W05 High Availability for Today s Process Market

2 Agenda High Availability Overview Controllers Networks I/O

What it is High Availability High availability is a system implementation that ensures a certain absolute degree of operational continuity during a given time period. (Mission Period) Availability is the readiness for a system to perform when needed. Availability refers to the ability of the user community to access the system, whether to submit new work, update or alter existing work, or collect the results of previous work. In a control system environment, availability also means the control system is performing it s designed function while doing any of the above things. High availability techniques are used to... 1. Modify a running system Reduce planned outages 2. Prevent unplanned outages Availability is measurable Represented as a % Commonly known as number of nines High availability is more than Redundancy! 3

High Level Availability in a ControlLogix System Availability % Possible Downtime per Year 99% 3.65 days 99.9% 8.76 hours 99.99% 52.6 minutes 99.999% 5.26 minutes 99.9999% 30 seconds Standard ControlLogix Redundant CLX Availability is measurable as a %: A = MTBF / MTBF+MTTR Copyright 2012 Rockwell Automation, Inc. All rights reserved. 4

How CLX increases Availability Maintainability Improved Diagnostics: Internal diagnostics to detect failures and LED indicators Diagnostic I/O modules: Wire off, shorts, etc. Hart and other Fieldbus technology with sensor & actuator diagnostics. Alarms and Events Inherent Machine Diagnostics Runtime Modifications: Runtime partial import. Online Edits RIUP of 1756, 1715 and 1794/1797 modules Addition of 1756 and 1715 modules in Run mode ControlLogix Redundancy adds the ability to update firmware at Runtime Ease of Maintainability Results in Minimized Downtime Copyright 2012 Rockwell Automation, Inc. All rights reserved. 5

6 The HA System Put Availability where you need it most Economics should drive How Much. Cost of Lost Product Cost of Lost Data Damage to Equipment Cost of Downtime Loss of View Cost of Hazard Common Applications Power Generation, Paper Machines Biotech Batches Reactors Fractional Distillation Baggage Handling

7 Agenda High Availability Overview Controllers Networks I/O

8 ControlLogix Redundancy Dual Chassis Design Full Redundancy Both Chassis match Transparent Primary/Secondary Chassis IP Address Swap ControlNet Node Swap Easy to use No special code Automatic Crossload Treat as one chassis Uses Standard 1756 hardware Up To: 2 Controllers 7 Communications Modules

9 CLX Redundancy Overview Operation Basics Application from Primary is automatically loaded into the Secondary processor Data changes are sent to secondary at the end of each program. The Secondary controller is Synchronized with the Primary via Sync Points at each crossload point. System is Floating Master type. Each chassis is capable of being Primary Primary Chassis 1756-RM2 Secondary Chassis

10 CLX Redundancy Overview Enable Redundancy Controller Properties New Controller Dialog

11 CLX Redundancy Considerations What can t I do with a CLX Redundancy System Put the following modules in a Redundancy Chassis I/O DH/RIO DNB Most Third party modules Motion Control Sercos or CIP Motion Inhibit a Task Event Task Unicast Data Redundancy System can be Producer to another controller as Unicast. Firmware Supervisor Anything that makes use of a storage card will be stored on two controllers in the event of a switchover.

12 CLX Redundancy Conclusion Easy to use Single program to maintain Data is automatically Crossloaded Single Checkbox to enable Redundancy Uses standard CLX hardware Transparent IP address and MAC address follows Primary Most devices on network are unaware of a switchover Chassis switchover in 20ms range on average Primary Chassis Secondary Chassis 1756-RM2

14 CompactLogix Hot Backup Features Uses standard hardware and firmware No added hardware cost Fast Scan time Very flexible Automatic configuration tool CompactLogix or ControlLogix ControlNet or Ethernet I/O V20 forward will only support Ethernet I/O 250 ms to a few seconds switchover time Application code dependent

15 Hot Backup Code Generator Tool 1 2 3 4 5 6

16 CompactLogix Hot Backup Update Tool was updated in Logix V20 New Features Windows 7 support Event Log Switching code contained in an AOI New CompactLogix Controllers Supported 1769-L30ER 1769-L33ER Available through RA Sales. No cost for the tool but sales must qualify the application.

19 Sil3 Process Safety Fully Scalable from Single to Triple (TMR) Transparent to the user and System Highest Availability: 3-2-0 Fault Tolerance Hot swap modularity IEC 61131-3 programming Safety certified communications Single to Triple I/O

20 Agenda High Availability Overview Controllers Networks I/O

Control Network Resiliency Ethernet/IP Many different Resiliency options Open Technology Ring or Star or Linear ControlNet Redundant Media Option

Resiliency Protocols and Redundant Topologies Layer 2 Copyright 2012 Rockwell Automation, Inc. All rights reserved. 22 Redundant Star Flex Links Cisco Catalyst 3750 StackWise Switch Stack Ring Resilient Ethernet Protocol (REP) Cisco Catalyst 3750 StackWise Switch Stack Star/Bus Linear Cisco Catalyst 3750 StackWise Switch Stack Cisco Catalyst 2955 HMI HMI Controller HMI HMI Controllers Controllers Controllers, Drives, and Distributed I/O Cell/Area Zone Cell/Area Zone Controllers, Drives, and Distributed I/O Cell/Area Zone Controllers, Drives, and Distributed I/O Cell/Area Zone Redundant Star Ring Linear Cabling Requirements Ease of Configuration Implementation Costs Bandwidth Redundancy and Convergence Disruption During Network Upgrade Readiness for Network Convergence Overall in Network TCO and Performance Best OK Worst

Network Resiliency Protocols Selection is Application Driven Resiliency Protocol Mixed Vendor Ring Redundant Star Network Convergence > 250 ms Network Convergence 60-100 ms Network Convergence 1-3 ms Layer 3 Layer 2 STP (802.1D) X X X X RSTP (802.1w) X X X X X MSTP (802.1s) X X X X X rpvst+ X X X X REP X X X EtherChannel (LACP 802.3ad) X X X X Flex Links X X X DLR (IEC & ODVA) X X X X StackWise X X X X X HSRP X X X X GLBP X X X X VRRP (IETF RFC 3768) X X X X X Copyright 2012 Rockwell Automation, Inc. All rights reserved. 23

High Availability Network Architecture Provides resiliency at the device level through dual port devices. Ideal applications include: Where there are Low cost and ease of use resiliency requirements Migration from field bus networks CIP Sync applications Where users do not want to use central switches Can recover in as fast as 3 ms for a 50 node ring worst case Lower cost to implement than other resilient network types Device-Level Ring Single fault tolerant network provides resiliency Device level ring requires no additional hardware to implement Copyright 2012 Rockwell Automation, Inc. All rights reserved. 24

25 Resiliency Protocols and Redundant Topologies Representative Example Production - VLANs IP Camera - VLAN Layer 2 Access Link Layer 2 Interswitch Link/802.1Q Trunk Safety Controller HMI Catalyst 3750 StackWise Switch Stack Controller Stratix 8000/8300 REP/MSTP Class 3 Only VLAN 103 Camera VLAN 43 I/O VFD Drive Controller Controller I/O Camera VLAN 103 VLAN 43 Any Commercial Safety Protocol I/O is I/O acceptable as long as it I/O meets the Servo Drive HMI I/O application requirements VLAN 104 I/O Industrial Zone Level 3 Cell/Area Zones Levels 0 2 HMI VFD Drive

26 Characterized Network Architecture Server A Cisco 2960_A 192.168.110.12 Cisco 3750 StackWise Switch Stack 192.168.11.1 192.168.20.1 192.168.110.1 FA0/1 G0/1 G1/0/25 G2/0/25 G1/0/27 G2/0/27 Client FA0/3 FA0/3 FA0/2 FA0/2 FA0/1 NIC teaming on servers and client G0/2 G1/0/26 G2/0/26 EtherNet/IP G1/0/28 G2/0/28 G0/1 G0/2 Server B Cisco 2960_B 192.168.110.13 VLANs 100, Native 110, Switch mgmt 10, I/O 11, Zone 20, HMI Stratix 8000, A 192.168.110.10 CIP, 192.168.11.8 G1/2 G1/1 G1/2 G1/1 FA1/1 Redundant Logix Controllers FA1/1 192.168.11.12 192.168.11.13 Stratix 8000, B 192.168.110.11 CIP, 192.168.11.9 Cell/Area Zone Levels 0-2 CLGX A CLGX B 192.168.10.10 192.168.10.11 Point I/O & ETAP 192.168.10.13 192.168.10.29 EtherNet/IP DLR

Additional Material Rockwell Automation Networks Website: http://www.ab.com/networks/ EtherNet/IP Website: http://www.ab.com/networks/ethernet/ Embedded Website: http://www.ab.com/networks/switches/embedded.html Embedded Switch Technology Manual http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/enet-ap005_- en-p.pdf Knowledgebase Website: www.rockwellautomation.com/knowledgebase/?openform Publications: ENET-UM001G-EN-P provides connection and packet rate specs for modules Copyright 2012 Rockwell Automation, Inc. All rights reserved. 27

28 Agenda High Availability Overview Controllers Networks I/O

29 1715 Redundant I/O Currently: 24VDC Digital Input 24VDC Digital Output 4-20mA Analog Input 4-20mA Analog Output Ethernet/IP Adapter Redundant 24VDC Power Supply Connectors Redundant or Simplex Configurations RIUP and Add Online at Runtime Fully Transparent to the user Uses RSLogix 5000 Profiles 24 I/O modules Max 12 pairs or 24 Simplex Automatic Field Wiring Diagnostics Short, Open SIL 2 Certification January 2013 Module Pair

30 1715 Assemblies Module Termination Assembly Base

1715 Transparency Modules appear as single modules for ease of use but are fully redundant Modules Configure from RSLogix 5000

32 System Review Controllers Networks I/O