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Manual State Industries GFK-0827

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Summary
  • State Industries GFK-0827 - page 1

    GE F anuc Automation Programmable Control Pr oducts Series 90 -70 Hot Standby CPU Redundancy User’s Guide GFK -0827 December 1993 ...

  • State Industries GFK-0827 - page 2

    GFL–002 W arnings, Cautions, and Notes as Used in this P ublication W ar ning W arning 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 ...

  • State Industries GFK-0827 - page 3

    iii GFK-0827 Pr eface This manual is a reference to the hardware components, configuration and operation of the Hot Standby CPU Redundancy system for the Series 90 -70 Programmable Logic Controller . This redundancy system is one of several redundancy alter natives that may be incorporated into a Series 90-70 Programmable Logic Controller system (s ...

  • State Industries GFK-0827 - page 4

    Pr eface iv Hot Standby CPU Redundancy User ’ s Manual - December 1993 GFK-0827 Series 90-70 PLC R eference Manual (GFK -0265). Reference manual which describes operation, fault handling, and Logicmaster 90-70 programming instructions for the Series 90-70 PLC. Series 90-70 R emote I/O Scanner User ’s Manual (GFK -0579). Reference manual for the ...

  • State Industries GFK-0827 - page 5

    Contents v GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 Chapter 1 Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Standby CPU Redundancy Product 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F eatures of the Hot Standby CPU Redu ...

  • State Industries GFK-0827 - page 6

    Contents vi GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 Chapter 2 System Components 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redundancy CPU 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU Architecture 14 . . . . ...

  • State Industries GFK-0827 - page 7

    Contents vii GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 Chapter 3 Configuration 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring a Hot Standby CPU Redundancy System 27 . . . . . . . . . . . . . . . . . Redundancy System Requirements 28 . . . . . . . ...

  • State Industries GFK-0827 - page 8

    Contents viii GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 Chapter 4 Operation 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1: System Operation 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P ower-Up Sequence of a Redundan ...

  • State Industries GFK-0827 - page 9

    Contents ix GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 Section 2: F ault Detection and Contr ol A ctions 72 . . . . . . . . . . . . . . . F ault Detection 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F ault Categories 72 . . . . . . . . . . . . ...

  • State Industries GFK-0827 - page 10

    Contents x GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 F igure 1. Example of a Local I/O Configuration with Expansion Racks in a Hot Standby CPU Redundancy System 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F igure 2. Synchronized Hot Standby CPU Redundancy System Configuration ...

  • State Industries GFK-0827 - page 11

    Contents xi GFK–0827 Series 90–70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 T able 1. Capacities for Redundancy CPU, IC697CPU780 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T able 2. V alid Operating Mode Selection 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • State Industries GFK-0827 - page 12

    1 section level 1 1 figure bi level 1 table_big level 1 restart lowapp ARestart oddapp: ARestarts for autonumbers that do not restart in each chapter . figure bi level 1, reset table_big level 1, reset chap_big level 1, reset1 Lowapp Alwbox restart evenap:A1app_big level 1, resetA figure_ap level 1, reset table_ap level 1, reset figure level 1, res ...

  • State Industries GFK-0827 - page 13

    1 2 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 contains all redundant Genius Bus Controllers at Serial Bus Address 31; the Secondary PLC contains all redundant Genius Bus Controllers at Serial Bus Address 30. The CPU that cur rently controls the system is called the active unit, the other CPU is the standby ...

  • State Industries GFK-0827 - page 14

    1 3 GFK-0827 Chapter 1 Introduction F eatures of the Hot Standby CPU Redundancy Product Bumpless switching Synchronized CPUs 20 millisecond scan e xtension (nominal). This figure is variable, depending on amount of data transferred. One scan switching (in most cases) Configurable back up data size No single point of failure (ex cluding Genius I/O) ...

  • State Industries GFK-0827 - page 15

    1 4 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 I/O Systems for Hot Standby CPU Redundancy Systems Both Series 90-70 Local I/O and Genius I/O systems can be present in a Hot Standby CPU Redundancy control system. The two units are not required to have matching I/O systems. They may have different numbers of I ...

  • State Industries GFK-0827 - page 16

    1 5 GFK-0827 Chapter 1 Introduction Y Y C B T M R C M G B C 31 PRIMARY UNIT SECONDARY UNIT 30 B L O C K B L O C K S C A N N E R REMOTE DROP I O I O I O I O I O I O P S I O I O P S P S B T M G B C B L O C K I O I O I O I O I O I O I O I O P S P U C P U B R M RACK 0 RACK 1 RACK 0 I O I O I O I O I O I O I O I O P S RACK 6 LOCAL I/0 CAN BE IN RACKS 0 ...

  • State Industries GFK-0827 - page 17

    1 6 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 for three consecutive Genius I/O bus scans, the outputs are then controlled by the Genius Bus Controller at serial bus address 30 (Genius Bus Controller in the Secondary PLC). If output data is not available from either bus address 31 or 30, the outputs go to th ...

  • State Industries GFK-0827 - page 18

    1 7 GFK-0827 Chapter 1 Introduction Redundancy CPU Module The same model of CPU must be installed in both the Primar y and Secondar y PLCs. This CPU, which is the only CPU that currently supports synchronized Hot Standby CPU redundancy , is the CPU 780 (catalog number IC697CPU780). This CPU is similar to the e xisting IC697CPU782 CPU in that it has ...

  • State Industries GFK-0827 - page 19

    1 8 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 the two CPUs and provides the communications path for the transfer of I/O data between the two units. An RCM must be configured in both the Primar y PLC and the Secondar y PLC. The RCM must reside in the CPU rack (rack 0) in a system and there can be no empty sl ...

  • State Industries GFK-0827 - page 20

    1 9 GFK-0827 Chapter 1 Introduction If the switch occurs due to a controlled condition such as toggling the unit selection switch on the Redundancy Communications Module or forcing a switch in the user logic program with a SVC_REQ, or because of a fault detected by the PLC CPU, then the switch- over will occur at the beginning of the ne xt sweep. T ...

  • State Industries GFK-0827 - page 21

    1 10 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Programming Considerations There are several features in the operation of the Redundancy CPU which are not supported or are different then operation of other CPUs. These features are listed below and are described in detail in Chapter 4, ”System Operation”. ...

  • State Industries GFK-0827 - page 22

    1 11 GFK-0827 Chapter 1 Introduction The Primary Unit and the Secondary Unit must be configured separately . That is, the programming device should be connected directly to either the Primar y or the Secondar y Unit to configure that unit. When you have completed configuring that unit, disconnect the programmer from the configured unit and move it ...

  • State Industries GFK-0827 - page 23

    1 12 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Commonly Used Acronyms A list of acronyms used in this manual are defined for your convenience in the following table. A cr onym Definition BRM Bus Receiver Module BS M Bus Switching Module BTM Bus T ransmitter Module CPU Central Processor Unit EPROM Erasable P ...

  • State Industries GFK-0827 - page 24

    2 section level 1 1 figure bi level 1 table_big level 1 13 GFK-0827 Chapter 2 System Components This chapter describes the hardware components for a Hot Standby CPU Redundancy system. It describes the modules required for the system and provides catalog numbers of the components. F or detailed installation instr uctions for the Series 90-70 PLC, re ...

  • State Industries GFK-0827 - page 25

    2 14 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 C P U C P U B T M R C M G B C 31 PRIMAR Y UNIT SECONDAR Y UNIT 30 P S P S B T M R C M G B C Genius Bus CPU 780 Redundancy Communications Link Redundancy Communications Link a47002 Figure 3. CPU 780 L ocations in a Hot Standby CPU R edundancy System The capaciti ...

  • State Industries GFK-0827 - page 26

    2 15 GFK-0827 Chapter 2 System Components timer is 10 milliseconds to 1000 milliseconds. The default value for the watchdog timer is 200 milliseconds. The watchdog timer resets at the beginning of each sweep. The fail wait time is included in the watchdog check. The watchdog timer should be set to allow for the expected scan plus two fail wait time ...

  • State Industries GFK-0827 - page 27

    2 16 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 CPU Mode Switch A three-position toggle switch is mounted near the top of the CPU board. This switch selects one of three operating modes for the CPU: RUN/ENABLED, RUN/DISABLED , or STOP . Although the mode of operation for the CPU can be controlled from both t ...

  • State Industries GFK-0827 - page 28

    2 17 GFK-0827 Chapter 2 System Components Memor y Protect K eyswitch The Memor y Protect k eyswitch is located at the top of the module and has two positions: ON and OFF . This keyswitch is used to manually lock program and configuration data. When the key is in the ”protected” (ON) position, program and configuration data can only be changed b ...

  • State Industries GFK-0827 - page 29

    2 18 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Serial Port Connector The 15-pin D -connector at the bottom of the module provides the connection to an RS-422/RS-485 serial port. Its port provides a serial connection to the W ork Station Inter face (WSI) board installed in the programming computer . F or app ...

  • State Industries GFK-0827 - page 30

    2 19 GFK-0827 Chapter 2 System Components Redundancy Communications Module The Re dundancy Communi c at i ons Mod ule (RCM), catal og numbe r IC 697RCM711, prov i des a communic a tions path for sh aring data betwe e n th e two CPUs in th e re dundant sys te m. In a syn chron ized sys t e m, I/ O dat a is cont roll e d by one un it (th e active uni ...

  • State Industries GFK-0827 - page 31

    2 20 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 C B T M R C M 31 PRIMARY UNIT SECONDARY UNIT 30 P S P S B T M R C M Redundancy Communications Link Redundancy Communications Link G B C G B C P U C P U ( RACK 0 ) ( RACK 0 ) a47005 Figure 6. Example of RCM Location in a Hot Standby CPU Redundancy System RCM Sys ...

  • State Industries GFK-0827 - page 32

    2 21 GFK-0827 Chapter 2 System Components L OC AL SYSTEM ACTIVE Indicates whether the local unit is the controlling (or active) unit in a redundancy system. It is the responsibility of the local unit to set the state of this LED at least once during each sweep; if the local unit is unable to set (or fails to set) the state of the LED, the hardware ...

  • State Industries GFK-0827 - page 33

    2 22 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Bus T ransmitter Module A Bus T ransmitter Module (BTM), catalog number IC697BEM713, is required in both the P rimar y PLC CPU rack (rack 0) and the Secondary PLC CPU rack (rack 0) in a Hot Standby CPU Redundancy system. The BTM provides a path for Redundancy c ...

  • State Industries GFK-0827 - page 34

    2 23 GFK-0827 Chapter 2 System Components BTM Connectors The re are two conn e ctors on the front of th e BTM board. Th e top one provi des a parall e l c onnec ti on t o a W or k S tat i on I nterf ac e (WS I) boa rd ins ta l l ed in t he pr og ra mmer f or the Series 90-70 PLC . Seri al conn e cti on to W orkmaster II is through a programmer cabl ...

  • State Industries GFK-0827 - page 35

    2 24 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 I/O Bus Signal T ermination The I/O bus signals must be ter minated at the end of the bus. In a standard PLC system this is done by installing a resistor pack, located inside of a terminator plug (catalog number IC697A CC702) on the bottom connector of the BRM ...

  • State Industries GFK-0827 - page 36

    2 25 GFK-0827 Chapter 2 System Components The Ho t St andby CPU Re dundancy system uses a si ngle Ge n ius bus and re qui res one GB C modul e in th e Pr i mar y PLC and one in the Se con dary PLC ; ho we ve r there can be multi ple Gen ius busses configured in th is man ne r in a system. The GB Cs in th e Pri mary PLC are ass i gned SB A 31, an d ...

  • State Industries GFK-0827 - page 37

    2 26 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 CH 1 OK The CH 1 OK LED is th e midd le LED. It ope rate s ide n tic al to th e Modul e OK LED in that it is ON aft er th e board has suc c e ssful ly complete d the powe r -up diagnosti c s and OFF if a fai l ur e has be e n de te cte d duri n g th e po we r - ...

  • State Industries GFK-0827 - page 38

    3 section level 1 1 figure bi level 1 table_big level 1 27 GFK-0827 Chapter 3 Configuration This chapter describes how to configure a Series 90-70 PLC system for Hot Standby CPU Redundancy . Several parameters in addition to the normally configured CPU parameters must be configured for the Redundancy CPU 780. A description of all of the parameters ...

  • State Industries GFK-0827 - page 39

    3 28 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Redundancy System R equirements F or a redundant CPU configuration using the Hot-Standby Redundancy scheme to be valid, the following requirements must be true in both the Primary Unit and the Secondar y Unit in the redundancy system. One configuration must be ...

  • State Industries GFK-0827 - page 40

    3 29 GFK-0827 Chapter 3 Configuration Screens for F ault Categor y Configuration A new F ault Category Configuration screen is displayed for the CPU 780. This new screen has two columns of fault actions for the configurable fault groups/categories. The following sample screens show the F ault Categor y Configuration screens as they appear in Logicm ...

  • State Industries GFK-0827 - page 41

    3 30 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 The F ault T ype is shown at the left. The first column under F ault Categor y (CFG) shows which faults are FA T AL and which faults are DIA GNOSTIC for this CPU, when it is the only running CPU (i.e., stand-alone with no backup available). This column can be e ...

  • State Industries GFK-0827 - page 42

    3 31 GFK-0827 Chapter 3 Configuration cable connecting the PLC to the programmer should only be plugged and unplugged when the programmer is powered up and offline. A void powering the parallel programmer up or down while connected to a running PLC. Configuration of a Redundancy CPU Module The redundancy CPU module, IC697CPU 780 must be configured ...

  • State Industries GFK-0827 - page 43

    3 32 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 The detail screen of the cur rently configured CPU module is displayed. The following screen shows the CPU module detail screen for the currently displayed module. T o select the CPU 780 Redundancy CPU module, press the cpu softkey (F1). A list of the available ...

  • State Industries GFK-0827 - page 44

    3 33 GFK-0827 Chapter 3 Configuration If the e xisting configuration does not require any modification to suit the redundant CPU configuration, the prompt ”REPLA CE displayed module ? (Y/N)” will be displayed beneath the softkey strip instead of the message bo x. If you answer ”Y ”, page 1 of the detail screen for the redundant CPU (IC697CP ...

  • State Industries GFK-0827 - page 45

    3 34 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 3. In a redundant CPU system, RCMs cannot be configured in expansion racks. 4. Rack 7 cannot be seen nor edited. Redund T ype This parameter specifies whether the CPU is configured as the primar y controller or the secondar y controller . The Redund T ype has t ...

  • State Industries GFK-0827 - page 46

    3 35 GFK-0827 Chapter 3 Configuration Constant Window Sweep Mode T o change the Sweep Mode, move the cursor to the Sweep Mode field and press the Ta b k ey until the desired mode is displayed. Below is the detail screen (page 2) of a redundant CPU configured for CNST WND (constant window) sweep mode. When a Series 90-70 redundant CPU is configured ...

  • State Industries GFK-0827 - page 47

    3 36 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 set for SIMPLEX mode. The parameters on this screen are Ctrl Strgy (Control Strategy), F ail W ait and SHARED I/O . Ctrl Strgy This parameter specifies which type of control strategy is selected for a redundancy system. The valid entry is three ASCII characters ...

  • State Industries GFK-0827 - page 48

    3 37 GFK-0827 Chapter 3 Configuration T able 4. Shared I/O Data Parameters I/O P arameter Description and V alid Entries %I Ref Adr Starting address for redundant %I data region. Range is %I00001...%I12288. The starting address is bit aligned. Default value is %I00001. %I LENGTH The bit length of the redundant %I data region. Range is 0...12288. De ...

  • State Industries GFK-0827 - page 49

    3 38 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Note that the memor y for the Shared I/O data that is stored at configuration must be subtracted from the amount of memory on the configured expansion memory module. The calculation for the size of the memor y for Shared I/O data is (bytes of Input data transfe ...

  • State Industries GFK-0827 - page 50

    3 39 GFK-0827 Chapter 3 Configuration Configuring a CPU Expansion Memor y Board T o configure a CPU e xpansion memory board for the CPU 780, press the expbd softkey (F9) and then the memory softkey (F1). P osition the cursor on the desired expansion memor y board and press Enter to select that board. The detail screen for the e xpansion memor y boa ...

  • State Industries GFK-0827 - page 51

    3 40 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Configuration of a Redundancy Communications Module As described previously , one Redundancy Communications Module (the Local unit) must be configured in rack 0 (can be in slots 2 to 9). There must not be an empty slot between the CPU 780 module and the RCM mod ...

  • State Industries GFK-0827 - page 52

    3 41 GFK-0827 Chapter 3 Configuration T o display the RCM catalog list, press the rcm softk ey (F3). The RCM catalog list is then displayed as shown below . Next, press the Enter key , the following screen is displayed to confir m that you have selected the RCM catalog entry . Y ou have just configured the Local RCM in rack 0. The system automatica ...

  • State Industries GFK-0827 - page 53

    3 42 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Configuration of a Genius Bus Controller F or this example, assume that a Genius Bus Controller has been configured in slot 3 of rack 0. In a Hot Standby CPU Redundancy system, the Redundancy parameter (Redund Mode) of a Genius Bus Controller can only be NONE o ...

  • State Industries GFK-0827 - page 54

    3 43 GFK-0827 Chapter 3 Configuration Serial Bus Address All redundant GB Cs in the Primar y CPU redundant system MUST be configured at SBA 31. In the sample screen on the previous page, the rack level GBC is configured at SBA 31. The Bus level GB C is automatically configured at SBA 30. All redundant GB Cs in the Secondar y CPU redundant system MU ...

  • State Industries GFK-0827 - page 55

    3 44 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Configuring a Primar y R edundant PLC The steps required for configuring a Primar y Redundant PLC are described below . The P rimar y PLC and the Secondary PLC must be configured separately . An e xample of the configuration screens for each system is provided ...

  • State Industries GFK-0827 - page 56

    3 45 GFK-0827 Chapter 3 Configuration Select the R edundancy CPU Module Move the cursor to the line for the Redundant CPU, IC697CPU 780, and press the Enter k ey . A message is displayed beneath the softkey selection strip: ”REPLA CE displayed module ? (Y/N)”. Press the Y key to replace the cur rently displayed CPU with the CPU 780. The detail ...

  • State Industries GFK-0827 - page 57

    3 46 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 P ress the PgDn key again to go to the next page of the CPU module. The default screen for page 3 of the CPU detail screen appears as shown below: Select an Expansion Memor y Board T o configure a CPU e xpansion memory board for the CPU 780, press the expnd sof ...

  • State Industries GFK-0827 - page 58

    3 47 GFK-0827 Chapter 3 Configuration P ress the Esc k ey twice to retur n to the rack level display , which now appears as shown below . Configure the R edundant Communications Module T o configure an RCM in rack 0, slot 2, move the cursor to slot 2 and press the bem softk ey (F3). The configuration screen for bus communication modules will appear ...

  • State Industries GFK-0827 - page 59

    3 48 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Configure a Genius Bus Controller T o configure a Genius Bus Controller module in rack 0, slot 3, position the cursor on slot 3 and press the genius softkey (F2). T o display the catalog list for the Genius Bus Controller , press the gbc softkey (F1). P ress th ...

  • State Industries GFK-0827 - page 60

    3 49 GFK-0827 Chapter 3 Configuration P ress the Esc key to retur n to the rack level screen. F rom the rack level screen press the zoom softkey (F10). The following bus level screen is displayed: T o view the Genius Bus Controller (block level) at SBA 30, position the cursor on BUS ADR 30 and press the zoom softk ey . The Genius Bus Controller ’ ...

  • State Industries GFK-0827 - page 61

    3 50 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 A t this point, Press the Esc k ey and the bus screen will appear as shown below . Configure Genius I/O Blocks W e will now configure a block for Bus A ddress 29. Move the cursor to block 29 and configure a bus block (Discrete Input block IC660BBD110 for this e ...

  • State Industries GFK-0827 - page 62

    3 51 GFK-0827 Chapter 3 Configuration When you have completed configuring Genius blocks, press the Esc key to go from the block level display back to the bus level display . The bus display will now appear as shown below . Configure the Bus T ransmitter Module P ress the Esc k ey to retur n to the rack level display . A message will be displayed re ...

  • State Industries GFK-0827 - page 63

    3 52 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Configuring a Secondar y R edundant PLC This section describes the steps for configuration of a Secondar y PLC. The programmer for Logicmaster 90-70 software must be connected to the Secondary PLC in order to configure the Secondar y PLC. There are several ways ...

  • State Industries GFK-0827 - page 64

    3 53 GFK-0827 Chapter 3 Configuration P osition the cursor on rack 0, slot 1. Press the zoom softk ey (F10) to zoom into the CPU module configured in slot 1. The detail screen (page 1) for the CPU module appears as shown below: Change R edund T ype Change the Redund T ype: parameter value from PRIMAR Y to SECND AR Y by pressing the Ta b key then th ...

  • State Industries GFK-0827 - page 65

    3 54 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 P ress the Esc k ey twice to save the changes you have just made. This completes the process of converting a Primar y PLC redundancy system configuration to a Secondar y PLC redundancy system configuration. The differences between the Primar y system and the Se ...

  • State Industries GFK-0827 - page 66

    4 section level 1 1 figure bi level 1 table_big level 1 55 GFK-0827 Chapter 4 Operation This chapter discusses: the normal operation of a Hot Standby CPU Redundancy PLC system; what happens when a fault is detected and the system does not operate normally; how to restore the system to normal operation; on-line repair procedures. Section 1 describes ...

  • State Industries GFK-0827 - page 67

    4 56 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 4. System Configuration verified. 5. System inter rogated and initialized. 6. P resence of other CPU detected and RCMs initialized. 7. Complete user program verification. 8. Synchronize with the Redundant CPU. When powering up the unit configured as the Seconda ...

  • State Industries GFK-0827 - page 68

    4 57 GFK-0827 Chapter 4 Operation Resynchronization of the Redundant CPU Whenever a CPU is attempting to get back in synchronization with the currently active CPU, a resynchronization process will occur . This resynchronization process will occur any time a CPU per for ms a STOP to RUN mode transition. This process will start by deter mining which ...

  • State Industries GFK-0827 - page 69

    4 58 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Hot-Standby R edundancy Control Strategy In the Hot-Standby Redundancy Control Strategy , the primar y CPU (designated by all GB Cs addressed at bus address 31), is always the prefer red CPU. The secondar y CPU (designated by all GBCs addressed at bus address 3 ...

  • State Industries GFK-0827 - page 70

    4 59 GFK-0827 Chapter 4 Operation Synchronous Scan The figure below shows the sweep components for the active and the backup CPUs. It shows the two communication points in the sweep. The first communication point is immediately after the inputs are scanned. A t this point in the sweep the newly read inputs are sent from the active CPU to the backup ...

  • State Industries GFK-0827 - page 71

    4 60 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 The transfer of the redundancy data during each sweep will be in blocks with each block checked for data integrity . The transfer red data will be held in a temporar y area by the back up CPU until all data has been received and verified from the active unit. T ...

  • State Industries GFK-0827 - page 72

    4 61 GFK-0827 Chapter 4 Operation through %P0008 on the backup unit will not change. %T0002 will be set whenever the operation is successful and the data can be used. |REM_RDY %T00001 |——| ↑ |——————————————————————————————————————————————————? ...

  • State Industries GFK-0827 - page 73

    4 62 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 If the switch occurs due to a controlled condition such as toggling the RCM unit selection switch, forcing a switch in the user logic program, or because of a fault detected by the PLC CPU, then the switch- over will occur at the beginning of the subsequent swe ...

  • State Industries GFK-0827 - page 74

    4 63 GFK-0827 Chapter 4 Operation %S References for CPU R edundancy There are seven special %S references which reflect the status of the Redundancy units: %S33 through %S39. The definition of these LEDs is shown in the following table. T able 7. Definition for% S R eference for R edundancy Status %S Bit Definition Nickname Description LED %S33 P r ...

  • State Industries GFK-0827 - page 75

    4 64 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Redundancy CPU Considerations The Redundancy CPU (CPU 780) has several restrictions and differences in operation as compared to other Series 90-70 CPUs. The following features are not available with the CPU 780: I/O Interr upts T imed Inter r upts VME Integrato ...

  • State Industries GFK-0827 - page 76

    4 65 GFK-0827 Chapter 4 Operation Differences in Operation for CPU 780 The following features operate differently with the CPU 780 than they do with other Series 90-70 CPUs: RUN/DISABLED mode Configuration of F ault Actions STOP to RUN mode transition Background W indow T ime (default is different) RUN Disabled Mode RUN/DISABLED mode causes all phy ...

  • State Industries GFK-0827 - page 77

    4 66 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 F ollowing are several examples that illustrate the above guidelines. Each e xample gives the role of each unit, its current operating mode, and the state of the LEDs on the RCMs. An X indicates that the corresponding LED and %S bit is ON. A. Role switches allo ...

  • State Industries GFK-0827 - page 78

    4 67 GFK-0827 Chapter 4 Operation E. Role switches are allowed on both units. Primary Unit Secondar y Unit Backup A ctive (see NOTE below) RUN/ENABLED RUN/ENABLED XO K XO K X LOC_RDY X LOC_RDY LOC_A CT X LOC_A CT X REM_RD Y X REM_RD Y X REM_A CT REM_A CT F . Role switches are not allowed on either unit. Primary Unit Secondar y Unit Backup A ctive ( ...

  • State Industries GFK-0827 - page 79

    4 68 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Specific fault actions are described in Section 2 of this Chapter . However , you can configure whether or not a stand-alone CPU (after failure of the other CPU) will stop if another fault occurs. Y ou can select the fault actions (either diagnostic or fatal) f ...

  • State Industries GFK-0827 - page 80

    4 69 GFK-0827 Chapter 4 Operation Background User Checksum and Background Window Timing Instructions The following infor mation is provided to allow you to guarantee full coverage of the number of program words verified by the User Program Checksum per sweep and the Background W indow Diagnostics within a certain amount of time. It is important to ...

  • State Industries GFK-0827 - page 81

    4 70 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Where the Background W indow T ime is the time in milliseconds that you should set the background window timer . The other elements in the for mula are described above in the calculation for words per sweep. The constants (F and C) are for the CPU 780. Backgrou ...

  • State Industries GFK-0827 - page 82

    4 71 GFK-0827 Chapter 4 Operation Genius Bus Controller Switching Genius Bus Controllers will stop sending outputs to blocks when no data has been received from the PLC CPU for a period equal to two times the configured watchdog timeout. If the CPU on the active unit becomes inoperative in an uncontrolled fashion (for example, because of a power fa ...

  • State Industries GFK-0827 - page 83

    4 72 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 Section 6: F ault Detection and Control A ctions This section describes how faults are handled in a Redundancy system. It discusses how faults affect the operation of the Redundancy system, describes categories of faults, describes how faults are detected, desc ...

  • State Industries GFK-0827 - page 84

    4 73 GFK-0827 Chapter 4 Operation 3. faults and failures that are detected in the background. F aults and failures that are detected immediately are those that are identified within the current sweep. These faults include I/O data corr uption, single bit RAM failures, power supply failures, processor failures, VME bus failures, and no response from ...

  • State Industries GFK-0827 - page 85

    4 74 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 PLC Fault T able The following table lists fault zoom Help text and messages for er ror codes associated with the redundancy fault group. T able 8. Fault Zoom Help T ext for Redundancy Error Codes Err or Code Message F ault Description Corr ective Action 1 Prim ...

  • State Industries GFK-0827 - page 86

    4 75 GFK-0827 Chapter 4 Operation F aulting RCMs, L osing Links, and T erminating Communications There are distinct differences between losing a redundant communications link, faulting an RCM, and terminating communications. F aulting the RCM module occurs only when a hardware related failure occurs such as a parity error or VME bus er ror . A ctio ...

  • State Industries GFK-0827 - page 87

    4 76 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 In this case, if the RCM is at fault, it will need to be replaced before power is restored. T er minating Communications occurs when the two units get out of synchronization. The action taken when communications is ter minated is the same as when a link has tim ...

  • State Industries GFK-0827 - page 88

    4 77 GFK-0827 Chapter 4 Operation F ault Actions in a CPU R edundancy System F ault actions in the Hot Standby CPU Redundancy System are handled differently than those in a non-redundancy (Simplex) system. Whenever there is a ”ready ” back up unit configured in the system, the fault actions in the active unit will not be those normally specifie ...

  • State Industries GFK-0827 - page 89

    4 78 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 T able 10. Maskable Fault Group Actions F ault A ction F ault Gr oup Simplex Mode R edundant Mode User Configurable LOSS_RA CK Non-F atal F atal Ye s LOSS_IOC Non-F atal F atal Ye s LOSS_IO_MOD Non-F atal Non-F atal Ye s LOSS_OTHR_MOD Non-F atal Non-F atal Ye s ...

  • State Industries GFK-0827 - page 90

    4 79 GFK-0827 Chapter 4 Operation T able 11. Non-Maskable F ault Group Descriptions F ault Gr oup T able T ype Description SYS_BUS_F AIL CPU System bus failure. NO_USER_PRG CPU No User ’s Program on P ower -up. BAD_USER_RAM CPU Corrupted User RAM detected on P ower -up. WIND_CMPL_F AIL CPU W indow Completion Failure in Constant Sweep Mode (i.e., ...

  • State Industries GFK-0827 - page 91

    4 80 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 On-Line Repair W ith a Hot Standby CPU Redundancy system most system component failures can be repaired by replacing the failed component while the system is on-line. These on-line repair procedures are possible because of the role switching capability of the u ...

  • State Industries GFK-0827 - page 92

    4 81 GFK-0827 Chapter 4 Operation Power Supply The power supply has adequate inter nal fault detection which will cause it to automatically shut down if there is a failure. In an orderly shut down, the power supply will first assert the A CF AIL signal before it asserts the SYSREST signal. This will give the active PLC time to notify the backup PLC ...

  • State Industries GFK-0827 - page 93

    4 82 Series 90-70 Hot Standby CPU Redundancy User ’ s Guide – December 1993 GFK-0827 If an RCM fault is detected, proceed as follows: STOP the unit with the suspected bad RCM. T ur n power off at that rack. Unplug the ter minated cable from the RCM and replace the module. Reconnect the terminated cable. P ower-up the rack (mode switch is still ...

  • State Industries GFK-0827 - page 94

    4 83 GFK-0827 Chapter 4 Operation Genius Bus Genius bus faults are not fatal to the PLC. However , if a bus fault e xists, it exists for both systems. There may be situations where one controller can communicate to more blocks than the other controller can. Since both controllers are running with the same outputs and shared inputs, and both control ...

  • State Industries GFK-0827 - page 95

    A section level 1 1 figure_ap level 1 table_ap level 1 85 GFK -0827 Appendix A Redundancy Alter natives Redundancy Alternatives There are several redundancy alternatives for the Series 90-70 Programmable Logic Controller . These redundancy options consist of implementation of the redundancy feature through a user logic program or through a redundan ...

  • State Industries GFK-0827 - page 96

    A 86 Series 90-70 Hot Standby CPU Redundancy User ’s Guide - December 1993 GFK -0827 HOT ST ANDBY (2 CPUS) OPTIONS SINGLE BUS REDUNDANT BUS LOW COST LOWEST COST I/O COUNT >512 IN/512 OUT VME ISO/ETHERNET THERMOCOUPLE/ RTD HIGH DENSITY ANALOG IN Redundancy Option Key (see T able 1) 1, 2, 3 1, 2 1B 1D 1A-C, 2, 3 1A-C, 2, 3 1A-C, 2, 3 1C, 3C 1A, ...

  • State Industries GFK-0827 - page 97

    A GFK -0827 87 Appendix A Redundancy Alter natives T able 13. R edundancy Options Option Ke y PLC Scan Sync Data Sync I/O System Output Selection Method R edund. Bus R edund. I/O Selection Guide 1A 2 90-70s no Application Logic 90-70 (I/O Scanner) Hot Standby yes - 2 no Higher Density Analog Inputs Hot Standby 1B 2 90-70s no Application Logic 90-30 ...

  • State Industries GFK-0827 - page 98

    A 88 Series 90-70 Hot Standby CPU Redundancy User ’s Guide - December 1993 GFK -0827 Series 90-70 Redundancy Through Application Logic The following restrictions apply using the cur rent Series 90-70 for redundancy applications requiring synchronization ( these restrictions do not apply to the Hot Standby CP U Redundancy product ). Do not use tra ...

  • State Industries GFK-0827 - page 99

    Index 89 GFK-0827 A A cronyms, list of , 12 A ctive and back up sweeps, 59 A ctive unit, 2 , 4 , 7 , 8 , 9 , 16 , 19 , 20 , 21 , 25 , 57 , 58 , 59 , 60 , 61 , 65 , 68 , 71 , 72 , 77 , 78 , 80 Appendix A, redundancy alternatives, 85 ASCII identifier for control strategy , 58 B Background user checksum, 69 Background window , 69 Background window tim ...

  • State Industries GFK-0827 - page 100

    Index 90 GFK-0827 Connecting Logicmaster 90, 31 Connector , serial port, 18 Connectors, batter y , 17 Considerations, programming, 10 Considerations, redundancy CPU, 64 Constant sweep mode configuration, 35 Constant window sweep mode configura- tion, 35 Contacts, timed, 70 Control actions, fault detection, 72 Control strategy , 5 , 58 CPU features, ...

  • State Industries GFK-0827 - page 101

    Index 91 GFK-0827 Genius bus, multiple, 26 Genius I/O , bus controller , 24 Genius I/O system, 4 Grounding, programmer , 9 Guidelines for r un disabled mode, 66 H Help text, redundancy error codes, 74 Hot standby CPU redundancy , 85 Hot standby cpu redundancy basic description of , 1 benefits of , 3 features of , 3 I/O systems genius I/O , 4 local ...

  • State Industries GFK-0827 - page 102

    Index 92 GFK-0827 Operation, differences for cpu 780, 65 Operation of a cpu redundancy system, 55 OVR_PRE %S reference, 70 P P arallel bus termination, 80 PID and T imer function blocks, 70 PLC fault table, redundancy error codes, 74 P ort, standard serial COM, 18 P ower–up sequence, 55 P refer red unit, 25 P rimar y redundant plc, configuration, ...

  • State Industries GFK-0827 - page 103

    Index 93 GFK-0827 S S (%), references, 7 Scan time, effect of bumpless switching, 8 Scan, synchronous, 59 Screens for fault category , 29 Secondar y unit, 25 Sequence, power -up, 55 Serial bus address 30, 4 , 6 , 9 , 25 Serial bus address 31, 4 , 6 , 9 , 25 Serial COM port, standard, 18 Serial port connector , 18 Ser vice request 27, 60 Ser vice re ...

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