PACSystems RX3i Max-ON Hot Standby Redundancy Manual, GFK

PACSystems RX3i Max-ON Hot Standby Redundancy Manual, GFK
GE Fanuc Automation
Programmable Control Products
PACSystems® RX3i
Max-ON Hot Standby Redundancy
User’s Manual, GFK-2409
June 2006
GFL-002
Warnings, Cautions, and Notes
as Used in this Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages,
currents, temperatures, or other conditions that could cause personal injury exist in this
equipment or may be associated with its use.
In situations where inattention could cause either personal injury or damage to equipment,
a Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Note
Notes merely call attention to information that is especially significant to understanding and
operating the equipment.
This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information contained herein does not purport to cover all
details or variations in hardware or software, nor to provide for every possible contingency in
connection with installation, operation, or maintenance. Features may be described herein
which are not present in all hardware and software systems. GE Fanuc Automation assumes no
obligation of notice to holders of this document with respect to changes subsequently made.
GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory
with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or
usefulness of the information contained herein. No warranties of merchantability or fitness for
purpose shall apply.
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©Copyright 2006 GE Fanuc Automation North America, Inc.
All Rights Reserved
Contents
Chapter 1
Introduction............................................................................................ 1-1
Welcome ........................................................................................................................... 1-1
Installing Max-ON RX3i Software..................................................................................... 1-3
System Requirements .............................................................................................. 1-3
To Install Max-ON RX3i Software ............................................................................ 1-3
Uninstalling Max-ON RX3i Software ....................................................................... 1-4
Max-ON RX3i Component Installation ..................................................................... 1-5
Technical Support ............................................................................................................. 1-9
GE Fanuc Global Care Web Site ............................................................................. 1-9
North America........................................................................................................... 1-9
Asia........................................................................................................................... 1-9
Europe, Middle East, and Africa............................................................................... 1-9
South America .......................................................................................................... 1-9
Online Help ............................................................................................................. 1-10
Chapter 2
System Overview ................................................................................... 2-1
Architecture .............................................................................................................. 2-1
Software Components .............................................................................................. 2-3
Hot Standby Redundancy Operation........................................................................ 2-4
Failover Time............................................................................................................ 2-5
Synchronized Data Transfers................................................................................... 2-5
I/O Bus Topologies ................................................................................................... 2-6
Genius Dual Bus I/O Capacity.................................................................................. 2-6
Selecting the I/O ....................................................................................................... 2-7
Demo Mode Operation ............................................................................................. 2-8
Chapter 3
Building a Max-ON RX3i Hot Standby Application.............................. 3-1
Max-ON RX3i Project........................................................................................................ 3-1
Project Workflow ............................................................................................................... 3-2
Step 1 - Gather Information ...................................................................................... 3-2
Step 2 - Create a New Max-ON RX3i Project .......................................................... 3-2
Step 3 - Configure the Controller Hardware ............................................................. 3-4
Step 4 - Add Your Application Logic......................................................................... 3-5
Step 5 - Configure the I/O Devices........................................................................... 3-5
Step 6 - Start the System ......................................................................................... 3-6
Step 7 - Debug the System ...................................................................................... 3-8
Chapter 4
The Max-ON RX3i Configuration Utility................................................ 4-1
Max-ON RX3i Projects ...................................................................................................... 4-1
Working with the Max-ON RX3i Configuration Utility ........................................................ 4-6
Adding Genius I/O Devices .................................................................................... 4-17
Project Information ................................................................................................. 4-29
User Defined Alarms .............................................................................................. 4-30
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iii
Contents
Chapter 5
Programming Considerations .............................................................. 5-1
Reserved References ....................................................................................................... 5-2
System Status Flags ......................................................................................................... 5-3
Local Status Flags – Instantaneous ......................................................................... 5-5
Local Status Flags – Latched ................................................................................... 5-7
Remote Status Flags - Latched................................................................................ 5-9
System Command Flags................................................................................................. 5-11
Mastership Modes .................................................................................................. 5-12
System Data Registers ................................................................................................... 5-17
Advanced Topics............................................................................................................. 5-18
PID Function Blocks ............................................................................................... 5-18
User-Defined Alarms....................................................................................................... 5-20
In Max-ON RX3i Configuration Utility ..................................................................... 5-20
In Your Application Folder ...................................................................................... 5-22
Alarm Table Organization ............................................................................................... 5-24
Alarm Record Structure .......................................................................................... 5-24
Chapter 6
Configuring the Hot Standby Redundancy CPUs ............................... 6-1
Configuring PLC A.................................................................................................... 6-2
Configuring PLC B.................................................................................................... 6-9
Chapter 7
Configuring the I/O Devices.................................................................. 7-1
Configuring the Ethernet I/O Devices....................................................................... 7-1
Configuring the Genius I/O Devices ......................................................................... 7-3
Chapter 8
Diagnostic Tools.................................................................................... 8-1
Step 1 – Create a Max-ON RX3i Diagnostic Tool View Project ............................... 8-1
Step 2 – Configure Ethernet Connections to the PLCs............................................ 8-3
Step 3 – Use the Max-ON RX3i Diagnostic Tool ..................................................... 8-4
System Status .......................................................................................................... 8-5
Alarms....................................................................................................................... 8-6
Appendix A
System Considerations .........................................................................A-1
General Max-ON RX3i Considerations .............................................................................A-1
Improving Ethernet Synch Efficiency Using PLC Sweep Mode........................................A-2
Automatic Mode Selection........................................................................................A-2
Manual Mode............................................................................................................A-3
Appendix B
Frequently-Asked Questions ................................................................B-1
Appendix C
Quick Start Guide Using Ethernet I/O ..................................................C-1
Appendix D
Updating the Max-ON Application ........................................................D-1
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PACSystems® RX3i Max-On Hot Standby Redundancy– June 2006
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Chapter Introduction
1
Welcome
Thank you for choosing Max-ON RX3i Hot Standby Redundancy software and GE Fanuc
PACSystems™ RX3i controllers to implement your critical control project.
Max-ON RX3i Software consists of several software components, some of which execute in a
pair of Hot Standby PACSystems Max-ON RX3i Controllers, and some of which execute upon
your programming workstation.
The PACSystems controller-based software consists of a set of application blocks that
perform the Redundancy portion of the Hot Standby application. These application blocks are
provided as part of a Proficy™ Machine Edition Project that is the starting point of your
redundant automation application. Using GE Fanuc’s Proficy Logic Developer PLC
programming software, you add your application logic to this project, and then store the
overall project to each of the Hot Standby controllers.
The Max-ON RX3i Configuration Utility, which is launched from the Logic Developer PLC
Project, provides a utility to allow the control system designer to customize the functionality of
the redundant system.
A Proficy View Max-ON RX3i Project is also provided to monitor the status of the Redundant
System and to display diagnostic information.
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1-1
1
With the Max-ON RX3i LD Project , you can:
•
Create a Hot Standby system that operates using a combination of GE Fanuc
Genius™ I/O, Field Control™, Series 90™-30 remote Genius drops, and Genius
VersaMax™ I/O, as well as Series 90-30 and PACSystems RX3i Ethernet NIUs.
•
Provide data synchronization using an Ethernet LAN.
With the Max-ON RX3i Configuration Utility software, you can:
•
View and Modify the parameters of the Hot Standby Redundancy system:
•
Redundant System Parameters
•
Synchronization Data Groups
•
Synchronization Network Interface Parameters
•
Genius I/O Bus definitions
With the Max-ON RX3i View Project, you can:
•
1-2
Establish a communication link to the Hot Standby CPUs to:
•
Monitor system-level alarms in real-time
•
Monitor performance characteristics in real-time
•
Display information about the Redundant system: Max-ON driver version, CPU
modules
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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1
Installing Max-ON RX3i Software
System Requirements
Max-ON RX3i Software may be installed on a PC that has the minimum requirements shown
below:
▪
1 GHz Pentium class processor
▪
256 MB RAM or more
▪
Windows NT 4.0 (Service pack 6a or later), Windows 2000 Professional (Service Pack
3 recommended), or Windows XP Professional (Service Pack 1 recommended)
▪
50 MB of free disk space
NOTE: Max-ON RX3i Software requires Logic Developer PLC Professional Edition Release
5.50 LD PLC SIM 1 or later.
To Install Max-ON RX3i Software
1. Make sure that you have installed Proficy Machine Edition release 5.5 SIM 1 or later.
This is required to configure and program the Max-ON RX3i CPU.
2. It is recommended that you close all applications including virus checking, Internet
Explorer, and HMI software that might be running in the background. You may need
to check the task manager to determine if other applications are running. As a further
precaution, it is also recommended that you re-boot the PC to make sure components
that Max-ON RX3i Configuration Utility needs to update are not running during the
installation process.
3. Put the Max-ON RX3i Software CD in CD-ROM Drive.
4. Select the CD drive from Windows Explorer.
5. Double click Setup.exe.
6. Follow the user prompts to complete the installation.
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Chapter 1 Introduction
1-3
1
Uninstalling Max-ON RX3i Software
Max-ON RX3i Software can be uninstalled only from the computer upon which it is installed. It
cannot be uninstalled over a network. You can uninstall Max-ON RX3i Software from the
Add/Remove Programs option on the Windows Control Panel or from the Windows Start
Menu.
If the computer has other GE Fanuc software products installed, Max-ON RX3i Software can
be uninstalled without removing any files needed by those applications. To uninstall Max-ON
RX3i Software, do the following:
1.
Choose Uninstall from the Start Menu or the Control Panel.
2.
A dialog box appears asking if you are sure you want to uninstall.
3.
Confirm the Uninstall.
▪
All files relating to Max-ON RX3i Software will be removed from the hard drive. Any
files used by both Max-ON RX3i Configuration Utility and another application will be
left on the system.
▪
All registry entries relating to Max-ON RX3i Software will be removed from the
systems registry.
▪
Icons for Max-ON RX3i Software will be removed from the Start Menu.
▪
Any data you created (for example, Project that you have created) will be left on the
system.
Note: You may also uninstall Max-ON RX3i Software by choosing Add/Remove Programs
from the Control Panel, then selecting Max-ON RX3i Tools.
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PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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1
Max-ON RX3i Component Installation
The default settings for the Max-ON RX3i software installation places the Max-ON RX3i
Software and the associated project components in the GE Fanuc Automation directory.
The Max-ON RX3i components are installed in the tree structure as shown below:
The Max-ON RX3i Configuration Utility is located in Max-ON RX3i Tools directory. It is
launched by double-clicking on the Max-ON RX3i configuration file (config.mx3) located in the
Proficy Logic Developer PLC project.
The default Max-ON RX3i Hot Standby Redundancy application project, named Max-ON RX3i
LD Project vx_yy.zip, is located in the Redundancy LD directory. This project must be
brought into your Proficy Machine Edition development environment using Proficy Machine
Edition’s File > Restore Project… menu.
A Proficy View Diagnostic project is located in the Diagnostics VIEW directory. When it is
active, this diagnostic utility displays key information regarding the operation and state of the
redundant CPU pair. This project must also be brought into your Proficy Machine Edition
development environment using Proficy Machine Edition’s File > Restore Project… menu.
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Chapter 1 Introduction
1-5
1
Adding the Max-ON RX3i Hot Standby Redundancy Application
Project to Proficy Machine Edition
The default Max-ON RX3i LD project is added to the Machine Edition project Navigator by
using the File > Restore Project…menu item. Select the Project Navigator window making
certain that there is no project open at this time.
Using the File menu, click on Restore Project...
Navigate to the Proficy Components directory, then to the Redundant LD directory. Make
certain that the selection for Files of Type has been set to Proficy Machine Edition (*.zip).
1-6
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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1
Select the Max-ON RX3i LD Project vx_yy.zip file.
When you click on Open, a new project will be added to the Proficy Navigator window.
Now you may give this new Project a descriptive project name. You may also use this project
to create a Machine Edition project template that can me used as a starting point for future
Max-ON Rx3i projects.
Launching the Max-ON RX3i Configuration Utility
The Max-ON RX3i Configuration Utility is launched from the Machine Edition project. Open
the project that you restored in the previous section. There are three targets in the project:
•
PLC_A_HW – This target contains the hardware configuration for PLC A. It must be
edited to reflect the hardware settings and components in your system. Then it must
be downloaded to PLC A (only).
•
PLC_B_HW – This target contains the hardware configuration for PLC B. It must be
edited to reflect the hardware settings and components in your system. It will be very
similar to PLC A hardware configuration, except for certain items such IP addresses,
Genius bus controller settings, etc. In a similar fashion, this configuration must be
downloaded to PLC B (only).
GFK-2409
Chapter 1 Introduction
1-7
1
•
PLC_COMMON_CODE – This target contains the core logic for the Max-ON RX3i
redundancy application. You must add your application logic starting in the rung that
follows the call to the core Max-ON RX3i logic (hbr_000). The logic from this target
will be downloaded to both PLC A and PLC B. Note that the download consists of the
PLC Logic Only, the Hardware Configuration option must be unchecked.
You navigate to the Max-ON RX3i Configuration Utility by following these steps:
1. Select the target PLC_COMMON_CODE.
2. Expand the tree structure so that the Supplemental Files folder named Documentation
Files is visible.
3. Double-click on Documentation Files. This will launch Windows Explorer for this
directory.
4. Click on the Max-ON Project directory to display its contents. The Explorer window will
be similar to what is shown below.
5. Double-click on the Max-ON RX3i Configuration file named config.mx3. This launches
the Max-ON RX3i Configuration Utility.
6. You may now examine and edit the parameters of the Max-ON RX3i redundant
system.
1-8
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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1
Technical Support
Technical Support is available at no charge for 90 days after purchase. A support agreement
can be purchased from your local GE Fanuc distributor if extended support is required.
If problems arise that can’t be solved using the information in your product manual, online
Help system, Proficy GlobalCare knowledge base, or the GE Fanuc Technical Advisor
knowledge base, contact us by telephone, fax, or mail. When contacting us, call from a
telephone near your computer and have your Machine Edition software running. Have the
following information handy to help us assist you as quickly as possible:
•
Proficy Machine Edition software installation serial number, the Proficy Machine
Edition software Product name, and version number from the Help >About dialog box.
•
The brand and model of any hardware in your system.
•
Operating system and version number.
•
The steps you performed prior to the problem occurring.
GE Fanuc Global Care Web Site
The GE Fanuc Global Care Web Site offers product, service, and support information for GE
Fanuc hardware and software products. The Global Care web site is located at:
http://globalcare.gefanuc.com/
Visit this site for the latest up-to-date technical information.
North America
Support Hotline: 1-800-GEFANUC (1-800-433-2682)
Fax: (780) 420-2049
Internet: http://globalcare.gefanuc.com/
Email: [email protected]
Comments about our manuals and help: [email protected]
Mailing Address: GE Fanuc, 2700 Oxford Tower, 10235 - 101 St., Edmonton, AB, Canada, T5J 3G1
Asia
Japan: Telephone 81-3-5405-7555; fax 81-3-5405-7550
China: Telephone 0086-21-32224555 x200; fax 0086-21-62793066
Europe, Middle East, and Africa
Europe, Middle East, and Africa: + 800 1 GE FANUC or + 1 780-401-7717
Internet: For up-to-date contact information, visit http://www.gefanuc-europe.com/.
E-mail: [email protected]
South America
Telephone: +58 (261) 760 2862
Fax: +58 (261) 765 0909
Internet: http://www.gefanuc.com/ (visit our Portuguese web site at http://www.gefanuc.com.br/)
E-Mail: [email protected]
Mailing Address: GE Fanuc Automation Latin America, Calle 120 con Av. 17, Los Haticos -GE Turbimeca
Maracaibo, Venezuela
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Chapter 1 Introduction
1-9
1
Online Help
If you have a question about Max-ON RX3i, first consult the online help. This may be
accessed from the main menu in Max-ON RX3i Configuration Utility software. To obtain help,
select the main menu item Help, then Contents & Index.
For PLC hardware questions, consult the documentation that was shipped with the hardware
product.
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PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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Chapter System Overview
2
Architecture
A Max-ON RX3i Hot Standby Redundancy system consists of two PACSystems Max-ON
RX3i Controllers, at least one dedicated Ethernet Synchronization link, and an I/O system
comprised of at least one I/O LAN.
The Ethernet Synchronization link is used to exchange status and synchronization data
between the two Max-ON RX3i Controllers. For higher system availability, dual redundant
LANs may be employed.
The I/O LAN is used to communicate with the I/O devices that are attached to it. The I/O
system may be implemented using a combination of Ethernet drops (Series 90-30 ENIU or
PACSystems RX3i ENIU); or Genius drops (Genius I/O, Field Control I/O, VersaMax I/O, or
Remote I/O drops based upon Series 90-30 I/O). The example below shows the Max-ON
RX3i controllers connected to a single Ethernet I/O LAN.
Max-ON Rx3i has been designed to satisfy applications that have high performance
requirements. It has support for up to 8 simplex or 4 dual Genius I/O busses, and up to 3
Ethernet I/O busses.
GFK-2409
2-1
2
The example below shows the Max-ON RX3i controllers connected to a single Genius I/O
LAN. This example includes dual Ethernet synchronization LANs:
Max-ON Rx3i provides the following functionality:
Discrete Inputs (%I)
Discrete Outputs (%Q)
Analog Inputs (%AI)
Analog Outputs (%AQ)
Synchronized Internal Coils (%M)
Synchronized Registers (%R)
I/O Busses
Synchronizing LANs
CPU Model
I/O Families
2-2
2048
2048
1024
256
4096
8000
Up to eight simplex Genius busses, or
Up to four dual Genius busses
Up to 29 devices per simplex or dual bus;
Up to 3 simplex Ethernet busses, or one dual Ethernet bus
One or two Ethernet LANs
IC695CMU310
Ethernet: Series 90-30 Ethernet NIU or
PACSystems RX3i Ethernet NIU
Genius: Genius Block, Field Control, VersaMax,
Remote 90-30 Drop
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
2
Software Components
Max-ON RX3i software consists of several components, some of which execute in the Hot
Standby Controllers, and some of which execute in your programming workstation. A base
Logic Developer PLC Project provides the basic template for the Logic of the Redundant
System. This project is modified by the system designer to add the other necessary Logic to
perform the user application, and then the final application is stored in the Controllers using
Proficy Logic Developer PLC.
You may think of the software provided in the Project template for the Controllers as “drivers”
that handle the complex tasks associated with Hot Standby redundancy. These drivers allow
the two Controllers to behave as a single Controller from the perspective of your application.
The Max-ON RX3i Configuration Utility allows the system designer to customize the
parameters of the Max-ON RX3i drivers and to specify the hardware that is contained within
the system. The Max-ON Configuration Utility software operates in Windows XP Professional,
Windows NT4.0, and Windows 2000 Professional.
The Max-ON RX3i Configuration Utility software allows you to define the way your system is
constructed and how you want the system to operate. It provides additional information that is
not included in the Hardware Configuration files produced by Logic Developer PLC.
The Max-ON RX3i software includes a Proficy View Diagnostic Project that allows you to
observe the way your system is operating and helps you to diagnose problems. This Project
displays the operational status of the redundant system in real time.
The Max-ON RX3i software also includes a set of projects to configure Series 90-30 Remote
Genius Drops.
The Max-ON RX3i software components are organized as follows:
A Max-ON RX3i Quick Start Project is also included on the Max-ON RX3i Software CD. This
Quick Start Project also includes 3 RX3i ENIU targets.
GFK-2409
Chapter 2 System Overview
2-3
2
Hot Standby Redundancy Operation
During each controller scan, the Max-ON RX3i redundancy drivers are solved first, and then
your application logic is solved. The Max-ON RX3i redundancy drivers handle the following
functions:
▪
Determine Mastership – One CPU operates as the Master. The other operates as the
Backup. Output devices use the output states from the Master only. In a Max-ON RX3i
system, the user may specify either PLC to be the preferred Master. If no preference is
specified, then Mastership “floats” between the PLCs. The current Master retains its
status until it fails or until the user switches Mastership, at which time the Master and
Backup exchange their roles.
▪
Transfer Synchronization Data – If the Master fails, the Backup must be prepared to
control the process using the latest internal states from the ex-Master. These states may
represent such things as latched coils, timer/counter values, PID values, system set
points, and perhaps user-calculated values.
▪
Enforce an Orderly PLC Startup – When a failed PLC is returned to service, it must not
attempt to assume control of the system prior to being synchronized to the current Master.
If both PLCs startup simultaneously, then whichever one was the last valid Master
assumes the Mastership.
▪
Process Genius Dual Bus I/O Devices – When the system uses dual Genius I/O
busses, input devices are mapped automatically from the active I/O LAN into the PLC’s
input reference tables.
▪
Auto-configure Genius VersaMax I/O – One of the Max-ON RX3i drivers generates
configuration messages that are sent automatically to any Genius VersaMax network
interface units. The messages configure the interfaces for Hot Standby operation, Single
or Dual Bus operation, expansion transmitter being present, and Genius bus baud rate.
▪
Execute Diagnostic Tests – Automatically post time-stamped fault messages into the
Max-ON RX3i Alarm Table. Identify system problems such as bus faults, loss of devices,
change of Mastership, program restart, and power-up event.
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PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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2
Failover Time
The Mastership Time of the Max-ON RX3i system determines the Failover Time. The Failover
Time is the time required for control of the system to transfer from the Master Controller to the
Backup Controller.
Mastership Time: This is the time interval for the Backup Controller to recognize that the
Master Controller has failed. It takes one or two CPU scans plus one Synchronized Data
Transfer period to determine that the Master has failed. Then it takes an additional scan to
activate the output data stream in the Backup Controller.
For the Ethernet I/O LAN, the Remote Ethernet drop will start using the data from the Backup
Controller as soon as it detects that:
1. The Backup is now the Master
2. The Master is no longer sending data
For the Genius IO LAN, lacking output data from the current Master’s GBC, each output
circuit on each device on the Genius I/O LANs will hold its last state for up to 2.5 seconds
before it assumes the Default State unless there is output data from the Backup GBC. (This
assumes that each device has been configured for either BSM present or for long timeout.)
Then the output device will begin using output data from the other GBC.
Synchronized Data Transfers
Data may be synchronized from the Master to the Backup on a continuous basis in order to
assure that the Backup controller’s data is always in sync with the Master’s. Max-ON RX3i
supports up to 6 groups of synchronization data for each data type listed below. The groups
do not have to be contiguous. Each group is specified by a starting reference address and a
length. For each data type, the lengths are added together and the sum must not exceed the
value in the corresponding column below.
Registers
Discrete Outputs
%R
%Q
%M
%AQ
Max Length
8000
2048
4096
256
Range
1 - 8000
1 - 2048
1 - 4096
1 - 256
GFK-2409
Chapter 2 System Overview
Internal Coils Analog Outputs
2-5
2
I/O Bus Topologies
The Max-ON RX3i application supports the use of single (non-redundant) and/or dual
(redundant) busses interfacing to the I/O devices.
▪
▪
A Max-ON Rx3i controller supports up to four Ethernet LANs. At least one Ethernet
Interface must be dedicated to the Synchronization Link. This allows up to 3 additional
Ethernet Interfaces that may be used as dedicated Ethernet I/O LANs. Support is also
available for a single duplex Ethernet I/O LAN.
Simplex Ethernet I/O
Busses
Dual Ethernet I/O Busses
Up to 3
1
Max-ON Rx3i supports up to four redundant Genius LANs or up to eight non-redundant
Genius LANs, or a mixture of the two. However, the system may not have more than
eight Genius bus controllers in a Controller.
Simplex Genius I/O
Busses
Dual Genius I/O Busses
Up to 8
Up to 4
Redundant busses are superior to non-redundant busses when there is a requirement to
protect against cable failures or Genius bus controller failures.
When the primary consideration is to protect against cable failures, then the system designer
should consider separating the cables so that a single mechanical failure does not damage
both cables.
Genius Dual Bus I/O Capacity
The maximum allowable I/O capacity for Max-ON RX3i redundant system that is configured
for Genius Dual busses is as follows:
2-6
Discrete
Inputs
Discrete
Outputs
Analog
Inputs
Analog
Outputs
2048
2048
1024
256
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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2
Selecting the I/O
Max-ON RX3i systems may be implemented using any combination of the following I/O:
Ethernet NIUs
Ethernet NIUs are remote I/O drops that as based on standard 90-30 or
PACSystems RX3i hardware. These remote drops communicate to the
redundant controllers using Ethernet Global Data. These NIUs are
configured using Logic Developer PLC.
Genius Block
Genius blocks are intelligent, self-contained, configurable I/O modules.
The blocks are available as discrete, analog, and special purpose types,
such as the high-speed counter. Many of the blocks offer advanced
diagnostic capabilities such as open circuit, short circuit, and overload
detection. Each block is configured using a hand-held monitor.
Genius Field
Control
Genius Field Control is a family of versatile, modular I/O devices. The I/O
modules are small and rugged and are available in both discrete and
analog versions.
I/O Terminal Blocks provide universal field wiring terminals for the I/O
modules, allowing I/O module types to be mixed on the same I/O
Terminal Block. The I/O Terminal block is mounted on a DIN rail.
As many as eight Field Control I/O modules (four I/O terminal blocks) can
be connected to one Bus Interface Unit. Together, they make up a Field
Control “station”. The bus interface unit provides either a single or a dual,
redundant LAN connection to the Hot Standby PLCs.
Each station is configured using a hand-held monitor.
Genius Remote
90-30 Drop
Genius Remote 90-30 drops consist of a Series 90-30 CPU, power
supply, base plate, and one Genius bus controller for a single LAN
connection or two bus controllers for a dual, redundant LAN connection.
Normally, input and output modules are installed in the base. A Scanner
routine executes in the drop’s CPU. This routine scans all input devices
and transmits the input states to the Hot Standby PLCs.
The routine also monitors outputs (%Q and %AQ) in the Synchronized
Data stream from the Hot Standby PLCs. Any output data that is
configured to be active in the remote drop is captured from the data
stream and then is mapped into the Drop’s output reference tables.
Configuration of the remote drop is accomplished using the Logic
Developer PLC software package. Also, a few rungs of ladder logic must
be edited in order to characterize the outputs in the drop.
Genius VersaMax
Genius Third
Party
Genius VersaMax I/O products feature DIN-rail mounted modules with up
to eight I/O and option modules per “rack” and up to 8 racks per
VersaMax I/O Station system. Expansion racks can be located up to 750
meters from the main VersaMax I/O Station rack. Expansion racks can
include any VersaMax I/O, option, or communications module.
In some cases, third party devices may be used on the LAN as well.
These devices must comply with the Genius I/O specification relating to
Controller Redundancy.
With a Max-ON RX3i system, you may select I/O devices based upon functionality, cost,
physical design, items carried in spare parts inventory, or personnel expertise.
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Chapter 2 System Overview
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2
Demo Mode Operation
A Max-ON RX3i application will operate in demo mode for 22 days on standard PACSystems
RX3i CPU hardware (IC695CPU310). In this mode, all of the system’s capabilities are fully
operational. At the end of the demo period, PLC A will either stop immediately, if it is the
backup, or begin an orderly transfer of Mastership to PLC B. If the transfer is successful, then
PLC A will shut down automatically. At this point, the system will be operating in a nonredundant manner.
A Max-ON RX3i system that is installed in a production environment MUST be running on a
Max-ON RX3i CPU (IC695CMU310) in order to allow PLC A to run indefinitely.
Running Max-ON RX3i on a standard RX3i CPU is helpful for short times in case of a
hardware failure or for non-production demonstration purposes.
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Chapter Building a Max-ON RX3i Hot Standby Application
3
Max-ON RX3i Project
▪
Max-ON RX3i encapsulates your entire application within a single Machine Edition
Project. Using a generic Max-ON RX3i Project, you can create a new Max-ON RX3i
Redundancy project. The generic project contains all of the base Max-ON RX3i
redundancy application components needed to perform the redundant application. You
add the hardware configuration information for each PLC in your application, add your
application logic, and define the parameters of the Redundant System using the MaxON RX3i Configuration Utility that us launched from the Logic Developer PLC Project.
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Project Workflow
Step 1 - Gather Information
Gather the information about your system:
▪
I/O Bus topologies and addresses
▪
Synchronization LAN locations
▪
Module types and locations
▪
I/O Devices including bus assignment, bus addresses, circuit references, number of
circuits and I/O family type.
Step 2 - Create a New Max-ON RX3i Project
In Proficy Logic Developer PLC:
3-2
1.
Create a new project based on the Generic Max-ON RX3i Project. The redundant
ladder project is added to the Machine Edition project Navigator by using the File >
Restore Project… menu item. Select the Project Navigator window making certain
that there is no project open at this time.
2.
Using the File menu, click on Restore Project...
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3.
Navigate to the Proficy Components directory, then to the Redundant LD directory.
Make certain that the selection for Files of Type has been set to Proficy Machine
Edition (*.zip).
When you click on Open, a new project will be added to the Proficy Navigator window.
4.
Give your project a descriptive name in the Machine Edition Navigator.
5.
Configure the Project Information in the Max-ON RX3i Configuration Utility, using the
information you gathered in step 1. (Refer to Chapter 4 for more information.)
Enter Project Setting information by launching the Project Settings dialog in the Max-ON RX3i
Configuration Utility. . (Refer to Chapter 4 for more information.)
6.
Enter Developer and End User Information by launching the Biographical Information
dialog in the Max-ON RX3i Configuration Utility. . (Refer to Chapter 4 for more
information.)
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3-3
3
Step 3 - Configure the Controller Hardware
In Logic Developer PLC:
For CPU A:
1. Open the Hardware Configuration for PLC_A_HW target in the Max-ON RX3i Project.
2. Configure the PLC hardware for PLC A:
▪
CPU Memory
▪
CPU SNP ID
▪
Genius Bus Controllers
▪
I/O Devices on the Genius Bus (or Busses)
▪
Ethernet Modules
▪
o
Ethernet IP Address and Subnet Mask
o
Device Status Address
Ethernet Global Data (EGD) Exchanges for Ethernet NIUs
3. Store the new hardware configuration into CPU A
4. Set the time and date for CPU A.
For CPU B:
1. Open the Hardware Configuration for PLC_B_HW target in the Max-ON RX3i Project.
2. Configure the PLC hardware for PLC B.
▪
CPU Memory
▪
CPU SNP ID
▪
Genius Bus Controllers
▪
I/O Devices on the Genius Bus (or Busses)
▪
Ethernet Modules
o
Ethernet IP Address and Subnet Mask
o
Device Status Address
o
Ethernet Global Data (EGD) Exchanges for Ethernet NIUs
3. Store the new hardware configuration into CPU B.
4. Set the time and date for CPU B.
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Step 4 - Add Your Application Logic
Using Logic Developer PLC, open the PLC_COMMON_CODE Target folder and add your
application logic after the call to the subroutine named HBR_000.
If you are using an Existing Project
If you have developed the application previously, then you may copy and paste the Max-ON
RX3i logic into the existing Project. A Machine Edition Toolchest drawer is also provided that
may be used to copy the Max-ON Blocks into the Project.
If this is a New Application
Add your application logic into the project folder directly after the CALL to the hbr_000 Block
in _MAIN Rung 3.
Step 5 - Configure the I/O Devices
Ethernet NIUs
If you are using Ethernet NIUs, then you will need to create Ethernet NIU targets, configure
the I/O in the remote drop, and then download the ENIU information to the remote drop using
Logic Developer PLC.
Genius or Field Control
If you are using Genius or Field Control, then set the appropriate parameters for Serial Bus
Address, I/O Settings, I/O Quantities, Redundant Controllers, BSM present (always set to
yes), BSM Controller (set to yes when a dual I/O bus is used), etc.
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Genius VersaMax I/O
If you are using Genius VersaMax NIU, then set the Serial Bus Address, Bus Baudrate, etc.
The Max-ON RX3i drivers in the Controller will set the parameters for Redundant Controllers,
BSM present, and BSM controller.
Remote Genius 90-30 Drops
If you are using Remote Genius 90-30 Drops, then configure the Genius bus controller(s), and
edit the configuration rungs in the remote’s I/O driver. Make certain that Syncronized Data
has been configured for the range of outputs used by the Remote Drop.
Step 6 - Start the System
Divide the system into manageable subsystems that may be verified as independent entities.
I/O Bus
3-6
▪
Make certain that the Ethernet LAN(s) have been installed and configured correctly.
▪
Make certain that the Genius LAN(s) have been installed correctly... LAN polarity and
shield IN/OUT are connected consistently and correctly. Also make certain that
terminating resistors are installed at each end of the LAN(s).
▪
Genius and Field Control – Using a Handheld Monitor, verify that output devices may
be turned ON or OFF from the LAN.
▪
Use the Handheld Monitor check the LAN for any Bus Error activity.
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I/O Devices
When Interfacing to CPU A:
With the I/O operating, place CPU A in RUN mode and CPU B in STOP mode.
▪
Verify that the system input devices return real-time values properly.
▪
Verify that system output devices may be controlled from the Output Reference
Tables.
Note: This might require that you place a temporary JUMP in your application. The JUMP
should be placed immediately after the CALL to HBR_000. The companion label should be
placed at the end of _MAIN.
When Interfacing to CPU B:
With the I/O operating, place CPU A in STOP mode and CPU B in RUN mode.
▪
Verify that the system input devices return real-time values properly.
▪
Verify that system output devices may be controlled from the Output Reference
Tables.
Hot Standby Operation
1. Place both CPUs into RUN mode.
2. Make certain that there is only one Master and only one Backup.
3. Make certain that there is no preferred Master.
4. Place CPU B into STOP mode, and then into RUN mode.
5. Make certain that Synchronized Data is transferred properly to CPU B.
6. Transfer Mastership from A to B by placing the CPU A into STOP mode.
7. Make certain that the I/O did not dropout during the transfer.
8. Place CPU A into RUN mode.
9. Make certain that it becomes a Backup properly.
10. Transfer Mastership from B to A by placing the CPU B into STOP mode.
11. Make certain that the I/O did not dropout during the transfer.
12. Place CPU B into RUN mode.
13. Make certain that it becomes a Backup properly.
14. Make certain that Synchronized Data is transferred properly to CPU B.
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Step 7 - Debug the System
Use the Max-ON Rx3i View Diagnostic Project
▪
Restore the Proficy View Project from the installation directory into Proficy Machine
Edition.
▪
Enter the Ethernet Addresses of PLC A and PLC B into the Proficy View Project.
▪
Download and Run the View Project on your workstation.
▪
Examine the Alarm and the Real-time Status displays.
Simplify the System
Here are a few suggestions from other system developers that have worked well.
3-8
▪
Turn OFF one PLC and troubleshoot the system using the remaining one.
▪
Disable Max-ON RX3i drivers by placing an #ALW_OFF contact prior to the call to
HBR_000. Now determine if input/output devices operate properly. This will require
that you modify the hardware configuration for the Genius bus controllers. Place them
in “Enable at Start”. Don’t forget to change the configuration to “Disable at Start” when
it is time to place the system into its final, redundant operation.
▪
Disable your application code and troubleshoot the Max-ON functionality. Check to
make certain that synchronized data items transfer properly. Check to make certain
that the Hot Standby CPUs will exchange mastership properly.
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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Chapter The Max-ON RX3i Configuration Utility
4
The Max-ON RX3i Configuration Utility is used to create or edit the operating parameters
used by the Max-ON RX3i redundancy drivers. These parameters specify such things as, bus
topologies, I/O addresses, and definitions for the ranges of synchronized data transfers.
Max-ON RX3i Projects
A Max-ON RX3i Project is a collection of items needed to define the elements of a redundant
system. If you inspected a Max-ON RX3i Project using Logic Developer PLC, you would see
that it consists of a Machine Edition Project with 3 Targets:
•
PLC_A_HW – This target contains the hardware configuration for PLC A. It must be
edited to reflect the hardware settings and components of PLC A in your system.
Then it must be downloaded to PLC A (only).
•
PLC_B_HW – This target contains the hardware configuration for PLC B. It must be
edited to reflect the hardware settings and components of PLC B in your system. It
will be very similar to PLC A hardware configuration, except for certain items such IP
addresses, and Genius bus controller settings. In a similar fashion, this configuration
must be downloaded to PLC B (only).
•
PLC_COMMON_CODE – This contains the core redundancy logic for the Max-ON
RX3i redundancy application. You must add your application logic starting in the rung
that follows the call to the core Max-ON RX3i logic (hbr_000). The logic from this
target will be downloaded to both PLC A and PLC B. Note that the download consists
of the PLC Logic Only, the Hardware Configuration option must be unchecked.
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4
The diagram below illustrates how the Max-ON RX3i Project is organized:
When creating a Max-ON RX3i Project, the best approach is to start with the generic project
that is supplied with the Max-ON RX3i software. This assures that all of the basic components
of the Max-ON RX3i redundant application are included in the project.
Creating a New Max-ON RX3i Project
To create a new Max-ON RX3i Project in Proficy Logic Developer PLC:
1.
4-2
Create a new project based on the generic Max-ON RX3i Project. A new Max-ON
RX3i Project is added to the Machine Edition project Navigator by using the File >
Restore Project… menu item. Select the Project Navigator window, making certain
that there is no project open at this time.
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2.
Using the File menu, click on the Restore Project... menu.
3.
Navigate to the Proficy Components directory where the Max-ON RX3i Tools software
has been installed, then to the Redundant LD directory. Make certain that the
selection for Files of Type in the Restore dialog has been set to Proficy Machine
Edition (*.zip).
4.
When you click on Open, a new project will be added to the Proficy Navigator window.
5.
Give your project a descriptive name in the Machine Edition Navigator.
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Chapter 4 The Max-ON RX3i Configuration Utility
4-3
4
Launching the Max-ON RX3i Configuration Utility
The Max-ON RX3i Configuration Utility is launched from the Max-ON RX3i Machine Edition
Project. For example, open the project that you created in the previous section. Navigate to
the Max-ON RX3i Configuration Utility by following these steps:
1. Select the target PLC_COMMON_CODE node in the Navigator.
2. Expand the tree structure so that the Supplemental Files folder named Documentation
Files is visible.
3. Double-click on Documentation Files. This will launch Windows Explorer for this
directory.
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4
4. Click on the Max-ON Project directory to display contents. The Explorer window will be
similar to what is shown below.
5. Double-click on the Max-ON RX3i Configuration file named config.mx3. This launches
the Max-ON RX3i Configuration Utility. You may now examine and edit the parameters
of the Max-ON RX3i redundant system.
The cfg_dat.gefelf file in the Max-ON Project directory is the C Block that is created and
modified by the Max-ON RX3i Configuration Utility. After the utility has updated this file,
you must update the cfg_dat C Block that is located in the PLC_COMMON_CODE target
in the Max-ON RX3i Project.
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Chapter 4 The Max-ON RX3i Configuration Utility
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Working with the Max-ON RX3i Configuration Utility
Now that you have created a Max-ON RX3i Project and launched the Max-ON RX3i
Configuration Utility, you can set the parameters of the redundant system. When the Max-ON
RX3i Configuration Utility is launched it will display the following:
As you can see from the Project Navigator, the utility allows you to specify the following
information about the Max-ON RX3i redundant system:
4-6
•
Developer: Biographical information of the engineer who developed the application.
•
End User: Biographical information about the end user.
•
Settings: Specifies the Max-ON RX3i System Parameters.
•
Sync Data: Specifies the synchronization data that is to be transferred from the
Master CPU to the Backup CPU in order for the redundant system to be synchronized.
•
Sync Networks: Specifies the Ethernet LAN configuration to be used to transfer the
Synchronized Data.
•
Genius Busses: Specifies the Genius Busses used by the redundant system for
Genius I/O.
•
User Alarms: Allows the user to create self-defined faults that can be logged by the
Max-ON RX3i redundant application.
Note: User Alarms are not available in the current version of Max-ON RX3i
Diagnostics.
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Developer and End User Information
By selecting the Developer and End User items in the Project tree, the information about the
engineer who developed the application –and- the end user may be displayed and modified.
To edit this biographical information, double-click on the Developer or End User item in the
project tree or select the Edit > Properties menu item. The Biographical Information dialog is
now displayed and the detailed information may be entered and saved.
Settings
By selecting the Settings item in the Project tree, the Max-ON RX3i System Parameters
settings may be displayed and modified. These parameters are defined as follows.
Fast Offline Detection - Enabling this option directs the CPUs to detect an offline condition
within one CPU scan. If the option is not enabled, then it will require two consecutive scans to
produce an offline condition.
Program Change Audit Trail - Checking this box instructs the Max-ON RX3i redundancy
system to monitor the program for changes to logic. If there is a change, the value in the
change counter, UR_N1 (%R9003/9004; DINT), will be incremented by one, and a date/time,
PDAT_01 (%R9005.9007, packed BCD), will be posted for the moment at which the change
was detected.
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Default Multiplexer Period - This value is the default time period used to advance the
Synchronized Data multiplexer. This is used when there are Remote 90-30 Drops present on
a Genius I/O LAN.
Sync Data
Synchronization data from the %M, %Q, %AQ, and %R reference tables may be transferred
from the Master CPU to the Backup CPU in order for the redundant system to be
synchronized. By selecting the Sync Data item in the Project tree, the Max-ON RX3i Sync
Data settings may be displayed and modified.
Synchronized data may be transferred in up to 6 groups for each of the reference tables listed
above. This allows transfer of non-contiguous data areas. The general format uses a Start
Reference and a Length.
To add a new address range to a data group, select the Data Group tab in the table, and then
select the Sync Data -> Add Data Item… menu.
Now enter the new range for the new data group for this reference table.
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Maximum Sync Data
For each Synchronized Data type, the system will sum the lengths in each configured group
to arrive at a total amount for that data type. The total must not exceed the size listed in the
table below:
*
Registers
Discrete Outputs
Internal Coils
Analog Outputs
%R
%Q
%M
%AQ
8000
2048
4096*
256
The system flags, although included in this number, are not transferred.
Sync Networks
When using Max-ON RX3i, one or two Ethernet LANs may be configured using an
IC695ETM001 interface card to transfer the Synchronization Data. If you are using a dual
Ethernet LAN topology, then you may use two ETM001 modules in each PLC for the Sync
LANs. When the Ethernet module has been configured in the Logic Developer PLC hardware
configuration, you must assign the module a device status address. Generally, it is a good
practice to place these in the upper area of the %I reference memory. (Note: The address
must be set to %I01969 or lower.)
When dual Ethernet LANs are used, you must specify which device is to be the Primary
device and which is to be the Secondary device. The Ethernet Modules must be in the same
slot positions in each of the two RX3i main racks.
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To display the configuration of the Sync Networks Interface Modules, expand the Sync
Networks node in the Project tree. Now the configurations of the two Primary Interface
modules are displayed.
To edit this information, double-click on the LAN Interface Modules item in the project tree or
select the Module > Properties… menu item. The Ethernet Modules configuration dialog is
now displayed and the information about them can be entered.
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Configuring Dual Sync Networks
If you want to use a dual Ethernet Sync Networks, then you must use two ETM001 modules in
each PLC for the Sync Network. In this case, you need to define the Secondary Sync
network. To add a Secondary Sync Network to the Max-ON RX3i system, select the Sync
Networks node in the project tree. Then select the Networks > Redundancy > Add Secondary
Network… menu item.
Now the Secondary Network will be added to the system, and parameters may be configured.
To edit the Secondary LAN information, double-click on the LAN Interface Modules item in the
project tree or select the Module > Properties… menu item.
Note: The Ethernet LAN information that is placed in the Max-ON RX3i Configuration must
match the configuration information that is placed in PLC_A_HW and PLC_B_HW hardware
configurations in order for the system to operate properly.
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Chapter 4 The Max-ON RX3i Configuration Utility
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4
Genius Busses
By selecting the Genius Busses item in the Project tree, the Max-ON RX3i Genius busses
may be displayed and their settings may be modified. By default, no Genius busses are
defined, so you must configure the bus definitions to match your hardware configuration.
Genius busses can be defined as a Simplex or a Duplex bus.
Simplex Genius Bus
A simplex Genius Bus is a non-redundant I/O bus that connects to one or more Genius I/O
devices.
To Add a Genius Bus
1. To add a new Genius Bus, select the Genius Busses item in the Project tree, then
select the Busses >Add Genius Bus.. menu item.
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4
2. Give the Genius bus a descriptive name, such as “Main”, and change the Baudrate
setting if necessary.
3. After the Genius bus has been created, it is added to the Project tree and now Genius
devices may be added to this bus.
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4. Double-click on the Primary Bus Controller item in order to configure parameters, or
select the Busses > Properties… or Module > Properties… menus. Enter the module’s
location in the RX3i main rack and it’s status address. A suggested practice is to
address devices such as Genius bus controllers and Ethernet modules at high
addresses. This leaves the low addresses available for Input devices such as field
sensors.
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Adding a Secondary Genius Bus
To add a Secondary Genius Bus to an Existing Genius Bus
1. Select the Genius Bus in the Project tree, and then select the Busses > Redundancy…
> Add Secondary Bus.. menu item to add a Secondary Genius Bus.
2. A Secondary Genius Bus Controller is added to the Project tree.
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3. Double-click on the Secondary Bus Controller in order to configure it’s parameters, or
select the Busses > Properties… or Module > Properties… menus. Enter the module’s
location in the RX3i main rack and it’s status address. A suggested practice is to
address Genius bus controllers at high addresses. This leaves the low addresses
available for Input devices such as field sensors. (Note: The input address must be
set to less than %I02017.)
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Adding Genius I/O Devices
To add Genius devices to a Genius Bus, select the Genius I/O item in the Project tree. Now
the I/O Assignments table is displayed which lists the Genius Devices that are assigned to the
various SBAs (Serial Bus Addresses).
To add a Genius I/O device to this Genius Bus:
1. Select an SBA for the new Genius device by clicking on the gray button to the left of the
SBA number. A “*” will be placed on the button to indicate it’s selection.
2.
Select the Bus Devices > Add Device… menu item. The Add New Genius Device dialog
is displayed.
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3. Click in the cell labeled I/O Family. A dropdown list will appear:
4. If the I/O Family is Genius, then select the I/O Type for the I/O device. Click in the cell
labeled I/O Type. A dropdown list will appear:
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5. Select the I/O Type for the device, using the drop down list selections. If your I/O device
does not match with any of the selections, then select Generic. Also, you should select
Generic if the device is a Remote 90-30 Genius drop.
6. Click the Apply button to assign the I/O Family and I/O Type. (Note: If this is a dual bus, a
reminder may be displayed to ask you to verify the starting address for the Secondary Bus
Reference.) Click Ok.
7. Click on the I/O Device type tab that is now active, [Discrete In], for example.
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8. Edit the device properties for both the Primary and Secondary busses.
9. Click Apply and Ok to complete the changes or Cancel to leave without making any
changes.
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Editing Genius I/O Devices
1. To edit a Genius device’s parameters, select the Genius I/O item in the Project tree for a
specific Genius Bus.
2. Select a Genius device by clicking on the gray button to the left of the SBA number. A “*”
will be placed on the button to indicate it’s selection.
3. Select the Bus Devices > Properties… menu item. The Edit Genius Device dialog is
displayed.
4. Edit the device properties
5. Click Apply and Ok to complete the changes or Cancel to leave without making any
changes.
Deleting Genius I/O Devices
1. To delete a Genius device, select the Genius I/O bus from the Project tree for the item to
be deleted.
2. In the device table, select the Genius device by clicking on the gray button to the left of its
SBA number. A “*” will be placed on the leftmost column and row to indicate that the
device has been selected.
3. Select the Bus Devices > Delete Device… menu item. The device will be deleted.
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Configuring Genius Discrete Inputs
The Genius Device dialog allows you to configure Genius discrete inputs. If the bus to which
this device is attached has been configured to have a Secondary bus controller, then both the
Primary Bus and Secondary Bus information will be displayed. If this is a single (nonredundant) bus, then only the Primary Bus information will be displayed.
Discrete Inputs – Primary Bus
This field defines the base address assigned to the discrete inputs. This address establishes
the references that the input devices will use while they are connected to the Primary bus.
These are the same references that will be used throughout the user application logic.
%I Reference
%I Length
4-22
The first reference address used within the discrete input group.
The number of discrete references that are to be included on this
device.
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Discrete Inputs – Secondary Bus
When a dual bus is used, there must be an alternate location for the Genius discrete inputs to
report their status. The alternate location is the reference area in which the inputs will appear
while they are connected to the Secondary Genius I/O bus.
Max-ON RX3i redundancy drivers detect when the Primary inputs are unavailable. If the
Secondary inputs are reporting into the Secondary reference area, the drivers will map the
data automatically from the Secondary area into the Primary address locations. This permits
the user-application to be written with references to the Primary addresses only.
Reference
The first reference address used in the Secondary (alternate) reference
table.
If the Primary Bus %I Length is a multiple of 16, then the inputs will be
mapped into the RX3i register table. This value is read-only.
If the Length is an odd multiple of 8, then the inputs may be mapped
into either %I or %G references. You may select the desired reference
type and address for the Secondary location.
Length (words)
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The number of discrete references that are to be included on this
device. This is a read-only value that is generated from the number
that was entered into the Primary Bus %I Reference.
Chapter 4 The Max-ON RX3i Configuration Utility
4-23
4
Configuring Genius Discrete Outputs
The Genius Device dialog allows you to configure the Genius discrete outputs. The main
purpose of this configuration is to identify the device and the circuit reference so that online
status may be monitored. Any offline/online activity will be reported in the Max-ON Rx3i Fault
Table.
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4
Configuring Genius Analog Inputs
The Genius Device dialog allows you to configure how the Max-ON RX3i redundancy driver
will process Genius analog inputs. The analog inputs may be configured on a per circuit
basis.
Analog Inputs - Primary Bus
The Primary Bus addressing is the base address assigned to the analog inputs. This address
establishes the references that the analog input devices will use while they are connected to
the Primary Bus. These are the same references that will be used throughout the user
application logic.
%AI Reference
%AI Length
The first reference address used within the discrete input group.
The number of discrete references that are to be included on this
device.
Analog Inputs - Secondary Bus
When a dual bus is employed, there must be an alternate location for the analog inputs to
report their values. The alternate location is the reference area in which the inputs will appear
while they are connected to the Secondary Genius I/O bus.
Max-ON RX3i redundancy drivers detect when the Primary inputs are unavailable. If the
Secondary inputs are reporting into the Secondary reference area, the drivers will map the
data automatically from the Secondary area into the Primary address locations. This permits
the user-application to be written with references to the Primary addresses only.
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Chapter 4 The Max-ON RX3i Configuration Utility
4-25
4
%AI Reference
The first reference address used in the secondary (alternate) reference
table. This value is read-only. The reference will always be
equal to the Primary reference plus an offset of 1024.
%AI Length
The number of discrete references that are to be included on this
device. This is a read-only value that is generated from the number
that was entered for the Primary Bus.
Circuit Configurations
Analog input scaling may be used to convert raw values received from the input device into
scaled values. Because many bus devices are able to perform their own scaling, this option
may be enabled for devices that do not provide scaling inherently. Please be aware that
enabling this option adds to overall scan time and consumes additional configuration memory.
The circuit configuration parameters are as follows:
Address
The analog circuit reference. This item is read-only.
Scaling
Enables scaling from raw units (RU) to engineering units (EU) for the
corresponding analog input circuit.
RU Lower
The lowest raw count value (RU) that the analog circuit will produce.
RU Upper
The highest raw count value (RU) that the analog circuit will produce.
EU Lower
The desired lowest value expressed in the sensor’s measurement unit
(EU).
EU Upper
The desired highest value expressed in the sensor’s measurement
unit (EU).
The acceptable range of values for any of the units is –32768 to +32767.
If the raw value produced by the analog circuit is less than the RU Lower value OR if the
value is greater than the RU Upper value, then an alarm will be generated for the analog
circuit.
Notes:
▪
Many of the GE Fanuc analog input devices are capable of performing scaling
independently. It is better to use the built-in capabilities of the devices. This will reduce
the CPU scan time by eliminating the extra processing associated with the scaling
function. Also, it reduces the amount of configuration memory consumed.
▪
If the device is configured to be on a dual bus, then the Secondary analog input addresses
will be at the Primary address plus an offset of 1024. For example, %AI00001 will have
an associated Secondary address at %AI01025.
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4
Configuring Genius Analog Outputs
The Genius Device dialog allows you to configure Genius analog outputs. The main purpose
of this configuration is to identify the device and the circuit reference so that online status may
be monitored. Any offline/online activity will be reported in the Max-ON Rx3i Alarm Table.
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4-27
4
Configuring the Secondary Address
On dual bus systems, discrete and analog inputs are mapped from the Primary bus
controller’s buffers into the normal input reference tables.
Inputs from the Secondary bus controller are placed into an alternate area and then the MaxON Rx3i redundancy driver remaps the alternate states into the table area used by the
Primary. Remapping occurs whenever the device is detected as being present on the
Secondary bus, but not present on the Primary. (In most instances the data will be available
on one of the busses, but not both. The exception is for Remote 90-30 Genius drops, in
which case, there are bus controllers on each bus.)
Analog Inputs
For analog inputs, the Secondary addressing is fixed at the primary’s address reference plus
1024. Thus an analog input circuit addressed at %AI00001 will have a Secondary address at
%AI01025.
Discrete Inputs
For discrete inputs, the addressing is more flexible.
▪
If the Primary address is on a word multiple (i.e. 1, 17, 33, etc.) AND the length is a word
multiple (i.e., 16, 32, 48, etc.), then the Secondary address will be mapped into %R space.
▪
If the primary address does not meet the criteria above, then the user may select an
alternate address at either a %G reference or a %I reference.
Secondary Bus References
The configuration utility will display the configuration options for the Secondary bus references
automatically. Please use the configuration information displayed in the text window to obtain
the information that is needed to configure the Secondary bus controllers for discrete and
analog inputs.
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4
Project Information
Configuration Summary
The configuration summary provides information about your project. You determine the
content of this report by the item that is selected in the project tree. Each time an item is
selected in the project tree, the configuration summary will update automatically.
The configuration summary window text can be selected (use the Select All right mouse
button), and pasted into a text editor for archiving and printing.
GFK-2409
Chapter 4 The Max-ON RX3i Configuration Utility
4-29
4
User Defined Alarms
The user may post user defined faults from within the application. However, before the MaxON RX3i Diagnostics can display the user alarms, they must be configured.
NOTE: User Defined Alarms are not available in the current version of the Max-ON RX3i
Diagnostics.
Adding a User Alarm
1. Select the User Alarms item in the Max-ON RX3i Configuration Utility Project tree.
2. Select the User Defined Alarms > Add Alarm… menu item.
3. Enter an Alarm Number and the corresponding Alarm Description. Note: The Alarm
Number must be within the numerical range 3840..4095. The descriptor may be up to
60 characters in length.
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4
4. Enter any additional alarms.
5. Save your Max-ON RX3i Configuration, update the cfg_dat C Block in the Max-ON
Project.
6. Download the new Max-ON RX3i Configuration to the CPUs.
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4-31
4
Deleting a User Alarm
1. Select the User Alarms item in the Max-ON RX3i Configuration Utility Project tree.
2. Select a User Alarm by clicking on the gray button to the left of the User Alarm
number. A “*” will be placed on the button to indicate it’s selection.
3. Select the User Defined Alarms > Delete Alarm menu item. The alarm has now been
removed.
4. Repeat steps 2 and 3 for any additional user-defined alarms.
5. Save your Max-ON RX3i Configuration, update the cfg_dat C Block in the Max-ON
Project.
6. Download the new Max-ON RX3i Configuration to the CPUs.
Note: In order for User-Defined Alarms to be active, ladder logic must be added to the
application. The logic passes the user specified alarm number to the Alarm handler. (See
Max-ON RX3i Advanced Programming topic: User-Defined Alarms.)
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Chapter Programming Considerations
5
This chapter provides additional information on programming considerations and system
resources for the Max-ON RX3i product. In many cases, Max-ON RX3i System Variables
have been predefined to use in application logic in order to interact with the Max-ON RX3i
redundancy driver.
GFK-2409
5-1
5
Reserved References
Max-ON RX3i redundancy drivers make use of a small number of variable references. Some
of these references are used for the internal operation of the drivers to hold system state
information. Many are available to your application logic to provide both information on the
system and to control the operation of the redundancy drivers.
I/O References
%I00001 to 2048
Available to all applications
%Q00001 to 2048
Available to all applications
%AI00001 to configured limit
Available to all applications
%AQ00001 to configured limit
Available to all applications
Boolean References
%G00001 to 1024
Available to all applications
%G01025 to 1280
Reserved by Max-ON RX3i
%M00001 to 0928
Available to all applications
%M00929 to 1024
Reserved by Max-ON RX3i
%M01025 to 4096
Available to all applications
%S (all)
Available to all applications
%T00001 to 256
Available to all applications
Word References
5-2
%R00001 to 8000
Available to all applications
%R08001 to 16384
Reserved by Max-ON RX3i
%R16385 to configured limit
Available to all applications
%W00001 to %W29999
Available to all applications
%W30000 to %W50000
Reserved by Max-ON RX3i
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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5
System Status Flags
The System Status Flags indicate key operating characteristics of a Max-ON RX3i system.
These flags may be monitored by an HMI to display such things as current Master.
Optionally, the system designer may use the status flags to control the operation of the
application.
Variable
Name
Reference
Description
ID_A
%M01017
ID Flag for CPU A
ID_B
%M01018
ID Flag for CPU B
CPU_RUN
%M01019
CPU is in RUN Mode
MASTER
%M01020
Master Flag
SYNC_OK
%M01021
All Data has been Synchronized
%M01022 –
Reserved
%M01024
%M01017
ID Flag for CPU A (ID_A) – This flag is ON in the CPU identified as PLC A.
(Setting the CPU Identity)
%M01018
ID Flag for CPU B (ID_ B) – This flag is ON in the CPU identified as PLC B.
(Setting the CPU Identity)
%M01019
CPU is in RUN Mode (CPU_RUN) – This flag is ON if the CPU is in RUN
Mode. It is OFF if the CPU is in STOP/Disabled or STOP/Enabled.
%M01020
Master Flag (MASTER) – This flag is ON in whichever CPU is the current
Master.
%M01021
All Data has been Synchronized (SYNC_OK) – This flag is always ON in the
CPU identified as the current Master. It is ON in the Backup CPU at the
moment when all Synchronized Data items have been updated.
GFK-2409
Chapter 5 Programming Considerations
5-3
5
Indicating Mastership
Using the System Status Flag %M01020 (Master) and the System Status Flags %M01017
and %M01018 (the CPU Identity flags), you may determine which PLC is the current Master.
By combining these flags it is possible to link discrete outputs to indicator lamps, link to
internal coils to provide status points to an HMI, or even link discrete outputs to data switches
to route communications lines from a peripheral to the CPU serial ports.
In the example below, the Flags are used to control discrete outputs that are attached to
indicator lamps.
The next two rungs will indicate which CPU is Master.
ID_A
MASTER
%M01017
%M01020
This is CPU A This CPU is
Master
ID_B
MASTER
%M01018
%M01020
This is CPU B This CPU is
Master
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PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
A_Master
CPU A is the
Master
B_Master
CPU B is the
Master
GFK-2409
5
Local Status Flags – Instantaneous
The following status flags represent the instantaneous (not latched) state corresponding to the
associated descriptors.
Variable
Name
Reference
Description
AUTH_ALM
%M00961
Authorization Alarm
REM_OFF
%M00962
Remote CPU Offline
PROG_CHG
%M00963
Program Changed
HWC_CHG
%M00964
HW Configuration Changed
%M00965 - %M00968
Reserved
%M00961
Authorization Alarm (AUTH_ALM) – This alarm bit indicates that the
corresponding PLC is operating in DEMO mode on a standard PACSystems
RX3i CPU (IC695CPU310). In a system that has been properly authorized,
this flag will be OFF.
%M00962
Remote CPU Offline (REM_OFF)– The companion PLC is offline. This may
be due to the CPU being in STOP, Fault, or Power-OFF. Also, it may be due
to a cable problem or Ethernet Interface failure.
%M00963
Program Changed (PROG_CHG) – The program in the Local CPU has
changed.
%M00964
HW Configuration Changed (HWC_CHG) – The hardware configuration in
the Local CPU has changed.
GFK-2409
Chapter 5 Programming Considerations
5-5
5
Local Status Flags – Instantaneous (cont.)
Variable
Name
Reference
Description
PWR_UP
%M00969
Power Up
PRG_RST
%M00970
Program Restart
E1_OFFL
%M00971
System Ethernet Bus Primary Offline
E2_OFFL
%M00972
System Ethernet Bus Secondary Offline
%M00973 -
Reserved
%M00992
%M00969
Power Up (PWR_UP) – The Local CPU has undergone a power-up event.
%M00970
Program Restart (PRG_RST) – The Local CPU has been switched from
STOP mode to RUN mode.
%M00971
System Ethernet Bus Primary Offline (E1_OFFL) – The primary Ethernet
LAN is offline. This may be due to a cable problem, a transceiver problem, a
hub/switch problem, an ETM001 module failure or a LAN configuration error.
%M00972
System Ethernet Bus Secondary Offline (E2_OFFL) – The secondary
Ethernet LAN is offline. This may be due to a cable problem, a transceiver
problem, a hub/switch problem, an ETM001 module failure or a LAN
configuration error.
%M00973 %M00992
Reserved
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5
Local Status Flags – Latched
The following status flags represent the latched state corresponding to the associated
descriptors. The states are set by the first instance of the associated event. The flags are
reset by either a Local Alarm Clear (RST_LOC or %M01015) or a Master Alarm Clear
(RST_ALL or %M01016). If the underlying alarm condition is persistent, then the flag will be
set again.
Reference
Description
%M00993
Authorization Alarm (A-Only)
%M00994
Authorization Fault (A-Only)
%M00995
Remote CPU Offline
%M00996
Program Changed
%M00997
HW Config Changed
%M00998
Programs Miscompare
%M00999
Reserved
%M01000
Reserved
%M00993
Authorization Alarm – This alarm bit indicates that the corresponding PLC is
operating in DEMO mode on a standard PACSystems RX3i CPU
(IC695CPU310). When the CPU is replaced by a Max-ON CPU
(IC695CMU310), this flag may be reset using the RST_LOC or RST_ALL
variables.
%M00994
Authorization Fault – This fault bit indicates that the system was operating in
DEMO mode for over 22 days and has subsequently shutdown. The PLC Fault
Table will indicate shutdown due a Service Request.
%M00995
Remote CPU Offline – The companion CPU is offline. This may be due to the
CPU being in STOP, Fault, or Power-OFF. Also, it may be due to a cable
problem or Ethernet Interface failure.
%M00996
Program Changed – The program in the Local CPU has changed.
%M00997
HW Config Changed – The hardware configuration in the Local CPU has
changed.
%M00998
Programs Miscompare – The program in CPU A is not the same as the
program in CPU B.
GFK-2409
Chapter 5 Programming Considerations
5-7
5
Local Status Flags – Latched (cont.)
Reference
Description
%M01001
Power Up
%M01002
Program Restart
%M01003
Max-ON Alarm (Fault) Present
%M01004
Max-ON Alarm (Fault) Table Full
%M01005
Config Fault
%M01006 –
Reserved
%M01008
%M01001
Power Up – The Local CPU has undergone a power-up event.
%M01002
Program Restart – The Local CPU has been switched from STOP mode to
RUN mode.
%M01003
Max-ON Fault Present – There is at least one fault entry in the Local CPU’s
Max-ON Alarm Table.
%M01004
Max-ON Fault Table Full – The Local CPU’s Max-ON Alarm Table is full.
%M01005
Config Fault – The Max-ON configuration has exceeded one or more limits for
the allowable size of Synchronized Data transfers.
%M01006 %M01008
Reserved
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5
Remote Status Flags - Latched
The following flags indicate the status as received from the companion (remote) CPU. For
instance, if you are attached to CPU A in Logic Developer PLC, then these bits in CPU A will
depict system status received from CPU B.
The flags below are latched. They may be cleared by resetting the alarms (see Command
Flags). If the alarm condition persists, then the flag(s) will be set again.
Reference
Description
%M00929
Remote is Offline
%M00930
Remote Forces (Overrides) Present
%M00931
Remote PLC Low Battery
%M00932
Remote Config Mismatch
%M00933
Remote Loss of I/O Module
%M00934
Remote Loss of Option Module
%M00935
Remote Option Module Hard Fault
%M00936
Remote Option Module Soft Fault
%M00929
Remote is Offline – CPU is offline, or there has been a bus failure on a
system that uses a single Ethernet Sync bus, or on a system using dual Sync
busses, both have failed.
%M00930
Remote Forces (Overrides) Present – There is at least one force (override)
present in the remote, same as #OVR_PRE (%S0011) in the remote.
%M00931
Remote PLC Low Battery – Same as #PLC_BAT (%S0014) in the remote.
%M00932
Remote Config Mismatch – Same as #CFG_MM (%SA0009) in the remote.
%M00933
Remote Loss of I/O Module – Same as #LOS_IOM (%SA0014) in the remote.
%M00934
Remote Loss of Option Module – Same as #LOS_SIO (%SA0015) in the
remote.
%M00935
Remote Option Module Hard Fault – Same as #HRD_SIO (%SA0027) in the
remote.
%M00936
Remote Option Module Soft Fault – Same as #SFT_SIO (%SA0031) in the
remote.
GFK-2409
Chapter 5 Programming Considerations
5-9
5
Remote Status Flags – Latched (cont.)
Reference
Description
%M00937
Remote System Fault Present
%M00938
Remote I/O Fault Present
%M00939
Remote Max-ON Fault Present
%M00940
Remote Max-ON Fault Table Full
%M00941
Remote Program Changed
%M00942
Remote HW Config Changed
%M00943
Remote Power Up
%M00944
Remote Program Restart
%M00945
Remote Authorization Alarm
%M00946 –
%M00960
Reserved
%M00937
Remote System Fault Present – Same as #SY_PRES (%SC0012) in the
remote.
%M00938
Remote I/O Fault Present – Same as #IO_PRES (%S0013) in the remote.
%M00939
Remote HBR Fault Present – there is at least one fault in the Max-ON fault
table.
%M00940
Remote HBR Fault Table Full – The Max-ON fault table is full.
%M00941
Remote Program Changed – The user application in the remote has
changed.
%M00942
Remote HW Config Changed – The hardware configuration in the remote has
changed.
%M00943
Remote Power Up – The remote has undergone a power-up event.
%M00944
Remote Program Restart – The remote has undergone a Program Stop-toRun event.
%M00945
Remote Authorization Alarm –The Remote CPU is operating in DEMO mode.
%M00946 %M00960
Reserved
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5
System Command Flags
Operation of the system may be influenced by interfacing to the Max-ON RX3i command
flags. They may be accessed within application logic, and in some instances by an HMI.
Variable
Name
Reference
Description
SEL_A
%M01009
Select A as Preferred
SEL_B
%M01010
Select B as Preferred
SW_MSTR
%M01011
Switch Master (self-resetting)
AUT_SWP
%M01012
Auto Sweep Mode
%M01013
Not used
%M01014
Clear Remote Alarms (self-resetting)
RST_LOC
%M01015
Clear Local Alarms (self-resetting)
RST_ALL
%M01016
Clear All Alarms (self-resetting)
The definitions of the flags are as follows:
%M01009
Select A as Preferred (SEL_A) - Used in conjunction with SEL_B (%M01010)
to determine the manner in which Mastership operates. (See Selecting the
Master)
%M01010
Select B as Preferred (SEL_B) - Used in conjunction with SEL_A (%M01009)
to determine the manner in which Mastership operates. (See Selecting the
Master)
%M01011
Switch Master (self-resetting) (SW_MSTR) - Used to exchange Mastership
(See Selecting the Master). If it is set ON, the Max-ON driver will reset it to
OFF automatically. (See Switching the Master)
%M01012
Auto Sweep Mode –When this is set to ON, the Backup CPU will be set to
Constant Sweep mode automatically, and the Master will be set to Normal
Sweep mode automatically. (See PLC Sweep Mode.)
%M01013
Not used.
%M01014
Clear Remote Alarms (self-resetting) - When issued to the Master, CLEARS
the alarms in the Backup CPU only. If it is set ON, the Max-ON driver will reset
it to OFF automatically.
%M01015
Clear Local Alarms (self-resetting) - Clears the alarms in the CPU to which it
is directed. Is reset automatically.
%M01016
Clear All Alarms (self-resetting) - When issued to the Master, CLEARS the
alarms in the Master and Backup CPUs. Is reset automatically.
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Chapter 5 Programming Considerations
5-11
5
Mastership Modes
You may specify the Mastership mode of operation for the Hot Standby CPUs. This may be
accomplished by setting the states of the System Command Flags, SEL_A (%M01009) and
SEL_B (%M01010). Both CPUs must have the states set identically in order to function
properly. The truth table shown below illustrates the operation of the Mastership Command
Flags.
SEL_A
%M01009
SEL_B
%M01010
Description
0
0
Float
1
0
A Preferred
0
1
B Preferred
1
1
Float
▪
A Preferred - In this mode, SEL_A (%M01009) is ON and SEL_B (%M01010) is OFF.
Assume that CPU A is currently the Master. If CPU A fails or is placed in STOP, then
CPU B will become the new Master. CPU B will remain the Master until CPU A is
repaired or is restored to RUN mode. As soon as the all of the Synchronized Data has
been updated in CPU A, the Mastership will return to CPU A.
▪
B Preferred - In this mode, SEL_A (%M01009) is OFF and SEL_B (%M01010) is ON.
The description is similar to A Preferred, except that the roles are transposed.
▪
Float - Either CPU may be the Master. Mastership will not change unless the current
Master fails or is placed into STOP mode. When the failed/stopped CPU is restored to
service, the current Mastership does not change. While the system is in Float Mode,
Mastership may be changed by setting the System Command Flag, SW_MSTR
(%M01011). Float Mode is required if you intend to switch Mastership using an HMI.
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5
Setting the Master Using a Selector Switch
A three position, center-OFF, selector switch may be connected to a pair of discrete inputs
shared by the two CPUs. This allows a system operator to chose either of the CPUs to be the
Preferred Master, or the Mastership may float between the two controllers.
In the example that follows, the switch contacts are wired to discrete inputs SEL_A (%I01009)
and SEL_B (%I01010). When the switch is in the A position, only SEL_A (%I01009) is ON.
When the switch is in the B position, only SEL_B (%I01010) is ON. When the switch is in the
center (Float) position, SEL_A (%I01009) and SEL_B (%I01010) are both OFF.
The next two rungs choose the preferred Master.
SSw_101A
SEL_A
%I01009
Selector
Switch Select
A
%M01009
Select A
Pref'd
SSw_101B
SEL_B
%I01010
Selector
Switch Select
B
GFK-2409
%M01010
Select B
Pref'd
Chapter 5 Programming Considerations
5-13
5
Setting a Preferred Master
You may set a permanent, Preferred Master. In this mode, if the corresponding CPU fails (or
is placed in STOP), then the companion CPU will assume Mastership. As soon as the
Preferred Master resumes operating normally, and its Synchronized Data has been updated,
then the Mastership will transfer.
The example shown below sets PLC A as the Preferred Master.
The next two rungs set the Mastership Mode for "Preferred A"
#ALW_ON
SEL_A
%S00007
Always ON
%M01009
Select A as
Pref'd Master
#ALW_OFF
SEL_B
%S00008
Always OFF
%M0101
Select B as
Pref'd Master
Setting the System for Floating Master
Set the system to Floating Master by including the logic shown below in your application.
Include this logic in any system that must change mastership based upon a command
initiated by either momentary pushbutton or HMI.
The next two rungs set the Mastership Mode
f "Fl "
#ALW_OFF
SEL_A
%S00008
Always OFF
%M01009
Select A
Pref'd
#ALW_OFF
SEL_B
%S00008
Always OFF
%M01010
Select B
Pref'd
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5
Switching Mastership Using a Momentary Pushbutton
You may switch Mastership using a momentary pushbutton switch that is wired to a discrete
input shared by the Hot Standby CPUs. In the example that follows, the switch is wired to
discrete input Sw_Mstr_Pb (%I01011). When this input transitions from Off to On, the System
Command Flag SW_MSTR (%M01011) will be set. The system will reset SW_MSTR
(%M01011) after it has completed processing the switchover.
First, you must set the system for Floating Mastership. (Refer to Setting the System for
Floating Master.)
Then include the following logic to implement the Toggle Master function.
The next rung switches the Master. The system will reset %M1001 automatically.
Sw_Mstr_Pb
SW_MSTR
%I01011
%M01011
Switch
Master (os)
If a command to set SW_MSTR (%M01011) has been issued, then the system will operate in
the following manner.
▪
If both CPUs receive the command, and there is no Preferred Master, then the
Mastership will change as soon as data synchronization is complete.
▪
If only the Master receives the command, and the Backup is available, and there is no
Preferred Master, and data synchronization is complete, then the transfer will occur.
▪
If one or both of the CPUs receive the command, and the Master is the Preferred
Master, then the request is discarded.
▪
▪
If only the backup receives the command, then no transfer will occur.
After the relevant conditions above have been evaluated, SW_MSTR (%M01011) will
be reset automatically.
GFK-2409
Chapter 5 Programming Considerations
5-15
5
Switching Mastership Using an HMI
In your HMI application, configure an operation that sets the command flag SW_MSTR
(%M01011) in the current Master CPU. Note that the HMI must be aware of which CPU is the
current master so that it know where to direct the command. The HMI must monitor MASTER
(%M01020) in each PLC to determine current mastership.
Assuming that there is no preferred Master set in either CPU, then the transfer will occur as
soon as data synchronization is complete. The system will reset SW_MSTR (%M01011) after
it has completed processing the switchover.
You must set the system for Floating Mastership. (Refer to Setting the System for Floating
Master.) No other logic is required.
5-16
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
System Data Registers
Variable Name
Reference
Function
CAT_NUM
REV_NUM
%R9001
%R9002
Catalog Number
Current Release Number
USR_N1
%R9003
%R9004
User Version Number
PDAT_01
%R9005 - mm:ss
%R9006 - dd:hh
%R9007 - yy:mm
%R9008
%R9009
User Version Date
Program Additive Checksum
Reserved
REM_SCN
%R9010
%R9011 %R9021
%R9022..
%R9023
%R9024
%R9025
LOC_SCN
%R9026
LOC_MUX
%R9027
IOM_UPD
%R9028
REG_UPD
%R9029
NUM_FLT
%R9030
NUM_FLT[001]
%R9031..
%R9036
%R9037..
%R9041
…
…
%R9186..
%R9190
NUM_FLT[007]
NUM_FLT[156]
GFK-2409
Program Size
Not used
Not used
Not used
Remote CPU’s Current Scan
time
Local CPU’s Current Scan
time
Average Mux. Packet Interval
%S, %M, %Q, %AQ Update
Interval
%R Update Interval
Number of Faults in Fault
Table
Fault Record #01
Description
integer with implied decimal point (e.g., +00101 =
v1.01)
(double precision) If audit trail has been enabled,
Max-ON will increment this register pair each time a
program change is stored or updated. If audit trail is
not enabled, then the user may enter any value here.
Related to above...this is a packed BCD date.
yy/mm/dd | hh:mm:ss
(double precision) An approximate program size.
Some users include this value with the checksum
value for additional security in revision control.
Instantaneous PLC Scan time in msec.
Instantaneous PLC Scan time in msec.
Average time interval for advancing to the next
multiplexer packet. (msec.)
Time to update all %S, %M, %Q, %AQ and time of
day in the backup PLC (sec. X 0.01)
Time to update registers in the backup PLC (sec. X
0.01)
0 = empty; 33 = full
Fault Record #02
…
…
Fault Record #32
Chapter 5 Programming Considerations
5-17
5
Advanced Topics
PID Function Blocks
The PID function block uses a data structure consisting of 40 registers. These registers
contain not only configuration parameters, but also intermediate and final terms used in the
internal calculations. Some of the internal calculations are based upon values from the PLC’s
system clock. Because the internal clocks in the two CPUs are not synchronized precisely to
each other, it is necessary to include a small amount of logic to compensate for the difference.
Also, it will be necessary to include the PID registers in one or more of the %R Synchronized
Data Groups. This ensures that the PID in the Backup CPU tracks the Master.
The ladder logic is straightforward:
The following rungs control the operation of the PID.
This first Rung allows the PID to be placed in Manual by an HMI or a local control station. This is accomplished by setting P01_Man (%M00501).
(Note that %M00501 operates only in the Master CPU. If P01_Man (%M00501) is SET in the Backup, then it will be reset before the
rung containing the PID is solved.)
If the PID is in Manual, then the raise P01_Up (%M00502) and lower P01_Dn (%M00503) contacts are operational. If this is the Master CPU,
then the output (CV) will respond to the UP/DN commands.
If this is the Backup CPU, the register block (%R01001..01040) will be overwritten by Synchronized Data values received from the Master
CPU. This forces the Backup's PID to "Track" the values in the Master.
MASTER P01_Man
P01_Man
%M01020 %M00501
This CPU is PID_01: Set
Master
in Manual
%M00501
PID_01: Set in
Manual
MASTER
%M01020
This CPU is
Master
5-18
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
In this example, the PID parameters begin at PID_P01 (%R01001). For PID loop 01, there
must be a synchronized data group configured that assures that registers %R01001 through
%R01040 are transferred. You must include the registers associated with other PID function
blocks as well.
PID ISA
PID_P01
P01_SP SP CV P01_CV
%R01001
%R00501 PID_01: %R00503
PID_01:
PID_01:Set Pt Paramet
Output Value
ers
P01_PV
PV
%R00502
PID_01:Prese
t value
P01_Man
MAN
%M00501
PID_01: Set in
Manual
P01_Up
UP
%M00502
PID_01: Raise
Output
P01_Dn
DN
%M00503
PID_01:
Lower Output
GFK-2409
Chapter 5 Programming Considerations
5-19
5
User-Defined Alarms
The user may post self-defined faults from within the application by performing the following
steps.
Note: User defined Alarms are not available in this version the Max-ON RX3i Diagnostic Tool.
In Max-ON RX3i Configuration Utility
1. Select the User Alarms item in the Max-ON RX3i Configuration Utility Project tree.
2. Select the User Defined Alarms > Add Alarm… menu item.
3. Enter an Alarm Number and then the corresponding Alarm Description. Note: The
Alarm Number must be within the numerical range 3840..4095. The descriptor may be
up to 60 characters in length.
5-20
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
4. Enter any additional alarms.
5. Save your Max-ON RX3i Configuration, update the cfg_dat C Block in the Max-ON
Project.
6. Download the new Max-ON RX3i Configuration to the CPUs.
GFK-2409
Chapter 5 Programming Considerations
5-21
5
In Your Application Folder
1. Move a user specified fault value into FLT_COD (%R9762). The fault value must be in
the range 3840..4095 (decimal) inclusive, and should correspond to the equivalent
user-defined fault created in Max-ON RX3i Configuration Utility.
2. In most cases, move a value 0 into FLT_CKT (%R9761). However, you may define
your own identifier that may be MOVed into this register. The diagnostic tool will
display this as a decimal value in the Circuit Reference position.
3. Call the subroutine named HBR_005. This must be done for only once, otherwise
each subsequent call will post an additional alarm into the alarm table. In the sample
logic shown below, ua_0002 (%M02050) has been used as an alarm latch. The userdefined alarm will be posted only if the coil is not already set. Note that a setcoil is
used so that the alarm state will be retained through a loss of power. Also, a rung has
been provided that resets the coil if the alarm clear flags are invoked.
Process a User Alarm
PSH_1402 ua_0002
MOVE
INT
MOVE
INT
CALL
hbr_005
%M02050
User_0002:P
402 High
Pressure
Alarm
%I00259 %M02050
User_0002:P
Pump
Discharge
402 High
Pressure High Pressure
Alarm
1
0
ua_0002
IN
1
Q
FLT_CK
%R0976
Fault Parm:
Ckt Number
3841 IN
Q
FLT_COD
%R09762
Fault parm:
Fault Code
RST_AL
%M0101
Reset All
Alarms (os)
ua_0002
%M02050
User_0002:P
402 High
Pressure
Alarm
RST_LO
%M0101
Reset Local
Alarms (os)
5-22
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
If a corresponding user-defined alarm has been entered during the Max-ON Rx3i
Configuration Utility configuration session, then the fault time-stamps, along with
appropriate descriptors will be displayed in the Max-ON RX3i Alarm Table in the Proficy
View Diagnostics application.
Max-ON RX3i variables used by subroutine HBR_005 to log a user defined alarm.
Variable Name
GFK-2409
Reference
Description
FLT_CKT
%R09761
Fault Parameter: Circuit Number
FLT_COD
%R09762
Fault Parameter: Fault Code
Chapter 5 Programming Considerations
5-23
5
Alarm Table Organization
The Alarm Table begins at %R9030 and ends at %R9190. The Alarm Table organization is
shown below.
Variable Name
Register
Description
NUM_FLT
%R9030
Number of Faults in Table (0 = empty; 33 = full)
NUM_FLT[001]
%R9031
Record 1 – Fault Type
NUM_FLT[002]
%R9032
Record 1 – Fault Location
NUM_FLT[003]
%R9033
Record 1 – Time Stamp
NUM_FLT[004]
%R9034
Record 1 – Time Stamp
NUM_FLT[005]
%R9035
Record 1 – Time Stamp
NUM_FLT[006]
%R9036
Record 2 - Fault Type
NUM_FLT[007]
%R9037
Record 2 - Fault Location
…
…
%R9186
Record 32 - Fault Type
NUM_FLT[156]
The value in NUM_FLT (%R09030) indicates the number of active faults (alarms) in the table.
A value of zero indicates that the fault table is empty. A value of 33 indicates that the table is
full. When the table is full, no further faults may be added to the table.
The first fault table entry is located in NUM_FLT[001..005] (%R9031..9035). The second fault
entry is in NUM_FLT[006..010] (%R9036..9040). This pattern is repeated for a total of 32
fault records.
Alarm Record Structure
Each record in the Alarm Table consists of 5 registers. Each register may be interpreted as a
pair of bytes whose definitions are shown in the table below. If the registers are displayed as
hexadecimal values in Logic Developer PLC, then the interpretation may be simplified.
Byte Offset
5-24
Description
0
Timestamp: Seconds (BCD)
1
Timestamp: Minutes (BCD)
2
Timestamp: Hours (BCD)
3
Timestamp: Day of Month (BCD)
4
Timestamp: Month (BCD)
5
Timestamp: Year (BCD)
6
Circuit Reference - lsb
7
Circuit Reference - msb
8
Alarm Subclass
9
Alarm Class
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
Bytes 0..5 These contain date and time information stored as BCD values. The simplest
way to view these in Logic Developer PLC is to display the fault table registers as
hexadecimal numbers.
Bytes 6..7 Bytes 6 and 7 contain the decimal value of an I/O circuit reference. The value in
this pair of bytes must be interpreted in the context of the Alarm Class that has
generated the message. The Alarm Class is contained in Byte 9. The value will
be zero for CPU or system-level hot standby faults.
Byte 8
This byte contains the Alarm Subclass code. The subclass contains the rack
number in the upper nibble and the slot number in the lower nibble. This number
implies different fault descriptions depending upon the value of the Alarm Class
contained in byte 9.
Byte 9
This byte contains the Alarm Class code. The valid range is 0000..4095.
Alarm Class
(Offset 9)
Alarm
Subclass
(Offset 8)
Circuit
Reference
Range (Integer)
Alarm Class Description
(Offset 6/7)
GFK-2409
00
00..FF
Always 0
01
00..FF
0001..2048
Discrete input circuit
02
00..FF
0001..2048
Discrete output circuit
03
00..FF
0001..1024
Analog input circuit
04
00..FF
0001..0256
Analog output circuit
05
00..FF
00..31
06..0E
00..FF
---
0F
00..FF
-32768..32767
Chapter 5 Programming Considerations
System level faults
I/O LAN device
Not defined
User-defined
5-25
5
Alarm Class 00h - System Level Alarms
Decimal
Code
Hex
Code
Description
001
0001
CPU Stopped
The CPU identified in the Source Column
has transitioned from Run to Stop.
002
0002
Program Restart
The CPU identified in the Source Column
has transitioned from Stop to Run.
003
0003
Power Up
Power has been restored to the CPU
identified in the Source Column
004
0004
Invalid CPU ID
The CPU identified in the Source Column
does not have a valid ID. Open the
hardware configuration. Zoom into the CPU
module and set the Checksum Length to 11
for CPU A or 12 for CPU B.
005
0005
Duplicate IDs
The CPUs have identical IDs. Verify that the
hardware configuration has been stored to
the proper CPUs. Verify the identities in the
project have been set so that the Checksum
Length for CPU A is 11 and 12 for CPU B.
006
0006
New
Authorization
Not used.
007
0007
Authorization
Alarm
This occurs after operating for a total of
approximately 22 days in Demo mode.
008
0008
Authorization
Fault
This occurs after operating for a total of
approximately 22 days in Demo mode.
009
0009
Authorization
Corruption
Not used.
010
000A
Program
Changed
The application program in the identified
CPU has changed either due to a program
store or due to online editing.
011
000B
HW Config
Changed
The hardware configuration in the identified
CPU has changed.
012
000C
Program
Checksum
Mismatch
There is a discrepancy between the
checksum in CPU A and CPU B. This
implies that the programs in the two CPUs
are not equivalent.
013
000D
Remote is Offline
The companion CPU has transitioned to an
Offline mode.
014
000E
Remote is Online
The companion CPU has transitioned to an
Online mode.
015
000F
Local Switches to
Master
The CPU identified in the Source Column
has become a Master.
5-26
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
Decimal
Code
Hex
Code
Description
016
0010
Local Switches to
Backup
The CPU identified in the Source Column
has become a Backup.
017
0011
Genius Sync P
Failure
Not used.
018
0012
Genius Sync S
Failure
Not used.
019
0013
Genius Sync P
LRC Error
Not used.
020
0014
Genius Sync S
LRC Error
Not used.
021
0015
%Q Configuration
Fault
A defective configuration has been entered.
There are either too many %Q groups, or the
reference range exceeds the capacity of the
system.
022
0016
%AQ
Configuration
Fault
A defective configuration has been entered.
There are either too many %AQ groups, or
the reference range exceeds the capacity of
the system.
023
0017
%M Configuration
Fault
A defective configuration has been entered.
There are either too many %M groups, or the
reference range exceeds the capacity of the
system.
024
0018
%R Configuration
Fault
A defective configuration has been entered.
There are either too many %R groups, or the
reference range exceeds the capacity of the
system.
025
0019
Corrupted Config
A defective configuration has been entered.
026
001A
Ethernet
Synchronization
Primary Failure
The System’s primary Ethernet LAN has
failed. CPU A and CPU B are unable to
transfer Synchronized Data via the primary
Ethernet LAN.
027
001B
Ethernet
Synchronization
Secondary
Failure
The System’s secondary Ethernet LAN has
failed. CPU A and CPU B are unable to
transfer Synchronized Data via the
secondary Ethernet LAN.
028
001C
Illegal Mastership
State
There are either two Masters or two Backups
in operation.
029
001D
Not used
…
…
…
032
0020
Not used
GFK-2409
Chapter 5 Programming Considerations
5-27
5
Fault Class 01h - Discrete Inputs
Decimal
Code
Hex
Code
Description
257
0101
Circuit Offline
258
0102
Not used
259
0103
Remote Rack Offline
The remote drop corresponding to the
discrete input reference displayed in
the Source Column has transitioned to
an offline state.
260
0104
Remote Rack Overrides Present
The corresponding remote drop has
I/O overrides present.
261
0105
Remote Rack PLC Low Battery
The corresponding remote drop has
an indication of low CPU Battery
voltage. Replace or connect the
battery in the remote drop.
262
0106
Remote Rack Config Mismatch
There is a configuration discrepancy
between the modules installed in the
remote rack and the hardware
configuration that has been stored
into the remote rack.
263
0107
Remote Rack Loss of I/O Module
An I/O module in the remote rack has
failed.
264
0108
Remote Rack Loss of Opt Mod
265
0109
Remote Rack Opt Mod Hard Fault
266
010A
Remote Rack Opt Mod Soft Fault
267
010B
Remote Rack Sys Fault Present
268
010C
Remote Rack I/O Fault Present
269
010D
Remote Rack Program Changed
270
010E
Remote Rack HW Configuration
Changed
271
010F
Remote Rack Power Up
Power has been lost and then
subsequently restored at the remote
rack.
272
0110
Remote Rack Program Restart
The remote rack has transitioned from
STOP to RUN.
273
0111
Remote Rack Gen Bus P LRC
274
0112
Remote Rack Gen Bus S LRC
275
011D
Not used
…
…
…
288
0120
Not used
5-28
The discrete input reference displayed
in the Source Column has transitioned
to an offline state.
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
5
Fault Class 02h - Discrete Outputs
Decimal
Code
Hex Code
Description
513
0201
Circuit Offline
514
0202
Not used
…
…
…
544
0220
Not used
The device corresponding to the circuit reference
number shown in the Source Column has
transitioned to offline.
Fault Class 03h - Analog Inputs
Decimal
Code
Hex
Code
Description
769
0301
Circuit Offline
The device corresponding to the circuit reference
number shown in the Source Column has transitioned
to offline.
770
0302
Not used
771
0303
Under-range
After scaling, the resulting value is less than the lower
engineering unit limit.
772
0304
Over-range
After scaling, the resulting value is greater than the
upper engineering unit limit.
773
0305
Not used
…
…
…
800
0320
Not used
Fault Class 04h - Analog Outputs
Decimal
Code
Hex
Code
Description
1025
0401
Circuit Offline
The device corresponding to the circuit reference
number shown in the Source Column has transitioned
to offline.
1026
0402
Not used
…
…
…
1055
0420
Not used
GFK-2409
Chapter 5 Programming Considerations
5-29
5
Fault Class 05h – I/O LAN Alarms
Decimal
Code
Hex
Code
Description
1089
0501
Addition of Device
The device corresponding to the circuit reference
number shown in the Source Column has transitioned
to online.
1090
0502
Loss of Device
The device corresponding to the circuit reference
number shown in the Source Column has transitioned
to offline.
1091
0503
Not used
…
…
…
1120
0520
Not used
5-30
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
Chapter Configuring the Hot Standby Redundancy CPUs
6
A Max-ON RX3i Project contains three Targets that are used to distinguish between hardware
configurations for CPU A, CPU B, and the user application that is common to both of the
CPUs.
The figure shown below illustrates the various components contained in the Generic X3i
Project named Max-ON Rx3i LD Project vx_yy.zip.
When a Max-ON RX3i project is created, a hardware configuration Target is provided for CPU
A and one is provided for CPU B. In most aspects, these targets are very similar to each
other. The significant differences between the two hardware configurations are:
1. Identity settings for the CPUs (via logic checksum words)
2. Serial communication port settings and SNP ID
3. Ethernet interface IP addresses
4. Ethernet Global Data configuration for the Ethernet I/O LANs
5. Genius bus controllers configuration
Many of the configuration items are completed during the process of developing the Project.
The following sections provide details on the configuration of these elements.
GFK-2409
6-1
6
Configuring PLC A
Open the Hardware Configuration for PLC_A_HW
In the Max-ON RX3i Project, select and expand the Hardware Configuration node of the
PLC_A_HW target.
Set the Max-ON Rx3i Identity for PLC A
The identity for CPU A is determined by the value set in the Logic Checksum Words CPU
parameter located in the CPU’s Hardware Configuration for CPU A.
1. Open the CPU module’s Hardware Configuration by double-clicking on the
IC695CMU310 module.
2. Click on the Scan tab to display the Logic Checksum Words parameter.
3. Verify that the Logic Checksum Words parameter value is 32. If it is not 32,
change the parameter to this value.
6-2
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
6
Set Memory Limits for PLC A
The Max-ON RX3i drivers have the minimum memory requirements shown below:
%W
%R
%AI
%AQ
Registers
Registers
Analog In
Analog Out
50000
(minimum)
16384
(minimum)
2048
(minimum)
512
(minimum)
Select the Memory tab of the CPU configuration and verify that these values have been
configured. Please note the memory limits required for your application may be larger than
these minimum values.
GFK-2409
Chapter 6 Configuring the Hot Backup CPUs
6-3
6
Configure Ethernet Sync Network for PLC A
Use the Sync LAN Interface Module configuration summary from the Max-ON Rx3i
Configuration Utility as a guide for configuring the Ethernet synchronization interfaces in the
system.
Add the Ethernet Interface module(s) to the appropriate slot(s) in the Hardware Configuration
for PLC A, and configure its parameters to match the Max-ON RX3i Configuration Summary.
6-4
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
6
Configure Ethernet Interface for Ethernet I/O LANS for PLC A (if used)
Configure the Ethernet Interfaces used in conjunction with the Ethernet NIUs. Add the
Ethernet Interface module(s) to the appropriate slot(s) in the Hardware Configuration for PLC
A. You will also need to configure this Module’s EGD information to match the definitions of
your ENIU EGD exchanges.
Please note that only 4 Ethernet Modules may be added to an RX3i Main Rack.
Configure Genius Bus Controllers for PLC A (if used)
Use the Genius Bus Primary/Secondary configuration summary from the Max-ON Rx3i
Configuration Utility as a guide for configuring the Genius busses in the system.
GFK-2409
Chapter 6 Configuring the Hot Backup CPUs
6-5
6
Add the Genius bus controllers to the appropriate slot(s) in the Hardware Configuration for
PLC A. Configure the parameters to match the Max-ON RX3i Configuration Summary.
Serial Bus Address (SBA)
All Genius bus controllers in PLC A must be configured to have their serial bus addresses set
at 31.
Inputs Default
Inputs should be set to Force OFF.
Status Reference Type
The recommended practice is set the device status address at the high end of the discrete
input status references. For instance, the first GBC might start at %I02017, length 32.
6-6
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
6
Output at Start
Outputs must be set to Disabled at Start.
Configure I/O Devices on the Primary Bus for PLC A
Use the Bus I/O configuration summary from the Max-ON Rx3i Configuration Utility as a guide
for configuring the Genius devices that reside on the Genius bus.
1. Add Genius devices to the GBC’s configuration and configure the Genius device
parameters to match. A sample is shown below.
2. Repeat this process for each Genius device in the Max-ON RX3i configuration.
Repeat the above process until there are no more bus controllers to be configured.
GFK-2409
Chapter 6 Configuring the Hot Backup CPUs
6-7
6
If there are no Secondary busses in the system, store the configuration into CPU A.
Configure I/O Devices on the Secondary Bus for PLC A
Use the Bus I/O configuration summary from the Max-ON Rx3i Configuration Utility as a guide
for configuring the Genius devices that reside on the Secondary Genius bus.
You can use the Copy Genius Bus function in the hardware configuration to facilitate the
speedy duplication of Genius bus configurations.
Select the location for the duplicate Genius Bus and an exact copy will be made to the
destination slot location.
6-8
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
6
Configuring PLC B
Open the Hardware Configuration for PLC_B_HW
In the Max-ON RX3i Project, select and expand the Hardware Configuration node of the
PLC_B_HW target.
Set the Max-ON RX3i Identity for PLC B
The identity for CPU B is determined by the value set in the Logic Checksum Words CPU
Parameter located in the CPU’s Hardware Configuration for CPU B.
1. Open the CPU module’s Hardware Configuration by double-clicking on the CMU310
module.
2. Click on the Scan tab to display the Logic Checksum Words parameter.
GFK-2409
Chapter 6 Configuring the Hot Backup CPUs
6-9
6
3. Verify that the Logic Checksum Words parameter’s value is 16. If it is not 16,
change the parameter to this value.
Set Memory for PLC B
Normally, the memory in CPU B is configured the same as for CPU A. Please refer to the
information used for CPU A, and make adjustments to the CPU B memory configuration if
necessary.
Configure Ethernet Sync Network for PLC B
Repeat the configuration process for the Ethernet synchronization interfaces in PLC B.
Configure Ethernet Interface for Ethernet I/O LANS for PLC B (if used)
Configure the Ethernet Interfaces used in conjunction with the Ethernet NIUs.
Configure Genius Bus Controllers for PLC B (if used)
Serial Bus Address
All Genius bus controllers in PLC B should be configured to have their serial bus addresses
set at 30.
Input Default
Inputs should be set to Force OFF.
Status Reference Type
The recommended practice is set the device status address at the high end of the discrete
input status references. For instance, the first GBC might start at %I02017, length 32.
6-10
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
6
Output at Start
Outputs must be set to Disabled at Start.
Configure I/O Devices on the Primary and Secondary Busses for
PLC B
The I/O devices for CPU B are configured exactly the same as for CPU A. Please refer to the
instructions earlier in this chapter to complete their configuration.
Copying PLC A Configuration to PLC B Configuration
A productivity tool that can also be used to speed the duplication of the Hardware
Configuration between PLC A and PLC B is to Export the Hardware Configuration from PLC A
and Import it into PLC B. This will accelerate the configuration of the hardware configuration
and you only need to modify the slight differences in PLC B.
To export the Hardware Configuration from the PLC_A_HW target and import it into the
PLC_B_HW target:
1. Select the Hardware Configuration node for PLC_A_HW target.
2. Select the Export to File… right mouse menu item.
GFK-2409
Chapter 6 Configuring the Hot Backup CPUs
6-11
6
3. Specify a file name for the configuration, or use the default name PLC_A_HW.hwc.
4. Select the Hardware Configuration node for PLC_B_HW target.
5. Select the Import from File… right mouse menu item.
6. Specify the file name used in Step 3 (default name PLC_A_HW.hwc).
7. Now modify the Hardware Configuration for PLC_B_HW Target to match the
parameters of PLC B in your system.
6-12
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
Chapter Configuring the I/O Devices
7
Configuring the Ethernet I/O Devices
Before you may use your system, you must configure the Ethernet I/O devices that are to be
installed on the Ethernet I/O bus. For Max-ON RX3i, the Ethernet devices may consist of
PACSystems RX3i Ethernet NIUs and/or Series 90-30 ENIUs.
For a complete description of how to configure and use the PACSystems RX3i ENIUs, please
see GFK-2434, the PACSystems RX3i Ethernet Network Interface Unit manual. A summary of
the process to configure this ENIU is as follows:
1. Determine the IP Addresses for the Primary (PLC A) and Secondary (PLC B)
Controllers and the Ethernet NIU.
2. Add the PACSystems ENIU target(s) to your Machine Edition Project by selecting the
Add Target > GE Fanuc Remote I/O > PACSystems RX3i Ethernet menu.
3. Set the IP Address and Subnet Mask on the Ethernet Transmitter module(s) ETM001
in the Ethernet NIU target. Set the Gateway IP Address if required.
4. Set the Ethernet Global Data Local Producer ID in the Ethernet NIU.
5. Add the input and output modules to the Ethernet NIU configuration. If you add or
change modules later in the project, EGD Exchanges in the ENIU and controller may
need to be updated.
6. Complete the Ethernet Global Data Exchanges for the ENIU.
GFK-2409
7-1
7
7. If the ENIU has any Local Logic, develop this logic for the ENIU target. The RX3i
Ethernet NIU allows the addition of up to 20K bytes of logic to be executed locally in
the I/O Station. A LD logic block named “Local User Logic” is provided for this
purpose.
8. Repeat steps 2 through 7 for each ENIU.
9. Store this information to each ENIU.
10. Add the Ethernet Global Data component to the Primary (PLC_A_HW target) and
Secondary (PLC_B_HW target) Controllers.
11. Set the EGD Local Producer ID in the controllers.
12. Create EGD Exchanges in the Primary controller (PLC A) to match the EGD
exchanges in each ENIU.
13. Create EGD Exchanges in the Secondary controller (PLC B) to match the EGD
exchanges in each ENIU.
14. If Remote COMMREQ Calls will be used with the ENIUs, add the RCC Parameterized
C Block to the PLC_COMMON_CODE target’s application, and add any logic needed
to execute these commands.
15. Store the Hardware Configurations (PLC_A_HW and PLC_B_HW targets) to PLC A
and PLC B.
16. Store the Application Logic (PLC_COMMON_CODE target) to PLC A and PLC B.
17. Verify that the EGD Exchanges are working.
18. Verify that any RCC commands are working.
19. Verify that any Local Logic is working.
7-2
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
7
Configuring the Genius I/O Devices
Before you can use your system, you must configure the Genius I/O devices that are to be
installed on the Genius I/O bus.
You must configure each device for:
•
•
•
•
Serial Bus Address (SBA)
Type of I/O (Input, Output, Combination)
Scaling
Defaults
Additionally, you must set the I/O to operate properly for redundancy:
•
•
Dual I/O busses
Hot Standby controller
Genius and Field Control I/O
While you are configuring the Genius I/O, you must configure extra parameters that govern
system operation with respect to redundant PLCs and redundant (dual) Genius I/O busses.
Please note that for Genius and Field Control I/O, you must have a Handheld Monitor
available to set these parameters.
Redundant Controllers
Using the Genius Handheld Monitor (HHM), set each Genus device for Redundant Controllers
= YES.
BSM Present
Using the Genius Handheld Monitor (HHM), set the BSM Present configuration parameter to
YES. This is required whether or not a dual Genius I/O bus is being used.
When this parameter is configured as YES, then the output default period is extended from 3
token rotation time periods to 2.5 seconds. The extra time allows the RX3i PLCs to exchange
mastership correctly.
GFK-2409
Chapter 7 Configuring the I/O Devices
7-3
7
BSM Controller
If the Genius I/O device is attached directly to a dual bus, either by a Bus Switching Module
(BSM) or a Bus Interface Unit (BIU), then you must configure this device to be a BSM
Controller.
Genius Block with BSM
In the case of a Genius Block connecting to the BSM, setting the block to be a BSM Controller
allocates its first output to the control of the BSM. It is assumed that the BSM is connected to
the first output circuit.
In the case of Field Control connecting to the BIU, setting the parameter to be a BSM
Controller directs the BIU to activate its internal bus switching circuitry.
If the device is connected to a “stub” downstream of another device that controls the
switching, then set BSM Controller to NO.
Genius VersaMax I/O
Set the serial bus address and baud rate using the rotary switches on the Genius Network
Interface Unit.
The Max-ON RX3i PLC drivers will set the remaining parameters associated with redundancy:
•
•
•
•
Controller Redundancy = YES
Default Time = 2.5 seconds
BSM Controller = YES, if the device is interfaced to dual busses
BSM Controller = NO, if the device is interfaced to a simplex bus
Each time a VersaMax device logs onto the system, the Max-ON RX3i driver will issue a Write
Device Datagram with the proper configuration parameters.
Note: In order for VersaMax I/O to work properly in a Max-ON Rx3i system, you must
configure the I/O in the Max-ON RX3i Configuration Utility. Make certain that the I/O Family
has been identified as VersaMax.
7-4
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
7
Remote 90-30 Genius Drops
A Remote 90-30 Genius Drop consists of a Series 90-30 CPU, power supply, base, and one
or more Genius bus controllers. Input and output modules are installed in the CPU base.
Modules also may be installed in an I/O Expansion base.
A Scanner routine executes in the drop’s CPU. This routine scans all input devices and
transmits the input states to the Hot Standby PLCs by way of the I/O bus.
Creating the Remote 90-30 Genius Drop Project
Follow these steps to create a Remote 90-30 Genius Drop Project in Proficy Logic Developer
PLC:
1.
Create a new project based on the appropriate Remote 90-30 Genius Drop template.
The Remote 90-30 Genius Drop project is added to the Machine Edition project
Navigator by using the File > Restore Project… menu item. Select the Project
Navigator window making certain that there is no project open at this time.
2.
Using the File menu, click on Restore Project...
GFK-2409
Chapter 7 Configuring the I/O Devices
7-5
7
3.
Navigate to the Proficy Components directory, then to the Remote Drops LD
directory. Open the desired Remote Drop directory, RemoteDrop CPU35x, 36x, 374
(small), for example. Make certain that the selection for Files of Type has been set to
Proficy Machine Edition (*.zip). Select the Remote Drop project backup file.
When you click on Open, a new project will be added to the Proficy Navigator window.
4.
7-6
Give your project a descriptive name in the Machine Edition Navigator.
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
7
Remote Drop Status Word
A remote drop always places important status information into its local references at %I00001
through %I00016 inclusive. The definition of these inputs is shown in the table below.
Bit Offset
Description
1
Offline
2
Overrides Present
3
PLC Low Battery
4
Config Mismatch
5
Loss of I/O Module
6
Loss of Option Module
7
Option Module Hard Fault
8
Option Module Soft Fault
9
System Fault Present
10
I/O Fault Present
11
Program Changed
12
HW Config Changed
13
Power Up
14
Program Restart
15
Bus 1 LRC Error
16
Bus 2 LRC Error
To ensure proper operation of the remote drop, you must not configure any local module such
that it overlaps these discrete input addresses. Make certain that addressing for your
modules begins at %I00017 or above.
GFK-2409
Chapter 7 Configuring the I/O Devices
7-7
7
Configuring the Drop’s GBC
The Genius bus controller in the remote drop must be configured to transmit the input data to
the Hot Standby PLCs and also to receive global data from the Hot Standby PLCs. In the
Remote Drop, global data contains the discrete and analog output data.
Primary Bus
The Genius bus controller should be configured as follows:
In the Settings Tab
Serial Bus Address (SBA):
Any address from 0 to 29 is acceptable. (Note: a Genius
Handheld Monitor normally is set for SBA=0. It is standard
practice to avoid 0 when using Field Control or Genius I/O.)
Status Reference Type:
%I00481 for M23, M31, and M40 drop folders
%I02017 for M5S and M5L drop folders
In the Global Data Tab
At the GBC’s Address:
Input 1 Address
Input 1 Length
Input 2 Address
Input 2 Length
Output 1 Address
Output 1 Length
Output 2 Address
Output 2 Length
%I00001
always 0
%AI00001
always 0
%I00001
16 plus the number of Discrete Inputs installed
%AI00001
The number of Analog Inputs installed
At SBA 30:
Input 1 Address
Input 1 Length
Input 2 Address
Input 2 Length
Output 1 Address
Output 1 Length
Output 2 Address
Output 2 Length
See Buffer Registers
62
%AI00001
always 0
%Q00001
always 0
%AQ00001
always 0
At SBA 31:
Input 1 Address
Input 1 Length
Input 2 Address
Input 2 Length
Output 1 Address
Output 1 Length
Output 2 Address
Output 2 Length
7-8
See Buffer Registers
62
%AI00001
always 0
%Q00001
always 0
%AQ00001
always 0
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
7
Secondary Bus (optional)
The Genius bus controller should be configured as follows:
In the Settings Tab
Serial Bus Address (SBA):
Any address from 0 to 29 is acceptable. (Note: a Genius
Handheld Monitor normally is set for SBA=0. It is standard
practice to avoid 0 when using Field Control or Genius I/O.)
Status Reference Type:
%I00449 for M23, M31, and M40 drop folders
%I01985 for M5S and M5L drop folders
In the Global Data Tab
At the GBC’s Address:
Input 1 Address
Input 1 Length
Input 2 Address
Input 2 Length
Output 1 Address
Output 1 Length
Output 2 Address
Output 2 Length
%I00001
always 0
%AI00001
always 0
%I00001
16 plus the number of Discrete Inputs installed
%AI00001
The number of Analog Inputs installed
At SBA 30:
Input 1 Address
Input 1 Length
Input 2 Address
Input 2 Length
Output 1 Address
Output 1 Length
Output 2 Address
Output 2 Length
See Buffer Registers
62
%AI00001
always 0
%Q00001
always 0
%AQ00001
always 0
At SBA 31:
Input 1
Input 1 Length
Input 2
Input 2 Length
Output 1
Output 1 Length
Output 2
Output 2 Length
GFK-2409
See Buffer Registers
62
%AI00001
always 0
%Q00001
always 0
%AQ00001
always 0
Chapter 7 Configuring the I/O Devices
7-9
7
The table shown below should be used to configure the Genius bus
controller(s) in a remote drop. The table lists the register references that must
be entered into the Logic Developer PLC hardware configuration based upon
the template folder that was used to create the remote drop.
Remote 90-30 Genius Drop Project Name
Description
Receive Buffer
Primary Bus, CPU A
SBA-31
Receive Buffer
Secondary Bus, CPU
A
SBA-31
Receive Buffer
Primary Bus, CPU B
SBA-30
Receive Buffer
Secondary Bus, CPU
B
SBA-30
RemD
rop
M23dx
yy.zip
RemD
rop
M31dx
yy.zip
RemD
rop
M4xdx
yy.zip
RemD
rop
M5sdx
yy.zip
RemD
rop
M5ldx
yy.zip
%R00
705
%R01
729
%R09
680
%R09
680
%R16
065
%R00
833
%R01
857
%R09
808
%R09
808
%R16
193
%R00
769
%R01
793
%R09
744
%R09
744
%R16
129
%R00
897
%R01
921
%R09
872
%R09
872
%R16
257
Configuring the Discrete Output Range
Discrete output states are broadcast as global data from the Hot Standby PLCs. The global
data is intercepted by the Remote Drop and then mapped to local output states. The mapping
process allows output references from the Hot Standby PLCs to be translated to a different
set of output references in the remote drop.
For example, assume that your Remote Drop is implemented using a model IC693CPU323.
This CPU supports a maximum of 512 discrete output addresses. Your Hot Standby CPUs
are each a model IC695CMU310. This CPU supports 32640 output addresses. The mapping
process allows a portion of the output addresses in the range %Q00001...02048 to be
mapped into the range %Q00001...00512 at the remote drop.
7-10
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
7
Configuring the Range
1.
In Logic Developer PLC, open the Remote Drop project.
2.
Using the navigator, open the Block named mxn_cfg.
3.
Edit the first rung of data moves.
4.
In the first MOVE function, a constant is moved into the reference named M_Q_ST
(Master CPU Starting Q Ref). Enter the starting reference for the outputs that are to be
received from the Hot Standby PLCs.
5.
In the second MOVE function, a constant is moved into the reference named L_Q_ST
(Local Rack Starting Q Ref). Enter the starting reference for the outputs in the Remote
Drop in that you wish to place the Hot Standby values.
6.
In the third MOVE function, a constant is moved into the reference named L_Q_LN
(Local Rack Q Length (bits). Enter the number of outputs that are to be mapped into
the Remote Drop.
7.
Save the Project.
MOVE
I NT
MOVE
I NT
1
1
IN
1
Q
M_Q_ST
1
IN
%R09288
Master CPU
Startng Q Ref
8.
MOVE
I NT
1
Q
L_Q_ST
%R09289
Local Rack
Startng Q Ref
256
IN
Q
L_Q_LN
%R09290
Local Rack Q
Length (bits)
Store the Project to the Remote Drop.
GFK-2409
Chapter 7 Configuring the I/O Devices
7-11
7
Configuring the Analog Output Range
Analog output values from the Hot Standby PLCs are intercepted by the Remote Drop and
then mapped (i.e. the output reference may be modified) to local output references.
For example, assume that your Remote Drop is implemented using a model IC693CPU323.
This CPU supports a maximum of 512 analog output addresses. Your Hot Standby CPUs are
each a model IC695CMU310. This CPU supports up to 32640 analog output addresses. The
mapping process allows a portion of the output addresses in the range %AQ00001...32640 to
be mapped into the range %AQ00001...00032 at the remote drop.
Configuring the Range
1.
In Logic Developer PLC, open the Remote Drop project.
2.
Using the navigator, open the Block named mxn_cfg.
3.
Edit the second rung of data moves.
4.
In the first MOVE function, a constant is moved into the reference named M_AQ_ST
(Master CPU Starting AQ Ref). Enter the starting reference for the outputs that are to
be received from the Hot Standby PLCs.
5.
In the second MOVE function, a constant is moved into the reference named
L_AQ_ST (Local Rack Starting Q Ref). Enter the starting reference for the outputs in
the Remote Drop in that you wish to place the Hot Standby values.
6.
In the third MOVE function, a constant is moved into the reference named L_AQ_LN
(Local Rack Q Length (words). Enter the number of outputs that are to be mapped into
the Remote Drop.
7.
Save the Project.
8.
Store the Project to the Remote Drop.
1
MOVE
I NT
MOVE
I NT
MOVE
I NT
1
1
1
IN
Q
M_A Q_ST
%R09291
Master CPU
Startng A Q
Ref
7-12
1
IN
Q
L_A Q_ST
%R09292
Local Rack
Startng A Q
Ref
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
25
IN
Q
L_A Q_LN
%R09293
Local Rack
A Q Length
(words)
GFK-2409
7
Configuring the Hot Standby GBCs
The bus controllers should be configured in the same fashion as other I/O devices.
Configuring the Synchronized Output Variables
Discrete and analog outputs in a Remote Drop receive values from the Hot Standby CPUs by
way of the Synchronized Variables data exchange. In order for outputs to update properly,
there must be a corresponding range of Synchronized Variables that has been configured in
Max-ON RX3i Configuration Utility.
For example, in the configuration shown below, remote drops would be able to access
discrete outputs only within the range %Q00001...00064. No other discrete output data is
being broadcast in the global data exchange, and thus no other discrete output data is
available for the remote drops.
GFK-2409
Chapter 7 Configuring the I/O Devices
7-13
7
7-14
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
Chapter Diagnostic Tools
8
Max-ON RX3i Diagnostic Tools software provides diagnostic functions that may be used to
obtain both real-time and historical operating information from your Hot Standby system. The
Diagnostic Tools are provided by a Proficy View project that is used to monitor the redundant
system.
Step 1 - Create a Max-ON RX3i Diagnostic Tool View Project
In Proficy Logic Developer PLC:
1.
Create a new project based on the generic Max-ON RX3i Diagnostic Tool project.
This project is added to the Machine Edition project Navigator by using the File >
Restore Project… menu item. Select the Project Navigator window, making certain
that there is no project open at this time.
2.
Using the File menu, click on Restore Project...
GFK-2409
8-1
8
3.
Navigate to the Proficy Components directory, then to the Diagnostics VIEW. Make
certain that the selection for Files of Type has been set to Proficy Machine Edition
(*.zip).
When you click on Open, a new project will be added to the Proficy Navigator window.
4.
8-2
Give your View project a descriptive name in the Machine Edition Navigator.
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
8
Step 2 – Configure Ethernet Connections to the PLCs
In order to conduct data transfers between Max-ON RX3i Diagnostics and the Hot Standby
PLCs, you need to establish an Ethernet communication connection to the PLCs. To
configure the Ethernet addresses of the PLCs in the View Project:
1. Open the View project that was restored in Step 1.
2. Expand the PLC Access Drivers node in the Navigator for the View target and select
the PLCA device.
3. Modify the Address of PLCA in the Inspector to match the IP address of PLC A in your
Max-ON RX3i system.
4. Repeat step 3 for PLCB.
5. Select the Download and Start Active Target toolbar button to start the Max-ON RX3i
Diagnostic program, or press the F9 key.
This will launch the View project to run on your PC.
GFK-2409
Chapter 8 Diagnostic Tools
8-3
8
Step 3 – Use the Max-ON RX3i Diagnostic Tool
Once the Diagnostic Tool starts on your PC, the main Diagnostics page will be displayed:
System Status
Clicking on this tab displays the Real-time Status page. The
page contains information on scan times, update rates, and
PLC status.
Alarms
Clicking on this tab will bring up the Alarm Table display page.
This page lists any alarms that have been archived within the
PLCs that have active connections. Alarms may be cleared
from this display page.
Project Info
Clicking on this tab will display the Project Information page.
Catalog number, version number, program checksum, and
other items are displayed.
Authorization
Clicking on this tab will display the Authorization page that
indicates if the system is operating in Demo mode or not.
Please note that if the Diagnostic Tool is not communicating with the PLCs, a
displayed for the items.
The
symbol indicates a Latched Alarm condition, where a
Alarm condition.
8-4
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
will be
symbol indicates a current
GFK-2409
8
System Status
You may view items that relate to the current operating characteristics of your system on the
System Status page. An example is shown in the picture above.
PLC A and PLC B Status
Indicates the operating status of the corresponding PLC, either
Running or Stopped.
Local Scan Time
The scan time, in milliseconds, for the Local PLC.
Remote Scan Time
The scan time, in milliseconds, for the Remote PLC.
%R Update Time
This is the time required to update synchronized data of type %R.
The time is reported in seconds.
%AQ, Q, M Update Time
This is the time required to update all configured synchronized data
of the types %AQ, %M, and %Q. The time is reported in seconds.
Failover Mode
This field indicates the mastership status of the corresponding PLC,
either Master or Backup. There never should be two Masters or two
Backups in a system that is operating properly.
PLC A and PLC C Identity
A-Preferred, B-Preferred, or Float
Program Restart
The local CPU has been switched from STOP mode to RUN mode.
Power Up
The local CPU has undergone a power-up event.
Remote CPU Offline
The companion PLC is offline. This may be due to the CPU being in
STOP, Fault, or Powered Off. Also it may be due to a cable problem
or Ethernet Interface failure.
Data Sync OK
This field indicates the completion status for the transfer of
synchronized data. The Backup CPU will indicate either Synced (all
Synchronized Variables have been received) or Not Synced. The
Master CPU always indicates Synced (ON). It is ON in the Backup
CPU at the moment when all Synchronized Data items have been
updated.
Authorization
This indicates that the corresponding PLC is running on a Max-ON
RX3i CPU, or operating in DEMO mode. In a system that is running
on a Max-ON RX3i CPU, this flag will be OFF.
GFK-2409
Chapter 8 Diagnostic Tools
8-5
8
Alarms
Historical information is stored in the alarm table. This table contains archived information for
up to 32 alarm records for each PLC. The records store information for both system alarms
and optional user-defined alarms. Each alarm record consists of an identifier for the event
that initiated the entry, along with a date/time stamp to indicate when the event occurred.
Typical events include change of Hot Standby mastership, loss of PLC power, program
restart, and loss of I/O devices.
Note: User defined alarms are not available in the current version of Max-ON RX3i Diagnostic
Tools.
8-6
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
8
Project Information
You may view certain items that relate to the general nature of your system. Select the
Project Info tab.
PLC Catalog Number
The catalog number of the GE Fanuc controller that is running
the Max-ON Rx3i project.
SW Version
The current version number of the Max-ON RX3i PLC drivers
User Version Number
If Audit trail has been enabled, then this represents the number
of times the application logic has been changed. If Audit trail
has not been enabled, the Max-ON RX3i drivers will not
update any value here.
User Version Date
If Audit trail has been enabled, then the current date and time
will be posted here each time the application logic is changed.
If Audit trail has not been enabled, then the Max-ON RX3i
drivers will not update any value here.
Program Size
An approximate program size. There will be a slight difference
between the value displayed in Logic Developer PLC and the
value displayed here. The Max-ON RX3i value includes the
memory overhead associated with subroutines.
Program Checksum
The additive checksum for the Program.
GFK-2409
Chapter 8 Diagnostic Tools
8-7
8
Authorization
You may view the information related to the authorization of your system by selecting the
Authorization tab.
Status
The Status field indicates whether the system is running on a
Max-ON RX3i CPU (IC695CMU310), or running in Demo
mode on a standard RX31 CPU (IC695CPU310).
Runtime Remaining
The Runtime Remaining field indicates how much demo time
remains when the system is in Demo mode.
8-8
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
GFK-2409
Appendix System Considerations
A
General Max-ON RX3i Considerations
There are a number of considerations and recommendations that should be taken into account
when defining a Max-ON RX3i system. This appendix summarizes the main items that the
application developer should keep in mind when planning and developing such a system.
1. Ethernet Synchronization LAN should use dedicated Ethernet Interface Modules. If other
devices such as I/O or HMIs are placed on the Sync LAN, they can have a negative
impact on the performance of the system in terms of Failover and Synchronization time.
Therefore, it is recommended that the Sync LAN be isolated. Adding a single device like
the Logic Developer PLC programmer or the Max-ON RX3i Diagnostic tool should be
acceptable and also useful when diagnosing the system.
2. Ethernet I/O LANs should use dedicated Ethernet Interface Modules and be isolated
from a main Ethernet network. Again, if other devices are placed on the I/O LAN, they
can have a negative impact on the performance of the I/O system in terms of IO update
time. Therefore, it is recommended that the I/O LAN be isolated.
GFK-2409
A-1
A
Improving Ethernet Synch Efficiency Using PLC Sweep Mode
For the Ethernet Synchronization interfaces to work efficiently, it is necessary to extend the
Scan Time in one or both of the PLCs. The extra time is used to transfer Synchronized
Variables through the CPU Communications Window. There are two approaches. Each has its
own advantage.
Automatic Mode Selection
In this approach, the system detects which CPU is the Backup and then sets the Backup to
Constant Sweep. If there is a transfer in Mastership, then the Max-ON RX3i driver will set the
new Master CPU into Normal Sweep and the new Backup to Constant Sweep.
Why you should consider this approach:
▪
The Master always operates with the fastest Scan Time possible.
▪
The Backup will adjust its timing regularly to meet current system requirements.
The period for Constant Sweep is determined automatically once per second. The value is
calculated by adding 75 milliseconds to the Master’s Scan Time and then rounding downward to
the nearest multiple of 5 milliseconds.
To enable this mode of operation:
1. Using Logic Developer PLC, open your Max-ON RX3i Project.
2. Select the PLC_COMMON_CODE Target as the Active Target.
3. Prior to the call to HBR_000 in the _MAIN Block, enter a rung that sets AUTSWP
(%M1012) to ON.
4. Store the Logic into CPU A.
5. Store the Logic into CPU B.
A-2
PACSystems® RX3i Max-On Hot Standby Redundancy June 2006
GFK-2409
A
Manual Mode
The second method is to configure the CPUs to execute in Constant Sweep mode. The
configuration is entered via the Logic Developer PLC Hardware Configuration. Both of the
hardware configurations for targets PLC_A_HW and PLC B_HW must be set and then stored
into the corresponding CPUs.
Why you should consider this approach:
▪
By having the Master in Constant Sweep mode, Ethernet communications with HMIs
may be improved dramatically.
Prerequisite: The system has been commissioned and is operating in its normal fashion:
▪
All application logic has been completed and is being executed in the hot-standby CPUs
▪
HMIs are attached and communicating
▪
All peripherals are connected and operating normally
The procedure is as follows:
Using Logic Developer PLC, record the peak CPU Scan Time in the Master CPU. You should
observe the system for several minutes to obtain this value.
1. Add 75 to the value you obtained in step 1. Round this value down to the nearest
multiple of 5.
2. Open the hardware configuration for CPU A.
3. Zoom into the CPU module. Click on the Scan tab.
4. Set the Sweep Mode to Constant Sweep.
5. Set the Sweep Timer to the value calculated in step 2.
6. Store the configuration into CPU A.
7. Open the hardware configuration for CPU B.
8. Repeat steps 3through 6.
9. Store the configuration into CPU B.
10. Using Logic Developer PLC, Select the PLC_COMMON_CODE Target as the Active
Target.
11. Prior to the call to HBR_000 in the _MAIN Block, enter a rung that resets AUTSWP
(%M1012) to OFF.
12. Store the Logic into CPU A.
13. Store the Logic into CPU B.
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Appendix A System Considerations
A-3
A
A-4
PACSystems® RX3i Max-On Hot Standby Redundancy June 2006
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Appendix Frequently-Asked Questions
B
Do Max-ON RX3i Configuration Tools generate my Logic Developer PLC hardware configuration?
No. You must create the Hardware Configuration in the Logic Developer PLC project to match
the parameters defined in the Max-ON RX3i Configuration Tool.
How is the hardware configuration in the Max-ON RX3i Project used in an application?
The memory limits on the CPU must be set to be compatible with your application requirements.
Note that you may have to adjust these in the PLC_A_HW and PLC_B_HW targets as well.
Can Max-ON Configuration Tools append the drivers onto one of my existing application folders?
No. You must start by creating a Max-ON Rx3i Project and then add your application to it. You
can add the Max-ON RX3i driver blocks to an existing Project using the Toolchest drawer
supplied with the Max-ON RX3i software.
My two CPUs will not start. What is wrong?
There are several possibilities. You should use Max-ON Rx3i Diagnostic Proficy View Project to
display the Fault Tables in the PLCs.
Error Message
Invalid CPU ID,
Duplicate IDs
%Q Configuration Fault,
%AQ Configuration Fault,
%M Configuration Fault,
Possible Cause
The checksum word lengths are incorrect. CPU A should
be configured to have a checksum word length of 32. CPU
B should be configured to have a checksum word length of
16.
One or more of the Synchronized Data types that you have
configured is greater than the maximum quantity allowed
for the product on which the project is based.
%R Configuration Fault
My system indicates that both PLCs are Masters. What is wrong?
The two PLCs are not exchanging Ethernet Sync LAN data properly.
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B-1
B
▪
If the system is being started up for the first time, there may be a problem with the hardware
configuration for the Ethenet Interface modules. Or, there may be a problem with the LAN
cabling.
I stopped one of my CPUs and then disabled the Max-ON RX3i PLC drivers in the remaining CPU.
Now my Genius output devices aren’t working. What has happened?
You will need to change the configuration in the Genius bus controllers. In the Logic Developer
PLC Hardware Configuration, open your Max-ON RX3i Project, zoom into the bus controller and
set Output at Start to Enabled. Store the new configuration into the CPU. Make certain that you
do this for both CPUs. Redundant operation is affected adversely by these settings. Don’t
forget to change the configuration to Disabled when you are ready to run the Max-ON RX3i
drivers again.
CPU A has stopped. I know that the demo period has expired, but I can’t get the CPU running
again. What can I do?
Make certain that you turn ON %M1016 while the CPU is in STOP. Then restart the CPU. This
will re-initialize the CPU to run in Demo Mode for an additional 22 days.
Can I use my existing Max-ON RX3i Configuration Tools to create new projects or do I need to reinstall the software each time?
You may use the Max-ON RX3i Configuration Tools as often as you like. However, you will
need to purchase a copy for each PC that you want to run the Configuration Tool on. The
software license for IC646MXN001 is a single-user license.
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Appendix Quick Start Guide Using Ethernet I/O
C
This appendix uses an example Max-ON RX3i Redundant system with two controllers to give an
overview of the steps needed to set up Max-ON RX3i systems with Ethernet NIUs for the I/O.
1. Create List of ENIUs and I/O like the example shown below. The list should include:
▪
Controller(s) with IP addresses and local I/O (if used).
▪
Each ENIU with IP Address, and the I/O for the ENIU. Leave expansion space for
additional I/O if the system is likely to change or grow.
Example System with Redundant Controllers
Primary
PLC A
IP 10.10.10.2
%I1 – 32
%Q1 – 32
%AI1 – 16
%AQ1 - 16
ENIU 11
IP 10.10.10.11
%I33 – 64
%Q33 – 64
%AI17 – 32
%AQ17 - 32
Ethernet Synchronization Link
IP 100.100.100.1
IP 100.100.100.2
ENIU 12
IP 10.10.10.12
%I65-128
%Q65 - 96
%AI (none)
%AQ (none)
Secondary
PLC B
IP 10.10.10.3
%I1 – 32
%Q1 – 32
%AI1 – 16
%AQ1 - 16
ENIU 13
IP 10.10.10.13
%I129 - 256
%Q97 - 128
%AI 33 - 56
%AQ (none)
A Machine Edition backup folder to start from is provided with the Max-ON RX3i Software:
▪
Max-ON RX3i Quick Start 3 ENIUs
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C-1
C
2. In Proficy Logic Developer PLC, create a new project based on the Project named above.
This project is added to the Machine Edition project Navigator by using the File > Restore
Project… menu item. Select the Project Navigator window making certain that there is no
project open at this time.
3. Using the File menu, click on Restore Project...
4. Place the Max-ON RX3i Installation CD in your CD drive and navigate to the Quick Start
directory. Make certain that the selection for Files of Type has been set to Proficy Machine
Edition (*.zip).
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C
When you click on Open, a new project will be added to the Proficy Navigator window.
5. Give your project a descriptive name in the Machine Edition Navigator.
6. The Quick Start project is set up with controller targets named Primary_Controller (PLC A)
and Secondary_Controller (PLC_B), and 3 Ethernet NIUs named ENIU11, ENIU12, ENIU13.
You can rename the Targets as appropriate. If you need fewer ENIUs, delete the ones you
don’t need. If you need more ENIUs, select hardware configuration of a ENIU, right click and
export the configuration. Create a new ENIU target, select hardware configuration, right click
and import the hardware configuration. You will need to adjust the IP address before
proceeding to the next step.
7. Using the list you created in step 1, change the hardware configuration for the controllers
and ENIU to match the I/O in your project. Make sure the I/O reference addresses are
correct.
8. Adjust the Produced exchange of the ENIUs and the Consumed exchange of the
Controller(s) to match the %I and %AI in the hardware configuration of the ENIUs.
9. If you are changing the IP addresses of the devices, you need to change the following items:
▪
▪
▪
▪
▪
IP address of each device. This must be done in two places: in the properties of the
Target (how programmer connects) and in the Ethernet settings in hardware
configuration.
Subnet mask of each device (if required).
Gateway IP address of each device (if required).
Check the Local Producer ID of each device and verify it is the IP address.
For Consumed Exchanges, change the Producer ID of the Exchange
10. Set default values for variables.
11. Download configurations to the Targets.
When downloading to new or unknown hardware, first set the physical port property of the
device in the programmer to a serial comm port (com1) and connect via a serial cable to the
power supply port. After the initial store of the configuration sets the IP Address, the physical
port property can be set to Ethernet and the IP address entered. This will allow connection
of the programmer via Ethernet.
If you know the device’s MAC Address, an alternative process is to use the Set IP Utility in
Machine Edition to set a temporary IP address so that you can connect to the devices from
Logic Developer PLC.
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Appendix C Quick Start Guide Using Ethernet I/O
C-3
C
12. To launch the Max-ON RX3i Configuration Utility, Open the Supplemental Files,
Documentation Files directory of the PLC_COMMON_CODE Target:
13. Select the Max-ON Project directory:
C-4
PACSystems® RX3i Max-On Hot Standby Redundancy – June 2006
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C
14. Double-click on the config.mx3 file. This will launch the Max-ON RX3i Configuration Utility
that can used to define the parameters of the Redundant System.
15. When the parameters of the Redundant Systems are entered or modified using the
Configuration Utility, the cfg_dat C block is updated in the Max-ON Project directory. This
block then must be used to update the C Block in the PLC_COMMON_CODE of the Project.
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Appendix C Quick Start Guide Using Ethernet I/O
C-5
C
16. Select the C Block Update… right mouse menu and select the cfg_dat C Block gefelf file.
17. At this point the updated Configuration Utility parameters have been added to the Max-RX3i
project. Now download the updates to the Primary and Secondary controllers.
C-6
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Appendix Updating the Max-ON Application
D
This appendix explains how to upgrade the Max-ON program blocks in your application to a
newer version of Max-ON using the Proficy Machine Edition Toolchest.
If you have a Max-ON RX3i application that was created with an earlier version of Max-ON RX3i
software, such as version 3.04, you must update the Max-ON Drivers in your application to take
advantage of the issue resolutions in a later version, version 3.10, for example. A Machine
Edition Toolchest drawer is provided on the Max-ON RX3i Software Release to aid in the
upgrade process.
To upgrade an existing Max-ON RX3i application to a later version perform the following steps:
1. Back-up your Max-ON RX3i application using the Backup feature in Machine
Edition.
2. Import the latest Max-ON RX3i Driver Toolchest drawer into Machine Edition.
a. Open your Max-ON RX3i Project in Machine Edition.
b. Open the Toolchest by pressing the Toolchest button on the Toolbar –or- by
pressing Shift+F9.
c. Select a node in the Toolchest.
d. Select the Import Drawer Toolchest right-mouse menu selection:
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D-1
D
e. Navigate to the Max-ON RX3i Driver Toolchest drawer located on the MaxON RX3i Software Release CD. This file is named: Max-ON RX3i Drivers
vx_yy.ZDRW, and Max-ON RX3i Drivers v3_10.ZDRW in the example below:
Press the Open button. This will add the drawer to your Toolchest.
3. Expand the MaxON_Components folder in the PLC_COMMON_CODE Target in
your project to display the current set of Max-ON Drivers. If you examine the Block
Properties of each Block, you can see the Block revision, such as v3.04.
4. Delete the Max-ON Driver blocks that start with “hbr_” from the MaxON_Components
folder.
DO NOT delete the cfg_dat C Block.
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D
5. Add the latest Max-ON RX3i Drivers to the MaxON_Components folder directory
using the Ctrl-Drag-and Drop operation from the Toolchest.
The Blocks must be added to the Machine Edition Project in the following order:
a. hbr_001, hbr_005, hbr_008
b. hbr_099
c. hbr_002 hbr_003, hbr_004, hbr_006, hbr_007, hbr_009, hbr_010, hbr_011,
hbr_cfg
d. hbr_000
6. When performing the Ctrl+Drag-and-Drop Toolchest operation, when the Variable
Conflict Resolution dialog is displayed, you must select the “Replace all existing
variables” option to ensure that the new MaxON RX3i variables are properly
defined.
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Appendix D Updating the Max-ON Application
D-3
D
7. A MaxON_RX3i_MAIN Block is also available in the Toolchest Drawer. This Block
has a comment in the first rung that details the revision history.
8. Validate your Max-ON RX3i application to verify that all Max-ON Driver blocks are
properly located in the Project.
9. You can also verify the version of each hbr_ Block by checking the description in the
Block Properties:
D-4
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Index
A
Adding a Secondary Bus to an Existing
Bus, 4-15
Adding an I/O Device, 4-17
B
BSM Controller, 7-4
BSM Present, 7-3
C
CIMPLICITY ME backup folders, C-1
Configuring Analog Inputs, 4-22
Configuring the Analog Output Range, 712
Configuring the Drop's GBC, 7-8
Configuring The Hot Standby GBCs, 7-13
Configuring the I/O Devices, 7-1, 7-3
Creating a Connection to a PLC, 8-3
Creating a New Project, 4-2
Creating Connections to the PLCs, 8-3
Creating the Drop Folder, 7-5
D
Diagnostics, 8-1
E
Ethernet Hardware, A-1
F
Fault Record Structure, 5-24
Fault Table, 5-24
G
Genius and Field Control I/O, 7-3
Genius and Field Control I/O (Config. I/O),
7-3
Genius Bus Controllers, 6-4, 6-5, 6-6, 6-10
Genius Bus Controllers - CPU A, 6-6
Genius Bus Controllers - CPU B, 6-10
I
I/O devices, 6-7, 6-8, 6-11
adding, 4-17
Identity - CPU A, 6-2
Identity - CPU B, 6-9
If You Have a Question or Problem, 1-10
GFK-2409
Indicating Mastership, 5-4
M
Mastership Modes, 5-12
Memory, 6-3, 6-10
O
Online Project Information, 8-5, 8-7, 8-8
P
PID Function Blocks, 5-18
PLC Sweep Mode, A-2
Programming, 5-1
Project information, 8-5, 8-7, 8-8
Project workflow, 3-2
Q
Quick Start project, C-3
R
Redundant Controllers, 7-3
Remote 90-30 Drops, 7-5
Remote Drop Status Word, 7-7
Remote Status Flags, 5-9
S
Secondary bus
adding, 4-15
Selecting a Master, 5-12
Setting a Preferred Master, 5-14
Simplex Genius Bus, 4-12
System Command Flags, 5-11
System Data Registers, 5-17
System Level Alarms, 5-28
System Status Flags, 5-3
T
Time Stamp Record Structure, 5-24
Troubleshooting
diagnostic tools, 8-1
U
Uninstalling Max-ON Tools, 1-4
V
VersaMax I/O, 7-4
Index-1
Index
Index-2
PACSystems® RX3i Max-On Hot Standby Redundancy– June 2006
GFK-2409
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