GE 90-70 manual On-Line Repair

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5

On-Line Repair

With a Hot Standby CPU Redundancy system, most system component failures can be repaired by replacing the failed component while the system is online. These online repair procedures are possible because of the role-switching capability of the units in the system. Status of the Primary and Secondary Units is determined by observing the LEDs on the Redundancy Communications Module.

There are two basic situations regarding the active and backup units that you should be aware of when a component needs to be replaced.

1.If the failure is in the active system, control switches to the backup system. Power can then be removed from the rack containing the failed component. When the component is replaced, power is restored to the rack, and the CPU is returned to RUN mode, the CPU becomes synchronized with the current active unit.

2.If the failure is in the backup system, remove power from the rack containing the failed component and replace the component. When power is restored to the backup unit and the CPU is returned to RUN mode, it becomes synchronized with the active unit.

The following paragraphs describe how the system can be repaired without interruption of control. The replacement of each replaceable component is described.

Note

If maintenance is to be performed on the active unit in a synchronized system, control should be switched to the other unit before powering down. This will allow for an orderly transfer of control.

After repairing a defective unit:

1.Power-up the CPU rack in STOP mode.

2.Verify that the Remote Ready and Remote Active LEDS are on while in STOP mode.

3.Verify that the Local Ready and Local Active LEDs are on in the Active unit.

4.Clear the fault tables of the repaired unit.

5.Put the repaired unit in RUN mode.

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Series 90™-70 Enhanced Hot Standby CPU Redundancy User's Guide – May 2000

GFK-1527A

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Contents GE Fanuc Automation GFL-002 Related Publications Content of This ManualPreface Preface Contents Contents Chapter Fault Detection Appendix a Cabling Information Introduction Definition of TermsEnhanced Hot Standby CPU Redundancy Using the Redundancy CPU for Non-Redundant Operation Compatibility with CPU780Differences in Operation for Redundancy CPUs Features not Available with Redundancy CPUsRedundancy CPUs as Compared to Other Series 90-70 CPUs Redundant Racks Enhanced Redundancy CPU ModuleRedundancy Communications Module Systems for Enhanced Hot Standby CPU RedundancyCable Connections Genius I/OLocal I/O Enhanced Hot Standby CPU Redundancy System with Local I/O Local I/0 Can beGDB Control Strategy Control StrategiesGHS Control Strategy Output Control with GDB Basic Enhanced Hot Standby OperationOutput Control with GHS Basic CPU Redundancy Setups Single Bus with Preferred Master GHS Control StrategySingle Bus with Floating Master GDB Control Strategy Critical Data + Redundant Outputs TransferredDual Bus with Floating Master GDB Control Strategy Paired GBC = INT/EXT Internal ExternalDuplex CPU Redundancy Online ProgrammingOn-Line Repair System Racks For Installation InstructionsSystem Components Features Redundancy CPUExpansion Memory Board Watchdog TimerCPU Architecture Battery Connectors CPU FeaturesMemory Protect Keyswitch CPU LEDsCPU Mode Switch PortRedundancy Communications Module Unit Select PushbuttonConnector RCM Status LedsBus Transmitter Module Status LEDs ConnectorsBus Transmitter Module Bus Receiver Module Status LEDs Bus Receiver ModuleCables and Termination Genius Bus Controller Location of GBCs and BlocksSingle Bus Genius Networks Dual Bus Genius NetworksBus Controller LEDs One Application Program in Both PLCs Configuration RequirementsProgrammer Connection for Configuration Program Folders in Control Programming SoftwareCPU Configuration Parameters Program Folders in LogicmasterConfiguring Shared I/O References Parameter Default Range DescriptionFinding the Memory Available for Application Program Storage System Communications Window ConsiderationsRack Module Configuration Parameters Bus Controller Configuration ParametersGenius I/O Block Configuration Parameters Normal Operation Powerup of a Redundant CPU Incompatible Configurations Resynchronization of a Redundant CPUGHS Control Strategy GDB Control StrategyReferences for CPU Redundancy Ovrpre %S Reference Not AvailableScan Synchronization Sweep Time SynchronizationOutput Data Transfer to the Backup Unit AT aData Transfer Time Fail Wait TimeGFK-1527A Normal Operation Programming a Data Transfer from Backup Unit to Active Unit Data Transfer ExampleDisabling Data Transfer Copy in Backup Unit Svcreq #43 Command Block for Svcreq #43 Validating the Backup PLCs Logic Solution Backup Qualification with Svcreq #43Validating the Backup PLCs Input Scan Switching Control to the Backup Unit Switching TimesExample 1 Role switches allowed on both units RUN Disabled ModeRUN Disabled Mode for GHS Control Strategy Example 4 Role switches allowed on both units Example 2 Role switches allowed on both unitsExample 3 Role switches not allowed on either unit Backup Active RUN Disabled Mode for GDB Control Strategy Example 8 InvalidFinding the Words to Checksum Each Sweep CGR772 CGR935Finding the Background Window Time Finding the Total Sweep TimeTimed Contacts Timer and PID Function BlocksMiscellaneous Operation Information Multiple I/O Scan SetsDebugger Stop to RUN Mode TransitionSequential Function Chart Programming SFC Background Window TimeGenius Bus Controller Switching Ethernet Global Data in a Redundancy CPU Ethernet Global Data ConsumptionEthernet Global Data Production Sntp TimestampingFault Detection Configuration of Fault ActionsFault Detection PLC Fault Table Messages for Redundancy Message Fault Description Corrective ActionWith redundancy in other fault groups Fault Response Faulting the Redundancy Communications Module Losing a LinkFault Actions in a CPU Redundancy System Configurable Faults Fault Group Type DescriptionNon-Configurable Fault Group Fatal Faults on Both Units in the Same SweepOn-Line Repair On-Line Repair Recommendations Power SupplyMaintaining Parallel Bus Termination RacksRedundancy Communications Link Failures Central Processor UnitRedundancy Communications Module and Cables Genius Bus Controller Single Bus Networks Bus faultsBus Transmitter Module Genius BusDual Bus Networks Genius BlocksIC690CBL714A Multi-drop Cable SpecificationsCabling Information PurposeConnector a Connector A, 15-pin Female Battery connectors Bus Controller, Genius IndexIndex Online programming Online repair Svcreq