Replacement, Introduction | Schneider Electric 840 USE 106 0

Maintenance

10.4 Replacement

Introduction

Purpose

What’s in this Section?

This section describes replacing a Hot Standby module.

This section contains the following topics:

Topic	Page

Replacing a Hot Standby Module	193

Changing the Program and Performing a Program Update	194

Updating PLC System Executives in a 984 HSBY System	198

Updating PLC System Executives in an IEC HSBY System	200

192	840 USE 106 00 January 2003

Image 192

Schneider Electric 840 USE 106 0 manual Replacement, Introduction

Contents

Quantum Hot Standby USE 106Page Table of Contents Using a Quantum 984 Hsby System Theory of IEC Hsby OperationPlanning a Quantum Hot Standby System Using a Quantum IEC Hot Standby System Additional Guidelines for IEC Hot Standby Ethernet Hot Standby Solution Maintenance Specifications for CHS 110 Hot Standby Appendix a Com Act Error PatternsAppendix C ProWORX Nxt Configuration Appendix B Fiber Optic Cable GuidePage Safety Information ProcedureImportant Information Please Note Persons Schneider Electric All Rights Reserved About the Book At a GlanceValidity Note Related Documents About the Book Overview of Quantum Hot Standby PurposeWhat’s in this Chapter? Overview of Quantum Hot Standby 1Control IntroductionPurpose What’s in this Section? Primary and Standby Control DescriptionRole of the CHS Hot Standby Hardware Components in a Quantum Hot Standby System Cables See Fiber Optic Cable Guide, p CHS 110 Hot Standby Module TopologyPanel Controls Following table shows the five status indicators LED DisplayModule 140 CHS 110 Keyswitch Slide SwitchUpdate Button Function 2Operation Modes of OperationHsby Modes of Hsby has three Modes of Operation Operation Run Mode Ignores your actionPrimary unit fails 3Cabling Fiber Optic Cable CableConnections CHS 210 Hot Standby Kit Hsby and IEC Hsby Hsby ArchitectureQuantum 984 Hot Standby involves Module Version Upgrade PLC firmware RIO is serviced differentlyIEC compliant languages FBD, LD, SFC, IL and ST Hsby system Fiber Optic CHS Link 5HPRWRUJUDWHU Standby Overview Theory of 984 Ladder Logic Hsby Operation This chapter contains the following topics How a 984 Hsby System Works System Scan Time Primary Rack ScanSolve Segment Scan Scan Time Increase table below PLC to CHS DataTransfer Rate Leads to the following results Example Scan Time Increase Table in PLC Scan Times, p State RAM Transfer and Scan Time Time Theory of 984 Hsby Operation Default Transfer Area AutomaticTransfer Primary to the Standby controller on every scan Example Alternatives to the default transfer area Customizing OptionsCustom State Area Setting up Up using multiple scans to transfer all the dataCustom Scans Custom Scans Theory of 984 Hsby Operation Theory of IEC Hsby Operation IEC Hot Standby Definitions DefinitionsFollowing are IEC Hot Standby definitions IEC runtime system IEC Heap Currently used IEC Heap Size and the Maximum IEC Heap SizeProgram Data Online -- Memory Statistics How an IEC Hsby System Works IEC TheoryProgram. There are three steps in the transfer process State RAM Defined System Scan Time Transfer diagram The following shows a transfer diagram Primary RackStandby Rack Time Scan Time Increase Table below Following resultIEC Scan Time Increase IEC Scan Time Increase Table See Overall PLC Scan Time, p State Ram Transfer and Scan Time Configured for IEC Hsby Layout Transferred RAMStandby’s IEC data consistency Theory of IEC Hsby Operation Planning a Quantum Hot Standby System Guidelines for Planning a Hot Standby System PrimaryControllers Positioning Electrical Safety Precautions Safety Precautions Remote I/O Cable Topologies Single Cable Configuration ConfigurationSingle Cable Dual Cable Configuration Dual Cable Standby systemStandby PLC Primary PLC Installation How to Install a Hot Standby SystemProcedure Installing a Hot Setting Designation Set to B Slide SwitchesBattery has been disconnected for at least five minutes Damage Following diagram illustrates the network connections Network Step Diagram Aligning Key Locking Ring Adding Hot Converting to You need backplanes with at least four slots Using a Quantum 984 Hsby System Using a Quantum 984 Hsby System 1Configuration Configuring 984 Hsby CHSModsoft Installed into your application ControllingSystem by CHS Instruction Configuration Extension Hot Standby System byExtension System Execute Hsby Unconditionally Enable Command CHS InstructionHsby System Active Using the CHS Instruction Block Using CHS Instruction Block Hot Standby Command Register Hazard Command Register Nontransfer Area Within the State RAM Transfer Elements of the Nontransfer Area Status Register Configuration CHS module Zoom screen of CHS Instruction Zoom ScreenScreens must be identical to those in the CHS block Hot Standby Status Register Status RegisterBits in the Hot Standby Status Register Reverse Transfer Registers Reverse Transfer Logic Example ReverseTransfer Logic Segment 000813 Using Configuration Extension Using a Quantum 984 Hsby System Concept shown Hot Standby Dialog Dialog Standby Concept Bits in the Hot Standby Command Register Commandsystem Register Hot Standby Command Register Hazard Keyswitch Override and Run Mode Keyswitch Override HazardRun Override Power up the system again. Download the new configuration Software Control ExampleOption Standby on Logic Mismatches Mismatch Hazard Switchover Modbus PlusPort Address Swapping at Transfer All State RAM Transfer AllTransferred if this check box is activated Check box Nontransfer Area Hot Standby Status Register for Configuration Extension Status Register for Configuration extension Advanced Options Advanced Defining the Transfer Area of State RAM Additional RAM State RAM dialog Dialog 12K Option User Defined Option State RAM Transfer Transferring Additional State RAM Data Transfer Additional State RAM Hazard 101 Scan Transfers Data TypeBegins again, sending the first 512 additional registers 4Operation Starting Your Hot Standby System Preconditions Starting the SystemStep Action Ready Fault RIO HeadStandby Backplane Synchronizing Time-of-Day Clocks ClockSynchronization Following diagram shows synchronizing time-of-day clocks Network 1 of SegmentNetwork 2 of Segment While Your System Is Running Using a Quantum IEC Hot Standby System This chapter presents operating procedures for the IEC Hsby Using a Quantum IEC Hot Standby System This section describes Quantum IEC Hot Standby configuration Loading the Software Concept Loadables Installation Screen @1SE V196 @2I7@2IE V196 V208 IEC Logic in a Standby controller executes the logic of segment Using ExtensionsTransfer from Primary to Standby Loadables are removed from the project automatically Hot Standby Dialog Activation of Hot Standby DialogConcept 2.5 shown Specifying the Command Register Standby Command RegisterSpecify Register is Hot Standby Command Register Enable itRange Register. However Enable Keyswitch Override SoftwareControl Example Options for OptionSoftware Control Stage Description Comment Exec Upgrade Without Stopping Application Stopped Cancel Advanced Options Concept System Executive Upgrade Procedure Stopping the process Map / Configuration Hazard Standby on Logic MismatchLogic Mismatch For Concept Logic Data that do not exist on both controllers is not updated Project global data that is updated includesUpdating Project Global Data Swapping Addresses at Switchover Is also IP Address NOE 771 cannot be controlled, it is always activatedMatter if they reside in the Standby or Primary rack Standby Backplanes Using a Quantum IEC Hot Standby System State RAM Nontransfer Area of State RAM 4nnnnn Controllers Supported only with Concept 2.5 or higher Diagram below shows a PLC Memory Partition Memory PartitionRegisters Shows how the number of IEC Hsby Registers can be modified State RAM Size State RAM Size Section Transfer Control Section Transfer Control FBD Select Component of Type Bool 5Operation PreconditionsStarting Regardless of its designation as a or B 140 CHS 110 RIO Head Normal Operation Memory/Scantime optimization IEC State RAMMap 142 Screenshot of the Memory Prediction dialog is shown below Memory Prediction Memory StatisticsFor IEC Hot Standby data Synchronizing Time of Day Clocks Constant Internal MonitoringRegular Data Transfers Additional Guidelines for IEC Hot Standby Additional Guidelines for IEC Hot Standby General Application Requirements Memory Savings AssessingExisting IEC Applications Memory Statistics Memory Following screen shows memory statistics Statistics 152 Optimization IEC Applications Needed to achieve it Configured State Efficient Use of State RAMRAM Registers Efficient Use IEC ApplicationAnything else Data Efficiency Tips Use Constants Instead of Equal Literals RealB RealC RealDRealF RealG RealH Use Constants Instead of Open Inputs 160 Programmed Logic Reduce the Use Of Complex Data Structures Ethernet Hot Standby Solution Solution Overview of Hot Standby Solution for NOEs SolutionPlease Note Service NOE 771 Hot Standby Topology Drop NOE Configuration and Hot Standby Device can be assigned the configured IP + 1 addressTo download a project to the PLC Configuring IP Address AssignmentTransparency Primary Mode Secondary ModeStandalone Mode Offline Mode CPU is stopped Effects on IP Address assignment and Ethernet services Offline Mode at Power-up Sequence tableAddress Assignment Power-Up ServicesEffects on the Ethernet services Ethernet Additional InformationGoing to Offline IP Address Assignment and Going Offline Service Typical Swap Time Maximum Swap Time Address Swap TimesConnections Network Effects of Hot Standby Solution BrowsersRemote Connection Request during Hot Standby Swap Hot Standby Swap during Remote Connection Request Service ScanningPublish Subscribe 176 Maintenance Maintenance Health of a Hot Standby System Verifying Health of a Hot Standby System Health Messages Additional Checks Recognizing Safety Or equipment damageAvoid Damage to Application I/O Devices Errors Startup Errors Communications Errors TroubleshootingInterface Errors LEDs Board Level Errors Board Level Error 140 CHS 110Replace the faulty CHS 110 module 10.3 Failures Detecting Failures in a Hot Standby System MainComponents Backplane Standby module and RIO head to the chart below Detecting Failures in the Primary BackplaneController CHS RIO Head Failure Type Description Detecting Failures in the Standby Backplane Controller CHS RIO Head Failure Description 191 Replacement Replacement Replacing a Hot Standby ModulePrimary Backplane Hazard Changing the Program and Performing a Program Update Battery HazardUpdating Standby Ogic Program Change Hazard Standby controller Off LineBefore You Begin Controller as well Updating Standby Procedure Amber Standby indicator begins to blink Updating Standby Updating PLC System Executives in a 984 Hsby System Steps to Upgrade Zoom or RDE PLC executives While HotStandby is Running Updating PLC System Executives in an IEC Hsby System Testing Forcing a SwitchoverSwitchover Forcing a Manually Take the following steps to force a switchover manually Primary Standby After Taking the Primary Controller Offline Bringing the Original Primary Unit Back Online Through Register, p Specifications for CHS 110 Hot Standby SpecificationsSpecifications for CHS 110 Hot Standby Specifications for CHS 110 Hot Standby Appendices At a GlanceIncluded here Appendix contains the following chapters Appendices Com Act Error Patterns Purpose What’s in this Chapter? CHS 110 Hot Standby Module Error Patterns CHS 110 ErrorNumber Blinks Code Error Patterns CRP Remote I/O Head Processor Error Patterns Error Patterns The following table shows error patternsNumber Code Error Blinks 212 Fiber Optic Cable Guide Connectors RecommenDations Other Tools Suggested Tools include Other Tools ProWORX Nxt Configuration ProWORX Nxt Hot Standby Configuration ExtensionMenu and select Hsby Extension from the Tree Control Dialog Screen Hot Standby Qua Field FunctionsHot Standby Quantum dialog screen Parameters of a Quantum Hot Standby system Initial Command Register Status Registers Dialog screenStatus Register Registers dialog screen Offline state Index Numerics Index Automatic, 108 swapping addresses 226