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1 /2010 Modicon Quantum Hot Standby with Unity User Manual 05/

2 The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage Schneider Electric. All rights reserved /2010

3 Table of Contents Part I Safety Information About the Book Introducing the Modicon Quantum Hot Standby with Unity System Chapter 1 Modicon Quantum Hot Standby with Unity Overview.. 13 Overview of the Modicon Quantum Hot Standby with Unity System Physical presentation and mounting of Hot StandBy High End modules. 18 Modicon Quantum Hot Standby with Unity System Overview Hot Standby Operating Mode Hot Standby Safety CPU Specifics Operating Modes of the Safety PLC Chapter 2 Chapter 3 Modicon Quantum Hot Standby with Unity Compatibility, Differences, and Restrictions Compatibility with Installed Hot StandBy Legacy Systems Understanding System Words and System Bits Understanding Multitasking Restrictions Local I/O and Distributed I/O Restrictions Understanding Other Module Restrictions Understanding USB Link Behavior Understanding Application Restrictions Using IEC Logic and Modicon Quantum Hot Standby with Unity Modicon Quantum Hot Standby with Unity and IEC Logic Understanding the Modicon Quantum Hot Standby with Unity State RAM Transfer Process Understanding System Scan Time in Modicon Quantum Hot Standby with Unity Systems Transferring Application Data in a Modicon Quantum Hot Standby with Unity System /2010 3

4 Part II Setting up and Maintaining a Modicon Quantum Hot Standby with Unity System Chapter 4 Setting up, Installing, and Cabling a Modicon Quantum Hot Standby with Unity System Setting Up the Modicon Quantum Hot Standby with Unity System Mapping the Rack Extension Connecting Two identical Modicon Quantum Hot Standby with Unity Processors Connecting the Remote I/O Testing the Modicon Quantum Hot Standby with Unity System Chapter 5 Configuring a Modicon Quantum Hot Standby with Unity System Configuring a System with the Unity Pro Tabs and Dialogs Introducing Unity Pro Processor Configuration Screen Using the Summary Tab Using the Overview Tab Using the Configuration Tab Using the Modbus Port Tab Using the Animation Tab and PLC Screen Dialogs Using the Hot Standby Tab Configuring the PCMCIA Cards Configuring the Modbus Plus Communication Type Adjustment of the Drop Hold-Up Time Value Setting the Invalidate Keypad Option Swapping Network Addresses at Switchover Configuring Registers with Unity Pro Understanding the Non-Transfer Area, Transferring State RAM, and Reverse Transfer Words Understanding the Unity Command Register Understanding the Unity Status Register Transferring User Data Using Initialized Data Synchronizing Time-of-Day Clocks Configuring a NOE with Unity Pro Quantum Hot Standby for Unity Pro NOE Operating Modes and Modicon Quantum Hot Standby with Unity. 108 IP Address Assignment Address Swap Times Network Effects of Modicon Quantum Hot Standby with Unity Solution. 115 Overloaded Network /2010

5 Chapter 6 Part III Maintaining a Modicon Quantum Hot Standby with Unity System Verifying the Health of a Modicon Quantum Hot Standby with Unity System Detecting and Diagnosing Errors in a Modicon Quantum Hot Standby with Unity System Primary CPU Controller, Copro, and RIO Head Detected Errors Standby CPU Controller, Copro, and RIO Head Detected Errors Detecting High-Speed Data Link Interruptions Detecting Remote I/O (RIO) Link Interruptions Checking for Identical Application Programs Checksum Replacing a Module Troubleshooting the Primary CPU Controller Troubleshooting the Standby CPU Controller Understanding the Modicon Quantum Hot Standby with Unity System Special Features Chapter 7 Enabling EXEC Upgrade with Unity Pro Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade. 138 Executing the EXEC Upgrade Procedure Chapter 8 Handling Application Mismatch with Unity Pro Understanding Modicon Quantum Hot Standby with Unity Application Mismatch Understanding Switchover Behavior during Application Mismatch Online or Offline Modifications and Application Mismatch Online Modifications to an Application Program in the Standby CPU and Application Mismatch Online Modifications to an Application Program in the Primary CPU and Application Mismatch Offline Modification of an Application Program and Application Mismatch 153 Switchover Methods and Application Mismatch Application Program Transfer Method and Application Mismatch Recommendations for Using Application Mismatch Chapter 9 Transferring an Application Program with Unity Pro Overview of Application Program Transfer Executing the Application Program Transfer Procedure Using the Command Register Automatic Application Program Transfer Executing the Application Program Transfer Procedure Using the Keypad /2010 5

6 Chapter 10 Using the Modicon Quantum Hot Standby with Unity EFBs Description: HSBY_RD Description: HSBY_ST Description: HSBY_WR Description: REV_XFER Part IV Changing Configuration On The Fly with Quantum Hot Standby Chapter 11 CCOTF Presentation Overview of the Modicon Quantum Hot Standby CCOTF with Unity System Chapter 12 Upgrade Procedure to Use CCOTF Function Overview of Upgrade Procedure General Executing the CCOTF Upgrade Procedure General Changing the Hardware Modules Upgrading the Firmware Chapter 13 Using CCOTF General Add / Delete a Module in the Quantum Hot Standby Local Racks Add / Delete a Module in the Quantum Hot Standby RIO Drop Modify Module Parameters Chapter 14 CCOTF Troubleshooting Hot Standby Specific Troubleshooting List Appendices Appendix A Modicon Quantum Hot Standby with Unity Additional Information Fiber Optic Cable CPU Specifications CPU S Specifications CPU Specifications CRP Remote I/O Head Processor Error Patterns TextIDs Appendix B Modicon Quantum Hot Standby Controls and Displays 235 Controls and Displays Using the 140 CPU / 140 CPU / 140 CPU S LED Indicators Using the LCD Display Screens Glossary Index /2010

7 Safety Information Important Information NOTICE Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure /2010 7

8 PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation, and has received safety training to recognize and avoid the hazards involved /2010

9 About the Book At a Glance Document Scope This guide describes the Modicon Quantum Hot Standby with Unity system consisting of the Unity Pro software, the Modicon Quantum Hot Standby with Unity 140 CPU / 140 CPU S and 140 CPU , power supplies and remote I/O (RIO). This guide describes how to build a Modicon Quantum Hot Standby with Unity system. Users of legacy Quantum Hot Standby systems should note that significant differences exist between Unity and legacy systems, and where important, this guide identifies those differences. NOTE: Who should use this document? Anyone who uses a Hot Standby system or needs fault-tolerant availability through redundancy in an automation system. You should have knowledge of programmable logic controllers (PLCs). Familiarity with automation controls is expected. You should possess a working knowledge of the Unity Pro software. Familiarity with Concept, ProWORX, or Modsoft will help. Validity Note This documentation is valid for Unity Pro /2010 9

10 Product Related Information WARNING UNINTENDED EQUIPMENT OPERATION The application of this product requires expertise in the design and programming of control systems. Only persons with such expertise should be allowed to program, install, alter, and apply this product. Follow all local and national safety codes and standards. Failure to follow these instructions can result in death, serious injury, or equipment damage. User Comments We welcome your comments about this document. You can reach us by at /2010

11 Introducing Modicon Quantum Hot Standby with Unity /2010 Introducing the Modicon Quantum Hot Standby with Unity System I Purpose This part introduces the Modicon Quantum Hot Standby with Unity system. The content describes the hardware available, the compatibility of Modicon Quantum Hot Standby with Unity system with legacy systems, and using IEC logic and Unity. What's in this Part? This part contains the following chapters: Chapter Chapter Name Page 1 Modicon Quantum Hot Standby with Unity Overview 13 2 Modicon Quantum Hot Standby with Unity Compatibility, Differences, and Restrictions 3 Using IEC Logic and Modicon Quantum Hot Standby with Unity /

12 Introducing Modicon Quantum Hot Standby with Unity /2010

13 Overview Modicon Quantum Hot Standby with Unity /2010 Modicon Quantum Hot Standby with Unity Overview 1 Overview In this chapter you will find a brief overview of the Modicon Quantum Hot Standby with Unity system, the module, and the indicators. What's in this Chapter? This chapter contains the following topics: Topic Page Overview of the Modicon Quantum Hot Standby with Unity System 14 Physical presentation and mounting of Hot StandBy High End modules 18 Modicon Quantum Hot Standby with Unity System Overview 19 Hot Standby Operating Mode 20 Hot Standby Safety CPU Specifics 23 Operating Modes of the Safety PLC /

14 Overview Modicon Quantum Hot Standby with Unity Overview of the Modicon Quantum Hot Standby with Unity System Quantum SIL2 Hot StandBy Offer Read thoroughly the Quantum Safety PLC - Safety Manual (part number ) to build a safety PLC according to the safety certifications. Schneider Electric provides a range of products that are certified to be used in a IEC and SIL2 safety system. This range includes: Hot StandBy safety CPU modules (140 CPU S) safety I/O modules (140 SAI S, 140 SDI S, 140 SDO S) non-interfering modules Unity Pro XLS NOTE: The Hot Standby safety system uses the existing Quantum remote I/O communication modules (140 CRA and 140 CRP plus remote racks wiring system). Purpose of a Hot Standby System Use a Modicon Quantum Hot Standby with Unity system when downtime cannot be tolerated. Hot standby systems deliver high availability through redundancy. A hot standby system consists of two identical configurations. One of the two processors acts as the Primary CPU controller, and the other acts as the Standby CPU controller. The Primary CPU controller runs the application program and operates the remote I/O. Either controller can be put in the Primary CPU state, but the other must be in the Standby CPU state or offline. Identical Configurations Two racks are configured with identical hardware and software. identical 140 CPU / 140 CPU S or 140 CPU processors which contain both a CPU and a Copro identical versions of the operating system and copro firmware identical power supplies identical RIO Heads identical cabling and cabling systems identical I/O drops identical sequential placement on the backplane If other modules are used, for example local I/Os, NOMs, NOEs, those modules must be identical /2010

15 Overview Modicon Quantum Hot Standby with Unity Primary CPU and Standby CPU Controllers The Primary CPU controller: executes the whole application program (first section included), controls the remote I/O, and updates the Standby CPU controller after every scan (program cycle). If the Primary CPU controller stops, the Standby CPU controller takes control within one scan. To determine if the Primary CPU controller has stopped, note controller s status displayed in the HE CPU LCD screen and the RIO Head s status displayed by the RIO Head s LEDs. The Standby CPU controller: executes only the first section of the application program, checks out the availability of the CPU and CRP modules, and does not control the remote I/O. NOTE: As the first section of the program is also executed by the Standby CPU controller, do not use (in the first section) Timer events or any logic which controls the process and the communication. Switchover Capability One of the two controllers may function as the Primary CPU controller and the other as the Standby CPU controller. Primary CPU and Standby CPU states are switchable. Therefore, if one of the two controllers is functioning as the Primary CPU controller, the other must be in Standby CPU mode. Otherwise, the second controller is in the default mode, which is offline. The remote I/O is controlled by the Primary CPU controller. Monitoring the System The Primary CPU and the Standby CPU controllers communicate with each other constantly to monitor the functionality of the system. If the Primary CPU controller stops, the state of the controllers is switched. The Standby CPU controller becomes the Primary CPU, executes the application program, and controls the remote I/O. If the Standby CPU controller stops, the Primary CPU controller continues to run without redundancy and acts as a stand alone system. Online Modification It is possible to make I/O configuration changes when the PLC is in RUN mode, and more specifically: Add a module (discrete or analog) in a free slot, Delete a module (discrete or analog), Modify the configuration parameters of a module (discrete or analog) /

16 Overview Modicon Quantum Hot Standby with Unity Services offered when the PLC is connected to the programming terminal.: Service PLC in RUN mode Automatic detection of the PLC configuration Yes Yes Adding/deleting a module Yes Yes Modification of configuration parameters Yes Yes Modification of adjustment parameters Yes Yes Display of errors Yes Yes Display of status information Yes Yes PLC in STOP mode For more details on this function refer to Changing Configuration On The Fly with Quantum Hot Standby (see page 183). Power Cycle On power cycle, the controller that has the lowest MAC address will become the Primary CPU. The second system automatically becomes the Standby CPU. Handling I/O NOTE: The Modicon Quantum Hot Standby with Unity system supports I/O connected to a Remote I/O network and Ethernet I/O scanning. Handling Local I/O Local I/O is not supported in a Modicon Quantum Hot Standby with Unity system environment. However, local I/O can be configured and run but will not have any corresponding backup. Software Requirements Required to use a Quantum Modicon Hot Standby with Unity system: Unity Pro 2.0 or higher for 140 CPU or 140 CPU Unity Pro XLS for 140 CPU S CRA firmware: Release 1.26 or higher CRP firmware: Release 1.15 or higher /2010

17 Overview Modicon Quantum Hot Standby with Unity Configuring Modbus Plus (MB+) Addresses WARNING UNINTENDED EQUIPMENT OPERATION. Do not change the Modbus Plus (MB+) address after the first configuration. Failure to follow these instructions can result in death, serious injury, or equipment damage. Configure MB+ address first time 1. Default MB+ address = 1 (140 CPU /60S) 2. Change MB+ address at first configuration (on both controllers) (see page 64) /

18 Overview Modicon Quantum Hot Standby with Unity Physical presentation and mounting of Hot StandBy High End modules Illustration The figure shows an Hot StandBy High End module and its components. 1 model number, module description, color code 2 lens cover (open) 3 LCD Display (here covered by lens cover) 4 key switch 5 keypad (with 2 red LED indicators) 6 Modbus port (RS-232) (RS-485) 7 USB port 8 Modbus Plus port 9 PCMCIA slots A and B 10 LED indicators (yellow) for Ethernet communication 11 HSBY fiber optic communication port 12 reset button 13 battery (user installed) 14 2 screws NOTE: Quantum High End processors are equipped with two receptacles (A and B) in which to install Schneider PCMCIA cards (other cards are not accepted) /2010

19 Overview Modicon Quantum Hot Standby with Unity Modicon Quantum Hot Standby with Unity System Overview System Components The following graphic shows the architecture of a Modicon Quantum Hot Standby with Unity system. 1 Primary PLC 2 Standby PLC 3 Modicon Quantum Hot Standby with Unity controller with integrated coprocessor 4 Modicon Quantum RIO head 5 Modicon Quantum RIO drop /

20 Overview Modicon Quantum Hot Standby with Unity Hot Standby Operating Mode Description of the Hot Standby States Run Primary CPU The Primary CPU PLC executes the application program and controls the remote I/O process. If a Standby CPU is present, the Primary CPU sends application data and I/O to it. Run Standby CPU The PLC indicates that it is running well and is ready to take over the process if the Primary CPU stops. Run Offline The PLC executes the complete application program but the I/O are not written. This state is either manually activated or the CPU detects it itself. Stop (Offline) the PLC executes neither the application program nor controls the process. The run offline and the stop offline state can occur in the Primary CPU and in the Standby CPU at the same time. Table of States The following table shows the possible states of the 2 controllers of a Hot Standby configuration: Controller B state Controller A state Run Prim Run Stby Run OffL Stop OffL Run Prim N/A Hot Standby active I/O processed Run Stby Run OffL Stop OffL Hot Standby active I/O processed Hot Standby inactive I/O processed Hot Standby inactive I/O processed Hot Standby inactive I/O processed N/A N/A N/A N/A N/A Hot Standby inactive I/O not processed Hot Standby inactive I/O not processed Hot Standby inactive I/O processed Hot Standby inactive I/O not processed Hot Standby inactive I/O not processed /2010

21 Overview Modicon Quantum Hot Standby with Unity Description of Run Offline Use Cases The following table describes the different situations of the Run Offline state: If... Then... The Primary CPU PLC enters Run Offline state The Standby CPU PLC enters Run Offline state The fibre optic link is disconnected The actual hardware configuration is different from the configuration defined in the project A application mismatch occurs The Standby CPU RIO head (CRP) stops operating The Standby CPU PLC takes over the process and becomes Run Primary CPU The Hot Standby function is no longer available The Standby CPU PLC enters Run Offline state Either the Primary CPU or the Standby CPU PLC starts in Run Offline state The Standby CPU PLC enters Run Offline state The Standby CPU PLC enters Run Offline state Run Offline State Recommendation On a Quantum CPU, the run offline state appears with the HSBY error mode. Note that the PLC is not configured as a primary nor Standby CPU. This occurs after the HSBY system detects an issue or hot Standby offline mode has been chosen. In this state, the CPU main actions are: Execution of the entire code sections (not only the first section as Standby state), No data transfer from primary, except for the %SW60 value, Address swap management, Local IO management. Solution: When using communication EFBs, some applications can be affected by the entire code execution. It is recommended to: Create a boolean variable, cpu_state:=(%sw61.1) AND NOT (%SW61.0); Assign the section or communication block execution to this variable. With such fix, unexpected EFB communication call will be avoided if the CPU in Standby state goes to an offline state /

22 Overview Modicon Quantum Hot Standby with Unity Description of the Hot Standby Operating Modes A Quantum Hot Standby PLC has some restrictions in terms of changing modes. The following picture shows the state diagram of the Hot Standby Quantum system: NOTE: A PLC that is Run Offline cannot go directly to Run Primary Mode. NOTE: A PLC that is Run Primary cannot go directly to Run Standby Mode /2010

23 Overview Modicon Quantum Hot Standby with Unity Hot Standby Safety CPU Specifics Introduction The 140 CPU S Quantum Safety CPU module is certified for use in Hot Standby SIL3 solutions compliant to IEC standard. For more details according to the safety certifications see the Quantum Safety PLC (see Modicon Quantum, Quantum Safety PLC, Safety Reference Manual). In a Hot Standby configuration, 1 CPU is the Primary CPU and the other is the Standby CPU. The Hot Standby Safety CPU differs from the standalone Safety CPU in the use of the Ethernet port. In the standalone Safety CPU, it is used to communicate with other devices using a normal Ethernet cable. In the Hot Standby Safety CPU, it is used to exchange data between the Primary CPU and the Standby CPU controller using a fiber optic link. Because the fiber optic link is not part of the Safety loop, the PFD and PFH values of the Hot Standby CPU are the same as those of the standalone CPU. Each Safety CPU includes a PCMCIA memory card (see Modicon Quantum, Quantum Safety PLC, Safety Reference Manual), but its use and presence is not mandatory. Description of the Hot Standby Configuration The Hot Standby configuration contains 2 identical local racks and at least 1 remote I/O drop because I/Os cannot be placed in the local rack of a Hot Standby configuration. Besides a power supply module (must be at least one 140 CPS ), each local rack must consist of both a: 140 CPU S module 140 CRP module Besides a power supply and I/O modules (must be at least one 140 CPS ), the remote drop(s) must include a 140 CRA module. CAUTION UNINTENDED EQUIPMENT OPERATION Only high availability RIO modules, which provide dual cabling, are allowed in a Safety-Related System. Failure to follow these instructions can result in injury or equipment damage. For Hot Standby configuration example, refer to the information on Connecting the Remote I/O (see page 56) /

24 Overview Modicon Quantum Hot Standby with Unity Description of the Operating Modes The Hot Standby Safety PLC can run in Safety Mode and in Maintenance Mode. Safety Mode: The Safety Mode is the default mode of the Quantum PLC. It is a restricted mode in which modifications and maintenance activities are prohibited. Maintenance Mode: The Maintenance Mode of the Quantum Safety PLC is a temporary mode for modifying the project, debugging and maintaining the application program. State Compatibility with Safe and Maintenance Modes Redundant configuration (1 CPU is primary, 1 is standby) The Standby CPU controller mode follows the Primary CPU controller mode. For example, if you switch the Primary CPU controller from Safety to Maintenance mode, the Standby CPU controller switches from Safety to Maintenance mode at the start of the next cycle. Non-redundant configuration (at least 1 CPU offline) The two controllers are independent, one can be in Safety mode and the other one in Maintenance mode. For example, the Run Prim controller can be in Safety mode while the Stop OffL controller is in Maintenance mode. Impact of the PLC Switch on the Process Safety Time If the primary CPU detects an internal or external problem, it stops exchanging data with the Standby CPU and stops processing the I/O. As soon as the Standby CPU detects that there is no more exchange with the primary CPU, it takes over the role of the primary CPU, executing the user logic and processing the I/O. Therefore, the output modules must filter the lack of exchange with the primary CPU to avoid glitches when a switch occurs. This is achieved by configuring the output module timeout. As a result, the PLC reaction time is greater than the timeout configured in the output module, thereby influencing the process Safety time. NOTE: The behavior of the Hot Standby Safety CPU is equivalent to that of the standalone Safety CPU. In case of a detected error, the PLC enters: Halt state when running in Maintenance Mode. Error state when running in Safety Mode /2010

25 Overview Modicon Quantum Hot Standby with Unity Availability of the Hot Standby Functions In addition to the standard Hot Standby functions, you can use an EFB to program an automatic swap between primary CPU and Standby CPU PLC in order to verify the ability of the Standby CPU PLC to take over from the primary CPU. That means that the Standby CPU PLC periodically becomes the primary CPU and the primary CPU PLC the Standby CPU. It is recommended to avoid using the USB link during swap. The following table lists the available Hot Standby functions in Maintenance Mode and Safety Mode: Function Maintenance Mode Safety Mode Hot Standby yes yes Switch Over yes yes EFB Swap no yes Keypad yes yes application mismatch yes no OS Upgrade yes, if Standby is in Stop Offline no Application Transfer yes no For details of how to configure and operate Quantum Hot Standby systems, see the Modicon Quantum Hot Standby with Unity User Manual (see page 9) /

26 Overview Modicon Quantum Hot Standby with Unity Operating Modes of the Safety PLC Introduction The default behavior of the Quantum Safety PLC is to perform Safety Functions in order to achieve and to maintain the Safe state of a process. Nevertheless, you must be able to debug and to maintain your project. Therefore, the Quantum Safety PLC can run in the following 2 operating modes: the Safety Mode the Maintenance Mode You can use the Safety Mode to control your process, whereas the Maintenance Mode is for debugging and refining your project. In Maintenance Mode, the I/O and CPU modules are still executing the diagnostics and establishing the Safe state if a fault is detected. Only the application program and the application data which may be changed in Maintenance Mode are not checked. Safety and Maintenance Mode Features The operating mode of the Quantum Safety PLC depends on events such as application exception, power on/off, and so on. The functions available in Unity Pro XLS depend on the operating mode. Switching between the modes requires defined conditions and follows certain procedures. For details, see the chapter "Switching Between Safety and Maintenance Mode" (see Unity Pro XLS Software, Operating Mode Manual, Safety PLC Specifics) in the Unity Pro XLS Operating Mode Manual Safety PLC Specifics. You can interact with the Safety PLC using: the programming tool Unity Pro XLS the keypad of the Quantum Safety CPU the key switch Depending on the operating mode, the Safety PLC can be in different states. After power up, it automatically enters run state of the Safety Mode if the following 2 conditions are fulfilled: There is a valid application. The Automatic start in Run option is activated. In case of an invalid application, it enters the not configured (no conf) state of the Maintenance Mode (only if the key state is unlocked), in which you are able to download your project. If a fault is detected, the PLC enters halt state when running in Maintenance Mode. error state when running in Safety Mode /2010

27 Overview Modicon Quantum Hot Standby with Unity PLC States The following figure shows the state diagram of the Quantum Safety PLC: Operating Mode Identification You can identify the running mode by a LCD display on the CPU or by a status bar field on the PLC screen provided by Unity Pro XLS. The LCD display on the CPU indicates the current operating mode by showing the letters M for Maintenance Mode or S for Safety Mode. The status bar field on the PLC screen indicates the current operating mode as shown in the following figure: /

28 Overview Modicon Quantum Hot Standby with Unity /2010

29 Compatibility, Differences, Restrictions /2010 Modicon Quantum Hot Standby with Unity Compatibility, Differences, and Restrictions 2 Overview In this chapter you will find an overview of compatibilities within a system that has already been installed, differences from Legacy Hot Standby systems, and restrictions for the Modicon Quantum Hot Standby with Unity system. What's in this Chapter? This chapter contains the following topics: Topic Page Compatibility with Installed Hot StandBy Legacy Systems 30 Understanding System Words and System Bits 32 Understanding Multitasking Restrictions 33 Local I/O and Distributed I/O Restrictions 34 Understanding Other Module Restrictions 35 Understanding USB Link Behavior 37 Understanding Application Restrictions /

30 Compatibility, Differences, Restrictions Compatibility with Installed Hot StandBy Legacy Systems Compatibility of the Main Elements The following table lists the equipment differences between a Quantum Hot Standby with Concept system (Legacy) and a Quantum Hot Standby with Unity system. Quantum Hot Standby with Concept system Quantum Hot Standby with Unity system processor module Legacy CPU (16 or 32 bit) CPU with integrated coprocessor (140 CPU or 60S) option module 140 CHS replaced by the coprocessor fiber connection CHS fiber connection new fiber connection remote I/O head modules 140 CRP Copro and Remote I/O Head Instead of a Modicon Quantum Hot Standby Option Module (140 CHS ), an embedded coprocessor (Copro) provides a dedicated communications link transferring data between the Primary CPU and Standby CPU controllers. This dedicated link cannot be used for any other communications. S908 Remote I/O Head Option Modules (140 CRP 93 x00) are required in the system for communicating with the remote I/O drops and exchanging status between the Primary CPU and Standby CPU controllers. Changes between Concept and Unity Command and Status Registers are no longer stored in the State RAM. Command and Status Registers are accessible in the system words %SW60 and %SW61. Reverse Transfer registers are no longer stored in the State RAM. System automatically allocates system words %SW62/63/64/65 as Reverse Transfer words. Reverse Transfer words are no longer part of the Non-Transfer Area of the 4xxxx registers. There is no longer the legacy requirement to reserve the 3xxxx area for transferring unlocated variables (140 CPU only.) (Unlocated variables are transferred with the State RAM). System words are used for the command and status registers, which are removed from the State RAM /2010

31 Compatibility, Differences, Restrictions Changes from LL984 NOTE: CHANGING FROM LEGACY There is no longer a Non-Transfer Area for the 0xxx, 1xxx, and 3xxx registers. Transferring over multiple scans is no longer available. In current Modicon Quantum Hot Standby Systems using the CHS option module, additional state RAM could be transferred over multiple scans. Not transferring over multiple scans minimizes the impact of state RAM transfers. In the Unity Pro Modicon Quantum Hot Standby with Unity 140 CPU , transfer speeds will be much faster, and the amount of state RAM used for transfers will be smaller since unlocated data will be used instead /

32 Compatibility, Differences, Restrictions Understanding System Words and System Bits Overview In compliance with IEC standards, Unity uses global objects called system bits and system words. Users of legacy Schneider Electric products may be familiar with registers (984LL notation). Regardless of notation, the behavior remains the same. System Word %SW60 System Word %SW60 can be used to read from and to write to the Modicon Quantum Hot Standby with Unity Command Register. NOTE: %SW60 is described using the IEC convention. System Word %SW61 System Word %SW61 can be used to read the contents of the Modicon Quantum Hot Standby with Unity Status Register. NOTE: %SW61 is described using the IEC convention. System Words %SW62, %SW63, %SW64 and %SW65 System Words %SW62/63/64/65 are reverse registers reserved for the Reverse Transfer process. The reverse registers can be written to the application program (first section) of the Standby CPU controller and are transferred at each scan to the Primary CPU controller /2010

33 Compatibility, Differences, Restrictions Understanding Multitasking Restrictions General In a Modicon Quantum Hot Standby with Unity system, the Standby controller is kept ready to assume the role of the Primary CPU controller by having the same application loaded (in the Standby) and by receiving from the Primary CPU once per scan a copy of the Primary CPU's data. During the scan, there is a tight synchronization between the Primary CPU and Standby CPU. MAST Schneider Electric recommends using only MAST to transfer data during a scan. Tasks are handled singly and sequentially. Using MAST is consistent with current Modicon Quantum Hot Standby systems because multi-tasking is not provided, and data transfer will be synchronized with MAST. NOTE: 140 CPU S safety CPU processor is not multitask. Only the MAST task is available. Asynchronous Events Using a Modicon Quantum Hot Standby with Unity system in a multitasking environment may cause data to change between scans. Because in a multi-tasking system, events may occur asynchronously to the normal scan. Those events may happen at a faster rate, the same rate, or at a slower rate. The result is that data modified by these events can be changed during a transfer. FAST and AUX FAST and AUX tasks are not available on 140 CPU S. For other CPUs, the FAST and AUX can be used. WARNING UNEXPECTED EQUIPMENT OPERATION Do analyze the system needs and the issues that can raise when using FAST and AUX tasks. Failure to follow these instructions can result in death, serious injury, or equipment damage /

34 Compatibility, Differences, Restrictions Local I/O and Distributed I/O Restrictions General Note the two following restrictions: Although local I/O and distributed I/O (DIO) can be used in a Modicon Quantum Hot Standby with Unity system, they are not considered as part of the redundant system. When either local I/O and/or distributed I/O (DIO) are used in a Hot Standby system, the following restrictions apply: the Standby does not have access to its own inputs but accesses the inputs of the Primary. for the outputs, the Standby can manage its own outputs (programmed in section 1) but only if the outputs are not forced in the Primary. If no outputs are programmed in the Standby, they take the state of the Primary. Local I/O can be used in the local rack of a Hot Standby configuration for managing I/O dedicated to each PLC. When local I/O and Distributed I/O are used, they have to be managed in the first section of the application by using located %MW that are not transferred from primary to Standby. NOTE: Distributed I/O are not compatible with the safety processor (140 CPU S). Local I/O Management It is possible to manage actuators locally in both PLC. They may be written with different values at the same time depending on the application program processing. For that, the section 0 of the application must be used. On the other hand, only the located variables that are not transferred from the Primary to the Standby must be used for managing the different values applied on the output modules. CAUTION RISK OF EQUIPMENT DAMAGE When Actuators are managed locally in each PLC, the output values must be evaluated in the section 0 at each PLC scan. If this is not done, the Standby output value will be erased by the value coming from the Primary PLC Failure to follow these instructions can result in equipment damage /2010

35 Compatibility, Differences, Restrictions Understanding Other Module Restrictions General The Modicon Quantum Hot Standby with Unity V2.0 and later versions do not support the following modules. Model Support Provided 140 NOE Module NOT supported in Unity Pro V2.0 and later versions 140 NOE Module NOT supported in Unity Pro V2.0 and later versions 140 CHS Module NOT supported in Unity Pro V2.0 and later versions 140 NOA Module NOT supported in Unity Pro V2.0 and later versions 140 NOA Module NOT supported in Unity Pro V2.0 and later versions 140 NOL Module NOT supported in Unity Pro V2.0 and later versions PTQ PDP MV1 00 Module NOT supported in Unity Pro V2.0 and later versions 140 HLI Module NOT supported in Unity Pro V2.0 and later versions Rectrictions on kind of operations The user can only perform the following operations on a module: Add a module Delete a module Change the parameter of a module The add /delete operations are possible only with ANALOG and DISCRETE modules at their first connection. In online Run mode: If the operation is authorized, the customer performs the operation (add, delete) directly in the bus editor by clicking on the empty slots or by Drag and Drop as usually If the operation is impossible, the customer is warned that it must build in offline STOP or in offline mode. If he validates, he can perform the operation in the bus editor. NOTE: The consequence of this new behavior is that in online STOP mode, the same operations must be possible /

36 Compatibility, Differences, Restrictions this table describes the authorized modifications on different kind of elements : Element type of Modification Authorized in Online Mode Module Add Yes (only ANALOG / DISCRETE module Delete Yes (only ANALOG / DISCRETE module change the parameters of a new module 1 Yes (only ANALOG / DISCRETE module change the parameters of a preexisting module 2 Yes (only ANALOG / DISCRETE module Cut Copy / Paste Yes (only ANALOG / DISCRETE module RACK Add rack No ( The Add extended rack is possible only if we are in the drop creation procedure Clear rack Yes Replace rack No Cut copy / paste No (there are 16 modules to copy DROP Add DROP No Move DROP No Delete DROP No Cut DROP copy / paste No 1 : Possibility to change all the parameters of the module 2 : Can not change the setting module parameters NOTE: Verification of the Status of The real configuration by a specific system WORD or symbols. Example: WORD %SW180 to %SW339 are associated with the PLC station. To work correctly the online modification functionnality requires that, the CRP Firmware version 1.14 or higher must be up to date and the CRA firmware release 1.25 or higher have to be used. If it is not the case a given system WORD indicates it. Then the station, forbids the build changes operation in RUN mode and display an adapted message /2010

37 Compatibility, Differences, Restrictions Understanding USB Link Behavior USB Link behavior in case of switchover The USB link is dedicated to the communication with the PLC to which it is physically connected. In case of switchover, the USB link remains with the same PLC /

38 Compatibility, Differences, Restrictions Understanding Application Restrictions Timer Events and I/O Errors Timer events are NOT synchronized in Modicon Quantum Hot Standby with Unity applications. Schneider Electric recommends not using timer events. NOTE: NOT EXCHANGING I/O ERRORS If timer events are used, I/O errors are not exchanged between Primary CPU and Standby CPU. Mast task cycle time and watchdog The Modicon Quantum Hot Standby with Unity system is optimised for applications with nominal Mast task cycle time between 30ms and 300ms. WARNING UNEXPECTED EQUIPMENT OPERATION The Drop hold-up time must be set to at least twice the mast task watchdog Failure to follow these instructions can result in death, serious injury, or equipment damage /2010

39 IEC Logic /2010 Using IEC Logic and Modicon Quantum Hot Standby with Unity 3 Overview This chapter provides information about using IEC Logic with a Modicon Quantum Hot Standby with Unity system. What's in this Chapter? This chapter contains the following topics: Topic Page Modicon Quantum Hot Standby with Unity and IEC Logic 40 Understanding the Modicon Quantum Hot Standby with Unity State RAM 41 Transfer Process Understanding System Scan Time in Modicon Quantum Hot Standby with Unity Systems Transferring Application Data in a Modicon Quantum Hot Standby with Unity System /

40 IEC Logic Modicon Quantum Hot Standby with Unity and IEC Logic Overview A Modicon Quantum Hot Standby with Unity system requires two racks configured with identical hardware, software, and firmware. One of the controllers (PLC) functions as the Primary CPU controller and the other as a Standby CPU controller. The Primary CPU updates the Standby CPU each scan through the Copro link. The Primary CPU and Standby CPU communicate constantly monitoring the health of the system. If the Primary CPU stops, the Standby CPU takes control within one scan. State RAM Definition State RAM is the memory range, which is used for: word-orientated input and output components (for example, analog modules), bit oriented input and output components (for example, digital modules), binary and word variables for the application program. State RAM is assigned the four reference types: %IW, %QW, %I and %Q. Data Transfer and User Data In a Modicon Quantum Hot Standby with Unity system, data is transferred from Primary CPU to Standby CPU each scan. The following data are transferred each scan: Located variables (State RAM 128 Kb) All unlocated variables up to 512 Kb (not applicable for 140 CPU S configurations) All instances of the DFB and EFB type SFC variable area (not applicable for 140 CPU S configurations) System bits and words NOTE: At each scan, all forced bits are transferred from the Primary CPU to the Standby CPU /2010

41 IEC Logic Understanding the Modicon Quantum Hot Standby with Unity State RAM Transfer Process Hot Standby Transfer Diagram (140 CPU ) The following diagram illustrates the transfer of data from the Primary CPU to the Standby CPU Copro in a configuration using 140 CPU processors /

42 IEC Logic Hot Standby Transfer Diagram (140 CPU S) The following diagram illustrates the transfer of data from the Primary CPU to the Standby CPU Copro in a configuration using 140 CPU S processors /2010

43 IEC Logic Understanding System Scan Time in Modicon Quantum Hot Standby with Unity Systems Effect on System Scan Time The scan time of any Modicon Quantum Hot Standby with Unity system depends on the amount of data transferred. Because data must be transferred from Primary CPU to Standby CPU, any Modicon Quantum Hot Standby with Unity system has a higher scan time than a comparable standalone system. NOTE: CHANGING FROM LEGACY In legacy systems, the CPU performed both application program (project) processing communication transfer In a Modicon Quantum Hot Standby with Unity system, in parallel CPU performs application program processing Copro performs communication transfer Result: reduced transfer time with Unity Do not set the period of periodic MAST task below 12 ms. Difference between CPU and 60S modules The following diagrams are made for 140 CPU For the 140 CPU S module, the scan time and the figures are similar but the transferred data are different. There is no unlocated data. They are replaced by private data (data internally used by the application and not accessible for the user). Performance Considerations A Modicon Quantum Hot Standby with Unity system increases the length of a MAST scan, creating system overhead. NOTE: System Overhead System overhead is the time required to copy the application data to the communication link layer. The network scan (communication between Primary CPU and Standby CPU copros) 1. exchanges data between both controllers 2. runs in parallel with the application program /

44 IEC Logic A Hot Standby system is illustrated below. Most of time, the MAST scan hides the network scan. Examples However, when processing some application programs, additional system overhead may occur. Example #1 Standalone application scan time: 80 ms Data (state RAM + unlocated variables): 100 Kb /2010

45 IEC Logic Example #2 Standalone application scan time: 80 ms Data (state RAM + unlocated variables): 300 Kb /

46 IEC Logic Transferring Application Data in a Modicon Quantum Hot Standby with Unity System Changing from Legacy Modicon Quantum controllers that use the Concept software have an application data transfer limit of approximately 128 Kb. This limit includes located data (in state RAM) and unlocated data. To transfer the unlocated data, the system must use a part of the 3x area in the state RAM. Schneider Electric chose this method to be compatible with the existing CHS option module (140 CHS ). Thus, a tradeoff is necessary: the more unlocated data, the less state RAM and vice versa. Modicon Quantum Hot Standby with Unity In the Modicon Quantum Hot Standby with Unity 140 CPU , the CHS option module is no longer used. Both the controller and Hot Standby functions are in the same unit. Thus, there is no need to force unlocated data through the 3x area. Not forcing means that all of the state RAM can be used as state RAM (up to 128 Kb). In addition to the state RAM, you may have a maximum of 512 Kb of unlocated data. Memory Consumption The amount of data to be transferred is automatically adjusted by the system. For Information on the size of the memory consumption, select PLC Memory Consumption. NOTE: The safety processors (140 CPU S) do not use unlocated data /2010

47 Maintaining Modicon Quantum Hot Standby with Unity /2010 Setting up and Maintaining a Modicon Quantum Hot Standby with Unity System II Purpose This part describes three important processes in using a Modicon Quantum Hot Standby with Unity system. setting up, installing, and cabling a Modicon Quantum Hot Standby with Unity system configuring a Modicon Quantum Hot Standby with Unity system using the Unity Pro software maintaining a Modicon Quantum Hot Standby with Unity system once installed What's in this Part? This part contains the following chapters: Chapter Chapter Name Page 4 Setting up, Installing, and Cabling a Modicon Quantum Hot Standby with Unity System 5 Configuring a Modicon Quantum Hot Standby with Unity System 6 Maintaining a Modicon Quantum Hot Standby with Unity System /

48 Maintaining Modicon Quantum Hot Standby with Unity /2010

49 Installation and Cabling /2010 Setting up, Installing, and Cabling a Modicon Quantum Hot Standby with Unity System 4 Overview This chapter provides an overview of setting up, installing, and cabling a Modicon Quantum Hot Standby with Unity system. What's in this Chapter? This chapter contains the following topics: Topic Page Setting Up the Modicon Quantum Hot Standby with Unity System 50 Mapping the Rack Extension 52 Connecting Two identical Modicon Quantum Hot Standby with Unity 54 Processors Connecting the Remote I/O 56 Testing the Modicon Quantum Hot Standby with Unity System /

50 Installation and Cabling Setting Up the Modicon Quantum Hot Standby with Unity System Overview Setting up a Modicon Quantum Hot Standby with Unity system involves a number of processes, summarized in the following paragraphs here and explained in detail elsewhere. Mapping the Rack Extensions A Modicon Quantum Hot Standby with Unity requires two racks with at least four slots. Map the two racks in an identical manner as described in Identical Configurations, page 14. Connecting Two High End CPUs Connect the two Modicon Quantum Hot Standby with Unity High End CPUs with a fiber optic cable as described in Connecting Two identical Modicon Quantum Hot Standby with Unity Processors, page 54. Establishing the Primary CPU and Standby CPU Controllers The system determines that one of the two Modicon Quantum Hot Standby with Unity HE CPUs will be the Primary CPU controller and the second controller as the Standby CPU. The Keypad may provide status information. Therefore, to view the status, use the Modicon Quantum Hot Standby with Unity HE CPU s keypad by selecting Quantum PLC Operations => PLC Operations Hot Standby => Hot Standby Order. See Using the LCD Display Screens, page 240. Connecting the Remote I/O Connect the Modicon Quantum RIO Heads with each other and with the RIO drops as described in Connecting the Remote I/O, page 56. Configuring in Unity Pro Using Unity Pro, configure a network that is appropriate for the installed racks and the cabling. Configure the Hot Standby Register for the Modicon Quantum Hot Standby with Unity HE CPU in Unity Pro as described in Processor Configuration Screen, page /2010

51 Installation and Cabling Transferring and Sending the Program from Primary CPU to Standby CPU Transfer the program from your PC to High End CPU using the Unity Pro command PLC Transfer program to PLC. See Overview of Application Program Transfer, page 162. Send your program from the Primary CPU to the Standby CPU using the CPU s keypad Primary or secondary. Select Quantum PLC Operations => PLC Operations Hot Standby => Hot Standby Transfer => Press <ENTER> to confirm Transfer =>. See Using the LCD Display Screens, page 240. NOTE: A program is always sent from the Primary CPU controller to the other CPU controller /

52 Installation and Cabling Mapping the Rack Extension Requiring Identical Racks Two racks must be configured with identical modules and in identical order. Then, both controllers may function either as a Primary CPU controller or as a Standby CPU controller. NOTE: INSTALLING CONTROLLERS Schneider Electric recommends referring to Schneider Electric planning and installation guidelines. You will find more information in the Quantum with Unity Pro - Hardware Reference Manual and in Remote I/O Cable System Planning and Installation Guide. Noting the Module Version The Primary CPU and Standby CPU must belong to the Modicon Quantum Hot Standby with Unity product family. The Modicon Quantum RIO drops can be from Schneider Electric s 800 series of modules. Installing Components and Modules A Modicon Quantum Hot Standby with Unity system requires two racks with at least four slots. The racks (1, 2) must be identically equipped with: Modicon Quantum Hot Standby with Unity with integrated coprocessor (Copro) (3) Modicon Quantum power supply module (4) Modicon Quantum RIO Head (5) Other modules for example, Modicon Quantum NOMs, NOEs (6) NOTE: The sequence of the modules on the rack is not predefined, but the sequence of the modules on the racks of the Primary CPU and the Standby CPU must be identical. Otherwise, a Modicon Quantum Hot Standby with Unity system does not exist /2010

53 Installation and Cabling The following graphic shows a possible scheme for components and their connectors. 1 Primary CPU controller rack 2 Standby CPU controller rack 3 Modicon Quantum Hot Standby with Unity with integrated coprocessor (Copro) 4 Modicon Quantum power supply module: Install power supply in first slot for better rack layout. 5 Modicon Quantum RIO head 6 Other modules, for example Modicon Quantum NOMs, NOEs 7 Fiber Optic Cable to connect to both processors. 8 Coaxial cable with splitters (8A) for connecting the RIO heads (5) with the RIO drops in the network. The dashed connection represents a redundant connection in the RIO network, which is not required for the Modicon Quantum Hot Standby with Unity system. 9 Connection to the Unity Pro computer via Modbus or Modbus Plus /

54 Installation and Cabling Connecting Two identical Modicon Quantum Hot Standby with Unity Processors Handling Cable Connections If the cable is not connected properly, the Modicon Quantum Hot Standby with Unity processors cannot communicate, and the Hot Standby system will not function. Therefore, the Primary CPU operates without a backup, and the Standby CPU remains offline. Fiber optic cables are sold separately. Multi mode Models for 140CPU NOR NOR00005 VDIF Description 3 m MTRJ/ MTRJ 5 m MTRJ/ MTRJ 15 m MTRJ/ MTRJ Fiber optic cable are sold separately. Single mode Models for 140CPU NOL10005 Description 5 m LC / LC 140CPU67160 Controllers connected by a crossed fiber optic cable /2010

55 Installation and Cabling WARNING UNEXPECTED EQUIPMENT OPERATION Do not use hubs and switches as part of the fiber optic link. Failure to follow these instructions can result in death, serious injury, or equipment damage. Therefore, the fiber connection between Primary CPU and Standby CPU must be a direct cable connection, which reduces the components that could become inoperative in the redundant system. Connecting Two Backplanes However, the Primary CPU and Standby CPU backplanes may be placed as much as: 4 km (2.5 miles) for the 140 CPU km (10 miles) apart from the 140 CPU If the modules will be placing more than 15m apart, a fiber cable (see page 222) will be required: 62.5/125 micrometer multi mode fiber cable with MTRJ for the 140 CPU /125 micrometer single mode fiber cable with LC type connector for the 140CPU /

56 Installation and Cabling Connecting the Remote I/O Connecting Cables to Remote I/O In each configuration: The cables connecting the RIO head processors to the RIO network have to be fitted with self-terminating F adapters. An MA coaxial splitter has to be installed between the RIO head processors and the RIO network. The remote drops have to be connected to the trunk cable via an MA tap and a drop cable. The last tap on a trunk cable must be terminated with a trunk terminator. Remote drops do not have to be connected directly to the trunk cable. An optional Ground Block at the head will provide earth ground connection when the cable and RIO processor are disconnected. Ground blocks may also be used at other ground points along the trunk cable, as required. Refer to the Remote I/O Cable System Planning and Installation Guide, 890 USE for details. NOTE: Using a Remote I/O rack required at least one I/O module configured and present in the rack. NOTE: CABLING REQUIREMENTS: If you are using a Modicon Quantum Hot Standby with Unity system for data logging, the RIO heads have to be configured and connected with coaxial cable /2010

57 Installation and Cabling The following diagram shows the hardware required for the Remote I/O cabling. 1 Primary CPU controller 2 Standby CPU controller 3 Modicon Quantum RIO head 4 Modicon Quantum RIO drop (optional) 5 Coaxial cable (components shown with dashed lines are not mandatory) 6 Self-terminating F adapter 7 Splitter (MA ) 8 Tap (MA ) 9 Trunk Terminator ( ) NOTE: In a single-cable configuration, it is recommended to connect the cable in channel A on both Local I/O (CRP) and Remote I/O (CRA). NOTE: In a dual-cable configuration, it is mandatory to connect channel A from Local I/O (CRP) with channel A from Remote I/O (CRA) and channel B from Local I/O (CRP) with channel B from Remote I/O (CRA) /

58 Installation and Cabling Connecting over Long Distances If you intend to place the units more than 3 meters apart, you have to consider the effect on the RIO network and any Modbus Plus network. The controllers are linked to the RIO network by coaxial cable. The longer the distance between the controllers, the higher the grade of trunk cable required to maintain signal integrity. Refer to the Remote I/O Cable System Planning and Installation Guide, 890 USE for details regarding cable grades, distances, and signal integrity. If no coaxial cable will be sufficient to maintain signal integrity throughout the RIO network, fiber optic repeaters may be used to boost the signal. Refer to the Modbus Plus Network Planning and Installation Guide, UNY USE V10E for details on extending a Modbus Plus network. Connecting Hot Standby without RIO drop To connect Hot Standby without RIO drop select the option No RIO Drop in Hot Standby tab. When the No RIO drop option is selected in the Hot Standby tab of the "Processor configuration screen", no RIO drop must be physically connected to the RIO link. If an RIO drop is connected, the PLC goes into NO CONF state. The error A and error B leds of the RIO Head (CRP) indicate communication status between Head and Drop. When using CRP module with firmware version lower than 2.00, the leds indicate a detected error but this has no impact on communication between the two RIO head. In order to avoid a detected error on the leds A and B, it is mandatory to update the CRP module with a firmware 2.00 or higher (on both Primary and Standby side), the Quantum Hot Standby processor with a firmware 2.70 or higher (on both Primary and Standby side) and to install Unity Pro V4.1 or higher. The HotStandby processor V2.70 must be selected in the Unity Pro application and taken into account through a Rebuild All, before the full download in both PLCs /2010

59 Installation and Cabling Testing the Modicon Quantum Hot Standby with Unity System Testing Methods (First Time) Follow these steps to conduct tests to observe: Hot Standby start-up, automatic application program transfer, switchover of control from Primary CPU to Standby CPU. These tests are not necessary but helpful. If your racks are horizontally parallel and within 1 meter (3 feet) apart, the transfer process is easier to observe. Hot Standby Start-up and Application Program Transfer Follow these steps. Step Action 1 Configure two racks with identical hardware and firmware in identical order. 2 Connect to a Remote I/O (RIO) drop (see page 50) Note: Ensure that the fiber optic cable is connected between the controllers. 3 Start Unity Pro software and configure the local rack and the Remote I/O drop as per your physical configuration. 4 After completing Step 3, execute the Build Project command, and save your application program. 5 Power up and connect to one controller. Note: The front panel keypad will display No Conf. 6 Download your application program and RUN the controller. Note: The controller will become RUN Primary CPU. 7 Power up the other controller. Note: Application Program Transfer will occur automatically. The "other" controller will become RUN Standby CPU. 8 Ensure the Primary CPU and Standby CPU controllers are in RUN Primary CPU and RUN Standby CPU mode /

60 Installation and Cabling Preparing to Switchover After completing the preceding steps, your Modicon Quantum Hot Standby with Unity system is ready to perform a switchover. Perform the switchover using either: Hot Standby submenu on the front panel keypad, Command Register, system bit %SW60.1 or %SW60.2. NOTE: Observing the Switchover If you would like to observe a switchover effect on the I/O modules, configure the Remote I/O (RIO) drop with a discrete output module during your initial start-up. Before performing a switchover, connect to the Primary CPU and force the output bits in the module. Perform the switchover and take note of the bumpless switchover effect on the forced bits. Switchover Test Using Front Panel Keypad To force a switchover using the front panel keypad, do the following: Step Action 1 Access the front panel keypad of the Primary CPU controller. 2 Go to PLC Operation menu. 3 Go to Hot Standby submenu. 4 Go to Hot Standby mode 5 Modify Run to Offline. Note: Ensure that Standby CPU switched to Primary CPU. 6 Modify offline to run. Note: Ensure that the LCD displays Run Standby CPU. Switchover Test Using Command Register Follow these steps. Step Action 1 Connect to the Primary CPU. 2 Observe whether the controller order on the Primary CPU is A or B using either of the following methods: Front panel keypad of the Primary CPU PLC Operation Hot Standby Hot Standby Order Unity Pro status dialog Refer to the bottom of the Unity Pro window when connected online 3 Access the Command Register system bit %SW60.1 (If the connected Primary CPU order is A.) %SW60.2 (If the connected Primary CPU order is B.) /2010

61 Installation and Cabling Step Action 4 Set bit to 0. NOTE: Ensure that the Standby CPU switched to Primary CPU NOTE: If bits %SW60.1 and %SW60.2 are set to 0 simultaneously, a switchover occurs: the Primary CPU controller goes RUN offline, and the Standby CPU controller now operates as RUN Primary CPU. 5 Connect to the new Primary CPU. 6 Access the Command Register system bit. Choose the same bit selected in Step 3. 7 Set bit to 1. NOTE: Ensure Standby CPU displays RUN Standby CPU. 8 Ensure the Primary CPU and Standby CPU controllers are in RUN Primary CPU and RUN Standby CPU mode. Restarting recommendation Powering methods (Warm Start). After a global power failure while system was running, the two CPU synchronize each other at power up (primary PLC selection). To insure synchronization at power recovery, 2 methods are proposed: The two PLCs must be powered at the same time (at least within 500 ms). NOTE: In this case, the CPU with lower MAC address starts as Primary. The two PLCs must be powered one after the other with a minimum delay of 2 seconds. NOTE: This second solution allows user to select which CPU will become Primary (the first that is powered up) /

62 Installation and Cabling /2010

63 Configuring a Modicon Quantum Hot Standby with Unity System /2010 Configuring a Modicon Quantum Hot Standby with Unity System 5 Overview This chapter describes how to configure the Modicon Quantum Hot Standby with Unity 140 CPU , 140 CPU and 140 CPU S modules. NOTE: The configuration of these three modules (140 CPU , 140 CPU and 140 CPU S) is similar except for the following differences: The safety module does not use unlocated data and variables. The safety module has a Safe/Maintenance mode. What's in this Chapter? This chapter contains the following sections: Section Topic Page 5.1 Configuring a System with the Unity Pro Tabs and Dialogs Configuring Registers with Unity Pro Configuring a NOE with Unity Pro /

64 Configuring a Modicon Quantum Hot Standby with Unity System 5.1 Configuring a System with the Unity Pro Tabs and Dialogs Purpose Use the Unity Pro editor dialog tabs to: 1. select options for configuring the Modicon Quantum Hot Standby with Unity 140 CPU /60S, 2. obtain system status information. This material describes how you can: Processor Configuration Screen, page 66, including Modbus Ports and HSBY, Configuring with Unity Pro, page 83, Configuring with Unity Pro, page 84. What's in this Section? This section contains the following topics: Topic Page Introducing Unity Pro 65 Processor Configuration Screen 66 Using the Summary Tab 67 Using the Overview Tab 68 Using the Configuration Tab 69 Using the Modbus Port Tab 75 Using the Animation Tab and PLC Screen Dialogs 77 Using the Hot Standby Tab 81 Configuring the PCMCIA Cards 83 Configuring the Modbus Plus Communication Type 84 Adjustment of the Drop Hold-Up Time Value 85 Setting the Invalidate Keypad Option 86 Swapping Network Addresses at Switchover /2010

65 Configuring a Modicon Quantum Hot Standby with Unity System Introducing Unity Pro Overview Unity Pro software is a fully Windows compatible application. Unity Pro supports only the IEC method of configuration. No Loadables Needed Unlike legacy Modicon Quantum where the CHS module owns the control functionality, the Unity Pro Modicon Quantum Hot Standby with Unity systems has the control functionality embedded in the executive. Command Register The Command Register defines the basic operational parameters of a Modicon Quantum Hot Standby with Unity solution. The command register s functionality is described in Understanding the Unity Command Register, page 95. Opening the Editor Dialog After starting Unity Pro, go to the Local Bus in the Structural View of the Project Browser. Step Action 1 Open the Local configuration editor either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open A graphical representation of the local bus appears in the configuration editor. 2 Select the Modicon Quantum Hot Standby with Unity 140 CPU /60S module and right-click. The context menu appears. 3 Select Open Module. 4 The editor appears. The Summary tab is the default /

66 Configuring a Modicon Quantum Hot Standby with Unity System Processor Configuration Screen Accessing with Unity Pro After starting Unity Pro, go to the Local Bus in the Structural View of the Project Browser. Step Action 1 Double-click on Local Bus to open the Local Bus configuration editor. 2 Select the CPU module and right-click. The context menu appears. 3 Select Open Module. The editor appears. 4 Choose one of these tabs: Overview Summary Configuration Quantum / (see Unity Pro, Operating Modes, ) Configuration Quantum Hot Standby PLCs / (see page 69) Configuration Quantum Safety PLCs (see Unity Pro XLS Software, Operating Mode Manual, Safety PLC Specifics) Modbus Port Quantum / (see Unity Pro, Operating Modes, ) Modbus Port Quantum Hot Standby PLCs / (see page 75) Modbus Quantum Safety PLCs (see Unity Pro, Operating Modes, ) Animation Port Quantum / (see Unity Pro, Operating Modes, ) Animation Port Quantum Hot Standby PLCs / (see page 77) Animation Quantum Safety PLCs (see Unity Pro XLS Software, Operating Mode Manual, Safety PLC Specifics) Hot Standby Faults I/O Objects NOTE: %MWi will reset with the cold start %S0 or a loading program. Cold start is typically after a program load, %S0 can be set with the user program to initiate a cold start /2010

67 Configuring a Modicon Quantum Hot Standby with Unity System Using the Summary Tab Viewing Use the Summary tab of the Unity Pro editor to determine if Peer Cop and Hot Standby are enabled. Describing Summary tab: Item Option Value Description CPU Name/Model: Quantum CPU N/A Read Only Peer Cop: Disabled Enabled Read Only Peer Cop="Enabled" if the function is valid in the Modbus Plus menu Hot Standby: Enabled Enabled Read Only /

68 Configuring a Modicon Quantum Hot Standby with Unity System Using the Overview Tab Viewing The read only Overview tab of the editor displays detailed information about the module s specifications /2010

69 Configuring a Modicon Quantum Hot Standby with Unity System Using the Configuration Tab Configuration Screen Change values using the Configuration tab of the editor. NOTE: The online modif in RUN function cannot be selected in the same time as the No Rio drop function which is located in the Hot Standby tab Description Configuration tab: Item Option Value Description Operating Mode On Automatic start in Run x Determines the operating Cold Start %MWi Reset on cold start x condition during Cold Start Cold Start Only x If you wish, enable the Cold Start Only (see page 72) feature. Memory Cards A: N/A Displays the configuration in B: N/A the PCMCIA Slots /

70 Configuring a Modicon Quantum Hot Standby with Unity System Item Option Value Description Communication By default, the bandwidth is 4x256 bytes, supported by the OS versions prior to V2.80 for the CPU and V4.60 for the NOE. For Quantum processors: 140 CPU CPU CPU For Quantum processors: 140 CPU CPU CPU CPU CPU x256 4x1024 4x256 4x1024 8x x1024 The maximum data volume exchanged each cycle between the NOE and CPU modules. State RAM Mem usage 1. A bar displays percent of memory used. %M-0x 2. Size of the different memory %MW-4x 2. areas Note: The values for %IW %I-1x 2. and %MW have to be divisible %IW-3x 2. by 8. Viewer N/A Opens the State RAM Viewer tab, which displays the allocation of used memory. (See the illustration following.) Configuration Online Modification Online modif in RUN x This check box allows to: Add or delete discrete or analog modules, Modify Parameters NOTE: These modifications can be done in RUN. 1. The value (expressed as a percentage and displayed on the scale) depends on the memory usage of the Hot Standby configuration. 2. Enter the appropriate values. All values depend on Hot Standby configuration /2010

71 Configuring a Modicon Quantum Hot Standby with Unity System Automatic start in RUN The enabling of this option automatically changes the PLC to Run mode (see Unity Pro, Program Languages and Structure, Reference Manual )on cold start. Two types of start: in the absence of a PCMCIA memory card, the PLC starts on the contents of the internal RAM of the processor, in the presence of a PCMCIA memory card it is its content which fixes the start. WARNING UNWANTED APPLICATION RUN ON PLC COLD START With the Automatic start in RUN option enabled, the following events will trigger the run of the application on cold start: Inserting the PCMCIA card when the PLC is powered Replacing the processor while powered Unintentional or careless use of the reset button Powering up a PLC with a defective battery after a power outage To prevent the run of the application on cold start: use the STOP input (on Premium PLCs) use the switch on the front panel of the processor (for Quantum PLCs) Failure to follow these instructions can result in death, serious injury, or equipment damage. %MWi Reset On application download: if you check the box, the %MWi values will be re initialized or set to 0, if you uncheck the box, the %MWi values will set to 0. On cold start or after inserting the PCMCIA memory card: if you check the box, the %MWi values will be re initialized or set to 0, if you uncheck the box, the %MWi values will retain their current value /

72 Configuring a Modicon Quantum Hot Standby with Unity System Cold Start Only If checked, this option forces the cold start (see Unity Pro, Program Languages and Structure, Reference Manual ) of the application, instead of the normal warm start (see Unity Pro, Program Languages and Structure, Reference Manual ). By default, the Cold Start Only option is unchecked. The Cold Start Only option is only supported on High End PLC since V2.7. An application using this functionality will not be: downloadable on a PLC with a previous version, executable on a PLC with a previous version, usable with Unity Pro V4.0 or lower. NOTE: The Cold Start Only check box is present only if the current selected PLC can support it. Communication When the UNITY protocol under TCP/IP is used (OFS or Unity Pro), it is possible to configure the maximum volume of data that can be exchanged each cycle between the CPU and the NOE modules using the Maximum Unity Data exchanged by Plc Scan option. This functionality is only supported on CPU modules with OS version 2.80 or higher, and on NOE modules with OS version 4.60 or higher. The bandwidth set is valid between the CPU and all existing NOE modules. It is not possible to set different bandwidths for each of the modules. Increasing this bandwidth has an impact on the cycle time of the controller (2ms per kbytes exchanged). This impact is proportional to the amount of data actually exchanged and not the bandwidth configured. So, if the channel is set to the maximum, but not used, the impact on cycle time will be negligible. State RAM memory The State RAM bar chart allows you to know the size of the State RAM memory used in your project in relation to the maximum memory size /2010

73 Configuring a Modicon Quantum Hot Standby with Unity System Using the State RAM Viewer The State RAM Viewer dialog Each cell in the grid represents an address location and displays the entity stored in that location. The contents of the grid may be changed by selecting options in either of two filters: 1. Memory used grid options Select one or all of the three options (using the check box) and one to three bar graphs appear. Modules Indicates the topological address used in the modules. Address appears as a bar graph in the grid. Language Indicates the topological address used in the program. Address appears as a bar graph in the grid. Variables Indicates the topological address used in the variables. Address appears as a bar graph /

74 Configuring a Modicon Quantum Hot Standby with Unity System 2. Memory Area options Using this option, you designate a state RAM address. Select one of four reference types. %M %I %IW %MW Your choice appears in the Address field of the Address Information area. Online Configuration Modification On PLCs supporting this functionality a check box is activated and appears in the CPU Editor (see page 69). The Configuration Online modification is only available on certain types of PLCs (see Unity Pro, Operating Modes, ). If the online modif in RUN check box is selected /2010

75 Configuring a Modicon Quantum Hot Standby with Unity System Using the Modbus Port Tab Viewing You may change Modbus communication options using the Modbus Port tab of the Unity Pro editor: NOTE: FINDING MODBUS ADDRESS If you need the Modbus address of the controller, go to the 140 CPU module and find the address using the keypad. (see page 241) /

76 Configuring a Modicon Quantum Hot Standby with Unity System Describing Modbus Port tab: Item Option Value Description Modbus Port Baud 9600 Data must be specified for kbit/s every link. Data Bits 8 Stop Bits 1 or 2 Parity EVEN ODD NONE Delay (ms) 10 ms Address for Modbus switchover (Primary CPU) (Standby CPU) Head Slot 0 Mode RTU ASCII Protocol RS232 RS /2010

77 Configuring a Modicon Quantum Hot Standby with Unity System Using the Animation Tab and PLC Screen Dialogs Accessing the PLC Screen Dialogs To access the Task, Realtime clock, and Information tabs of the Unity Pro Animation tab, Step Action 1 Select the Animation tab. 2 The PLC screen tab appears automatically. NOTE: The dialogs illustrated here are depicted in offline mode. When Unity Pro is connected to a PLC, the information displayed in these tabs changes. Viewing the Task Tab Unity Pro Task tab dialog: NOTE: Click to see the PLC screen in online mode (see Unity Pro, Operating Modes, ) and the corresponding description (see Unity Pro, Operating Modes, ) /

78 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Task Tab Description of the Task tab: Item Option Value Description Events State: xxx Status information of events available Online Number: xxx N/A Activate or Disable all Click button Button to control the events Start/reStart Warm Start Click button To initialize Warm Start Cold Start Click button To initialize Cold Start Output fallback Applied Outputs N/A Not used in Modicon Output Fallback N/A Quantum Hot Standby with Unity system Last Stop Read only Day DD/MM/YY Time Indicates the day, date, time, and cause of the last controller stop Viewing the Realtime Clock Tab Unity Pro Realtime clock tab dialog: /2010

79 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Realtime Clock Tab Description of the Realtime clock tab: Item Option Description PLC Date and Time Read only Indicates the current PLC date and time PC Date and Time Update PC->PLC Updates the PLC with the PC system time User Date and Time Update User->PLC Updates the PLC with the time set by the user Viewing the Information Tab Unity Pro Information tab dialog: /

80 Configuring a Modicon Quantum Hot Standby with Unity System Describing the Information Tab Description of the Information tab: Item Option Value Description System Information PLC / Identification PLC Range Only Online Processor Name Processor Version Hardware ID Network address available PLC / Memory RAM CPU Application / Identification Name Creation Product Date Modification Product Date Version Signature Application / Option Upload Information Comments Animation Table Section Protection Application Diagnostic Application / Miscellaneous Forced Bits Hot Standby PLC Hot Standby Status Peer PLC Hot Standby Status application mismatch between PLC and Peer PLC PLC Name Variable Transfer Status Hot Standby Entire System State /2010

81 Configuring a Modicon Quantum Hot Standby with Unity System Using the Hot Standby Tab Viewing the Hot Standby Tab Configure Hot Standby values in the Hot Standby tab of the Unity Pro editor: /

82 Configuring a Modicon Quantum Hot Standby with Unity System Hot Standby Tab Description Description of the Hot Standby tab: Item Option Value Description Run Mode Controller A Offline/Online Indicates which controller will Controller B Offline/Online be offline and online at the next start. Invalidate Keypad Disable Yes is NOT selected Standby On application mismatch Swap Address At Switchover State RAM: Non- Transfer Area HSBY Configuration Option On RIO Bus Behaviour of the CPU in Run Offline mode Enable Offline Online Modbus Port 1 Yes is selected (Check mark displays) Default Offline button selected Default Online button not selected Default All selected When selected, you prevent keypad changes to the Hot Standby submenu. If mismatch is detected, Standby goes Offline If button is selected and mismatch is detected, Standby remains Standby When selected, enables Modbus switchover to occur. Start: %MW 1. %MW is not transferred. Length: 1. Specify the range of the length. At least one drop Default selected One or more RIO configured and monitored. No RIO drop Default not selected No RIO drop installed. When selected no RIO drop must be physically connected to the RIO link. If an RIO drop is connected, the PLC goes into NO CONF state. All sections Default Regarding the option First section No section at all selected, the CPU will or will not execute the program when CPU is in Run Offline mode. 1. Enter the appropriate values. All values depend on Hot Standby configuration /2010

83 Configuring a Modicon Quantum Hot Standby with Unity System Configuring the PCMCIA Cards Configuring with Unity Pro Allocating memory to the memory card Step Action 1 If not opened, open the Local Bus configuration editor. 2 Go to the local bus in the Structural View of the Project Browser. 3 Open the local bus either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open. A graphical representation of the local bus appears. 4 Point to and select either PC CardA (1 slot) or PC CardB (2 slot). 1 Memory configuration of the PCMCIA card 1 2 Memory configuration of the PCMCIA card 2 5 Double-click or right-click either PCMCIA card. The New/Replace Submodule dialog appears. 6 Add or replace the desired memory /

84 Configuring a Modicon Quantum Hot Standby with Unity System Configuring the Modbus Plus Communication Type Configuring with Unity Pro Configuring the Modbus Plus communication type Step Action 1 If not opened, open the Local Bus configuration editor. 2 Go to the local bus in the Structural View of the Project Browser. 3 Open the Local Bus editor either by double-clicking on the Local Bus or by selecting the Local Bus and executing right-click Open. A graphical representation of the local bus appears. 4 Point to the Modbus Plus port, No Double-click or right-click on the Modbus Plus port. The Submodule dialog appears. The General tab is default. 6 Select one or both Communication Type: DIO bus Peer Cop /2010

85 Configuring a Modicon Quantum Hot Standby with Unity System Adjustment of the Drop Hold-Up Time Value Modification of the Default Value The hold-up time value must be modified to 1200 ms minimum when a 140CPU67160 Quantum processor is used in a Hot Standby configuration ( therefore the default value, 300 ms, must be changed) WARNING UNEXPECTED EQUIPMENT OPERATION The Drop hold-up time must be set to at least twice the mast task watchdog. Failure to follow these instructions can result in death, serious injury, or equipment damage. How to Configure The following table describes the procedure to change the hold-up time value. Step Action 1 Create a RIO bus with the 140CPU67160 Quantum processor and the 140CRP93x00 communication module. 2 Add a rack on RIO bus with the 140CRA93x00 communication module. 3 Open the Remote IO Quantum Drop and change the Drop hold-up time /

86 Configuring a Modicon Quantum Hot Standby with Unity System Setting the Invalidate Keypad Option Overview The keypad is located on the front panel of the Modicon Quantum Hot Standby with Unity 140 CPU /60S modules. Setting the Invalidate Keypad option can disable the Hot Standby submenu (PLC Operations Hot Standby). (see page 241) When the Invalidate Keypad option is selected, the Hot Standby submenu is read only. You may choose to prevent access to the Hot Standby control through the keypad to avoid the possibility of accidental (or malicious) state changing, for security or convenience. Methods for Selecting the Invalidate Keypad Option There are two methods for selecting/enabling this option: Method Used Hot Standby tab Description Select the Invalidate Keypad option in the Hot Standby tab using the Unity Pro software. (see page 81) Selecting the Invalidate Keypad option requires that the application program be downloaded to the CPU. Command Register Set the system bit %SW60.0 to 1. Selecting the system bit %SW60.0 must be performed online in the Primary CPU controller. NOTE: By setting the Invalidate Keypad option, the Run/Stop PLC control option on the PLC Operation menu is NOT disabled /2010

87 Configuring a Modicon Quantum Hot Standby with Unity System Disabling Options When the Invalidate Keypad option has been set, two Hot Standby options/controls are disabled using the front panel keypad: Changing the HSBY mode (Run/Offline), Command an application program transfer to Standby. NOTE: CHANGING FROM LEGACY In the legacy Quantum Hot Standby system, setting command register bit 16 affects both the mode (offline or run) of controllers A and B and affects the state of bit 14 and bit 15. Bit 16 set to 0 disables (overrides) Command Register bit 14 and bit 15 state, enables key switch state. Bit 16 set to 1 enables Command Register bit 14 and bit 15 state, disables key switch state. In Unity, The state/condition of system bit %SW60.0 ONLY disables/enables the Hot Standby submenu option in the front panel keypad. Setting system bit %SW60.0 does NOT affect the state of system bits %SW60.1 and %SW60.2. Regardless of the setting for system bit %SW60.0, system bits %SW60.1 and %SW60.2 control the mode (offline or run) of controllers A and B. (see page 95) /

88 Configuring a Modicon Quantum Hot Standby with Unity System Swapping Network Addresses at Switchover Overview The following material describes handling network addresses at Switchover. A Modicon Quantum Hot Standby with Unity system can communicate data over different network protocols: Modbus Modbus Plus TCP/IP WARNING UNEXPECTED EQUIPMENT OPERATION In Hot Standby applications, correct address assignment must be fulfilled for proper operation of network address swap at switchover. In particular, offset address must not be assigned to another device than the peered PLC of the Hot standby system. Failure to follow these instructions can result in death, serious injury, or equipment damage. Handling Modbus Addresses at Switchover In a Modicon Quantum Hot Standby with Unity system, the Modbus port addresses are: Primary CPU: Standby CPU: Offset +128 Maximum address: 247 Range The Modbus port addresses can be changed using one of two methods: Communication menu in the front panel keypad, Modbus Port tab in the Unity Pro editor /2010

89 Configuring a Modicon Quantum Hot Standby with Unity System Changing addresses: Using the Communication menu in the Front Panel Keypad Change address on either Primary CPU 1. Access the front panel keypad of the Primary CPU. 2. Go to Communication menu 3. Go to Serial Port submenu 4. Select address 5. Change address 6. Perform application program transfer 7. Verify Standby CPU Modbus address is Standby CPU 1. Access the front panel keypad of the Standby CPU. 2. Go to Communication menu 3. Go to Serial Port submenu 4. Select address 5. Change address 6. Perform switchover 7. Ensure Standby CPU switched to Primary CPU 8. Perform application program transfer 9. Verify Standby CPU Modbus address is +128 Using the Modbus Port Tab in Unity Pro Editor To change address, download application program. (see page 153) Note: If the Modbus address is changed in the Primary CPU using the front panel keypad, ensure that application program transfer is made to enable the corresponding Modbus switchover in the Standby CPU. NOTE: CHANGING FROM LEGACY In a Modicon Quantum Hot Standby with Unity system only one port is available for Modbus. By default address swap at switchover is maintained between the Primary CPU and Standby CPU Modbus ports. This default condition can be changed using the following two methods: Using Hot Standby menu in the Unity Pro editor. This choice requires the application program to be downloaded. Using the Command Register system bit %SW60.8. This choice MUST be performed online in the Primary CPU /

90 Configuring a Modicon Quantum Hot Standby with Unity System Selecting/deselecting address swap at Switchover Using Hot Standby Menu in Editor 1. Open Hot Standby menu in Unity Pro. 2. Go to Swap Address at Switchover area. 3. Deselect Modbus Port Verify modifications. 5. Download application program to controller. (see page 153) 6. Perform switchover. 7. Ensure Standby CPU switch to Primary CPU. 8. Perform application program transfer. Using the Command Register system bit %SW Connect to Primary CPU 2. Access the Command Register System bit %SW Set bit to 1 Default is 0 Swap Modbus Addresses at Switchover If controller A is the Primary CPU controller and its Modbus port has an address of 1, then the default addresses for the comparable port on controller B, the Standby CPU, is 129, which is 1 plus the offset of 128. If controller B becomes the Primary CPU controller as the result of a switchover, its Modbus port assumes the address of 1, and the comparable port on controller A assumes the address of 129. No Swap Modbus Addresses at Switchover If controller A is the Primary CPU controller and its Modbus port 1 address is 1, then that port address remains at 1 after the switchover occurs. Likewise, if controller B becomes the Primary CPU controller as a result of a switchover, its Modbus port 1 address is remains at 1. NOTE: 1. If you change the options, the port addresses are not affected until a switchover occurs. 2. If NOM modules are used in the configuration, the offset of the Modbus address is +/-32 following the Modbus Plus address switchover. Handling Modbus Plus Addresses at Switchover In a Modicon Quantum Hot Standby with Unity system, the Modbus Plus port addresses on the Standby CPU controller are offset +/-32 from the comparable ports on the Primary CPU controller /2010

91 Configuring a Modicon Quantum Hot Standby with Unity System Modbus Plus address swap behavior at switchover Default Behavior at Switchover Controller A = Primary CPU MB+ address = 1 Controller B = Standby CPU MB+ address = 33 (1 +32) (+32 = Offset) Switchover occurs. Controller A = new Standby CPU MB+ address = 33 (1 +32) Controller B = new Primary CPU MB+ address = 1 NOTE: Numerical address of both ports (A and B) range: If Primary CPU address = 50, corresponding Standby CPU = 18 (50-32) The Modbus Plus address of the controllers can be changed using the front panel keypad: Communication Modbus Plus Modify Address NOTE: The Modbus Plus port will be inactive for about 10 seconds after the RUN standby CPU state is shown on the LCD display. Modbus Plus address swap behavior when addressed is changed Forced Behavior at Switchover Controller A = Primary CPU MB+ address = 1 Controller B = Standby CPU MB+ address = 33 (1 +32) (+32 = Offset) Change address of Primary CPU = 5. Controller A = Primary CPU MB+ address = 5 Controller B = Standby CPU MB+ address = 33 Perform Application Program Transfer. Controller A = Primary CPU MB+ address = 5 Controller B = Standby CPU MB+ address = 37 (5 +32) Force switchover /

92 Configuring a Modicon Quantum Hot Standby with Unity System Forced Behavior at Switchover Controller A = new Standby CPU MB+ address = 37 (5 +32) Controller B = new Primary CPU MB+ address = 5 If he Modbus Plus address is modified, perform an Application Program Transfer. (see page 161) Failure to perform a transfer creates a different offset address in the Standby CPU. NOTE: SWAPPING ADDRESSES At switchover, the Modicon Quantum Hot Standby with Unity system and NOMs swap Modbus Plus addresses almost instantaneously (within one or two milliseconds). This almost instantaneous switchover means that host devices which are polling the controller should be talking to the Primary CPU controller and that the network should have minimal network interruption during switchover. NOTE: EXEC UPGRADE USING OSLOADER When using Modbus Plus communication and OSLoader, only address 1 is valid. (see page 139) Handling TCP/IP Addresses at Switchover When used in a Modicon Quantum Hot Standby with Unity system, the Modicon Quantum Ethernet TCP/IP network option modules NOE and 11 support address swapping at switchover. The swapping of IP addresses behaves much like the address swap of the Modbus Plus ports, except that the offset is 1 instead of 32. At switchover, the modules exchange their IP addresses. NOE 771 address swapping occurs automatically and can not be controlled by options selected in any of the tabs of the editor or controlled by turning ON/OFF any of the bits in the command register. All standard rules apply to IP addressing with the additional restriction that the IP address cannot be greater than 253 or the broadcast address minus 2. Also, no other device should be assigned the configured IP +1 address. NOTE: NOE and 11 ADDRESS SWAP: NOE and 11 are the only Ethernet option modules that support the IP address swap in Modicon Quantum Hot Standby with Unity system V2.0. NOE and 11 modules must be configured in the same slot of the Primary CPU and Standby CPU backplanes. NOE , 11 requires minimum firmware revision 2.0 or higher /2010

93 Configuring a Modicon Quantum Hot Standby with Unity System 5.2 Configuring Registers with Unity Pro Purpose This material describes the configuration of a Modicon Quantum Hot Standby with Unity system by selecting options that affect the registers. You may want to use this method if your system has specific configuration needs. What's in this Section? This section contains the following topics: Topic Understanding the Non-Transfer Area, Transferring State RAM, and Reverse Transfer Words Understanding the Unity Command Register 95 Understanding the Unity Status Register 99 Transferring User Data 102 Using Initialized Data 103 Synchronizing Time-of-Day Clocks 104 Page /

94 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Non-Transfer Area, Transferring State RAM, and Reverse Transfer Words Designating a Non-Transfer Area Using the Hot Standby tab of the editor dialog, you may designate a block of %MW words as a Non-Transfer area. Step Action 1 Ensure that the Hot Standby tab is selected. If you want to review the process for starting Unity Pro and opening the editor dialog, please see Processor Configuration Screen, page Enter the starting address in the system word field, %MW. The field is located in the Non-Transfer Area of the Hot Standby tab. 3 Enter the number of contiguous registers in the Length: field. The field is located in the Non-Transfer Area of the Hot Standby tab. Non-Transfer Area of State RAM The designated registers will be ignored when state RAM values are transferred from the Primary CPU controller to the Standby CPU. Placing registers in the Non- Transfer Area is one way to reduce scan time. NOTE: With the hardware design of the Modicon Quantum Hot Standby CPU with Unity processors, the scan time optimization provided by the Non-Transfer area may be very low. Transferring Data to the Primary CPU The system words,%sw62/63/64/65 are dedicated to transfer data from the Standby CPU controller to the Primary CPU. These system words can be used by the application program (in the first section) to register diagnostic information. The data coming from the Standby CPU are transferred at each scan and are available to the Primary CPU /2010

95 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Unity Command Register Setting the Bits in the Command Register The Command Register defines the operating parameters of a Hot Standby application for both the Primary CPU and Standby CPU and is located at system word %SW60. At each scan, the Command Register is replicated and transfers data from the Primary CPU to the Standby CPU. Transfer occurs only from Primary CPU to Standby CPU. Any changes made to the Command Register on the Standby CPU will have no effect because the values transferred from the Primary CPU overwrite the values in the Standby CPU. The following illustration identifies the operating options provided by the Command Register: System Word %SW60.0 Invalidate Keypad (see page 86) is an option that allows a controller to accept or refuse commands from the Hot Standby submenu in the front panel keypad. %SW60.0 = 1 Invalidate Keypad enabled. The Modicon Quantum Hot Standby with Unity system refuses all changes from the Hot Standby submenu in the front panel keypad. %SW60.0 = 0 Invalidate Keypad disabled. The Modicon Quantum Hot Standby with Unity system accepts all changes from the Hot Standby submenu in the front panel keypad /

96 Configuring a Modicon Quantum Hot Standby with Unity System System Word %SW60.1 Controller A OFFLINE/ONLINE mode %SW60.1 = 1 Controller A goes to Online mode. %SW60.1 = 0 Controller A goes to Offline mode. System Word %SW60.2 Controller B OFFLINE/ONLINE mode %SW60.2 = 1 Controller B goes to Online mode. %SW60.2 = 0 Controller B goes to Offline mode. NOTE: The Primary CPU controller goes to RUN Offline only if the secondary CPU is RUN Standby. At Startup of the Secondary PLC, the secondary CPU goes to Online mode (RUN Standby) only if both bits %SW60.1 and %SW60.2 are set to 1 (regardless of A/B assignment). If bits %SW60.1 and %SW60.2 are set to 0 simultaneously, a switchover occurs: the Primary CPU controller goes RUN Offline, and, the Standby CPU controller now operates as RUN Primary CPU. To complete the switchover, bits %SW60.1 and %SW60.2 must be set back to 1. This makes the Offline CPU going back to Online mode (Run Standby). The OFFLINE/ONLINE mode controlled by the %SW60.1 and %SW60.2 bits is not linked to the LCD Keypad ONLINE/OFFLINE mode (see page 243). System Word %SW60.3 Application mismatch (see page 143) %SW60.3 = 0 If a Application mismatch is detected, Standby CPU forced to Offline mode. %SW60.3 = 1 Standby CPU operates normally even if a mismatch occurs /2010

97 Configuring a Modicon Quantum Hot Standby with Unity System System Word %SW60.4 EXEC upgrade %SW60.4 = 1 Allows the executive to be upgraded on the Standby CPU and the Primary CPU continues to control the process. %SW60.4 = 0 Allows the executive to be upgraded and to stop the Primary CPU s control of the process. Upgrading allows a Hot Standby system to operate with different versions of the OS running on the Primary CPU and Standby CPU upgrades without shutting down the process To perform the executive upgrade (see page 137), the Standby CPU must be stopped. When started again, the Standby CPU operates as a valid Standby CPU. System Word %SW60.5 Commands Standby CPU to initiate an application transfer. %SW60.5 = 1 means Standby CPU requests an application program transfer from Primary CPU %SW60.5 = 0 is default and no transfer occurs NOTE: %SW60.5 is a Monitor Bit. %SW60.5 monitors an action. Once the action occurs, %SW60.5 returns to the default, which is zero (0). NOTE: In the case of Online application mismatch selected, the HSBY system needs 2 seconds to check the consistency of the application and the detection of application mismatch (%SW61.4). Therefore the request for application transfer (%SW60.5) has to be done with a minimum delay of 2 seconds after any modification of the application. WARNING UNEXPECTED BEHAVIOR OF APPLICATION When the Online application mismatch option is selected, a request for application transfer (%SW60.5) has to be done with a minimum delay of 2 seconds after any modification of the application. Failure to follow these instructions can result in death, serious injury, or equipment damage /

98 Configuring a Modicon Quantum Hot Standby with Unity System System Word %SW60.8 Swap Modbus on port 1 %SW60.8 = 1 Swaps Modbus addresses on port 1when a switchover occurs. Note: In a Modicon Quantum Hot Standby with Unity system only Modbus port 1 is available for use. System Word %SW60.9 Swap Modbus on port 2 %SW60.9 = 0 address switch on Modbus port 2 during a primary CPU swap. %SW60.9 = 1 no address switch on Modbus port 2 during a primary CPU swap. System Word %SW60.10 Swap Modbus on port 3 %SW60.9 = 0 address switch on Modbus port 3 during a primary CPU swap. %SW60.9 = 1 no address switch on Modbus port 3 during a primary CPU swap /2010

99 Configuring a Modicon Quantum Hot Standby with Unity System Understanding the Unity Status Register Bits in the Hot Standby Status Register The Hot Standby Status Register is a readable register located at system word %SW61 and is used to monitor the current machine status of the Primary CPU and Standby CPU. Both the Primary CPU and the Standby/Offline CPU have their own copy of the Status register. The Status register is not transferred from Primary CPU to Standby CPU. Each PLC must maintain its local Status Register based on the regular communication between the two controllers. The following illustration identifies the operating options provided by the Status Register /

100 Configuring a Modicon Quantum Hot Standby with Unity System System Words %SW61.0 to %SW61.3 These four bits display the states of the local and remote Hot Standby controllers. Status of local PLC %SW61.1 = 0 and %SW61.0 = 1 mean the local PLC is in OFFLINE mode. %SW61.1 = 1 and %SW61.0 = 0 mean the local PLC is running in Primary CPU mode. %SW61.1 = 1 and %SW61.0 = 1 means the local PLC is running in Standby CPU mode. Status of remote PLC %SW61.3 = 0 and %SW61.2 = 1mean the remote PLC is in OFFLINE mode %SW61.3 = 1 and %SW61.2 = 0 mean the remote PLC is running in Primary CPU mode. %SW61.3 = 1 and %SW61.2 = 1 mean the remote PLC is running in Standby CPU mode. %SW61.3 = 0 and %SW61.2 = 0 mean the remote PLC is not accessible (Power off, no communication) System Word %SW61.4 %SW61.4 is set = 1 whenever a application mismatch is detected between the Primary CPU and Standby CPU controllers. %SW61.4 depends on %SW60.3 (Command Register) set = 1. System Word %SW61.5 %SW61.5 identifies the Order reported by the Copro at start time. The order depends on the range of the MAC addresses. If the A/B designation is A, then bit 5 will be set = 0. If the A/B designation is B, then bit 5 will be set = 1. NOTE: On controller LCD displays A. B. System Word %SW61.6 %SW61.6 indicates if the CPU-sync link between the two PLCs is valid. If %SW61.6 is set to 0, the CPU-sync link is operating properly. The content of bit 5 is significant. If %SW61.6 is set to 1, the CPU-sync link is not operating properly. In this case, the contents of bit 5 are not significant because the comparison of the two MAC addresses cannot be performed /2010

101 Configuring a Modicon Quantum Hot Standby with Unity System System Word %SW61.7 If %SW61.7 is set to 0, the two PLC have the same Operation System version. If %SW61.7 is set to 1, the two PLC have a different Operation System version. System Word %SW61.8 If %SW61.8 is set to 0, the two Copro have the same Operation System version. If %SW61.8 is set to 1, the two Copro have a different Operation System version. System Word %SW61.12 and 13 If %SW61.12 is set to 1, the %SW61.13 indicates the value of the address taken by the NOE: If %SW61.13 is set to 1, address is IP+1. If %SW61.13 is set to 0, address is IP. If %SW61.12 is set to 0, %SW61.13 is not relevant. System Word %SW61.15 If %SW61.15 is set = 1, the setting indicates that the Copro device is set up correctly and working /

102 Configuring a Modicon Quantum Hot Standby with Unity System Transferring User Data General At each scan in a redundant system the Primary CPU must send its data to the Standby CPU in order to keep it ready to assume the role of Primary CPU if the need arises. Variables, Instances, Bits, Words The user data that will be transferred includes: Located variables (in state RAM) All unlocated variables (for the 140 CPU module only) All instances of DFB and EFB data SFC states (for the 140 CPU module only) System Bits and Words /2010

103 Configuring a Modicon Quantum Hot Standby with Unity System Using Initialized Data Loading at Cold-start Time The Modicon Quantum Hot Standby with Unity 140 CPU /60S supports initialized data. Initialized data allows you to specify initial values for the data that are to be loaded at cold-start time. Declare the variables before a cold start. Updating Online In addition to declaring values before a cold start, you can update the initial values online. Updating the initial values online creates a mismatch situation in a redundant system. NOTE: Add a configuration change on the fly is possible only if a new version of CRP (140 CRP 9 module) and CRA (140 CRA 2 module) firmware is provided Handling Problems at Switchover Updating the initial values online presents a problem: if a switchover occurs to the non-updated PLC, then you execute a cold-start, the older initial values will be used. NOTE: WINDOW OF TIME Pay attention to the fact that there is a window of time during which a mismatch can occur. Mismatches may cause inconsistent operations. Solving Mismatch Problems However, application mismatches cause the same problems. Thus, value mismatches will be treated in the same way as application mismatches. Value mismatches give the same indications and the same update requirements /

104 Configuring a Modicon Quantum Hot Standby with Unity System Synchronizing Time-of-Day Clocks Setting the Time-of-Day Clocks in the Primary CPU and Standby CPU Controllers In a Modicon Quantum Hot Standby with Unity system, the Primary CPU and Standby CPU controllers have their own Time-of-Day clocks, which are not implicitly synchronized. If the clocks are not synchronized, then at switchover, the Time-of-Day would change by the difference between the two clocks. Non-synchrous clocks could cause problems if you are controlling a time-critical application /2010

105 Configuring a Modicon Quantum Hot Standby with Unity System 5.3 Configuring a NOE with Unity Pro Purpose This material describes how to configure a NOE, a Quantum Ethernet module, using Unity Pro. For a complete description of all NOE models, see the Quantum NOE 771 xx Ethernet Modules User Guide, 840 USE What's in this Section? This section contains the following topics: Topic Page Quantum Hot Standby for Unity Pro 106 NOE Operating Modes and Modicon Quantum Hot Standby with Unity 108 IP Address Assignment 112 Address Swap Times 114 Network Effects of Modicon Quantum Hot Standby with Unity Solution 115 Overloaded Network /

106 Configuring a Modicon Quantum Hot Standby with Unity System Quantum Hot Standby for Unity Pro Description of the Hot Standby Solution NOTE: The Modicon Quantum Hot Standby with Unity system supports up to 6 NOE 771xx Ethernet adapters on bus controllers. The NOE Hot Standby allows automatic IP address swap. Both controllers are configured identically. One controller is the primary CPU NOE; the other controller is the secondary NOE. If the primary CPU NOE stops, the controllers switch over, and the system recovers. The NOEs coordinate the swapping of IP addresses. After closing both the client and the server connections, each NOE sends a swap UDP message to its peer NOE. The sending NOE then waits a specified timeout (500 ms) for the peer swap of UDP messages. Either after receiving the messages or after a timeout, the NOE changes its IP address. NOTE: NOEs must communicate with each other in order to swap IP addresses. Schneider Electric recommends that you connect the primary CPU and secondary NOEs to the same switch because: Communication interuptions between the NOEs increases the time to swap. Connecting 2 NOEs to the same switch minimizes the probability of a communication interuption. CAUTION LOSS OF CONTROL - COMMUNICATION INTERRUPTION Use an Ethernet switch (not a hub) to connect Quantum Ethernet 771xx modules to each other and to the network. Failure to follow these instructions can result in injury or equipment damage /2010

107 Configuring a Modicon Quantum Hot Standby with Unity System The NOE waits for either a change in the controller s Hot Standby state or the swap of UDP messages. Then the NOE performs 1 of 2 Hot Standby actions. If the NOE... Detects that the new Hot Standby state is either primary CPU or standby CPU Receives a swap UDP message Then The NOE changes the IP address. The NOE transmits a Swap UDP message and swaps the IP address. All client/server services (I/O scanning, global data, messaging, FTP, SNMP, and HTTP) continue to run after the switch from the old to the new primary CPU NOE. NOTE: If an NOE module stops communicating, it is not a condition that will cause the primary CPU to leave the primary CPU state. WARNING UNINTENDED EQUIPMENT OPERATION Design your application so that unmonitored modules support communication only to noncritical parts of the application. Failure to follow these instructions can result in death, serious injury, or equipment damage. Hot Standby and NOE Module Functionality The NOE 771 family provides different Ethernet services. Some services are available or unavailable in a Modicon Quantum Hot Standby with Unity system. The following table identifies the services that are available and unavailable. Service I/O Scanning Global Data Modbus Messaging FTP/TFTP SNMP HTTP Server DHCP NOE 771 Family Available Available Available Available Available Available Unavailable NOTE: Only the 140 NOE or 140 NOE (TCP/IP Ethernet modules) support a Modicon Quantum Hot Standby with Unity V2.0 system /

108 Configuring a Modicon Quantum Hot Standby with Unity System NOE Operating Modes and Modicon Quantum Hot Standby with Unity The NOE Modes The NOE module modes are: Primary CPU Mode The Hot Standby state is primary CPU, and all client/server services are active. Secondary Mode The Hot Standby state is standby, and all server services are active except DHCP. Standalone Mode The NOE is in a non-redundant system, or the HE CPU module is not present or is not healthy. Offline Mode The CPU is stopped. The Modicon Quantum Hot Standby with Unity and the NOE operating modes are synchronized by the conditions described in the following table: HE CPU Module Status HSBY State NOE Operating Mode Present and Healthy Primary CPU Primary CPU Present and Healthy Standby CPU Secondary Present and Healthy Offline Offline Present and Healthy Unassigned Standalone Not present or unhealthy N/A Standalone Any 1 of 4 events will affect the NOE operating mode. These 4 events occur when: the NOE is powered up an NOE executes a Hot Standby switch over an NOE goes to offline mode a new application is downloaded to the NOE /2010

109 Configuring a Modicon Quantum Hot Standby with Unity System Power Up and IP Address Assignment An NOE obtains its IP address assignment at power up as follows: If the HSBY state is... Then the IP address assigned is... unassigned configured IP address primary CPU configured IP address secondary configured IP address + 1 unassigned to offline See the Offline Mode at Power-up Sequence in the next table. If two NOEs power up simultaneously, a resolution algorithm: determines the primary CPU NOE assigns the configured IP address to that primary CPU NOE assigns the configured IP address + 1 to the secondary NOE Offline Mode at Power-up Sequence Result Controller A powers-up before controller B IP address of controller A is the configured IP address IP address of controller B is the configured IP address + 1 Both controller A and controller B power-up at the same time The resolution algorithm will assign controller A the configured IP address, and it will assign controller B the configured IP address + 1. The NOE performs a duplicate IP test by issuing an ARP request to the configured IP address. If a response is received within 3 seconds, the IP address remains at the default IP and blinks a diagnostic code. If no IP configuration exists, the NOE remains in standalone mode, and the IP address must be obtained from either a BOOTP server or a MAC address. Power Up and Ethernet Services The following table shows how the status of an NOE service is affected by the Modicon Quantum Hot Standby with Unity HSBY state. HSBY State Status of NOE Services Client Services Client/Server Services I/O Scanner Global Data Modbus Messaging Server Services FTP SNMP HTTP Unassigned Run Run Run Run Run Run Primary CPU Run Run Run Run Run Run /

110 Configuring a Modicon Quantum Hot Standby with Unity System HSBY State Status of NOE Services Client Services Client/Server Services Server Services I/O Scanner Global Data Modbus Messaging FTP SNMP HTTP Secondary Stop Stop Run Run Run Run Offline Stop Stop Run Run Run Run Hot Standby Switchover The following table describes the manner in which NOEs coordinate the Hot Standby switchover. Step Action 1 NOE A is running in the primary CPU PLC and NOE B is in the secondary PLC in a hot standby configuration. 2 NOE A detects that its PLC has changed from primary CPU to offline mode. 3 NOE A changes its HSBY state from primary CPU to offline with the same Ethernet services running, and starts its watchdog timer (with 500 ms timeout setting). It waits for a UDP request to swap IP addresses from NOE B. 4 NOE B detects that its PLC has changed state from secondary to primary CPU. 5 NOE B stops all its Ethernet services, sends a UDP request to NOE A for the synchronization of the IP address swap, starts its watchdog timer (with 500 ms timeout setting), and waits for an UDP response from NOE A. 6 Once NOE A receives the UDP request from NOE B (or after its watchdog timer times out), it stops all its Ethernet services. If it has received a UDP request, NOE B sends a UDP response to NOE A; if its watchdog timer has timed out, NOE B does not send a UDP response. NOE A then swaps its IP address and starts secondary services. 7 NOE B swaps IP addresses and starts Ethernet services as primary CPU. 8 After NOE A senses that its local controller changes state from offline to standby, it takes the secondary IP address. 9 NOE B now becomes the primary CPU NOE. 10 NOE B opens all client connections and listens for all server connections and reestablishes those connections. 11 NOE A listens for all server connections and reestablishes those connections. NOTE: During the Hot Standby switchover, there is a loss of communication during 500 ms between the PLC and the HMI and/or Unity Pro /2010

111 Configuring a Modicon Quantum Hot Standby with Unity System Going to Offline When either the CPU stops or the Hot Standby state goes to offline mode, 2 events occur: 1. NOE mode goes to offline 2. NOE uses the IP address of the present configuration IP Address Assignment and Going Offline HSBY State IP Address Assigned Is... Primary CPU to Configured IP address, if other controller does not go to primary CPU offline Standby CPU to offline Configured IP address /

112 Configuring a Modicon Quantum Hot Standby with Unity System IP Address Assignment Configuring the Module The module can be configured to work in conjunction with the Modicon Quantum Hot Standby with Unity controller. Since the primary CPU and secondary controllers must have an identical configuration, the configured IP addresses will be the same. The module s IP address is either the configured IP address or the configured IP address + 1. The current local Hot Standby state determines the IP address. In the offline state, the IP address is determined by whether or not the other controller is in transition to the primary CPU state. This table shows the IP address assignments: Hot Standby State IP Address Primary CPU Configured IP address Standby CPU Configured IP address + 1 Transition from primary to offline Configured IP address, if peer controller does not go to primary CPU Transition from standby to offline Configured IP address + 1 IP Address Restriction Do not use either broadcast IP address or broadcast IP address - 2 to configure the module /2010

113 Configuring a Modicon Quantum Hot Standby with Unity System IP Address Transparency WARNING UNINTENDED EQUIPMENT OPERATION For a Quantum Hot Standby configuration: Do not use the address IP + 1. Do not use consecutive IP addresses of the configured IP address. Do not configure the primary CPU address as nnn.nnn.nnn.254. This causes the standby CPU IP address to be: nnn.nnn.nnn.255. The module would then return the diagnostic code Bad IP configuration. Failure to follow these instructions can result in death, serious injury, or equipment damage. When a switchover occurs, a new primary CPU PLC takes the IP address of the old primary CPU PLC. When the PLC that has stopped becomes operational again and rejoins the hot standby system, it takes the IP address of the secondary PLC. A new primary CPU NOE must have the same IP address as the former primary CPU NOE. The IP address in the secondary NOE (an NOE in the secondary state) is IP address + 1. The NOEs integrated into the Modicon Quantum Hot Standby with Unity configuration coordinate this swapping IP address with the management of Ethernet services used /

114 Configuring a Modicon Quantum Hot Standby with Unity System Address Swap Times Description The following table details address swap times, such as the time to close connections, time to swap IP addresses, or time to establish connections. Service Typical Swap Time Maximum Swap Time Swap IP addresses 6 ms 500 ms I/O Scanning 1 initial cycle of I/O scanning 500 ms + 1 initial cycle of I/O scanning Global data For swap times, please see 500 ms + 1 CPU scan the Quantum NOE 771xx Ethernet Modules User Guide (840 USE 116). Client messaging 1 CPU scan 500 ms + 1 CPU scan Server messaging 1 CPU scan + the time of the client re-establishment connection 500 ms + the time of the client reestablishment connection FTP/TFTP server The time of the client reestablishment connection 500 ms + the time of the client reestablishment connection SNMP 1 CPU scan 500 ms + 1 CPU scan HTTP server The time of the client reestablishment 500 ms + the time of the client re- connection establishment connection /2010

115 Configuring a Modicon Quantum Hot Standby with Unity System Network Effects of Modicon Quantum Hot Standby with Unity Solution Overview The Modicon Quantum Hot Standby with Unity Pro solution is a powerful feature of NOEs, a feature that increases the reliability of your installation. Hot Standby uses a network, and using the Hot Standby feature over a network can affect the behavior of: browsers remote and local clients I/O scanning service global data service FTP/TFTP server The following are factors you may encounter while using the Modicon Quantum Hot Standby with Unity solution. Browsers NOTE: In Modicon Quantum Hot Standby with Unity Pro configuration, the NOE s I/O Scanner must be enabled. If a browser requests a page and during the process of downloading that page an IP address switchover occurs, the browser will either hang or time out. Click the Refresh or Reload button. Remote Clients Hot Standby switchover affect remote clients. An NOE will reset under the following conditions: Remote Connection Request during Hot Standby : If a remote client establishes a TCP/IP connection during a Hot Standby switchover, the server closes the connection using a TCP/IP reset. Hot Standby Switchover during Remote Connection Request : If a remote client makes a connection request and a Hot Standby switchover occurs during the connection request, the sever rejects the TCP/IP connection by sending a reset. Outstanding Requests : If there is an outstanding request, the NOE will not respond to the request, but the NOE will reset the connection. The NOE will do a Modbus logout if any connection has logged in. Local Clients During a switchover, the NOE will reset all client connections using a TCP/IP reset /

116 Configuring a Modicon Quantum Hot Standby with Unity System I/O Scanning Service WARNING UNINTENDED EQUIPMENT OPERATION - DEVICES GO TO THEIR FALL- BACK STATES DURING SWITCHOVER Configure Ethernet output devices to their Hold Last Value fallback state whenever possible. Output devices that support only a Set to Zero fallback state may produce a pulse during switchover. Failure to follow these instructions can result in death, serious injury, or equipment damage. I/O scanning provides the repetitive exchange of data with remote TCP/IP nodes I/O devices. While the PLC is running, the primary CPU NOE sends Modbus read/write, read, or write requests to remote I/O devices, and transfers data to and from the PLC memory. In the secondary controller, the I/O scanning service is stopped. When the Hot Standby switchover occurs, the primary CPU NOE closes all connections with I/O devices by sending a TCP/IP reset. The I/O scanning service in this NOE is standby CPU. After the switchover, the new primary CPU NOE re-establishes the connection with each I/O devices. It restarts the repetitive exchange of data with these reconnections. The module provide the I/O scanning feature. Configure this feature with the Unity Pro software. Using either method, the configuration and transfer of data between network addresses can be done without using the MSTR/IEC function block. NOTE: You must account for the following Ethernet I/O scanning considerations during a switchover. If MSTR/IEC function block is used for TCP/IP, only some of the opcode will be used. Therefore, the block does not complete its transaction, and it returns error code While the NOE is in the process of performing the transaction, a new MSTR/IEC function block may become active. The output states of the scanned I/Os will follow the state defined in the last value option configured in the I/O scanning table of the NOE module (in Unity Pro software). These 2 states are either: a. set to 0 b. hold last With the above considerations, we recommend using switchover with Ethernet I/O scanning for less critical applications /2010

117 Configuring a Modicon Quantum Hot Standby with Unity System Global Data (Publish/Subscribe) Service The Hot Standby primary CPU NOE is 1 station within a distribution group. Distribution groups exchange application variables. Exchanging application variables allows the system to coordinate all the stations in the distribution group. Every station publishes local application variable in a distribution group for all other stations and can subscribe to remote application variables independent of the location of the producer. The communication port has only 1 multicast address. In this network service, the Modicon Quantum Hot Standby with Unity controllers are viewed like only 1 station. The primary CPU NOE publishes the Hot Standby application variables and receives the subscription variables. The secondary NOE global data service is in a stopped state. When the Hot Standby switchover occurs, the primary CPU NOE stops the global data service. The NOE does not publish the local variable during a switchover. And after the switchover, the new primary CPU NOE starts to publish application variables and to receive the subscription variables. FTP/TFTP Server The FTP/TFTP server is available as soon as the module receives an IP address. Any FTP/TFTP client can logon to the module. Access requires the correct user name and password. Modicon Quantum Hot Standby with Unity allows only 1 active FTP/TFTP client session per NOE module. When the Hot Standby switchover occurs, the primary CPU and secondary NOEs close the FTP/TFTP connection. If you send an FTP/TFTP request during the switchover, the communication is closed. Whenever you re-open communication, you must re-enter a user name and a password /

118 Configuring a Modicon Quantum Hot Standby with Unity System Overloaded Network Overview If a NOE771xx is used to run in a 100Mb/s Ethernet and a persistent overloaded network occurs, the NOE771 may go into Kernel mode. This could the cause the primary CPU to STOP. Example An example of a persistent overloaded network would be when two ports of an Ethernet switch are linked to each other: this would be seen by all Ethernet nodes connected to the sub-network and result in a massive overloaded network - something that should not occur on properly configured network. NOTE: Broadcasts and especially ARPs, are part of standard Ethernet traffic and will have no adverse effects on a NOE. Even "small" storms that take up to 5% of the basic network traffic over short periods (from several seconds to 2-3 minutes) would not overload the NOE. It is only the massive and enduring overloaded network (such as those created by a looped nework cable) that can cause problems of the HSBY system with NOEs. Impact on CPU In order to serve the backplane communication, the NOE has direct access (DMA) to the memory of the CPU module. Therefore, if the NOE goes into Kernel mode while accessing the CPU, this may have an impact on the CPU behavior. In rare cases, it can even cause the Primary CPU to STOP. In this case, the Standby CPU will take the hand as Primary CPU. Recommended Actions Take the following steps to protect against the unwanted effects of excessive broadcast traffic: Step Action 1 Reduce the speed of the port allocated to communicate with the respective NOEs from 100Mb/s to 10Mb/s. 2 Limit the potential effects of an overloaded network to the NOE by filtering it with an appropriate ConneXium switch set, with a limit of 500 packets per second. (Schneider Electric offers a line of a configurable ConneXium switch, capable of broadcast limiting.) 3 If the Ethernet switch must be set at 100Mb/s speed, the set the watchdog timer to 1.5 seconds (independent of the number of NOEs). Otherwise, if the watchdog timer is set too low, the the remaining system may also stop working if a persistent overloaded network occurs /2010

119 Maintaining a Modicon Quantum Hot Standby with Unity System /2010 Maintaining a Modicon Quantum Hot Standby with Unity System 6 Overview This chapter provides information about maintaining a Modicon Quantum Hot Standby with Unity system. What's in this Chapter? This chapter contains the following topics: Topic Page Verifying the Health of a Modicon Quantum Hot Standby with Unity System 120 Detecting and Diagnosing Errors in a Modicon Quantum Hot Standby with 121 Unity System Primary CPU Controller, Copro, and RIO Head Detected Errors 123 Standby CPU Controller, Copro, and RIO Head Detected Errors 125 Detecting High-Speed Data Link Interruptions 126 Detecting Remote I/O (RIO) Link Interruptions 128 Checking for Identical Application Programs Checksum 130 Replacing a Module 131 Troubleshooting the Primary CPU Controller 132 Troubleshooting the Standby CPU Controller /

120 Maintaining a Modicon Quantum Hot Standby with Unity System Verifying the Health of a Modicon Quantum Hot Standby with Unity System Generating and Sending Health Messages The Modicon Quantum Hot Standby with Unity modules exchange a health message approximately every 10 ms. If the Primary CPU has an error, the Standby CPU is notified and assumes the Primary CPU role. If the Standby CPU has an error, the Primary CPU continues to operate as a standalone.the RIO head processors periodically verify communication with one another. The Primary CPU sends a health message to the Standby CPU either 1. every 10 milliseconds when no other data is being sent on the high speed Copro link, 2. every 5 milliseconds if no communication is required with any drop on RIO link. If the Standby CPU never receives any message on either link, the Standby CPU will try to determine the cause and assumes control if necessary. If the Primary CPU does not receive a valid response from the Standby CPU, the Primary CPU will operate as if there was no back up available as if the Primary CPU were a standalone. Performing Automatic Confidence Tests The system automatically performs two kinds of confidence tests on the Modicon Quantum Hot Standby with Unity Copro: Startup tests Run time tests Conducting Startup Tests Startup confidence testing on the Modicon Quantum Hot Standby with Unity Copro attempt to detect hardware errors in the module before the application is allowed to run. If any of the module tests do not pass, it will remain offline and will not communicate with the other Modicon Quantum Hot Standby with Unity module. Conducting Run Time Tests Run time tests are performed whenever the Copro is in the operational state. Run time tests are executed in small slices to prevent delays in scan time. If any of the module tests do not pass, the module remains offline and will not communicate with the other module /2010

121 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting and Diagnosing Errors in a Modicon Quantum Hot Standby with Unity System Diagnostic Information Please note. If... Then... A component of the Primary CPU becomes Control shifts to Standby CPU inoperative A component of the Standby CPU becomes inoperative Fiber optic cable link becomes inoperative Standby CPU goes offline Standby CPU goes offline Understanding Health Messages The Primary CPU sends a health message to the Standby CPU over Copro link every 10 milliseconds. If... No communication is required with any drop on RIO link All systems OK Then Primary CPU Sends Health Message over RIO link... every 5 milliseconds every scan Exceptions If... Then... Standby CPU never receives any message on either link Primary CPU does not receive a valid response from the Standby CPU 1. Standby CPU determines the cause 2. Standby CPU assumes control Primary CPU operates as if 1. no back up available 2. Primary CPU were a standalone Standalone = 1) no working Copro 2) no Hot Standby Functionality Finding Diagnostic Information with Unity Pro Errors and switchovers are logged in the diagnostic buffer. To view the log, Step Action 1 Select Tools Diagnostic Viewer from the main menu /

122 Maintaining a Modicon Quantum Hot Standby with Unity System Finding More Information in this Manual Refer to the following sections Type of detected error Primary CPU controller Primary CPU Copro Primary CPU RIO head Standby CPU controller Standby CPU Copro Standby CPU RIO head High speed data link interuptions Remote I/O link Application program checksum errors Refer to section Primary CPU Controller, Copro, and RIO Head Detected Errors, page 123 Standby CPU Controller, Copro, and RIO Head Detected Errors, page 125 Detecting High-Speed Data Link Interruptions, page 126 Detecting Remote I/O (RIO) Link Interruptions, page 128 Checking for Identical Application Programs Checksum, page /2010

123 Maintaining a Modicon Quantum Hot Standby with Unity System Primary CPU Controller, Copro, and RIO Head Detected Errors Understanding CPU to Copro Communication Facts 1 On every scan, CPU communicates with Copro. 2 Main CPU executes the Hot Standby control at the start of the scan, the main CPU asks the Copro to service its requests. 3 CPU reports any errors detected. 4 If the Primary CPU copro stops, there is no more communication to the Standby CPU. Therefore the standby CPU cannot exchange data with the Primary CPU and goes Offline. The Primary CPU controller operates as standalone and the HSBY system is no longer available. Detection between Two Controllers If an error occurs in either one of two controllers, Situation Controller with error Controller without error Response Reports error to other controller by sending a message through either 1. high speed Copro transfer link 2. RIO link Detects error from a timeout which occurs because of no activity on link NOTE: Primary CPU maintains continuous activity on link, which allows Standby CPU to detect an error as soon as possible. Detected Error within One CPU Detected Hardware Errors Facts 1 RAM corruption is a hardware error. 2 Copro detects hardware errors. Detecting errors: If... Then... Hardware error occurs 1. Copro sends a take control command to the Standby CPU 2. Primary CPU Copro stops because of an interface error /

124 Maintaining a Modicon Quantum Hot Standby with Unity System Detected Error in Either Copro Detecting errors If... Then... Primary CPU Copro reports any error 1. Primary CPU controller acknowledges the error 2. Primary CPU controller attempts to transfer control to the other controller by sending a take control command to the Standby CPU through the RIO link Primary CPU Copro does not respond within 5 milliseconds Primary CPU Copro sends a take control command to the other Copro Standby CPU copro experiences an error 1. Primary CPU controller acknowledges the error 2. Primary CPU controller attempts to transfer control to the other controller by sending a take control command to the Standby CPU through the RIO link 1. Primary CPU Copro relinquishes control 2. Primary CPU Copro does not expect any response 1. Standby CPU controller reports the error by sending a No Standby CPU message 2. Standby CPU controller goes offline Detected Error by an RIO Head Detecting errors If RIO Head... Responds Does NOT respond Then... Primary CPU Controller Releases control and the Standby CPU station becomes a Standalone. Standalone = 1) no working Copro 2) no Hot Standby functionality Continues to scan the I/O. Understanding RIO Head Detected Error If the RIO Head detects an error:, 1 Main CPU times out when it does not communicate with the RIO Head. 2 Main CPU stops. 3 Main CPU reports RIO error to log. 4 Main CPU reports RIO error to the Copro. 5 Copro goes offline /2010

125 Maintaining a Modicon Quantum Hot Standby with Unity System Standby CPU Controller, Copro, and RIO Head Detected Errors Standby CPU Error When a Standby CPU error is detected, Stage Description 1 The Standby CPU reports errors to the Standby Copro. 2 The Standby Copro sends a No Standby message to the Primary CPU Copro. 3 The Standby CPU and the standby copro go offline. Standby CPU Copro Error When a Standby Copro error is detected, Stage Description 1 When the Primary CPU communicates with the Standby CPU, the Standby CPU Copro reports its error to the Primary CPU. 2 The Primary CPU requests the Copro to go offline. 3 The Standby CPU Copro will also report its error to the Primary CPU Copro by sending a No Standby CPU message. 4 Standby CPU goes offline. Standby CPU RIO Head Detected Error When a Remote I/O Head error is detected, Step Description 1 The CPU stops and reports a RIO error. 2 The CPU reports the error to the Copro 3 The Copro sends a No Standby CPU command to the Primary CPU. 4 The Standby CPU goes offline /

126 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting High-Speed Data Link Interruptions Diagnostic Information Facts 1 High-speed data link connects the two Copros. 2 Using the high-speed data link, the Primary CPU controller communicates with the Standby CPU every 10 milliseconds. 3 Primary CPU sends either 1. data message 2. health message NOTE: If both the Primary CPU and Standby CPU do not hear from each other, either station can detect a high speed data link interruption. Standby CPU Detects an Error At first, Step Action Result 1 Standby CPU does not hear from the Primary CPU on the high-speed data link When the RIO Head receives the request, 1. Standby CPU requests the Primary CPU to monitor the RIO link 2. Primary CPU sends a request to the RIO Head If... Then... RIO Head finds the RIO link not active 1. RIO Head assumes that the Primary CPU must be down 2. Standby CPU assumes control RIO Head finds the RIO link is active Message received from Primary CPU must be either 1. health message Messages are sent every 5 milliseconds from Primary CPU RIO Head to Standby CPU RIO Head. 2. I/O transaction data message Messages are sent from the Primary CPU RIO Head to the I/O drops at the request of the controller /2010

127 Maintaining a Modicon Quantum Hot Standby with Unity System Facts about the I/O 1 If the message is an I/O transaction, the RIO Head 1. concludes an interruption occurred on the high-speed data link 2. informs the Primary CPU controller to go to offline 2 If you never configure an I/O drop, the high-speed data link could cause the Standby CPU to assume control since the Standby CPU RIO head will never receive any I/O transaction message. 3 After any CPU error is detected, 1. RIO Head will not perform drop communication 2. RIO Head sends only health messages Standby CPU Assumes Control The Standby CPU becomes Primary CPU Step Action Result 1 After the Primary CPU controller goes offline, 2 Standby CPU controller listens to the high-speed data link for one scan. 3 If Standby CPU controller hears nothing, 4 Standby CPU assumes control. A health message from the Standby CPU controller is the only message received by the Standby CPU RIO Head. Standby CPU knows that the cause must be on both the Primary CPU Copro and Primary CPU /

128 Maintaining a Modicon Quantum Hot Standby with Unity System Detecting Remote I/O (RIO) Link Interruptions Information Facts 1 Remote I/O (RIO) Link connects the two RIO Heads. 2 Primary CPU RIO Head performs a health check on the RIO link by sending health messages. 3 Primary CPU RIO Head sends a health message every 5 milliseconds. 4 Unlike the health communication check performed on the Copro link, the Primary CPU Copro does not wait for a response from the Standby CPU Copro. Instead the Primary CPU Copro expects a reply every second. Expecting a reply every second minimizes the impact on the Primary CPU's performance. Standby CPU Controller and Messages How the Standby CPU handles messages depends on: If Standby CPU... Then... Action Never Responds to any message Never Receives a message from the Primary CPU Primary CPU assumes that the Standby CPU RIO Head is inoperable. Standby CPU assumes the interruption may be in the RIO link. Standby CPU continues to control the drops. Standby CPU cannot assume control. Standby CPU Monitors RIO and Copro Links To start the process, Step Action Result 1 Standby CPU RIO Head sends a request to the Primary CPU RIO Head. 2 Standby CPU requests that the Main CPU monitor the Copro link. Confirm whether Primary CPU RIO 1. Head is inoperable or 2. there is a link interruption Main CPU passes this request to Copro either as a 1. monitor RIO request 2. Copro link request /2010

129 Maintaining a Modicon Quantum Hot Standby with Unity System To complete the process, the Standby CPU determines If... Then... Copro link is down and the Primary CPU is Standby CPU assumes control down Copro link is up Standby CPU Copro sends a message to the Primary CPU Copro and 1. Primary CPU Copro passes this request to the Primary CPU 2. Primary CPU checks the Primary CPU RIO link Understanding Communication Status to the Drops Depending on the status, the Primary CPU RIO Head continues either to operate as the Primary CPU or goes offline. If communication to drops is Healthy Not healthy Then RIO link interruption must be on Standby CPU side. RIO link interruption is on Primary CPU side. Action 1. The station continues to operate as the Primary CPU 2. Standby CPU RIO Head shows the link error pattern on the LEDs 1. The Primary CPU RIO Head displays a link error 2. Standby CPU assumes control /

130 Maintaining a Modicon Quantum Hot Standby with Unity System Checking for Identical Application Programs Checksum Information Please note Fact A Hot Standby system requires that both stations must have the same application program. Result This requirement prevents the Standby CPU from executing a different application program if transfer of control occurs. NOTE: OVERRIDING SAME APPLICATION PROGRAM REQUIREMENT To override the requirement that both controllers have the same application program, ensure that the Command Register s %SW60.3 is set = 1. (see page 96) Standby CPU Checks for Mismatches Checking for identical application programs Step Action Result 1 At each scan, the application program's instruction, checksum (CKSM), is transferred from the Primary CPU to the Standby CPU along with any other necessary data. 2 Standby CPU determines if mismatch occurs. The Standby CPU validates the new checksum (CKSM) against its existing checksum (CKSM). 1. Mismatch: Standby CPU goes Offline 2. No mismatch: system operates normally 3 The controller returns to Online and is the Standby CPU as soon as the application programs are identical /2010

131 Maintaining a Modicon Quantum Hot Standby with Unity System Replacing a Module Replacing a module without Stopping You may replace a module while a system is running. Ensure that the module being replaced: 1. installs into the Standby CPU backplane 2. resides in the same position in both backplanes 3. is same type of module Same type of module means CPU replaces CPU, NOE replaces NOE, CRP replaces CRP, etc. NOTE: Perform a switchover before replacing module installed into the Primary CPU backplane. WARNING UNEXPECTED EQUIPMENT BEHAVIOUR Do not remove a Primary CPU controller under power (Hot Swap). Failure to follow these instructions can result in death, serious injury, or equipment damage /

132 Maintaining a Modicon Quantum Hot Standby with Unity System Troubleshooting the Primary CPU Controller Troubleshooting the Primary CPU To determine which component has become inoperative, note controller s status displayed in the HE CPU LCD screen and the RIO Head s status displayed by the RIO Head LEDs. Controller Status RIO Head Status Error Type Description Stop All LEDs off except READY on and Com Act blinks four times Controller An Interface error occurred. Offline Stop Stop All LEDs off except READY on All LEDs off except READY on and Com Act displays error pattern READY on and Com Act blinks four times Fiber Optic connection between both controllers RIO Head RIO Cable becomes inoperative at Primary CPU End A Com Act error occurred. A Com Act error occurred. In a dual cable system, if only one cable is inoperative, the Error A or Error B indicator on the RIO Head lights instead of stopping the system, and the system continues to operate. When the RIO cable becomes inoperative at the Primary CPU end, input data may be reset to 0 for one scan because the communication interruption to the drop occurs before the broken link is detected. NOTE: In a Quantum Hot Standby configuration without RIO drop (see page 58), the errors A and B LEDs are not relevant when using CRP module with firmware version lower than /2010

133 Maintaining a Modicon Quantum Hot Standby with Unity System Troubleshooting the Standby CPU Controller Troubleshooting the Standby CPU To determine which component has become inoperative, note controller s status displayed in the HE CPU LCD screen and the RIO Head s status displayed by the RIO Head s LEDs. Controller Status RIO Head Status Detected Error Type Stop Offline Stop Stop Offline All LEDS off except READY on or READY on and Com Act blinks once a second READY on and Com Act stops blinking Com Act displays detected error pattern READY on and Com Act blinks four times Com Act stops blinking Controller Fiber Optic connection between both controllers RIO Head RIO Cable becomes inoperative at Standby CPU end Fiber Link interruptions: from Standby CPU Transmit to Primary CPU Receive from Primary CPU Transmit to Standby CPU Receive Description A detected Interface error occurred. A detected Com Act error occurred. After you have replaced the module and cycled power, to ensure that the controllers have identical application programs, you must perform an application program update. In a dual cable system, the RIO Head gives no indication if only one cable has become inoperative /

134 Maintaining a Modicon Quantum Hot Standby with Unity System /2010

135 Understanding Modicon Quantum Hot Standby with Unity Special Features /2010 Understanding the Modicon Quantum Hot Standby with Unity System Special Features III Purpose This part describes the special features of a Modicon Quantum Hot Standby with Unity system. enabling an EXEC upgrade handling logic mismatch transferring application programs What's in this Part? This part contains the following chapters: Chapter Chapter Name Page 7 Enabling EXEC Upgrade with Unity Pro Handling Application Mismatch with Unity Pro Transferring an Application Program with Unity Pro Using the Modicon Quantum Hot Standby with Unity EFBs /

136 Understanding Modicon Quantum Hot Standby with Unity Special Features /2010

137 Enabling EXEC Upgrade /2010 Enabling EXEC Upgrade with Unity Pro 7 Overview In this chapter you will find information regarding the EXEC upgrade method for a Modicon Quantum Hot Standby with Unity system. Upgrading allows you to update the EXEC for the standby CPU controller while the process is still controlled by the primary CPU controller. What's in this Chapter? This chapter contains the following topics: Topic Page Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade 138 Executing the EXEC Upgrade Procedure /

138 Enabling EXEC Upgrade Overview of Modicon Quantum Hot Standby with Unity EXEC Upgrade Upgrading while Process is Running The Executive Upgrade feature allows upgrading the EXEC of the Standby CPU controller while the Primary CPU controller continues to control the process. However, during the upgrade, the system can no longer be considered redundant. That is, there is no Standby CPU available to assume control if the Primary CPU should stop before the Standby CPU upgrade is complete. Upgrading EXEC without Stopping Under normal operating conditions, both controllers in a redundant system must have the same versions of firmware. In fact, there are checks by the controllers to detect if there is a mismatch in firmware. Normally, when a mismatch exists, performing a switchover would not be possible because the Standby CPU controller would not be allowed to go online. However, to allow an EXEC Upgrade without stopping the application, overriding is possible by setting the Command Register system bit %SW60.4. Details of the Modicon Quantum Hot Standby with Unity command register can be found in Understanding the Unity Command Register, page 95. NOTE: Enabling EXEC upgrade without stopping the application overrides the process of checking whether the Primary CPU and Standby CPU are configured identically. Disable the upgrade without stopping bit as soon as the EXEC upgrade is finished. NOTE: EXEC upgrade is possible only with compatible firmware /2010

139 Enabling EXEC Upgrade Executing the EXEC Upgrade Procedure General Perform an EXEC upgrade using the installed OSLoader tool. Use one of two communication methods available in the OSLoader: Modbus RTU Modbus Plus Using Modbus List of the useful material: PC with Unity Pro and OSLoader. Cable 110XCA2820x and adaptator 110XCA All the references about the keyboard are detailled in the Quantum Hardware Reference Manual: Controls and Displays (see page 236) Using the LCD display screens (see page 240) Upgrading the OS without Stopping Under normal operating conditions, both controllers in a redundant system must have the same versions of firmware. In fact, there are checks done by the controllers to detect if there is a mismatch in firmware. Normally, when a mismatch exists, performing a switchover would not be possible because the Secondary controller would not be allowed to be Standby. However, to allow an OS Upgrade without stopping the application, it is possible to set the upgrade without stopping command in Command Register system word %SW60 (see page 97) NOTE: Enabling OS upgrade without stopping the application disable the checking between the Primary and Standby configuration. Disable the upgrade without stopping bit as soon as the OS upgrade is finished. OS upgrade is possible only with compatible firmware. Upgrade Procedure Using Modbus or Modbus Plus, only address 1 is allowed for downloading. Ensure that no other device on the network is using address 1. Step Action 1 Connect to the Primary CPU (through Modbus, Modbus Plus or USB). 2 Access the Command Register system bit %SW60.4; set bit to 1. 3 Disconnect the PC from the Primary CPU /

140 Enabling EXEC Upgrade Step Action 4 Depending on the communication media chosen for the upgrade procedure, note the Modbus or Modbus Plus address of the Standby CPU using the keyboard functions. For Modbus Plus PLC Communications - Communications Serial Port For Modbus Plus PLC Communications - Communications Modbus Plus 5 Stop the Standby CPU with the keyboard functions. NOTE: The standby CPU goes to STOP Offline mode ; the Primary operates without a Standby. 6 Disconnect all the communication links (Hot Standby fiber optic cable, Ethernet cables, Modbus Plus cables ) from the Standby rack and remove the CRP module from the Standby rack. 7 Switch off the power of the Standby rack. 8 When using an application in the PCMCIA card: Remove the PCMCIA card from the Standby CPU. Remove the PCMCIA batteries to empty the card content. 9 Power on the Standby CPU. 10 If not set to 1, change the Modbus or Modbus Plus address of the Standby CPU to 1 with the keyboard functions For Modbus Plus PLC Communications - Communications Serial Port For Modbus Plus PLC Communications - Communications Modbus Plus 11 Coprocessor Upgrade Step: Connect the PC to the Standby CPU using Ethernet (appropriate switch and optical cable needed) Open the OSLoader tool. Select the FTP communication option. Connect to the Standby using the PLC IP address (read on the keypad). Download the OS to the Standby coprocessor. Power cycle the CPU. 12 CPU OS Upgrade Step: Connect the PC to the Standby CPU using Modbus or Modbus Plus. Open the OSLoader tool. Select the Modbus or Modbus Plus communication option. Connect to the Standby using address 1. Download the OS to the Standby. 13 Disconnect the PC from the Standby CPU. 14 Switch off the power of the Standby CPU. 15 When using an Application in the PCMCIA: Insert the PCMCIA batteries. Insert the PCMCIA card in the Standby CPU /2010

141 Enabling EXEC Upgrade Step Action 16 Power on the Standby CPU. NOTE: The CPU must be in No Conf state. 17 Check the Copro and OS versions in the LCD Screen. 18 Reconnect all the communication cables (CRP module, Ethernet cables, ) but not the Hot Standby fiber optic cable. 19 At last, reconnect the fiber optic cable to both CPUs. 20 Check the application program is automatically transferred to the Standby CPU. If not, perform the transfer with the keyboard. NOTE: Ensure that the Modbus or Modbus Plus address is the same as the adress indicated in Step Put in RUN mode. NOTE: Ensure Primary CPU is in Run Primary Mode and Standby CPU is in RUN Standby Mode. 22 Perform a switchover by stopping the Primary CPU with the keyboard. NOTE: Ensure Standby CPU becomes Primary CPU on the LCD screen. 23 Repeat Steps 4 through 21 on the new Standby. 24 Connect to the new Primary CPU with the PC and Unity Pro (through Modbus, Modbus Plus or USB). 25 Access Command Register system bit %SW60.4; set bit to Disconnect the PC and ensure Primary CPU is in RUN Primary Mode and Standby CPU is in RUN Standby Mode. Compatibility Issues To upgrade a Modicon Quantum Hot Standby with Unity EXEC without shutting down the process, the current application program must be executable by the new EXEC. Observe this requirement when installing minor revisions targeted for bug fixes or minor enhancements. When a major function enhancement needs to be made, maintaining this compatibility may not be possible. In this case, to perform an EXEC upgrade requires a system shut down /

142 Enabling EXEC Upgrade /2010

143 Application Mismatch /2010 Handling Application Mismatch with Unity Pro 8 Overview This chapter provides information about using the Application Mismatch feature available in Unity Pro. What's in this Chapter? This chapter contains the following topics: Topic Understanding Modicon Quantum Hot Standby with Unity Application Mismatch Understanding Switchover Behavior during Application Mismatch 148 Online or Offline Modifications and Application Mismatch 150 Online Modifications to an Application Program in the Standby CPU and 151 Application Mismatch Online Modifications to an Application Program in the Primary CPU and Application Mismatch Page Offline Modification of an Application Program and Application Mismatch 153 Switchover Methods and Application Mismatch 155 Application Program Transfer Method and Application Mismatch 157 Recommendations for Using Application Mismatch /

144 Application Mismatch Understanding Modicon Quantum Hot Standby with Unity Application Mismatch Needing Identical Application Programs In a fault-tolerant redundant system and under normal operating conditions, both controllers must load the identical application program (also called a logic program). The application program is updated every scan by transferring data from the Primary CPU to the Standby CPU. Both controllers conduct tests to detect if a mismatch exists between the application programs. The following conditions cause a mismatch in the application program: a difference between: programs animation tables comments (on variables) I/O configuration change in RUN NOTE: Animation Tables and Comments Both animation tables and comments (on variables) may be excluded from the mismatch by not including in the upload information. Exclude by selecting Tools Project Settings Build tabs (default). In the Upload Information area, select without. Not including requires downloading application program When a mismatch exists, a switchover is not possible, and the Standby CPU controller would NOT go online. However, there are situations when you may want to allow a mismatch between the application programs. To enable this condition, use the Modicon Quantum Hot Standby with Unity application mismatch feature. NOTE: Switchover can NOT occur while the Standby CPU controller is offline. Defining Application Mismatch Application Mismatch is a Modicon Quantum Hot Standby with Unity feature that allows a mismatch between the application programs and the I/O configuration of the Primary CPU and Standby CPU controllers. Use the Application Mismatch feature to modify an application program and the I/O configuration without having the process not redundant. Using the Build Project Function NOTE: Build Project vs. Rebuild All Project 1. Use the Build Project function to perform an application mismatch with Unity Pro. Schneider Electric recommends that the Rebuild All Project must not be used to create an application mismatch. The Rebuild All Project function creates a completely new project even if nothing has been changed in the application /2010

145 Application Mismatch Causing a Mismatch NOTE: CHANGING FROM LEGACY Legacy Hot Standby systems reserved areas of the State RAM for user data, which was transferred from the Primary CPU to the Standby CPU during scans. Because of the transfer process, legacy Hot Standby systems could support different application programs in the two controllers. One application program resided in one controller, and a different application program resided in the other controller. In the legacy system, the user could program the logic (now called application program) and decide where to store the data. With this method of programming, the memory is known as static data memory layout and is necessary to have different user data accessing the same variables. In the Modicon Quantum Hot Standby with Unity system, all memory is allocated by a memory manager, which automatically transfers the logical memory to a physical memory location. This dynamic data memory layout is the heart of the programming flexibility and platform independence that Unity Pro provides, but on a Modicon Quantum Hot Standby with Unity system with different user logic, dynamic data memory layout makes a cyclical data update very difficult. Therefore, mismatches occur. Allowing a Mismatch In a Modicon Quantum Hot Standby with Unity system, Application mismatch allows the following without stopping the application program process. modify (edit) online an application program in the Standby CPU while the Primary CPU controls the process (see page 151) modify online an application program in the Primary CPU while the Primary CPU controls the process (see page 152) download an offline-modified application program to the Standby CPU and perform a switchover to run the modified application program (see page 153) Creating a Mismatch Use one of two methods to create an application Mismatch condition: 1. select Standby CPU on Application Mismatch; select online (Hot Standby Tab in the Unity Pro dialog) This action requires the application program to be downloaded to the controller. 2. set to 1 the Command Register system bit %SW60.3 This action MUST be performed online in the Primary CPU controller /

146 Application Mismatch Transferring User Data during a Mismatch The table following shows which user data is transferred when a mismatch occurs Data Type Located variables (State RAM) Unlocated global variables DFB & EFB instance data SFC variable area System Bits and Words Transferred on Application Mismatch Yes Yes (for the 140 CPU module only) unless variables exist ONLY in modified controller Yes unless data exist ONLY in modified controller Yes (for the 140 CPU module only) unless associated-sfc section is modified Yes Using Application Mismatch with Care WARNING UNEXPECTED APPLICATION BEHAVIOR - I/O MAP OR CONFIGURATION MISMATCH Ensure that there is no mismatch between I/O maps or configurations: Ensure that both I/O maps are identical. Ensure that both configurations are identical. Failure to follow these instructions can result in death, serious injury, or equipment damage. Selecting the Standby CPU On Application mismatch option, allows you to override this default condition (Standby CPU going offline). If you change the parameter in this field from Offline to Online, the Standby CPU remains online if an application mismatch is detected between the application program of the Standby CPU and the application program of the Primary CPU /2010

147 Application Mismatch Updating Section Data in an Application Program All data of a section will be fully updated during every scan if the data in the Standby CPU is equal to the counterpart data on the Primary CPU. CPU Section data will not be updated if it is not equal to its counterpart on the Primary CPU. If the sections are equal on the Primary CPU and the Standby CPU, the section data that is updated is: Internal states of Elementary Function Blocks (EFBs) used in the section For example, Timers, Counters, PID All Derived Function Block (DFB)-Instance data blocks of each DFB instantiated in the section including nested DFBs. Updating Global Data in an Application Program With the Application mismatch enabled, application program global data will be updated with every scan. Global data that does not exist on both controllers is not updated. The application program s updated global data includes both: 1. All declared variables in the Variable-Editor. 2. All section and transition variables. The process of updating the application program global data in a Hot Standby system affects: Declared variables All declared variable will be updated on every scan as long as they are declared on both controllers. Updating Standby CPU If a complete application program transfer is done to the controller that did not receive the modified changes, then both controllers will have equal application programs, and the Standby CPU controller is fully updated. Deleted and redeclared variables If, due to a modification, a global variable has been deleted first, and then redeclared, this variable would be treated as a NEW variable, even if the same name is used. The update procedure must be followed to bring the controllers to an equalized state. NOTE: GLOBAL DATA VARIABLES The system reserves space for these variables whether they are used in the controller s application program or not. Unused variables consume space and require time to be transferred from the Primary CPU to the Standby CPU. Therefore, in the Primary CPU s application program, Schneider Electric does not recommend using variables that are defined but not used /

148 Application Mismatch Understanding Switchover Behavior during Application Mismatch Modifying the Application Variables If a switchover occurs during application mismatch, the new Primary CPU will execute its own application program with the data received from the other controller. Depending on the modification, different behaviors occur: Modification Only code changed (same variables). Variables added to the initial Primary CPU Variables deleted from the initial Primary CPU Variables added to the initial Standby CPU Variables deleted from the initial Standby CPU Effect All the variables exchanged between the controllers are equal. Variables are not used by the new Primary CPU. New Primary CPU executes application program using the latest values for these variables. New Primary CPU executes application program using initial values for these variables. New Primary CPU will not use these variables /2010

149 Application Mismatch Modifying an SFC Section with Unity Pro (140 CPU ) The SFC code-generation process does not generate direct executable code but generates a set of data used by the SFC interpreter in the controller s OS to compute the next state. As with Concept, Unity Pro does not maintain the equality between the two application programs when a modification of a SFC section occurs does execute an SFC section by restarting the controller from its initial state after a switchover When a SFC section is modified in the Primary CPU, its data are not transferred to the Standby CPU. When a transfer of logic occurs from the Primary CPU to the Standby CPU, the first section of the logic is diagnostic information. NOTE: SFC Programming Language Schneider Electric recommends not using the SFC programming language. This language is not available for the following module: 140 CPU S. NOTE: If switchover occurs when the Run mode is selected and there is an application mismatch between the two controllers, the standby CPU assumes Primary CPU responsibilities and starts solving a different application program from the previous Primary CPU WARNING UNINTENDED EQUIPMENT OPERATION - SWITCHOVER HAZARD Ensure that the controllers contain the same application program and remove any application mismatch by performing an application program transfer upon completing modifications. Failure to follow these instructions can result in death, serious injury, or equipment damage /

150 Application Mismatch Online or Offline Modifications and Application Mismatch Modifying Application Programs Normally, once a fault-tolerant redundant system is configured, programmed, and controlling its process, the system is not shut down not even for periodic maintenance. However, there may be situations when you may need to make modifications to the application program and continue to control the process. The application mismatch feature allows you to modify application programs online or offline while controlling the process. WARNING UNEXPECTED EQUIPMENT BEHAVIOR - LOSS OF CONTROL Before switching a modified application to the standby: Examine carefully all the impacts of the modifications on the application. Check that the modified application does not have adverse effects on the process. Failure to follow these instructions can result in death, serious injury, or equipment damage /2010

151 Application Mismatch Online Modifications to an Application Program in the Standby CPU and Application Mismatch Executing the Procedure To make online modifications to an application program (logic program or project) in the Standby CPU controller, follow these steps. Step Action 1 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. 2 Connect to the Primary CPU controller and access the Command Register system bit %SW Set to 1 the Command Register system bit %SW Connect to the Standby CPU controller. 5 Modify online the application program. 6 After completing the modifications, perform Build Project. NOTE: In case of adding/removing modules, the build changes can be used. 7 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. 8 Perform a switchover (see page 155). Note: Standby CPU will change to Primary CPU. 9 Perform application transfer (see page 157) to Standby CPU. 10 Connect to the new Primary CPU controller and access the Command Register system bit%sw Set to 0 the Command Register system bit %SW60.3 Note: Command Register is returned to 0 from 1. NOTE: For more details using Application Mismatch (see page 158) /

152 Application Mismatch Online Modifications to an Application Program in the Primary CPU and Application Mismatch Executing the Procedure To make online modifications to an application program (logic program or project) in the Primary CPU controller, follow these steps. Step Action 1 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. 2 Connect to the Primary CPU controller and access the Command Register system bit %SW Set to 1 the Command Register system bit %SW Modify online the application program. 5 After completing the modifications, perform Build Project. NOTE: In case of adding/removing modules, the build changes can be used. 6 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. NOTE: In case of adding/removing modules, the build changes can be used. 7 Perform an application transfer to the Standby CPU. Application Program Transfer Method and Application Mismatch, page Connect to the new Primary CPU controller and access the Command Register system bit %SW Set to 0 the Command Register system bit %SW60.3 Note: Command Register is returned to 0 from 1. NOTE: For more details using Application Mismatch (see page 158) /2010

153 Application Mismatch Offline Modification of an Application Program and Application Mismatch Executing the Procedure To make offline modifications to an application program in either controller, follow these steps. Step Action 1 Modify the application program offline. 2 After completing the modifications, perform Build Project and save. Note: Do NOT use the Rebuild All Project option because using Rebuild All Project will cause the Standby CPU to go offline when the application program is downloaded. 3 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. 4 Connect to the Primary CPU controller and access the Command Register system bit %SW Set to 1 the Command Register system bit %SW Open the modified program and connect to the Standby CPU controller. 7 Download the program and select RUN. Note: Check your controller s state and ensure state is Run Standby. 8 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode. 9 Perform a switchover. (see page 155) Note: Ensure Standby CPU switched to Primary CPU. 10 Perform application transfer to Standby CPU. Application Program Transfer Method and Application Mismatch, page Connect to the new Primary CPU controller and access the Command Register system bit %SW Set to 0 the Command Register system bit %SW60.3 Note: Command Register is returned to 0 from 1. NOTE: For more details using Application Mismatch (see page 158) /

154 Application Mismatch WARNING UNEXPECTED EQUIPMENT BEHAVIOR - LOSS OF CONTROL Before switching a modified application to the standby: Examine carefully all the impacts of the modifications on the application. Check that the modified application does not have adverse effects on the process. Failure to follow these instructions can result in death, serious injury, or equipment damage /2010

155 Application Mismatch Switchover Methods and Application Mismatch General Switchover can be performed using one of two methods: Hot Standby submenu on the front panel keypad Command Register either system bit %SW60.1 or %SW60.2 NOTE: If bits %SW60.1 and %SW60.2 are set to 0 simultaneously, a switchover occurs: the Primary CPU controller goes RUN offline, and the Standby CPU controller now operates as RUN Primary CPU. Switchover Using Front Panel Keypad To force a switchover using the front panel keypad, do the following: Step Action 1 Access the front panel keypad of the Primary CPU controller. 2 Go to PLC Operation menu. 3 Go to Hot Standby submenu. 4 Go to Hot Standby mode 5 Modify Run to Offline. Note: Ensure that Standby CPU switched to Primary CPU. 6 Modify offline to run. Note: Ensure that the LCD displays Run Standby. Command Register Switchover To perform the switchover using Command Register system bit %SW60.1 or %SW60.2, ensure that following are considered: application program is saved twice. Each save uses a different file name. file 1 Saved before modification file 2 Saved after modification order of the controller is [(A) or (B)]; use one of two methods: Hot Standby submenu on the front panel keypad (PLC Operation Hot Standby Hot Standby Order). Unity Pro status dialog (refer to the bottom of the Unity Pro window when connected online) /

156 Application Mismatch Switchover Using Command Register System Bit %SW60.1 or %SW60.2 To force a switchover by setting the bits in the Command Register, do the following: Step Action 1 Open file 1. 2 Connect to the Primary CPU. 3 Ensure the controller order of the Primary CPU is A or B. 4 Access Command Register system bit %SW60.1 If the connected controller order is A. Command Register system bit %SW60.2 If the connected controller order is B. 5 Set bit to 0. Note: Ensure that the Standby CPU switched to Primary CPU. 6 Open file 2. 7 Connect to the new Primary CPU controller. 8 Access the Command Register system bit used in Step 4. 9 Set bit to 1. Note: Ensure Standby CPU controller is now online. 10 Ensure both Primary CPU and Standby CPU controllers are in Run Primary CPU and Run Standby CPU mode /2010

157 Application Mismatch Application Program Transfer Method and Application Mismatch General Application Program Transfer can be performed using one of two methods: Hot Standby submenu on the front panel keypad Command Register system bit %SW60.5 Application Program Transfer Using Front Panel Keypad To transfer an application program (logic program or project) to either the Primary CPU or Standby CPU controller using the front panel keypad, do the following> Step Action 1 Access the front panel keypad of any controller (Primary CPU or Standby CPU) 2 Go to PLC Operations menu 3 Go to Hot Standby submenu 4 Go to Hot Standby transfer and press ENTER to confirm the transfer. Note: Ensure transfer to Standby CPU occurs. Application Program Transfer Using Command Register System Bit %SW60.5 To transfer an application program (logic program or project) to either the Primary CPU or Standby CPU controller using Command Register system bit %SW60.5, do the following. Step Action 1 Connect to the Primary CPU controller. 2 Access Command Register system bit %SW Set bit to 1. Note: The process of setting the bit toggles the bit from 0 to 1 and back to /

158 Application Mismatch Recommendations for Using Application Mismatch General When using the Application Mismatch feature, Schneider Electric recommends noting that the following are affected: Upload Information Management, Online modifications to the Standby CPU, Application Program Transfer, Setting the Command Register system bit %SW60.3. Upload Information Management Feature General During online modifications, your system detects that the application-program information in the controller differs from the application-program information in the computer. Because this information will be used later when an upload is performed, the system requires you to update this information and constantly presents a confirmation dialog. To avoid constant display of the dialog, use the Upload Information Management feature. Using the Upload Information Management Feature Before doing any modifications and at the initial start up of your system, do the following: Step Action 1 From the menu, select Tools Option. 2 In the Options window, select the General tab (default). 3 Select Automatic in the Upload Information Management area. 4 Press OK to close the window. 5 Save the program and download to the controller /2010

159 Application Mismatch Handling Online Modifications to the Standby CPU For major modifications to the application program on the Standby CPU, ensure the Standby CPU is in offline mode. Two benefits result from this action: Run process continues Primary CPU does NOT perform a switchover during modification of the Standby CPU NOTE: SWITCHOVER DURING MODIFICATION If the Standby CPU is online during modifcations, there is a possibilty of switchover occuring. If a switchover occurs, the Standby CPU becomes Primary CPU, and the process may run with incomplete modifications. Performing Application Program Transfer When performing an application program transfer, you want to avoid the possibility of having two different application programs running in the Primary CPU and Standby CPU. Step Action 1 Perform Application program transfers after completing online modifications with Application Mismatch. Resetting Command Register System Bit %SW60.3 When resetting the Command Register system bit %SW60.3 to 0, you want to avoid the possibility of having two different application programs running in the Primary CPU and Standby CPU. Step Action 1 Connect to Primary CPU. 2 Access the Command Register system bit %SW Reset bit to /

160 Application Mismatch /2010

161 Application Program Transfer /2010 Transferring an Application Program with Unity Pro 9 Overview This chapter provides information about the Application Program Transfer feature that enables you to configure the Standby CPU controller from the Primary CPU controller. What's in this Chapter? This chapter contains the following topics: Topic Page Overview of Application Program Transfer 162 Executing the Application Program Transfer Procedure Using the Command 164 Register Automatic Application Program Transfer 165 Executing the Application Program Transfer Procedure Using the Keypad /

162 Application Program Transfer Overview of Application Program Transfer Overview The Application Program Transfer feature provides you with the ability to configure the Standby CPU from the Primary CPU controller. Use this feature when you reprogram the Primary CPU controller or replace the Standby CPU controller because the process copies the full application program of the Primary CPU to the Standby CPU. This feature not only saves time but ensures that the controllers have identical configurations. The system transfers the application program over the dedicated Modicon Quantum Hot Standby with Unity communications link. In a redundant system, this link connects the two Copros. Methods of Transferring Programs Application transfer is from the Primary CPU to the Standby CPU. There are three methods of transferring application programs: Hot Standby submenu on the front panel keypad Command Register system bit %SW60.5 Automatic transfer (Occurs when you start a Hot Standby system for the first time.) Therefore, the Primary CPU automatically transfers the application program to the Standby CPU. (see page 165) Validating Transfer The Standby CPU validates the transferred application program. After validating, the Standby CPU starts automatically. Understanding Transfer Time Application Program Transfer time depends on the size of the application program, the larger the program, the longer the time. Application Program Transfer takes a few seconds. NOTE: During application program transfer, the system can no longer be considered redundant. If the Primary CPU should stop before the Standby CPU is ready to assume the role of Primary CPU, there is no Standby CPU available /2010

163 Application Program Transfer Updating from the Primary CPU An application program update may only be performed from the Primary CPU to the Standby CPU. NOTE: UPDATING STANDBYS CPU The Standby CPU controller cannot update the Primary CPU. Understanding Transfer Size Limits NOTE: CHANGING FROM LEGACY Legacy Modicon Quantum controllers running Concept have an Application Program Transfer limit of 1 megabyte. In the Modicon Quantum Hot Standby with Unity 140 CPU transfer size depends on the configuration. For example, using a card bridge you may transfer up to 7 Mb. Therefore, transfer the complete application program regardless of the size. This transfer takes place over multiple scans, thus will be broken up into multiple transfer packets /

164 Application Program Transfer Executing the Application Program Transfer Procedure Using the Command Register Overview To transfer, use the command register in the Unity Pro software tools. The Primary CPU copies the complete application program and data to the Standby CPU. Transferring the Application Program Using Command Register System Bit %SW60.5 To transfer an application program (logic program or project) to either the Primary CPU or Standby CPU controller using Command Register system bit %SW60/5, do the following. Step Action 1 Connect to the Primary CPU controller. 2 Access Command Register system bit %SW Set bit to 1. Note: The process of setting the bit toggles the bit from 0 to 1 and back to /2010

165 Application Program Transfer Automatic Application Program Transfer Overview New in a Modicon Quantum Hot Standby system with Unity is automatic application program transfer. As soon as a Primary CPU controller detects a blank controller, the Primary CPU transfers the program to the blank controller, which becomes the Standby CPU. After application program transfer both controllers have identical application programs. This new feature works well when two controllers are at a maximum of 2 Km apart. NOTE: Same Configuration The controllers need to have the same configuration (with the same PCMCIA cards or without cards) /

166 Application Program Transfer Executing the Application Program Transfer Procedure Using the Keypad Overview For specifics on setting Modicon Quantum Hot Standby with Unity state, mode, order, and transfer from the keypad, see Configuring a Modicon Quantum Hot Standby with Unity System, page 63. Using the Keypad To transfer, use the front panel keypad on the controller unit (Primary CPU or Standby CPU). The Primary CPU copies the complete application program and data to the Standby CPU. NOTE: CHANGING FROM LEGACY In legacy Quantum Hot Standby systems, an application program transfer could be performed ONLY on the Standby CPU controller. The Standby CPU requested from the Primary CPU an application transfer. The process was performed on the CHS module and required setting the key in the Xfer key position while pushing the update button. In Modicon Quantum Hot Standby with Unity, an application transfer is performed either: by using the command register: An application program transfer can be performed at any time. automatically: Transfer occurs first time Primary CPU finds an empty Standby CPU. by using the keypad: Use either the Primary CPU or Standby CPU /2010

167 Application Program Transfer Transferring the Application Program The following table shows the Application Program Transfer Procedure. Step Action 1 Ensure the Primary CPU Controller is in RUN PRIMARY CPU mode. Result: The LCD on the PLC will display the mode as RUN PRIMARY CPU. 2 Check that both 1. Invalidate Keypad option is NOT selected 2. the key switch is unlocked 3 Go to the submenu Hot Standby Transfer. 4 Push Enter to execute the application program transfer from the Primary CPU to the Standby CPU. 5 Note: The Hot Standby Transfer command can be performed either in the Primary CPU or Standby CPU controller, BUT only the Standby CPU controller will be updated. Identical Configurations and Application Programs After the transfer, the Primary CPU and Standby CPU have identical configurations and application programs. In the event of a detected error in the Primary CPU and depending on the mode selected for the Standby CPU (Run or Offline), the Standby CPU may or may not be ready to assume the role of Primary CPU /

168 Application Program Transfer /2010

169 Using Modicon Quantum Hot Standby with Unity HSBY EFBs /2010 Using the Modicon Quantum Hot Standby with Unity EFBs 10 Overview This chapter describes the Modicon Quantum Hot Standby with Unity elementary function blocks (EFBs): HSBY_RD HSBY_ST HSBY_WR REV_XFER What's in this Chapter? This chapter contains the following topics: Topic Page Description: HSBY_RD 170 Description: HSBY_ST 173 Description: HSBY_WR 176 Description: REV_XFER /

170 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description: HSBY_RD Function Description This EFB allows you to use the Hot Standby function. It searches (together with other EFBs in the Hot Standby family) the configuration of the respective Quantum PLC for the required components. These components refer to hardware that is actually connected. Therefore the correct behavior of this EFB on the simulators cannot be guaranteed. The HSBY_RD EFB independently checks if a Hot Standby configuration exists. (%SW60 (see Unity Pro, Program Languages and Structure, Reference Manual )). If a configuration is present the contents of the command register are given and the HSBY output is set to "1". If there is no Hot Standby configuration present the HSBY_ConfigurationFound output is set to "0". EN and ENO can be configured as additional parameters. Representation in FBD Representation: /2010

171 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation in LD Representation: Representation in IL Representation: CAL HSBY_RD_Instance (HSBY=>HSBY_ConfigurationFound, INV_KEY=>InvalidateKeypad, PCA_RUN=>PLC_A_Running, PCB_RUN=>PLC_B_Running, SBY_OFF=>StandbyOff, EXC_UPD=>ExecUpdate, SWP_MB1=>SwapAddressModbusPort1) Representation in ST Representation: HSBY_RD_Instance (HSBY=>HSBY_ConfigurationFound, INV_KEY=>InvalidateKeypad, PCA_RUN=>PLC_A_Running, PCB_RUN=>PLC_B_Running, SBY_OFF=>StandbyOff, EXC_UPD=>ExecUpdate, SWP_MB1=>SwapAddressModbusPort1); /

172 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter Description Description of the output parameters: Parameter Data type Meaning HSBY BOOL "1" = Hot Standby configuration found INV_KEY BOOL "1" = The submenu for the Hot Standby PLC button is disabled. PCA_RUN BOOL "1" = The PLC with the Hot Standby CPU 1. function is "A" on local rack 2. Command Register is selected RUN "0" = The PLC with the Hot Standby CPU 1. function is "A" on local rack 2. Command Register is selected OFFLINE PCB_RUN BOOL "1" = The PLC with the Hot Standby CPU 1. function is "B" on local rack 2. Command Register is selected RUN "0" = The PLC with the Hot Standby CPU 1. function is "B" on local rack 2. Command Register is selected OFFLINE SBY_OFF BOOL "0" = The standby PLC switches to the offline mode as soon as both PLCs receive a different program. EXC_UPD BOOL "1" = Exec-(Operating system-)update in the Standby-PLC is possible with the primary CPU PLC still running. (After Exec-Update the standby CPU PLC changes back to the online mode.) SWP_MB1 BOOL If a switchover has occurred, "1" = No Swap address of Modbus ports 1. "0" = Swap address of Modbus ports 1. SWP_MB2 BOOL Not used. Reserved SWP_MB3 BOOL Not used. Reserved /2010

173 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description: HSBY_ST Function Description This EFB allows you to use the Hot Standby function. It searches (together with other procedures in the Hot Standby family) the configuration of the respective Quantum PLC for the required components. These components refer to hardware that is actually connected. Therefore the correct behavior of this EFB on the simulators cannot be guaranteed. The EFB is used to read the IEC Hot Standby status register (%SW61 (see Unity Pro, Program Languages and Structure, Reference Manual )). If there is no Hot Standby configuration present the HSBY output is set to "0". EN and ENO can be configured as additional parameters. Representation in FBD Representation: /

174 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation in LD Representation: Representation in IL Representation: CAL HSBY_ST_Instance (HSBY=>HSBY_ConfigurationFound, THIS_OFF=>PLC_Offline, THIS_PRY=>Primary_PLC, THIS_SBY=>Standby_PLC, REMT_OFF=>Remote_PLC_Offline, REMT_PRY=>PrimaryRemote_PLC, REMT_SBY=>StandbyRemote_PLC, LOGIC_OK=>IdenticalPrograms, THIS_ISA=>HSBY_ModuleSwitchA, THIS_ISB=>HSBY_ModuleSwitchB) /2010

175 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation in ST Representation: HSBY_ST_Instance (HSBY=>HSBY_ConfigurationFound, THIS_OFF=>PLC_Offline, THIS_PRY=>Primary_PLC, THIS_SBY=>Standby_PLC, REMT_OFF=>Remote_PLC_Offline, REMT_PRY=>PrimaryRemote_PLC, REMT_SBY=>StandbyRemote_PLC, LOGIC_OK=>IdenticalPrograms, THIS_ISA=>HSBY_ModuleSwitchA, THIS_ISB=>HSBY_ModuleSwitchB); Parameter Description Description of output parameters: Parameter Data type Meaning HSBY BOOL "1" = Hot Standby configuration found THIS_OFF BOOL "1" = This PLC is offline THIS_PRY BOOL "1" = This PLC is the primary CPU PLC THIS_SBY BOOL "1" = This PLC is the standby CPU PLC REMT_OFF BOOL "1" = The other (remote) PLC is offline REMT_PRY BOOL "1" = The other PLC is the primary CPU PLC REMT_SBY BOOL "1" = The other PLC is the standby CPU PLC LOGIC_OK BOOL "1" = The programs for both PLCs are identical and application mismatch is active. THIS_ISA BOOL "1" = This PLC chose the CPU with the lower IP address between both Hot Standby CPUs. This is the Hot Standby CPU "A". THIS_ISB BOOL "1" = This PLC chose the CPU with the higher IP address between both Hot Standby CPUs. This is the Hot Standby CPU "B" /

176 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description: HSBY_WR Function Description This EFB allows you to use the Hot Standby function. It searches (together with other EFBs in the Hot Standby family) the configuration of the respective Quantum PLC for the required components. These components refer to hardware that is actually connected. Therefore the correct behavior of this EFB on the simulators cannot be guaranteed. The EFB HSBY_WR is used to set different Hot Standby Modes permitted for Hot Standby. Setting the respective modes means a change in the Hot Standby command register (%SW60 (see Unity Pro, Program Languages and Structure, Reference Manual )), which is carried out automatically by the function block. If there is no Hot Standby configuration, the HSBY_ConfigurationFound output is set to "0", otherwise it is set to "1". NOTE: This function only affects the primary CPU. EN and ENO can be configured as additional parameters. Representation in FBD Representation: /2010

177 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Representation in LD Representation: Representation in IL Representation: CAL HSBY_WR_Instance (INV_KEY:=InvalidateKeypad, PCA_RUN:=PLC_A_Running, PCB_RUN:=PLC_B_Running, SWP_MB1:=SwapAddressModbusPort1, HSBY=>HSBY_ConfigurationFound) Representation in ST Representation: HSBY_WR_Instance (INV_KEY:=InvalidateKeypad, PCA_RUN:=PLC_A_Running, PCB_RUN:=PLC_B_Running, SWP_MB1:=SwapAddressModbusPort1, HSBY=>HSBY_ConfigurationFound); /

178 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter Description Description of the input parameters: Parameter Data type Meaning INV_KEY BOOL In the submenu for the Hot Standby PLC button "1" = Changes are disabled. "0" = Changes are allowed. PCA_RUN BOOL "1 -> 0" = The Hot Standby CPU with A function on the local rack is forced into OFFLINE mode. "0 -> 1" = The Hot Standby CPU with "A" function is forced into RUN mode if its own button mode is in RUN mode. PCB_RUN BOOL "1 -> 0" = The Hot Standby CPU with "B" function on the local rack is forced into OFFLINE mode. "0 -> 1" = The Hot Standby CPU with the "B" function is forced into RUN mode if its own button mode is in RUN mode. SWP MB1 BOOL "0" and a switchover happened: The Modbus address on port 1 of the NEW primary CPU PLC changes. new primary CPU PLC address = old primary CPU address new standby CPU PLC address = new primary CPU address "1" and a switchover happened: The Modbus address on Port 1 of the PLC don t changes. new primary CPU PLC address = old standby CPU address new standby CPU PLC address = old primary CPU address SWP_MB2 BOOL Not used. Reserved SWP MB3 BOOL Not used. Reserved Description of the output parameters: Parameter Data type Meaning HSBY BOOL "1" = Hot Standby configuration found /2010

179 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Description: REV_XFER Function Description This EFB allows you to use the Hot Standby function. Together with other EFBs in the Hot Standby family, it checks the configuration of the respective Quantum PLC for the components required for a Hot Standby configuration. These components are hardware that is actually connected. The EFB REV_XFER provides the ability to transmit 2 registers from the standby PLC to the primary CPU PLC. The two registers transferred by this EFB are %SW62/63, and are used by the application program (in the first section) to register diagnostic information. REV_XFER can only be used in the first executable section of the project. The parameter addresses TO_REV1 and TO_REV2 have to be in the non-transfer area to prevent being overwritten by the Primary CPU PLC. NOTE: In the legacy (Concept) Hot Standby System, these four registers (Reverse Transfer Registers) are the first addresses in the non-transfer area. This is not the case with the current (Unity) Hot Standby System. See Configuring Registers with Unity Pro, page 93. As additional parameters, EN and ENO are projected. Appearance in FBD Appearance: /

180 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Appearance in LD Appearance: Appearance in IL Appearance: CAL REV_XFER_Instance (TO_REV1:=Standby_PLC_FirstReg, TO_REV2:=Standby_PLC_SecondReg, HSBY=>HSBY_ConfFlag, PRY=>Primary_PLC_Flag, SBY=>Standby_PLC_Flag, FR_REV1=>FirstRevTransReg, FR_REV2=>SecondtRevTransReg) Appearance in ST Appearance: REV_XFER_Instance (TO_REV1:=Standby_PLC_FirstReg, TO_REV2:=Standby_PLC_SecondReg, HSBY=>HSBY_ConfFlag, PRY=>Primary_PLC_Flag, SBY=>Standby_PLC_Flag, FR_REV1=>FirstRevTransReg, FR_REV2=>SecondtRevTransReg); /2010

181 Using Modicon Quantum Hot Standby with Unity HSBY EFBs Parameter Description Description of input parameters: Parameter Data type Description TO_REV1 INT Describes the first reverse transfer register if this PLC is the standby PLC. Data in this register are transferred from the standby CPU PLC to the primary CPU PLC at each scan. TO_REV2 INT Describes the second reverse transfer register if this PLC is the standby CPU PLC. Data in this register are transferred from the standby CPU PLC to the primary CPU PLC at each scan. Description of the output parameters: Parameter Data type Description HSBY BOOL "1" = Hot Standby configuration PRY BOOL 1 = This PLC is the primary CPU PLC. SBY BOOL 1 = This PLC is the standby CPU PLC. FR_REV1 INT Content of first reverse transfer register (%SW62 (see Unity Pro, Program Languages and Structure, Reference Manual )). Output only if HSBY is "1". FR_REV2 INT Content of second reverse transfer register (%SW63 (see Unity Pro, Program Languages and Structure, Reference Manual )). Output only if HSBY is "1" /

182 Using Modicon Quantum Hot Standby with Unity HSBY EFBs /2010

183 CCOTF Quantum Hot Standby /2010 Changing Configuration On The Fly with Quantum Hot Standby IV Contents of this Part This part describes the Change Configuration On The Fly (CCOTF) function in Quantum Hot Standby systems. This function is referred to as CCOTF in the following chapters. What's in this Part? This part contains the following chapters: Chapter Chapter Name Page 11 CCOTF Presentation Upgrade Procedure to Use CCOTF Function Using CCOTF CCOTF Troubleshooting /

184 CCOTF Quantum Hot Standby /2010

185 CCOTF Presentation /2010 CCOTF Presentation 11 Overview of the Modicon Quantum Hot Standby CCOTF with Unity System Purpose The objective is to allow CCOTF modification when the PLC is in RUN mode (see Quantum with Unity Pro, Hardware, Reference Manual). Modifications can be made to the discrete or analog I/O modules in the local rack or RIO drop as follows: add a module in a free slot, delete a module, modify the adjust and command parameter of a module. NOTE: Those modifications can only be done if the module is compatible (see Quantum with Unity Pro, Hardware, Reference Manual) /

186 CCOTF Presentation /2010

187 Upgrade Procedure to use CCOTF Function /2010 Upgrade Procedure to Use CCOTF Function 12 Subject of this Chapter This chapter describes the method to upgrade a Modicon Quantum Hot Standby to be CCOTF compatible. What's in this Chapter? This chapter contains the following sections: Section Topic Page 12.1 Overview of Upgrade Procedure Executing the CCOTF Upgrade Procedure /

188 Upgrade Procedure to use CCOTF Function 12.1 Overview of Upgrade Procedure General Main Upgrade Cases Different main cases have to be considered: A complete STOP of the system is required when doing a firmware upgrade on the Hot Standby system. When the applications cannot be stopped for a long time, an upgrade by changing the hardware modules is possible. Stop While Upgrading It is necessary for the Quantum Hot Standby system to be stopped during the upgrade procedure. The system is stopped for a few seconds if changing the hardware modules and is brought to a complete STOP if upgrading the firmware /2010

189 Upgrade Procedure to use CCOTF Function 12.2 Executing the CCOTF Upgrade Procedure Purpose This section describes the procedure to upgrade the Modicon Quantum Hot Standby PLCs in order to use the CCOTF function. The upgrade can be done in two ways: Changing the hardware modules with a temporary stop (approximately one minute), Upgrading the firmware, that requires a complete stop. NOTE: To download the CPU, Copro, CRA and CRP firmwares, please access to Schneider electric web site WARNING SYSTEM NO LONGER ACTIVE NOR REDUNDANT Before stopping the system, always positively confirm that there is no critical operation in progress. The system is no longer active nor redundant. Failure to follow these instructions can result in death, serious injury, or equipment damage. What's in this Section? This section contains the following topics: Topic Page General 190 Changing the Hardware Modules 191 Upgrading the Firmware /

190 Upgrade Procedure to use CCOTF Function General Upgrade CCOTF The picture below shows the example of a Quantum Hot Standby configuration that will be upgraded to be CCOTF compatible: In order to make a Quantum Hot Standby configuration CCOTF compatible, there are several steps to follow: Upgrade the CPU and CRP in Standby PLC B, Upgrade the CPU and CRP in Primary PLC A, Upgrade the CPU application in the two PLCs, Upgrade all the CRA connected to the RIO bus. The CPU and CRA / CRP modules can be upgraded in two ways: By changing the hardware modules to use CCOTF compatible modules. NOTE: In this case, it is possible to stop the Hot Standby system a minimum amount of time. By upgrading the CPU, Copro and CRA / CRP modules firmware. NOTE: In this case, the Hot Standby system must be stopped during the firmware upgrade procedure /2010

191 Upgrade Procedure to use CCOTF Function Changing the Hardware Modules Changing PLC B Procedure The objective of the procedure below is to describe how to upgrade the modules in the Standby PLC: 1. Make sure that the application program running on the Quantum Hot Standby CPUs has been exported in the XEF format and is available on the computer. If not, upload the application program from one of the two PLCs to Unity Pro, and export it in the XEF format. 2. If not yet installed, install Unity Pro 4.1 XL or XLS (or higher software version), 3. Stop the Standby PLC (PLC B) and power it off. NOTE: At this point, the system is no longer operating redundantly. 4. When using a PCMCIA, remove the PCMCIA card, 5. When using a PCMCIA, remove the batteries of the memory card to empty the card, 6. Disconnect the fiber optic cable on CPU B. 7. Disconnect the RIO cables from CRP B. 8. Replace CPU B and CRP B with compatible versions V2.70 (or higher firmware version) and V Power on PLC B. 10.When using a PCMCIA, insert the batteries in the PCMCIA card then insert the PCMCIA card in CPU B. NOTE: The CPU must be in a No Conf state. 11.Import the XEF file of the application in Unity In the Local Bus editor replace the current version of the 140 CPU / 140 CPU x0 with the new version 140 CPU / 140 CPU (or higher firmware version). 13.Click on the online modification in Run check box in the CPU configuration screen to enable the new function /

192 Upgrade Procedure to use CCOTF Function The picture below shows the specific check box added in the configuration tab: 14.Rebuild the application using Rebuild all and download it onto CPU B. The CPU is in STOP mode. 15.Reconnect the RIO cable from CRP B, then the fiber optic onto the CPU B. WARNING LOSS OF COMMUNICATION Before changing the state of PLC A to STOP, always positively confirm that there is no critical operation in progress. The system is no longer active nor redundant. Failure to follow these instructions can result in death, serious injury, or equipment damage. 16.Connect Unity Pro 4.1 to the PLC A. Stop PLC A /2010

193 Upgrade Procedure to use CCOTF Function WARNING UNEXPECTED APPLICATION BEHAVIOR - LOSS OF DATA At the end of the application download, all the application data in the PLC B have their initial value. Before changing the state of the PLC B to RUN, always confirm that the application can restart with initial values. Failure to follow these instructions can result in death, serious injury, or equipment damage. 17.Connect Unity Pro to PLC B and put the PLC in RUN mode. Ensure PLC B becomes Primary. Changing PLC A Procedure The objective of the procedure below is to describe how to upgrade the second PLC A: 1. Power off PLC A that is in stop mode, NOTE: At this point, the system is no longer operating redundantly. 2. When using a PCMCIA, remove the PCMCIA card, 3. When using a PCMCIA, remove the batteries of the memory card to empty the card, 4. Disconnect the fiber optic cable from CPU A. 5. Disconnect the RIO cables from CRP A. 6. Replace CPU A and CRP A by the new ones. 7. Power on PLC A. 8. When using a PCMCIA, insert the batteries in the PCMCIA card then insert the PCMCIA card in CPU A. NOTE: The CPU must be in a No Conf state. 9. Reconnect the RIO cable to CRP A, then the fiber optic on the CPU A. 10.An automatic transfer from Primary to Standby is done, 11.Make sure PLC A runs in Standby /

194 Upgrade Procedure to use CCOTF Function Changing the CRA Modules in the Quantum RIO Drops Changing CRA modules in the RIO drops must only be done after the local rack of the Primary PLC and the Standby PLC have been updated with new CPU and CRP modules: 1. Make sure that a powered off RIO drop is supported by the application. 2. Power off the RIO drop to update. 3. Disconnect the RIO cable from the CRA module, then remove the CRA module from the drop 4. Insert the new CRA module. 5. Reconnect the RIO cable on the CRA module. 6. Power on the RIO drop. 7. Repeat steps 2 through 6 for all RIO drops. NOTE: All RIO drops configured in the RIO bus must be CCOTF compatible. This means that the corresponding bit in the system word %SW98 and %SW99 must be set to 1. If not, CCOTF modification is not allowed. NOTE: 800 Series I/O and Sy/Max I/O are not CCOTF compatible. When the CCOTF function is configured, neither 800 Series I/O nor Sy/Max I/O must be connected to the RIO bus /2010

195 Upgrade Procedure to use CCOTF Function Upgrading the Firmware CPU / Copro Compatibility Table The Copro firmware version is dependent on the Quantum Hot Standby CPU firmware. The table below shows the compatibility and the version between the CPU firmware and Copro firmware to be CCOTF compatible: Quantum Hot Standby CPU Firmware Versions V2.70 V2.70 V2.80 V2.80 The objective of the procedure below is to describe how to upgrade the PLC to be CCOTF compatible: 1. Make sure that the application program running on the Quantum Hot Standby CPUs has been exported in the XEF format and is available on the computer. If not, upload the application program from one of the two PLCs to Unity Pro, and export it in the XEF format. 2. If not yet installed, install Unity Pro 4.1 XL or XLS (or a higher software version), 3. Put the 2 PLCs in STOP mode. Copro Firmware Versions WARNING SYSTEM NO LONGER ACTIVE Before changing the state of both PLCs to STOP, always positively confirm that there is no critical operation in progress. The system is no longer active. Failure to follow these instructions can result in death, serious injury, or equipment damage. CPU Firmware Upgrade The CPU firmware download can be done through Modbus or Modbus Plus by using the Unity Pro OS Loader tool. The following procedure describes the main steps to perform a CPU upgrade: 1. Open the OS Loader tool, 2. Select the Modbus or Modbus Plus communication option, 3. Connect to the CPU using Modbus or Modbus Plus, 4. Open the binary file: Example: 140CPU67160_Vxxx.bin, where xxx is equal to 270 or higher than 270, 5. Download the binary file to the CPU /

196 Upgrade Procedure to use CCOTF Function Copro Firmware Upgrade The Copro firmware download can be done by using Unity Pro OS Loader tool. The following procedure describes the main steps to perform a Copro upgrade: 1. Modify the PC IP address, 2. Open the OS Loader tool, 3. Select the file transfer protocol (FTP), 4. Connect to the CPU using Modbus or Modbus Plus, 5. Open the binary file: Example: 140CPU67160_HysbyCopro_Vxxx.bin, where xxx is equal to 270 or higher than 270, 6. Download the binary file to the Copro. NOTE: The CPU / Copro firmware upgrade must be done on both of the PLC. CRP Firmware Upgrade The CRP firmware download can be done by using Unity Pro OS Loader tool. The following procedure describes the main steps to perform a CRP upgrade: 1. Open the OS Loader tool, 2. Select the Modbus or Modbus Plus communication option, 3. Select the Local Head and indicate the Slot Number, 4. Select the Download OS to Device option, 5. Open the binary file: Example: QCRP932_Vxxx.bin, where xxx is equal to 200 or higher than 200, 6. Download the binary file to the CRP. CRA Firmware Upgrade The CRA firmware download can be done by using Unity Pro OS Loader tool. The following procedure describes the main steps to perform a CRA upgrade: 1. Open The OS Loader tool, 2. Select the Modbus or Modbus Plus communication option, 3. Select the Remote I/O Drop and indicate the Drop Number (rotary switch), 4. Select the Download OS to Device option, 5. Open the binary file: Example: QCRA932_Vxxx.bin, where xxx is equal to 200 or higher than 200, 6. Download the binary file to the CRA /2010

197 Using CCOTF /2010 Using CCOTF 13 Subject of this Chapter This chapter describes how to add / delete and modify modules in a Quantum Hot standby configuration that has been upgraded to the CCOTF compatible version. What's in this Chapter? This chapter contains the following topics: Topic Page General 198 Add / Delete a Module in the Quantum Hot Standby Local Racks 204 Add / Delete a Module in the Quantum Hot Standby RIO Drop 209 Modify Module Parameters /

198 Using CCOTF General Quantum Hot Standby System Configuration Overview A Quantum Hot Standby configuration can be made of a local rack and Remote I/O drops. The local rack and each remote I/O drop can be made of two backplanes: The Primary backplane contains the CPU or the Remote I/O drop adapter, The Secondary backplane is linked to the Primary backplane with two backplane expanders. The picture below shows the elements that can be part of a Quantum hot standby configuration: 1. Power Supplies 2. CPU or RIO Adapter 3. First backplane Expander (140 XBE ) 4. Second backplane Expander (140 XBE ) 5. Backplane expander Cable (140 XCA ) 6. Cable end marked as Primary /2010

199 Using CCOTF General Advice WARNING RISK OF UNEXPECTED EQUIPMENT BEHAVIOUR Before doing any CCOTF modification, ensure that your system responds appropriately. Modifications made when the on line modification in RUN check box is selected can have an immediate impact on the process. Failure to follow these instructions can result in death, serious injury, or equipment damage. There are recommendations to take into account before adding / removing a module from the local racks or RIO drop: Adding a module in the Unity Pro configuration: Configure the module in Unity Pro, Plug the module in the hardware configuration, Write the sequences of application program to manage the new module. Removing a module from the configuration: Remove the sequence of application program that is related to the removed module, Unplug the module from the hardware configuration, Remove the module from the unity Pro configuration. NOTE: It is recommended to add first the module in the Unity Pro configuration screen before adding the module in the PLC. The status bit of the module is set to 0 during the time where the module is configured but not present (Refer to Description of Quantum System Words %SW180 to %SW640 (see Unity Pro, Program Languages and Structure, Reference Manual )). This impacts the diagnostic bits like %S118 or %S119 and %S10. This effect must be taken into account in the application program. On the other hand, when a parameter is changed, the module is re-started and status bit is set to 0 during several ms. This impacts also the diagnostic bits like %S118 or %S119 and %S /

200 Using CCOTF WARNING UNEXPECTED EQUIPMENT BEHAVIOUR Always transfer the application to the Standby PLC after modifying the configuration in the Primary PLC. The application in both PLCs must be the same. Failure to follow these instructions can result in death, serious injury, or equipment damage. %SW98, %SW99 and %SW100 System Words In order to manage the CRP / CRA compatibility, two system words (see Unity Pro, Program Languages and Structure, Reference Manual ) are used: %SW98 and %SW99. The system words %SW98 and %SW99 can be used to diagnose compatibility issues regarding the CRA / CRP modules that are configured in a Quantum Hot Standby configuration /2010

201 Using CCOTF The following illustrations identify the operating options provided by the Status Register for the two system words %SW98 and %SW99: NOTE: All RIO drops configured in the RIO bus must be CCOTF compatible. This means that the corresponding bit in the system word %SW98 and %SW99 must be at 1. If not, no CCOTF modification is allowed. The system word %SW100 is incremented each time a CCOTF modification is performed in a PLC. %SW100 = XXYY, where: XX is incremented each time an CCOTF modification is done in RUN state in an RIO drop, YY is incremented each time an CCOTF modification is done in RUN state in the local rack. NOTE: 800 Series I/O and Sy/Max I/O are not CCOTF compatible. When the CCOTF function is configured, neither 800 Series I/O nor Sy/Max I/O must be connected to the RIO bus /

202 Using CCOTF CCOTF Allowed Actions The table below describes the possible main actions that can be done on discrete or analog modules in a Quantum Hot Standby local rack and a Quantum Hot standby RIO Drop: Local Rack (Primary or Secondary backplane) Add in RUN mode Delete in RUN mode Modify the parameters in RUN mode Rio Drop (Primary or Secondary backplane) Add in RUN mode Delete in RUN mode Modify the parameters in RUN mode NOTE: It is not possible to move a module in RUN mode. If this action is done, a pop-up is displayed in Unity Pro that indicates that this action must be done in STOP or OFFLINE mode. The move action can be replaced by a delete module from one slot and then an add module in an other slot. NOTE: A CCOTF modification can only be done when the PLCs are in Primary / Standby state. Otherwise no CCOTF modification can be achieved. NOTE: When a discrete output module is inserted in RUN in a Quantum Hot Standby configuration: all the output bits associated to this module in the state RAM are set to 0 (and all forced bits are immediately unforced). When an analog output module is inserted in RUN in a Quantum Hot Standby configuration, all the output words associated to this module in the state RAM are set to 0. When a discrete or analog input module is inserted in RUN in a Quantum Hot Standby configuration, all the input bits or words associated to this module in the state RAM are kept in the same state (included forced bits). Number of CCOTF Modifications Validating a CCOTF modification requires a Build change and only one CCOTF modification is allowed at a time. This is true in both the Standard connected mode as well as in the Virtual connected mode /2010

203 Using CCOTF The picture below shows what happens if the number of allowed CCOTF modifications is exceeded: NOTE: A CCOTF modification is valid with these two actions: Adding / Deleting / Modifying a module in the Unity Pro configuration screen is carried out. Performing a Build Change of the modifications. Example of CCOTF Modification Recommended CCOTF modification: Insert a new module in a free slot, Modify the parameters of this module, Validate the parameters modification. These 3 actions are considered as one CCOTF modification and require one build change. NOTE: Program modifications (add a new sequence of code, suppress a sequence of code, modify a sequence of code) are not considered part of the CCOTF modification. Only I/O configuration modifications (if they are allowed) are counted /

204 Using CCOTF Add / Delete a Module in the Quantum Hot Standby Local Racks Nominal Use Case in Standard Connected Mode NOTE: In a Hot Standby system it is not recommended to use local I/O. Please refer to Local I/O and Distributed I/O Restrictions (see page 34) WARNING POSSIBLE UNEXPECTED EQUIPMENT BEHAVIOR Remove the field wiring terminal strip on the module before adding or deleting a module. Failure to follow these instructions can result in death, serious injury, or equipment damage /2010

205 Using CCOTF The flow-chart below describes the action to be done when adding a module in the Primary PLC : /

206 Using CCOTF The flow-chart below describes the action to be done when deleting a module in the Primary PLC : /2010

207 Using CCOTF Nominal Use Case in Virtual Connected Mode NOTE: In a Hot Standby system it is not recommended to use local I/O. Please refer to Local I/O and Distributed I/O Restrictions (see page 34) WARNING POSSIBLE UNEXPECTED EQUIPMENT BEHAVIOR Remove the field wiring terminal strip on the module before adding or deleting a module. Failure to follow these instructions can result in death, serious injury, or equipment damage. In this mode, it is possible to modify the I/O configuration when the application is offline. The application that is downloaded onto the PLCs has to be generated with the Virtual connected mode checkbox enabled in the Project settings General Build settings. In OFFLINE mode: The flow-chart below describes the action to be done in case of Add or Delete a module: /

208 Using CCOTF When connected to the Hot Standby system: The flow-chart below describes the action to be done when connected to the Hot Standby system: /2010

209 Using CCOTF Add / Delete a Module in the Quantum Hot Standby RIO Drop Nominal Use Case in Standard Connected Mode WARNING POSSIBLE UNEXPECTED EQUIPMENT BEHAVIOR Remove the field wiring terminal strip on the module before adding or deleting a module. Failure to follow these instructions can result in death, serious injury, or equipment damage /

210 Using CCOTF The flow-chart below describes the action to be done when adding a module in the Primary PLC: /2010

211 Using CCOTF The flow-chart below describes the action to be done when deleting a module in the Primary PLC: /

212 Using CCOTF Nominal Use Case in Virtual Connected Mode WARNING POSSIBLE UNEXPECTED EQUIPMENT BEHAVIOR Remove the field wiring terminal strip on the module before adding or deleting a module. Failure to follow these instructions can result in death, serious injury, or equipment damage. It is possible to modify the I/O configuration when the application is offline. The application that is downloaded in the PLCs has to be generated with the Virtual connected mode check box enabled in the Project settings dialog box. In OFFLINE mode: The flow-chart below describes the action to be done when connected to the Hot Standby system: /2010

213 Using CCOTF When connected to the Hot Standby system: The flow-chart below describes the action to be done when connected to the Hot Standby system: /

214 Using CCOTF Modify Module Parameters General There are two kinds of parameters to take into account: Configuration parameters which are linked with the application memory mapping or the CPU operating system. Examples: Input / Output starting address. Command or adjust parameters which impacts the module behavior. Examples: data format, fallback value, etc. (see Unity Pro, Program Languages and Structure, Reference Manual ) NOTE: In a pre-existing module only the command and adjust parameters can be modified. NOTE: When a new module is inserting for the first time, all parameters can be modified. The picture below shows the configuration parameters screen: WARNING RISK OF UNEXPECTED EQUIPMENT BEHAVIOUR Before doing any CCOTF modification, ensure that your system responds appropriately. Modifications made when the on line modification in RUN check box is selected can have an immediate impact on the process. Failure to follow these instructions can result in death, serious injury, or equipment damage /2010

215 Using CCOTF Nominal Use Case in Standard Connected Mode The flow-chart below describes the action to be done: Nominal Use Case in Virtual Connected Mode It is possible to modify the I/O configuration and the application offline. The application that is downloaded in the PLCs has to be generated with the Virtual connected mode check box enabled in the Project settings dialog box. In OFFLINE mode: /

216 Using CCOTF When connected to the Hot Standby system: The flow-chart below describes the action to be done when connected to the Hot Standby system: /2010

217 Troubleshooting /2010 CCOTF Troubleshooting 14 Hot Standby Specific Troubleshooting List Overview If a CCOTF modification cannot be performed in the Quantum Hot Standby system, follow potential problems and their solutions in the table below: Potential Problem Solution The system is running as a stand alone Verify that one PLC is in RUN Primary state system, without redundancy and the other is in RUN Standby state Unity Pro 4.1 or higher version is not installed Install Unity 4.1 or higher version At least one of the two PLCs has an application that is not CCOTF compatible The application must be "rebuilt all" (after changing the processor and checking the Online Modification in RUN check box) and downloaded in both PLCs If the potential problem is not described refer to the CCOTF general Troubleshooting list (see Quantum with Unity Pro, Hardware, Reference Manual). NOTE: Before doing any CCOTF modification, Make sure that the system word %SW60.3 is set to 1. If not, the Standby PLC will go in OFFLINE state after the first CCOTF modification and no other CCOTF modification will be allowed /

218 Troubleshooting /2010

219 /2010 Appendices At a Glance The appendices for the Quantum Hot Standby Planning and Installation Guide are included here. What's in this Appendix? The appendix contains the following chapters: Chapter Chapter Name Page A Modicon Quantum Hot Standby with Unity Additional 221 Information B Modicon Quantum Hot Standby Controls and Displays /

220 /2010

221 Additional Information /2010 Modicon Quantum Hot Standby with Unity Additional Information A Overview This chapter describes the necessary cables, design specifications, error codes. What's in this Chapter? This chapter contains the following topics: Topic Page Fiber Optic Cable CPU Specifications CPU S Specifications CPU Specifications 230 CRP Remote I/O Head Processor Error Patterns 232 TextIDs /

222 PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## ENTER PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## ENTER Additional Information Fiber Optic Cable Schneider Electric Recommends Recommendations: For 140 CPU modules, use up to 4 km of 62.5/125 µm, graded index, duplex, multi mode glass fiber (usually referred as OM1 type fiber). NOTE: This type of fiber are rated at maximum attenuation of 1.5 db per km (maximum, at 1300nm). For 140 CPU modules, use up to 16 km of 9/125 µm, duplex, single mode glass fiber (usually referred os OS1 or G652 type fiber). NOTE: This type of fiber are rated at maximum attenuation of 0.35 db per km (maximum, at 1300nm). Wherever possible, use a multifiber cable since the cable is inexpensive and provides a backup in case one of the fiber is cut in the process of pulling. Typical Configuration Scheme The following graphic represent the direct connection with possible splices between two modules : USB USB MODBUS MODBUS MTRJ connector 2. Duplex 62.5 / 125 µm, graded index, multi-mode fiber optic Cable NOTE: Use only single mode with 140CPU67160 : up to 4km 3. LC connector 4. Duplex 9 / 125 µm, single-mode fiber optic Cable NOTE: Use only single mode with 140CPU67261 : up to 16km 5. Splices /2010

223 PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## ENTER ENTER PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## PENTIUM CONTROLLER ESC COM STS RESTART MOD Mac Address 00:00:##:##:##:## ENTER ENTER Additional Information The following graphics represent the direct connection with possible splices between two modules when using a multi-fiber cable: USB USB MODBUS MODBUS 1 1 Multimode (140CPU67160 models): up to 4km USB USB MODBUS MODBUS 3 3 Single mode (140CPU67261 models): up to 16km 1. MTRJ / MTRJ fiber jumper 2. Duplex 62.5 / 125 µm, graded index, multi-mode fiber optic Cable 3. LC / LC fiber jumper 4. Duplex 9 / 125 µm, single-mode fiber optic Cable 5. Splices 6. Fiber distribution box 7. Backup fiber 8. MTRJ jack (or MTRJ coupler) 9. LC jack (or LC / LC coupler) /

224 Additional Information Optical Power Budget Calculation The maximum length of Hot Standby fiber optic link must be calculated by considering total loss in all components used in the path : fiber optic cable, optical connectors and splices : For 140 CPU modules, the Power Loss Budget in 62.5/125 µm fiber cable equals 9.9dB (including system margin). For 140 CPU modules, the Power loss Budget in 9/125 µm fiber cable equals 9dB (including system margin) Max distance = Power Loss Budget [db] - number of connectors 0.35dB - number of splices 0.15dB) fiber attenuation [db/km] NOTE: There is no minimum distance requirement /2010

225 Additional Information Cables Available From Schneider Electric Multi mode part numbers for 140 CPU Description 490 NOR m MTRJ / MTRJ 490 NOR m MTRJ / MTRJ 490 NOR m MTRJ / MTRJ Single mode part numbers for 140 CPU Description VDIF m LC / LC /

226 Additional Information 140 CPU Specifications Module Specifications Element Communication ports Bus current required Max. number of NOM, NOE, PTQ PDP MV1 and MMS modules supported (any combination) Key switch Keypad Description 1 Modbus (RS-232/RS-485) 1 Modbus Plus (RS-485) 1 USB 1 Ethernet (used as HSBY port) 2.5 A 6 Yes Yes Processor Function Model Clock speed Coprocessor Watchdog timer Description Pentium 266 MHz Yes, Built-in Ethernet 250 ms software adjustable Memory RAM IEC program memory (and/or application data and configuration IEC program memory (max. with PCMCIA card) 2 MByte 1024 kbyte 7168 kbytes Program Execution Time Kilo Instruction executed per millisecond (Kins/ms) Execution time per instruction (ms/kins) 100 % Boolean 65 % Boolean + 35 % digital 100 % Boolean 65 % Boolean + 35 % digital NOTE: When considering the execution time with the RAM or the PCMCIA card, the values are identical as the program execution takes place within the CACHE memory /2010

227 Additional Information Reference Capacity Discrete (bits) Registers (words) 64 k (any combination) 64 k max. Remote I/O Max. I/O words/drop 64 in / 64 out* Max. number of remote drops 31 * This information can be a mix of discrete or register I/O. For each word of configured I/O, one of the I/O words must be subtracted from the total available. Battery and Clock Battery type Service life Shelf life Battery load power-off TOD clock 3 V Lithium 1.2 Ah 10 years with 0.5% loss of capacity/year typical: 14 μa max. 420 μa +/ C Diagnostic Power-up Run Time RAM RAM address Executive Checksum User Logic Check Processor RAM RAM address Executive Checksum User Logic Check /

228 Additional Information 140 CPU S Specifications Module Specifications Component Communication ports Bus current required Max. number of NOE modules supported Key switch Keypad Description 1 Modbus (RS-232/RS-485) 1 Modbus Plus (RS-485) 1 USB 1 Ethernet (used as HSBY port) 2.5 A 6 Yes Yes Processor Feature Model Clock speed Coprocessor Watchdog timer Description Pentium 266 MHz Yes, Built-in Ethernet 250 ms software adjustable Memory RAM IEC program memory (and/or application data and configuration) IEC program memory (max. with PCMCIA card) 4 MByte 1024 kbyte 7168 kbytes Reference Capacity Discrete (bits) Registers (words) 64 k (any combination) 64 k max /2010

229 Additional Information Remote I/O Max. I/O words/drop 64 in / 64 out* Max. number of remote drops 31 * This information can be a mix of discrete or register I/O. For each word of configured I/O, one of the I/O words must be subtracted from the total available. Battery and Clock Battery type Service life Shelf life Battery load power-off TOD clock 3 V Lithium 1.2 Ah 10 years with 0.5% loss of capacity/year typical: 14 μa max. 420 μa +/ C Diagnostic Power-up Run Time RAM RAM address Executive Checksum User Logic Check Processor RAM RAM address Executive Checksum User Logic Check /

230 Additional Information 140 CPU Specifications Module Specifications Component Description Communication ports 1 Modbus (RS-232/RS-485) 1 Modbus Plus (RS-485) 1 USB 1 Ethernet (used as HSBY port) Bus current required 2.5 A Max. number of NOE modules 6 supported Key switch Keypad Yes Yes Processor Feature Model Clock speed Coprocessor Watchdog timer Description Pentium 266 MHz Yes, Built-in Ethernet 250 ms software adjustable Memory RAM IEC program memory (and/or application data and configuration) IEC program memory (max. with PCMCIA card) 4 MBytes 3172 kbytes 8MBytes Reference Capacity Discrete (bits) Registers (words) 64 kbytes (any combination) 64 kbytes max /2010

231 Additional Information Remote I/O Max. I/O words/drop 64 in / 64 out* Max. number of remote drops 31 * This information can be a mix of discrete or register I/O. For each word of configured I/O, one of the I/O words must be subtracted from the total available. Battery and Clock Battery type Service life Shelf life Battery load power-off TOD clock 3 V Lithium 1.2 Ah 10 years with 0.5% loss of capacity/year typical: 14 μa max. 420 μa +/ C Diagnostic Power-up Run Time RAM address Executive Checksum User Logic Check Processor RAM address Executive Checksum /

232 Additional Information CRP Remote I/O Head Processor Error Patterns Error Patterns The following table displays both number of times the Com Act indicator blinks for each type of error possible codes for each type of blink All codes are in hex. Number of blinks on Com Act Indicator Code in hex Error Slow (steady) 0000 requested kernel mode hcb frame pattern error 6822 head control block diag error 6823 mod personality diag error 682A fatal start IO error 682B bad read IO pers request 682C bad execute diag request 6840 ASCII input xfer state 6841 ASCII output xfer state 6842 IO input comm state 6843 IO output comm state 6844 ASCII abort comm state 6845 ASCII pause comm state 6846 ASCII input comm state 6847 ASCII output comm state 6849 building 10 byte packet 684A building 12 byte packet 684B building 16 byte packet 684C illegal IO drop number interface bus ack stuck high coax cable initialization error 6617 coax cable dma xfer error 6619 coax cable dumped data error 681A coax cable DRQ line hung 681C coax cable DRQ hung RAM address test error /2010

233 Additional Information Number of blinks on Com Act Indicator Code in hex Error RAM data test error PROM checksum error (exec not loaded) 6301 PROM checksum error kernel PROM checksum error 8002 flash prog / erase error 8003 unexpected executive return /

234 Additional Information TextIDs TextIDs TextIds define the warning messages written in the diagnostic buffer. TextIDs switching from Primary CPU to Offline TextID Warning message System halt Remote IO error ETH device error ETH communication problem Stop PLC command Offline keypad switch Offline Command register request TextIDs switching from Standby CPU to Offline TextID Warning message System halt Remote IO error ETH device error ETH communication problem Stop PLC command Offline keypad switch Offline Command register request TextIDs switching from Standby CPU to Primary CPU TextID Warning message Control command over ETH Control command over RIO TextIDs switching from Offline to Primary CPU/Standby CPU TextID Warning message Switch from Offline to Primary CPU Switch from Offline to Standby CPU BY /2010

235 Controls and Displays /2010 Modicon Quantum Hot Standby Controls and Displays B Overview This chapter provides an overview of controls and displays, LED description and screen menu structure. What's in this Chapter? This chapter contains the following topics: Topic Page Controls and Displays 236 Using the 140 CPU / 140 CPU / 140 CPU S LED 239 Indicators Using the LCD Display Screens /

236 Controls and Displays Controls and Displays Lens Cover The protective lens cover can be opened by sliding upwards. With the lens cover open you have access to the following items: key switch battery reset button Key Switch The key switch is a security feature and a memory protection switch. The key switch has two positions: locked and unlocked. The key switch is only read and deciphered by the PLC OS (executive) portion of the firmware and not by the OS loader portion. The Quantum High End processor has a set of system menus that enable the operator to: perform PLC operations (i.e., start PLC, stop PLC) display module parameters (i.e., communications parameters) switch to the maintenance mode (Safety processors) The effect of the key position is shown below: Key Position PLC Operation unlocked: System menu operations can be invoked and changeable module parameters can be modified by the operator with the LCD and keypad. Memory protection is OFF. You can switch to Maintenance mode (Safety processors). locked: No system menu operations can be invoked and module parameters are read-only. Memory protection is ON. Safe mode forced (Safety processors). Switching the key switch position from locked to unlocked or vice versa turns on the LCD's backlight. NOTE: For more explanations about Maintenance and Safe mode of Safety processors (see Modicon Quantum, Quantum Safety PLC, Safety Reference Manual) Reset Button When pressed, this button forces a cold start of the PLC /2010

237 Controls and Displays LCD Display The high-end CPU with Unity has a standard 2-line by 16-character liquid crystal display (LCD) with changeable backlight state and contrast: The backlight handling is entirely automated to save the life of the LCDs. The backlight turns on when one of the following occurs: a key is pressed the key switch state is changed an error message is displayed on the LCD The backlight will stay on for error messages as long as the error message is displayed otherwise, the backlight automatically turns off after five minutes. Adjusting the Contrast The contrast is adjustable from the keypad when the Default screen is displayed. Step Action 1 Press the MOD key: 2 To adjust the contrast darker press: 3 To adjust the contrast lighter press: 4 To confirm the setting press: /

238 Controls and Displays Keypad The high-end processor has a keypad with five keys that are mapped to a hardware address. On each of the two arrow keys is an LED: 1 5 keys 2 2 LEDs Using the Keys Keypad functionalities Key Function To cancel an entry, or suspend or stop an action in progress To display the preceding screens successively (step up the menu tree) To confirm a selection or an entry To set a field on the display into modify mode LED: on LED: flashing LED: off LED on LED flashing LED off key active To scroll through menu options To scroll through modify mode field options key active Field in modify mode has options to scroll through key inactive No menu options, no field options key active To move around in a screen, field to field To go to the sub-menu key active To move around in a field that is in modify mode, digit to digit key inactive No sub-menu for menu option No moving around in a screen No moving around in a field /2010

239 Controls and Displays Using the 140 CPU / 140 CPU / 140 CPU S LED Indicators Overview The Modicon Quantum Hot Standby with Unity modules has two types of indicators: 1. LCD display screen The default display screen serves as a controller status screen. (see page 240) 2. LED Indicators The following figure shows the two types of indicators. 1 LCD Display (lens cover closed) 2 LED Indicators LED Description The following table shows the description for the LED indicators of the different Modicon Quantum Hot Standby with Unity modules. LEDs COM STS Indication Controlled by the Coprocessor hardware Indicates Primary CPU or Standby CPU activity Controlled by the Coprocessor firmware Blinking: system is redundant and data are exchanged from the Primary CPU to Standby CPU controller ON: system not redundant / Copro booting from power-on to end of self-tests OFF: Copro auto tests not OK /

240 Controls and Displays Using the LCD Display Screens Overview The controller s LCD displays messages. These messages indicate the controller s status. There are four levels of menus and submenus. Menus are accessed using the keypad (see page 238) on the front of the controller. For detailed information about the menus and submenus see: PLC Operations Menus and Submenus (see page 243) Using the Communications Menus and Submenus (see page 246) Using the LCD Settings Menus and Submenus (see page 248) Using the System Info Menus and Submenus (see page 249) Structure: LCD display menus and submenus 1 Default Screen 2 System Menus 3 Sub Menus 4 Sub Screens /2010

241 Controls and Displays Accessing the Screens Use the keys on the keypad to access the system menus and submenus. Step Action 1 To access the screens, ensure that the key switch is in the unlocked position. 2 To step down to a lower menu, operate one of the following keys: 3 To return to the previous menu, press: Default Screen The Default screen displays the following information. The default screen is read-only. Fields Available Options Available Description Mode M Maintenance Mode (on safety processors only) S Safe Mode (on safety processors only) State RUN application program is running RUN Prim RUN as primary CPU processor (HotStandBy processors only) RUN Stby RUN as standby CPU processor (HotStandBy processors only) RUN OffL RUN offline (HotStandBy processor not connected to another processor) STOP application program is NOT running STOP offline No Conf processor has no application program Halt detected state error (in maintenance mode for safety modules) /

242 Controls and Displays Fields Available Options Available Description BatL indicates battery health: steady = battery is low no message = battery is OK Port USB indicates that port has activity Modbus MB+ indicates Modbus Plus activity Plus mb+ no activity Dup Duplicate MB+ address ERR Modbus communications Error INI Initial Network Search Modbus 232 serial port activity for RS serial port activity for RS-485 PCM 1 displayed status indicates battery health of the PCMCIA card in slot 1: steady = battery is OK flashing = battery is low (only for green PCMCIAs (PV<04)) * 2 displayed status indicates battery health of the PCMCIA card in slot 2: steady = battery is OK flashing = battery is low (only for green PCMCIAs (PV<04)) * * With blue PCMCIAs (PV>=04), when main battery is low there is no flash /2010

243 Controls and Displays PLC Operations Menu Structure: PLC Operations menu and submenus /

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