not up-todate in the back-up PLC). The fault is indicated by bits W4,9 and W4,D (both = 1).

In a system with redundant networks (main and back-up), both networks are tested separately. In the event of a fault on the back-up network, the behavior of the system is not affected and a successful switch-over remains possible. The fault is indicated by bit W4,A (=1). After repair of the fault, this network can re-assume its back-up role.

In the event of a fault on the primary network, the inter-PLC dialog switches to the backup network. The behavior of the system is not affected. The data base of the back-up

PLC may not be up-to-date for a few seconds; a switch-over can then take place if need be. The network fault is indicated by bit W4,9 (=1).

After repairing the primary network, the inter-PLC dialog returns to this network. On a system with redundant networks, a network fault makes the system equivalent to a single-network configuration.

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5.5 System maintenance

5.5-1 Reinsertion of a PLC following repair

• Start situation:

The main PLC is in RUN state and in "solo" mode. The PLC to be reinserted is necessarily the back-up PLC.

• Reinsertion sequence of the back-up PLC:

1. Reload the program of this PLC, if necessary.

2. Set the PLC to RUN state.

3. Check the normal operation of the PLC.

4. On the TSX LES 240 modules connected to this PLC check that the RUN LED is off and the I/O LED is on.

5. Carry out the following checks:

- Check that the two redundant PLCs are correctly identified:

W7,3 = 1; W7,4 = 1 and W7,8 = 0 on both PLCs

- Check that the back-up PLC is able to switch:

(wait about 1 minute for the initial exchange of the data base to be completed

before carrying out this check)

W4,6 = 0: data base updated

W4,8 = 0: able to switch

- On the TSX DST 8xx module of this PLC, the LEDs should be as follows:

LED 0 and 4 on

LED 1 and 5 off

LED 6 on

5.5-2 Reinsertion of the TSX LES 240 module after exchange

• Start situation:

Both PLCs (main and back-up) are in RUN state.

• Reinsertion sequence for a TSX LES 240 module on the I/O bus of the passive

CPU:

1. Fit the module in the slot provided in the shared extension rack under power.

Check that none of the RUN or I/O indicator lights come on.

2. Connect the cable from the TSX LES 805 tap to the front panel connector of the TSX

LES 240 module.

3. Check that the RUN LED of the TSX LES 240 module remains off and the I/O LED comes on.

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100

Use of the system 5

5.5.3 Exiting the fallback state programmed by the user

The system goes into fallback state following a switch-over to a PLC whose data base is not up-to-date.

The main PLC then executes indefinitely and exclusively the sub-program SR14, input by the user.

It is possible to exit this situation:

- either by reinitializing the system,

- or, after making sure the process will react correctly when the normal program starts executing (values of data), by:

1) resetting the application variables whose values have been changed by SR14,

2) setting bit W8,1 to 1. Once this bit is set the program SR14 is no longer executed

and the program returns to normal execution (see § 3.5-4, sub-program SR14).

Remark:

The program managing the private I/Os is still executed, even in fallback state.

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101

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102

Appendixes

6.1 Installation of a new version of the software

Remark: it is important to follow exactly the order of operations described below.

- Open the PL7-3 window on your old station

- Enter program mode (operating mode 2)

- Open the screen MOD SCR (screen module) and delete the REDUND macromodule. to do this, use the arrow keys to move the cursor to the REDUND line, then press Del and confirm the deletion by pressing F9. Ignore any error messages

(press Del repeatedly until the REDUND macro-module is completely eliminated).

Be careful not to touch the PARAM macro-module; if you do, you will have to recover your old application, then repeat the installation of the software update.

Copy the new version of the files of the BACKUP 240 software package to the hard disk.

The procedure is identical to that described in section 3.3-1 "Loading the files".

Reply "NO" to the question: "Is this a new application ? (Y/N)" .

Installation of the new modules on the station to be made redundant

Install the new modules :

- On the main screen of the PL7-3 window, run the RETRIEVE command (F9).

- Deselect the line APPLICATION (.BIN): UNSELECT command (F2).

- Select the line READ XTEL-MOD/PL7-PMS2: execute the SOURCE command

(F9), position on this line, then execute the SELECT command (F2).

- Choose MANUAL mode (F4).

- Press ENTER to start reading the modules.

- Press ENTER to copy all the sub-programs of the REDUND macro-module, except for the sub-modules of the PARAM macro-module (the PARAM module includes the user-modified programs SR12, 13 and 14, MAST PRL and MAST POST (or MAIN)).

- If the message "module not empty: delete?" appears, reply YES.

- Return to the main screen of the PL7-3 window.

- Check the CW constants of the program.

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103

6.2 Converting a BACKUP 240 application without FIPIO into an application with FIPIO

In this case, proceed as for an update of the version of the software (see § 6.1), replacing

REDUND 240 by REDUND FIP.

6.3 Performance

1) Maximum data base update time

The maximum duration of an update depends on the number of variables that have been modified during each PLC cycle and the cycle time of the MAST task.

FIPWAY network used for the inter-PLC dialog

Max. update time (ms)

PLC cycle time

Max. update time (ms)

No. of variables modified during each cycle

PLC cycle time

No. of variables modified during each cycle

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104

Appendixes 6

ETHWAY or MAPWAY network used for the inter-PLC dialog

Max. update time (ms)

PLC cycle time

Max. update time (ms)

No. of variables modified during each cycle

PLC cycle time

No. of variables modified during each cycle

2) Duration of a copy of the entire data base

The time required to copy over the entire data base between the PLCs can be deduced from the graphs above, by taking the number of variables modified during each cycle

(abscissa) to be equal to the size of the data base (CW55).

3) Inter-PLC dialog

If other equipment is present on the inter-PLC network, make sure that this does not overload the network, thereby degrading the performance of the data base transfers.

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105

6.4 PMS2 regulation application

Prerequisite:

In order to integrate the regulation sub-program PL7-3 correctely, the following file must be deleted:

STATION.M5M located in XPROPRJ\"projet"\"station"\PL7-3\MOD.

The execution of a PMS2 regulation program in a BACKUP 240 architecture requires the following conditions to be met:

• the same regulation system must be used in both the main and back-up PLCs;

• the regulation task must must run in both the main and back-up PLCs;

• the OFBs of PMS2 V6 must be used; these have the initialization inputs TR_I and

TR_S (e.g. OFB ANIN, PIDFF, DTIMD).

The principle is as follows:

1) In the passive PLC, the regulation OFBs are executed in initialization mode (by TR_S

= not W4,1); the value on TR_I is that of the output of the corresponding OFB calculated in the active PLC (and transferred via the data base).

Example :

• Regulation system:

ANIN 0

OUTP

DW5000 – TR_I

PIDFF 0

PV OUTP

ANOUT 0

INP

Not W4,1 – TR_S

– RSP

– FF

DW6000 – TR_I

Not W4,1 – TR_S

• SR12 ANIN 0, OUTP --> DW3000

PIDFF 0, OUTP --> DW3002

• SR13 DW3000 --> DW5000

DW3002 --> DW6000

DW3000 and DW3002 are in the data base.

2) Starting the regulation task:

The auxiliary task containing the regulation program must be started in the initialization field provided in the software (in this way the AUX task is started then executed, whether the PLC is active or passive).

3) Fallback:

If it is required to stop the regulation task when the PLC goes into fallback state, then the instruction RESET CTRL i must be included in the fallback sub-program SR14.

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106

Appendixes 6

This task is restarted:

• when the PLC is re-initialized,

• or when the operator deliberately exits the fallback (bit W8,1) by executing the following instruction in SR14 :

IF (user condition)

THEN SET W8,1 ;

START CTRL i

4) Transfer of the OFB data from the active PLC to the passive PLC: the transfer concerns the variables that are not generated by the regulation loop itself.

Example: set point of a PIDFF:

• if it comes from a supervisor, via a word, it must be transferred,

• if it is the output of a RAMP OFB, it must not be transferred.

The data that must obligatorily be transferred (taking account the previous remark) are:

• for PIDFF, RM and PIDFZ OUTP

RSP

SP_USED

MAN_AUTO

SP_RSP

• for ANIN, LDLGD, DTIMD,

INTD, LEAD, RAMP

• for ONOFF

OUTP

RSP

SP_USED

MAN_AUTO

SP_RSP

5) The other data (such as the adjustment parameters) can also be transferred via the database.

Remark:

The saving of the OFB parameters (by the OFB SAVE) is not handled by the software.

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