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PACSystems Max-On Hot Standby Redundancy Manual

1. uueseeuusse 8 3 Step 3 Use the Max ON RX3i Diagnostic Tool eeeeeeeeeeeeeeeeeeeee 8 4 xiii elc 2 eR E 8 5 Ala S e 8 6 System Considerations uci Cocco costo Caceres Come circ rence oce cin Cos aou aude A 1 General Max ON RX3i Considerations eeeseeessesesseeeeeeee rennen A 1 Improving Ethernet Sync Efficiency Using PLC Sweep Mode A 1 Hot Swapping IC693 ICG94BEM331 Modules eeeeeeeeeeeeeeeeeeee A 3 Frequently Asked Questions ccccccssseeseeseeeceenseeseenseesenseesenneesens B 1 Quick Start Guide Using Ethernet I O C 1 Updating an Existing Application D 1 VENIE LL toc Hic EL I ee M D 1 Updating an Existing Max ON RX3i Application eeeeeseeeeeeeeeeennne D 3 BACKUP IMGs ADDICTION asst ctia CC D 3 Updating from Releases Prior to 3 14 cc eccceccccceeceseeeeeeeeceeeeseeeeseeeeseeesaeeeseueesaees D 5 Add EGD Exchanges t PLO Aiacis mto ESPERE Dc acht esa u a ea aaaea D 5 Add EGD Exchanges tO PLO B 2 essei deti ene rete e neut pr dbe n etae ua dE ach outils D 11 Update the Max ON Drivers ssi ote dte orae te ate era E eet ai Dor o e cte Stud uad D 17 vi PACSystems RX3iMax On Hot Standby Redundancy February 2009
2. Prraay Hue Lerida B i epum Humber 2 Buses ET bem s LT f dpeacem Settings Lerprdap Fun Cond ober Default Mum Feriti ag mee Audit Tt all d d d rt 1 CL s4bled EZ User AET Byrne LAM Topela gy 2 Iued Lae ar Failover Period Cmm Stan Teeredatanad ALATA Himlher of Alarms Fact 0 1235 128 A The configuration summary window text can be selected use the Select All right mouse button and pasted into a text editor for archiving and printing GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 29 User Defined Alarms The user may post user defined faults from within the application However before the Max ON RX3i Diagnostics can display the user alarms they must be configured NOTE User Defined Alarms are not available in the current version of the Max ON RX3i Diagnostics Adding a User Alarm 1 Select the User Alarms item in the Max ON RX3i Configuration Utility Project tree e ege inc Hiroa uma Burms Oger Detined Alarms Emm Humber cf ALecms 2 Select the User Defined Alarms gt Add Alarm menu item 3 Enter an Alarm Number and the corresponding Alarm Description Note The Alarm Number must be within the numerical range 3840 4095 The descriptor may be up to 60 characters in length Add Mew Une Alan Pump 1402 Stari Sequence F akad 4 30 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 4 Enter any additional a
3. M00996 Program Changed MO00997 HW Config Changed MO00998 Programs Miscompare M00999 Y M00993 Authorization Alarm This alarm bit indicates that the corresponding PLC is operating in DEMO mode on a standard PACSystems RX3i CPU IC695CPU310 When the CPU is replaced by a Max ON cpu IC695CMU310 this flag may be reset using the RST LOC or RST ALL variables joMO00994 Authorization Fault This fault bit indicates that the system was operating in DEMO mode for over 22 days and has subsequently shutdown The PLC Fault Table will indicate shutdown due a Service Request 9o0M00995 Remote CPU Offline The companion CPU is offline This may be due to the CPU being in STOP Fault or Power OFF Also it may be due to a cable problem or Ethernet Interface failure 9oM00996 Program Changed The program in the Local CPU has changed MO00997 HW Config Changed The hardware configuration in the Local CPU has changed MO00998 Programs Miscompare The program in CPU A is not the same as the program in CPU B 5 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Local Status Flags Latched cont 70MO 1001 MO01002 90MO 1003 9oMO 1004 9o0MO 1005 MO01006 9oMO 1008 GFK 2409A Max ON Alarm Fault Present MO01004 Max ON Alarm Fault Table Full MO01005 Config Fault 96MO 1006 Reserved M01008 Power Up The Local CPU has undergone a power up event Pr
4. ee Elash ed Dyno LEN Topology Badundank Failover Faricd Cra doen Paar detained kiarms Himbeer of Alarm TEARS o HI As you can see from the Project Navigator the utility allows you to specify the following information about the Max ON RX3i redundant system 4 6 Developer Biographical information of the engineer who developed the application End User Biographical information about the end user Settings Specifies the Max ON RX3i System Parameters Sync Data Specifies the synchronization data that is to be transferred from the Master CPU to the Backup CPU in order for the redundant system to be synchronized Sync Networks Specifies the Ethernet LAN configuration to be used to transfer the oynchronized Data Genius Busses Specifies the Genius Busses used by the redundant system for Genius I O User Alarms Allows the user to create self defined faults that can be logged by the Max ON RX3i redundant application Note User Alarms are not available in the current version of Max ON RX3i Diagnostics PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Developer and End User Information By selecting the Developer and End User items in the Project tree the information about the engineer who developed the application and the end user may be displayed and modified To edit this biographical information double click on the Developer or End User item in
5. February 2009 GFK 2409A BSM Controller Output Time Default CPU Redundancy Set this to Yes if there are two Genius busses that connect directly to the NIU Set this to No if there is a single bus connection Normally this is set to 2 5 Seconds oet this to Hot Standby InfoViewer 0 0 1C200GBI001 Target23 Settings Network Memory Power Consumption Parameters Values Serial Bus Ages 2 Baud Rate 153 6 Kbps Standard Report Faults Enabled BSM Present Yes BSM Controller Ma Output Time Default 2 DEC CPU Redundancy Hot Standby Duples Default Ott BSM Forced Untorced BSM State Bus A Series b Reference 65535 Contig Pratect Disabled 5 Select this as the active target 6 Set the Comm port characteristics 7 Connect a serial programming cable to your workstation and to the VersaMax I O drop 8 Store the configuration into the drop 9 Repeat this for any other VersaMax I O drops in the system GFK 2409A Chapter 7 Configuring the I O Devices 7 5 Remote 90 30 Genius Drops A Remote 90 30 Genius Drop consists of a Series 90 30 CPU power supply base and one or more Genius bus controllers Input and output modules are installed in the CPU base Modules also may be installed in an I O Expansion base A Scanner routine executes in the drop s CPU This routine scans all input devices and transmits the input states to the Hot Standby PLCs by way of the I O bus Creat
6. Primary Bus This field defines the base address assigned to the discrete inputs This address establishes the references that the input devices will use while they are connected to the Primary bus These are the same references that will be used throughout the user application logic l Reference The first reference address used within the discrete input group l Length The number of discrete references that are to be included on this device 4 22 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Discrete Inputs Secondary Bus When a dual bus is used there must be an alternate location for the Genius discrete inputs to report their status The alternate location is the reference area in which the inputs will appear while they are connected to the Secondary Genius I O bus Max ON RX3i redundancy drivers detect when the Primary inputs are unavailable If the Secondary inputs are reporting into the Secondary reference area the drivers will map the data automatically from the Secondary area into the Primary address locations This permits the user application to be written with references to the Primary addresses only Reference The first reference address used in the Secondary alternate reference table If the Primary Bus l Length is a multiple of 16 then the inputs will be mapped into the RX3i register table This value is read only If the Length is an odd multiple of 8 then the inputs may be mapped
7. This is the time required to update all configured synchronized data of the types AQ M and Q The time is reported in seconds This field indicates the mastership status of the corresponding PLC either Master or Backup There never should be two Masters or two Backups in a system that is operating properly A Preferred B Preferred or Float The local CPU has been switched from STOP mode to RUN mode The local CPU has undergone a power up event The companion PLC is offline This may be due to the CPU being in STOP Fault or Powered Off Also it may be due to a cable problem or Ethernet Interface failure This field indicates the completion status for the transfer of synchronized data The Backup CPU will indicate either Synced all oynchronized Variables have been received or Not Synced The Master CPU always indicates Synced ON It is ON in the Backup CPU at the moment when all Synchronized Data items have been updated This indicates that the corresponding PLC is running on a Max ON RX3i CPU or operating in DEMO mode In a system that is running on a Max ON RX3i CPU this flag will be OFF Chapter 8 Diagnostic Tools 8 5 Alarms Historical information is stored in the alarm table This table contains archived information for up to 32 alarm records for each PLC The records store information for both system alarms and optional user defined alarms Each alarm record consists of an identifier for the event that initiate
8. Instantaneous cont Variable Reference Description Name PWR UP mM00969 PRG RST MO00970 Program Restart E1 OFFL 70M0097 1 System Ethernet Bus Primary Offline E2 OFFL MO00972 System Ethernet Bus Secondary Offline MO00973 Reserved MO0992 MO00969 M00970 M0097 1 M0097 2 MO00973 90M00992 GFK 2409A Power Up PWR UP The Local CPU has undergone a power up event Program Restart PRG RST The Local CPU has been switched from STOP mode to RUN mode System Ethernet Bus Primary Offline E1 OFFL The primary Ethernet LAN is offline This may be due to a cable problem a transceiver problem a hub switch problem an ETMOO1 module failure or a LAN configuration error System Ethernet Bus Secondary Offline E2 OFFL The secondary Ethernet LAN is offline This may be due to a cable problem a transceiver problem a hub switch problem an ETMOO1 module failure or a LAN configuration error Reserved Chapter 5 Programming Considerations 5 5 Local Status Flags Latched The following status flags represent the latched state corresponding to the associated descriptors The states are set by the first instance of the associated event The flags are reset by either a Local Alarm Clear RST LOC or M01015 or a Master Alarm Clear RST ALL or M01016 If the underlying alarm condition is persistent then the flag will be set again Authorization Alarm A Only Authorization Fault A Only
9. F hbr noz ET hbr noa FP hbr_oo4 Appendix C Quick Start Guide Using Ethernet I O C 5 16 Select the C Block Update right mouse menu and select the cfg dat C Block gefelf file E MP El PLC COMMON CODE gay Data Watch Lists c i Hardware Configuration o Eff Rack o c695CH5012 EB Logic c Eta Program Blocks E ET MAIN M Fl MaxoM Components sii TF hbr Rename Fe ETT hbr Update DE hbr cut Ctrl H hbro copy Ckrl C i H hbr m 1F hbr Delete Del ETT hbr Properties Alt Enter ALP hbr Look irc E Mac Propet 4 t eE Femme fol duger O Flee of Ippe C Block Fies gerE ii T Cancel 17 At this point the updated Configuration Utility parameters have been added to the Max RX3i project Now download the updates to the Primary and Secondary controllers C 6 PACSystems RX3iMax On Hot Standby Redundancy February 2009 GFK 2409A Appendix Updating an Existing Application D This appendix explains how to upgrade the Max ON program blocks in your application to a newer version of Max ON using the Proficy Toolchest Overview The general sequence for updating an application is as follows 1 Revise the Hardware Configurations e Update the existing hardware configuration for the target named PLC A HW Include any changes that need to be made especially the EGD exchanges e Update the existing hardware configuration for the target named PLC B HW Again considering
10. IP address of each device This must be done in two places in the properties of the Target how programmer connects and in the Ethernet settings in hardware configuration Subnet mask of each device if required Gateway IP address of each device if required Check the Local Producer ID of each device and verify it is the IP address For Consumed Exchanges change the Producer ID of the Exchange 10 Set default values for variables 11 Download configurations to the Targets When downloading to new or unknown hardware first set the physical port property of the device in the programmer to a serial comm port com1 and connect via a serial cable to the power supply port After the initial store of the configuration sets the IP Address the physical port property can be set to Ethernet and the IP address entered This will allow connection of the programmer via Ethernet If you know the device s MAC Address an alternative process is to use the Set IP Utility in Machine Edition to set a temporary IP address so that you can connect to the devices from Logic Developer PLC Appendix C Quick Start Guide Using Ethernet I O C 3 12 To launch the Max ON RX3i Configuration Utility Open the Supplemental Files Documentation Files directory of the PLC COMMON CODE Target Lug D Using H l E Program Blocks S oe Reference view Tables m Eig Default Tables pani ih Supplemental Files ax 3 AUP Files hs B PAINI M
11. 0305 Notused o O 0320 Notused 00 0 O m Fault Class 04h Analog Outputs Decimal Hex Description Code Code 0 Circuit Offline The device corresponding to the circuit reference number shown in the Source Column has transitioned to offline 401 402 E S 0420 Notused o O lass 05h l O LAN Alarms N Fault C Decimal Hex Description Code Code 1089 0501 Addition of Device The device corresponding to the circuit reference number shown in the Source Column has transitioned to online 1090 0502 Loss of Device The device corresponding to the circuit reference number shown in the Source Column has transitioned to offline 1091 503 Notued o O 1120 ps20 Notued o o GFK 2409A Chapter 5 Programming Considerations 5 27 5 28 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter Configuring the Hot Standby Redundancy CPUs A Max ON RX3i Project contains three Targets that are used to distinguish between hardware configurations for CPU A and CPU B and the user application that is common to both of the CPUs The figure shown below illustrates the various components contained in the Generic X3i Project named Max ON RX3i LD Project vx yy zip 4 2 Ba mk at E PLT i b i Ms OR I ict HeU PLE B torri Cerda i i H uum lsi po sr LE I dl e ac Qon cone e Me Ferien rennen Ha DH REM Orset plus yow Eh sd Applicaton logic p
12. at ix Spe Propert ET Proficy Machine Edition GFK 2409A 8 1 3 Navigate to the Proficy Components directory then to the Diagnostics VIEW Make certain that the selection for Files of Type has been set to Proficy Machine Edition zip Max ON Rx3i Tools pe L3 Documents A Proficy Components ie _ Redundancy LO H Remote Drops LD When you click on Open a new project will be added to the Proficy Navigator window Restore Look ir 23 Diagnostics VIEW amp fe Max ON Rx3i view Project v2_06 zip File name Max ON Fix3i View Project v2 D6 zip Files of type zip Files zip L ancel E 4 Give your View project a descriptive name in the Machine Edition Navigator 8 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Step 2 Configure Ethernet Connections to the PLCs In order to conduct data transfers between Max ON RX3i Diagnostics and the Hot Standby PLCs you need to establish an Ethernet communication connection to the PLCs To configure the Ethernet addresses of the PLCs in the View Project 1 Open the View project that was restored in Step 1 2 Expand the PLC Access Drivers node in the Navigator for the View target and select the PLCA device E PLC Acciess Drivers H ot Fanu TOF PL fy Sangin ad Files 23 Docamentation Files HHI Ha Crer ia HAL Overvate im teh Derren T 10
13. m eT as Maximum Sync Data For each Synchronized Data type the system will sum the lengths in each configured group to arrive at a total amount for that data type The total must not exceed the size listed in the table below Registers Discrete Outputs Internal Coils Analog Outputs R Q M AQ 8000 2048 4096 256 The system flags although included in this number are not transferred Sync Networks When using Max ON RX3i one or two Ethernet LANs may be configured using an IC695ETMOO 1 interface card to transfer the Synchronization Data If you are using a dual Ethernet LAN topology then you may use two ETMOO1 modules in each PLC for the Sync LANs When the Ethernet module has been configured in the Logic Developer PLC hardware configuration you must assign the module a device status address Generally it is a good practice to place these in the upper area of the l reference memory Note The address must be set to 96101969 or lower When dual Ethernet LANs are used you must specify which device is to be the Primary device and which is to be the Secondary device The Ethernet Modules must be in the same slot positions in each of the two RX3i main racks GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 9 To display the configuration of the Sync Networks Interface Modules expand the Sync Networks node in the Project tree Now the configurations of the two Primary Interface modules are displayed To ed
14. place CPU A in STOP mode and CPU B in RUN mode Verify that the system input devices return real time values properly Verify that system output devices may be controlled from the Output Reference Tables Hot Standby Operation 1 Place both CPUs into RUN mode Make certain that there is only one Master and only one Backup Make certain that there is no preferred Master Place CPU B into STOP mode and then into RUN mode Make certain that Synchronized Data is transferred properly to CPU B Transfer Mastership from A to B by placing the CPU A into STOP mode Make certain that the I O did not dropout during the transfer Place CPU A into RUN mode 9 Make certain that it becomes a Backup properly 10 Transfer Mastership from B to A by placing the CPU B into STOP mode 11 Make certain that the I O did not dropout during the transfer 12 Place CPU B into RUN mode 13 Make certain that it becomes a Backup properly Oe a Ya oS CIN 14 Make certain that Synchronized Data is transferred properly to CPU B GFK 2409A Chapter 3 Building a Max ON RX3i Hot Standby Application 3 7 Step 7 Debug the System Use the Max ON RX3i View Diagnostic Project Restore the Proficy View Project from the installation directory into Proficy Machine Edition Enter the Ethernet Addresses of PLC A and PLC B into the Proficy View Project Download and Run the View Project on your workstation Examine the Alarm and the Real time Status displays
15. 10 some GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 13 Set the Max ON RX3i Identity for PLC B The identity for CPU B is determined by the value set in the Logic Checksum Words CPU Parameter located in the CPU s Hardware Configuration for CPU B Open the CPU module s Hardware Configuration by double clicking on the CMU310 module Click on the Scan tab to display the Logic Checksum Words parameter Verify that the Logic Checksum Words parameter s value is 16 If it is not 16 change the parameter to this value Verify that the Number of Last Scans is set to 1 If itis not 1 change the parameter to this value EEUTIENZERNTHDIGUEXIL Set Memory for PLC B Normally the memory in CPU B is configured the same as for CPU A Please refer to the information used for CPU A and make adjustments to the CPU B memory configuration if necessary Configure Ethernet Sync Network for PLC B Repeat the configuration process for the Ethernet synchronization interfaces in PLC B 6 14 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A L Configure EGD Exchanges for Sync LANS for PLC B Repeat the configuration process for the Ethernet synchronization interfaces in PLC B As stated for PLC A if the IP address needs to be changed then you must also change the IP addresses in the Produced and Consumed Exchanges that follow PLC B Primary PLC B Secondary Destination 10
16. 3 Targets PLC A HW This target contains the hardware configuration for PLC A It must be edited to reflect the hardware settings and components of PLC A in your system Then it must be downloaded to PLC A only PLC B HW This target contains the hardware configuration for PLC B It must be edited to reflect the hardware settings and components of PLC B in your system It will be very similar to PLC A hardware configuration except for certain items such IP addresses and Genius bus controller settings In a similar fashion this configuration must be downloaded to PLC B only PLC COMMON CODE This contains the core redundancy logic for the Max ON RX3i redundancy application You must add your application logic starting in the rung that follows the call to the core Max ON RX3i logic hbr 000 The logic from this target will be downloaded to both PLC A and PLC B Note that the download consists of the PLC Logic Only the Hardware Configuration option must be unchecked GFK 2409A 4 1 The diagram below illustrates how the Max ON RX3i Project is organized m ES ET EE Max CN Bcd LO Project v3 04 Bj 4 PLC A HW PLC A Hardware Canflquration Target DE d Pic Bi HW PLC B Hardware Confiquration Target Fi 4 PLC COMO CODE Common Application Logic target H Da Watch Lists MaxOM RX3i Data Watch Lists EB teh i Logic for Max ON RX3I Redundant Application ayan Blocks 4 7 MAN RS be ents Max ON Rai Drivers and Config File E erence Vues
17. Family is Genius then select the I O Type for the I O device Click in the cell labeled O Type A dropdown list will appear 4 18 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A fidd Sew benus Device 5 Select the O Type for the device using the drop down list selections If your I O device does not match with any of the selections then select Generic Also you should select Generic if the device is a Remote 90 30 Genius drop 6 Click the Apply button to assign the I O Family and I O Type Note If this is a dual bus a reminder may be displayed to ask you to verify the starting address for the Secondary Bus Reference Click Ok Max ON Config 7 Click on the I O Device type tab that is now active Discrete In for example GFK 2409A Chapter 4 The Max ON RXS3Si Configuration Utility 4 19 8 Edit the device properties for both the Primary and Secondary busses 9 Click Apply and Ok to complete the changes or Cancel to leave without making any changes 4 20 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Editing Genius I O Devices 1 To edit a Genius device s parameters select the Genius I O item in the Project tree for a specific Genius Bus 2 Select a Genius device by clicking on the gray button to the left of the SBA number A will be placed on the button to indicate it s selection 3 Select the Bus Devices gt
18. Interface module s to the appropriate slot s in the Hardware Configuration for PLC A You will also need to configure this Module s EGD information to match the definitions of your ENIU EGD exchanges E PLC Hw Parameters PO Pes Data Watch Lists EA Hardware Configuration Adapter Name Ell Rack 0 c ascHso12 Use BOOTP far IP f Slot a IC695P5 4040 IP Address Slot 1 Used with Slot 0 Bl slot 2 IC6SscMus10 Slot 3 Used with Slot 2 fi slot 4 IC695ETMOO1 Subnet Mask Gateway IP Address Mame Server IP A B Slot 5 IC695ETMO01 EE B slot 6 IC695ETMO01 EAU EEE e gl Slot 7 IC69SETMOO1 Status Address Length VO Scan Set Please note that only 4 Ethernet Modules may be added to an RX3i Main Rack Configure Genius Bus Controllers for PLC A if used Use the Genius Bus Primary Secondary configuration summary from the Max ON RX3i Configuration Utility as a guide for configuring the Genius busses in the system Geereur Bur Peer Tm Bessi B uere Bus Controllers Frimar y Bus Controller 4B eres Bae Hae Popa pea eae earereaearse Bain Eazk 1 ALE ves we ees we ee ee Blot 6 ux Etstur Addrmzxm aIZO17 th Bera Un Becorsdary Bum Controller Beem 22 22 222252 132222 23 in Kack J Taia Bus Corde BLEE i 2 222 2z252Z252522z Slot 1 Stratum dale Cem ETLUAS GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 9 K Add the G
19. M01011 after it has completed processing the switchover Momentary Switch 24 Vdc Sw Master Input Device O 101011 First you must set the system for Floating Mastership Refer to Setting the System for Floating Master Then include the following logic to implement the Toggle Master function im next rung switches the Master The system will reset 90M 1001automatically Sw Mstr Pb SW_MSTR 9d 01011 9aM OO 11 Switch Master os If a command to set SW_MSTR M01011 has been issued then the system will operate in the following manner If both CPUs receive the command and there is no Preferred Master then the Mastership will change as soon as data synchronization is complete f only the Master receives the command and the Backup is available and there is no Preferred Master and data synchronization is complete then the transfer will occur If one or both of the CPUs receive the command and the Master is the Preferred Master then the request is discarded f only the backup receives the command then no transfer will occur After the relevant conditions above have been evaluated SW MSTR M01011 will be reset automatically 5 14 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Switching Mastership Using an HMI In your HMI application configure an operation that sets the command flag SW MSTR 99M01011 in the current Master CPU The HMI should set SW MSTR M01
20. O module in the remote rack has failed 264 p108 RemoteRackLossofOptMod 265 p109 Remote Rack Opt Mod Hard Fault 266 010A Remote Rack Opt Mod Soft Fault o 267 p10B Remote Rack Sys Fault Present 0000000000 268 10C Remote Rack I O Fault Present 010D Remote Rack Program Changed 10E Remote Rack HW Configuration Changed 010F Remote Rack Power Up Power has been lost and then subsequently restored at the remote rack 272 0110 Remote Rack Program Restart The remote rack has transitioned from STOP to RUN 273 0111 Remote Rack Gen BusPLRC 274 0112 Remote Rack Gen BusSLRC o 275 DMD Notued o O 288 0120 Notued o O 0 0 110 0111 0112 011D 0120 5 26 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Fault Class 02h Discrete Outputs Decimal Hex Description Code Code 0 Circuit Offline The device corresponding to the circuit reference number shown in the Source Column has transitioned to offline hh Bu pmo Mau Fault Class O3h Analog Inputs Decimal Hex Description Code Code 0301 Circuit Offline The device corresponding to the circuit reference number shown in the Source Column has transitioned to offline SERE c EN EE RENE RECEN 0303 After scaling the resulting value is less than the lower engineering unit limit 0304 Over range After scaling the resulting value is greater than the upper engineering unit limit
21. Taie gg Default Tables Hity Supplemental Files Oy AUP Fikes 3 Controller 2 Documentation Files Max ON RX3i Configuration File Launch Utility from here Lj FSS Maw Files When creating a Max ON RX3i Project the best approach is to start with the generic project that is supplied with the Max ON RX3i software This assures that all of the basic components of the Max ON RX3i redundant application are included in the project Creating a New Max ON RX3i Project To create a new Max ON RX3i Project in Proficy Logic Developer PLC 1 Create a new project based on the generic Max ON RX3i Project A new Max ON RX3i Project is added to the Machine Edition project Navigator by using the File gt Restore Project menu item Select the Project Navigator window making certain that there is no project open at this time Prodigy leche nition Inlniessr 2cxamumnessGg s X M coldgu Proficy Machine Edition Cor Sana Logic Developer PLC okey Cnm T AE 2005 Lab 1 Mioch 4 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 2 Using the File menu click on the Restore Project menu Prolicy Machine Edition Inbhe _ BD ci oi dmh pot Tyt abin oi iedo teb JEN Heer 1 Hp Gren Project MEET ET io OF 4 Proficy Machine Edition 3 Navigate to the Proficy Components directory where the Max ON RX3i Tools software has been installed then to th
22. Tg Propam Blocks DO NOT delete the cfg_dat C Block D 18 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 4 Add the version Max ON RX3i Drivers to the MaxON Components folder directory using the Ctrl Drag and Drop operation from the Toolchest Mant Adi RE 14 Prediew Machine Fadi M Dis gdi Seech Project k Jp PAJE E Inn Inia Te Target Werisbles Took Wires Hain eas be ium r m f P ie Ind ese B Pl idees LS Project v 18 c d ric A Hu E db PIC D HW 4 PLC DD CDDE Baia Watch Lets v ME Hardware Configurator D Logk hg Prog Blocks Ham Dd Pac Conponents Ez dag dal Eres BESE T F SSS Eksi hir Oe v d Bock jhi e Br hir DEC JB hack hir 004 0 Sep 2 Fg Bock nir reri PRESSES ERE Zt WE 2 Et MEHienDeasbepeus amp Mation Developed Flawchart iB Pacdewenns Elli Hah Arai Enabless 7 Cases Ey Favoris oTe terete LOC L fee Re TERETE Is J The Blocks must be added to the Machine Edition Project in the following order a hbr_001 hbr_005 hbr_008 b hbr 099 c hbr 002 hbr 003 hbr 004 hbr 006 hbr 007 hbr 009 hbr 010 hbr 011 hbr cfg d hbr 000 5 When performing the Ctrl Drag and Drop Toolchest operation when the Variable Conflict Resolution dialog is displayed you must select the Replace all existing variables option to ensure that any new MaxON RX3i variables are properly defined GFK 2409A D
23. W40147 W40223 W49613 W40072 W40148 W40224 W49614 W40073 W40149 W40225 W49615 W40074 W40150 W40226 W49616 Data that is to be transferred to the companion PLC should be placed in one or more of the Transmit Buffer words T Buff Data from the companion PLC may be retrieved by reading from the corresponding Common Buffer CommBuff The other two buffers contain the received data on the Primary and Secondary Ethernet Sync LANs If the Primary LAN is functioning then its data is moved into the CommBuff If the system is configured for dual Sync LANs AND the Primary fails AND then the Secondary buffer is available then the secondary is moved into the CommBuff If neither LAN is available then the buffer is cleared GFK 2409A Appendix B Frequently Asked Questions B 3 B 4 PACSystems RX3i Max ON Hot Standby Redundancy User s Manual February 2009 GFK 2409A Appendix Quick Start Guide Using Ethernet I O C This appendix uses an example Max ON RX3i Redundant system with two controllers to give an overview of the steps needed to set up Max ON RX3i systems with Ethernet NIUs for the I O 1 Create List of ENIUs and I O like the example shown below The list should include Controller s with IP addresses and local I O if used Each ENIU with IP Address and the I O for the ENIU Leave expansion space for additional I O if the system is likely to change or grow Example System with Redundant Controllers Primary E
24. add the hardware configuration information for each PLC in your application add your application logic and define the parameters of the Redundant System using the Max ON RX3i Configuration Utility that us launched from the Logic Developer PLC Project cm m MeO Roc U0 Progect v3 09 i d PLC A Hw PLC A Hardware Configuration Target PLC B Hw PLC EH Hardware Configuration Target b PLE COMMON CONE Common Application Logic target F 2 Data atch Lists MaxOM RX3i Data Watch Lists 4 T Loge Logic for Max OH ASG Redundant lication i n z Tg Program Blocks a man E E MaccN Components M ax ON Radi Drivers and Config File pg Reference ness Tables x eau Tables Sy AUP Pies J Controle 23 Documentation Pies Max 0N RX3i Configuration File Launch Utility fram here A RX3I MaxoN Files GFK 2409 3 1 Project Workflow Step 1 Gather Information Gather the information about your system O Bus topologies and addresses Synchronization LAN locations Module types and locations O Devices including bus assignment bus addresses circuit references number of circuits and I O family type Step 2 Create a New Max ON RX3i Project In Proficy Logic Developer PLC 1 Create a new project based on the Generic Max ON RX3i Project The redundant ladder project is added to the Machine Edition project Navigator by using the File gt Restore Project menu item Select the Project Navigator window making certain that th
25. be placed in Manual by an HMI or a local control station This is accomplished by setting PO1_Man M00501 Note that M00501 operates only in the Master CPU If POI Man M00501 is SET in the Backup then it will be reset before the rung containing the PID is solved If the PID is in Manual then the raise POI Up 70M00502 and lower PO1 Dn M00503 contacts are operational If this is the Master CPU then the output CV will respond to the UP DN commands If this is the Backup CPU the register block RO1001 01040 will be overwritten by Synchronized Data values received from the Master CPU This forces the Backup s PID to Track the values in the Master MASTER P01 Man P01 Man MO01020 M00501 96M00501 This CPU is PID 01 Set PID 0I Set in Master in Manual Manual MASTER d MO01020 This CPU is Master 5 16 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A PID P01 PO1SP 1SP CV P01 CV 90801001 74 30050 py D Ot 94300503 PI D OfSet Pt Paramet PI D Ot ers Output Value P01 PV 94800502 PID OtPrese t value P01 Man 90M 00501 PID Ot Setin Manual P01 Up M 00502 PID 0f Raise Output P01 Dn M 00503 PID Ot Lower Output In this example the PID parameters begin at PID_P01 R01001 For PID loop 01 there must be a synchronized data group configured that assures that registers R01001 through R01040 are transferred You must include the registers associated with o
26. been entered 026 001A Ethernet The System s primary Ethernet LAN has failed CPU A and CPU B are Synchronization unable to transfer Synchronized Data via the primary Ethernet LAN Primary Failure Synchronization are unable to transfer Synchronized Data via the secondary Ethernet Secondary Failure LAN 028 001C Illegal Mastership State There are either two Masters or two Backups in operation 029 001D Notused 032 0020 Notused n B Ethernet The System s secondary Ethernet LAN has failed CPU A and CPU B GFK 2409A Chapter 5 Programming Considerations 5 25 Fault Class 01h Discrete Inputs Decimal Hex Description Code Code 2 0101 Circuit Offline The discrete input reference displayed in the Source Column has transitioned to an offline state 57 258 102 259 0103 Remote Rack Offline The remote drop corresponding to the discrete input reference displayed in the Source Column has transitioned to an offline state 260 0104 Remote Rack Overrides Present The corresponding remote drop has I O overrides present 261 0105 Remote Rack PLC Low Battery The corresponding remote drop has an indication of low CPU Battery voltage Replace or connect the battery in the remote drop 262 0106 Remote Rack Config Mismatch There is a configuration discrepancy between the modules installed in the remote rack and the hardware configuration that has been stored into the remote rack 263 0107 Remote Rack Loss of I O Module An I
27. busses e Hot Standby controller Genius and Field Control l O While you are configuring the Genius I O you must configure extra parameters that govern system operation with respect to redundant PLCs and redundant dual Genius I O busses Please note that for Genius and Field Control I O you must have a Handheld Monitor available to set these parameters Redundant Controllers Using the Genius Handheld Monitor HHM set each Genus device for Redundant Controllers YES BSM Present Using the Genius Handheld Monitor HHM set the BSM Present configuration parameter to YES This is required whether or not a dual Genius I O bus is being used When this parameter is configured as YES then the output default period is extended from 3 token rotation time periods to 2 5 seconds The extra time allows the RX3i PLCs to exchange mastership correctly BSM Controller NV m LL Genius Bus Interface Unit BRIERE TLBLLLLI xxu s ux VE ERAS Ax Ops ux xxu zx xu ux Bus Interface Unit Terminal Block GFK 2409A Chapter 7 Configuring the I O Devices 3 If the Genius I O device is attached directly to a dual bus either by a Bus Switching Module BSM or a Bus Interface Unit BIU then you must configure this device to be a BSM Controller Genius Block with BSM In the case of a Genius Block connecting to the BSM setting the block to be a BSM Controller allocates its first output to the control of the BSM It is assumed that th
28. communicating All peripherals are connected and operating normally The procedure is as follows Using Logic Developer PLC record the peak CPU Scan Time in the Master CPU You should observe the system for several minutes to obtain this value 1 Add 75to the value you obtained in step 1 Round this value down to the nearest multiple of 5 Open the hardware configuration for CPU A Zoom into the CPU module Click on the Scan tab oet the Sweep Mode to Constant Sweep Set the Sweep Timer to the value calculated in step 2 otore the configuration into CPU A LU SE XY cpu IY Open the hardware configuration for CPU B PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 8 Repeat steps 3 through 6 9 Store the configuration into CPU B 10 Using Logic Developer PLC Select the PLC COMMON CODE Target as the Active Target 11 Prior to the call to HBR 000 in the MAIN Block enter a rung that resets AUTSWP M1012 to OFF 12 Store the Logic into CPU A 13 Store the Logic into CPU B Hot Swapping IC693 IC694BEMS331 Modules Genius Bus Controller modules 1C693 694BEM331 that are included in a Max ON redundancy system should not be removed from or installed in the PLC that is operating as a Master If a module is removed from the Master and then reinstalled the outputs for that module will not be enabled until the next Backup to Master transition Note Any time a Genius bus controller is removed or ins
29. into either 9ol or G references You may select the desired reference type and address for the Secondary location Length words The number of discrete references that are to be included on this device This is a read only value that is generated from the number that was entered into the Primary Bus l Reference GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 23 Configuring Genius Discrete Outputs The Genius Device dialog allows you to configure the Genius discrete outputs The main purpose of this configuration is to identify the device and the circuit reference so that online status may be monitored Any offline online activity will be reported in the Max ON RX3i Fault Table Add New Genius Device ae Ru 4 24 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring Genius Analog Inputs The Genius Device dialog allows you to configure how the Max ON RX3i redundancy driver will process Genius analog inputs The analog inputs may be configured on a per circuit basis Add New Genius Device EM LO Device Discrete Out Analog In Analog Out Analog Inputs Primary Bus Analog Inputs Secondary Bus 24 Reference anm Reference 1025 zA Length E zA Length E Analog Inputs Primary Bus The Primary Bus addressing is the base address assigned to the analog inputs This address establishes the references that the analog input devices will use while they are connected to the P
30. records Alarm Record Structure Each record in the Alarm Table consists of 5 registers Each register may be interpreted as a pair of bytes whose definitions are shown in the table below If the registers are displayed as hexadecimal values in Logic Developer PLC then the interpretation may be simplified LIEEEEEENM Timestamp Seconds BCD ec l Timestamp Minutes BCD HE Timestamp Hours BCD ec Timestamp Day of Month BCD 2 Timestamp Month BCD 5B Timestamp Year BCD 6 CircuitReference Isb o 8 Alarm Subclass o 9 AamClas 9 0 Bytes 0 5 These contain date and time information stored as BCD values The simplest way to view these in Logic Developer PLC is to display the fault table registers as hexadecimal numbers 5 22 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Bytes 6 Bytes 6 and 7 contain the decimal value of an I O circuit reference The value in this pair of bytes must be interpreted in the context of the Alarm Class that has generated the message The Alarm Class is contained in Byte 9 The value will be zero for CPU or system level hot standby faults Byte 8 This byte contains the Alarm Subclass code The subclass contains the rack number in the upper nibble and the slot number in the lower nibble This number implies different fault descriptions depending upon the value of the Alarm Class contained in byte 9 Byte 9 This byte contains the Alarm Class co
31. well as Series 90 30 and PACSystems RX3i Ethernet NIUs e Provide data synchronization using an Ethernet LAN With the Max ON RX3i Configuration Utility software you can e View and Modify the parameters of the Hot Standby Redundancy system e Redundant System Parameters e Synchronization Data Groups e Synchronization Network Interface Parameters e Genius I O Bus definitions With the Max ON RX3i View Project you can e Establish a communication link to the Hot Standby CPUs to Monitor system level alarms in real time Monitor performance characteristics in real time Display information about the Redundant system Max ON driver version CPU modules 1 2 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Installing Max ON RX5i Software System Requirements Max ON RX3i Software may be installed on a PC that has the minimum requirements shown below 1 GHz Pentium class processor 256 MB RAM or more Windows XP Professional Service Pack 2 Windows 2000 Professional Service Pack 4 50 MB of free disk space NOTE Max ON RX3i Software requires Logic Developer PLC Professional Edition Release 5 80 LD PLC SIM 1 or later To Install Max ON RX3i Software 1 Qr Ol dps ee Make sure that you have installed Proficy Machine Edition release 5 8 SIM 1 or later This is required to configure and program the Max ON RX3i CPU It is recommended that you close all applications including virus checking
32. 0 300 10011 FmaducedPe od 10 Reply Rata n Serd Typa Sakea Fun Mode Store Ensbie Fake B Fan Hode Store Ensbie Fake Hame Moran Pinducai ID 10010011001 Broun ID n Proce ID 10010011001 GeuplD n Exchange ID 2 Adepier Name 5 UodaeTimexi 0 Fin Mode Slore Enable Falp Updae Teu Fan Mode Store Enable Falp GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 15 Configure Ethernet Interface for Ethernet l O LANS for PLC B if used Configure the Ethernet Interfaces used in conjunction with the Ethernet NIUs Configure Genius Bus Controllers for PLC B if used Serial Bus Address All Genius bus controllers in PLC B should be configured to have their serial bus addresses set at 30 Input Default Inputs should be set to Force OFF Status Reference Type The recommended practice is set the device status address at the high end of the discrete input status references For instance the first GBC might start at 99102017 length 32 Output at Start Outputs must be set to Disabled at Start SE EE Lh TEMMEN PLC B HW 7 T A ae l Data Wash Lie Hatara Configuestion EN nas fice 2 METTE Ern Sor 1 Tuned wir ier C6 B a ipni ot 3il With Sit 25 B x tiam M 3x SCS TAL x 4 Shek amp oa B uxo 6 16 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A L Configure I O Devices on the Primary and Secondary Buss
33. 011 in each PLC This command will be executed in the current Master CPU but will be ignored in the current Backup CPU Each CPU will reset the command automatically Assuming that there is no preferred Master set in either CPU then the transfer will occur as soon as data synchronization is complete In most cases this will happen immediately You must set the system for Floating Mastership Refer to Setting the System for Floating Master No other logic is required System Data Registers Variable Name CAT NUM 9o RR9001 Catalog Number REV NUM 9o 9002 Current Release Number integer with implied decimal point MRS n 00101 v1 01 R9003 User Version Number double precision If audit trail has been enabled R9004 Max ON will increment this register pair each time a program change is stored or updated If audit trail is not enabled then the user may enter any value here PDAT 01 R9005 mm ss User Version Date Related to above this is a packed BCD date R9006 dd hh yy mm dd hh mm ss R9007 yy mm 9o FR9008 Program Size double precision An approximate program size R9009 Some users include this value with the checksum value for additional security in revision control ARDO Program Additive Checksum fo R9011 Reserved R9021 ARDOR 9eR9023 E H 90R9024 REM SCN R9025 Remote CPU s Current Scan Instantaneous PLC Scan time in msec time LOC SCN 9o 9026 Local CPU s C
34. 1001001 Scan Plate 11000 Erat Conditional Scar F abe 3 Modify the Address of PLCA in the Inspector to match the IP address of PLC A in your Max ON RX3i system 4 Repeat step 3 for PLCB 5 Select the Download and Start Active Target toolbar button to start the Max ON RX3i Diagnostic program or press the F9 key M ne D peh moea Tung mmidi piahi eie reip mex o1 E f H M d ck This will launch the View project to run on your PC GFK 2409A Chapter 8 Diagnostic Tools 8 3 Step 3 Use the Max ON RX3i Diagnostic Tool Once the Diagnostic Tool starts on your PC the main Diagnostics page will be displayed Tew Hur rection ial E Max ON RX3i Diagnostics System Status Alarme Project info Authorization PLC A is the Master PLC B is the Back Up Local Scantime Local Scamtime MIDER Renee Seatime Hamiti Searire ull I AR Update Time cmc SA Update Time pr SNB Update Tina TI pa Ben Update Tims ee Failover Mode Falover Mode PL A identity PLC B Identity LAN Statue LAN Siriu Program Fee start Program Foestart Power Up Power Lap Remote CPL Offline Remote CPU Oline Data Syme OK Data Sync OF Primary ETM Primary ETM Secondary ETM Secondary ETM Authorization Nuttveriz atian Fakire TOR System Status Clicking on this tab displays the Real time Status page The page contains information on scan times update rates and PLC status Alarms Clicking on this tab will bring up the Al
35. 2 Local Producer I Nus D Local Producer ID Hue 8071 337 27 Use Configueation Serve Falte Use Configueation Serve Falte Primary LAN EGD Consumed Exchange In the Navigator window expand Ethernet Global Data to reveal the Consumed and Produced exchanges Te i MEA fee Meac OH AXA LD Protect v3 13 x d PLC A Hw PCE HW Cake Watch Lists Eai Gkal Cant BE consumed Exchanges MS Produced Exchanges NE ardere Configuration Loge py Reference vee Tables Supplemental Filles 4 C OoN CODE B Data watch Lists i Right click on Consumed Exchanges The following pop up menu will be displayed ei ris D 12 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Click on New to create the first Consumed Exhange The default name for the exchange is ConsExch1 In the nspector window set these properties as follows Name Set to MxnCons1 Producer ID Set to the IP address of the Primary Ethernet module in PLC A Group ID Defaults to 0 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM normally Rack 0 Slot 4 Consumed Period 200 not configurable Update Timeout Defaults to O no Timeout Run Mode Store Defaults to False Ee oni 100 100 1001 D Adapter Marre Lorumed Pence Ligfaibar T irea 0 i Fun Mode Sion Ens Faks Fan Mode Sine Erle Faks In the Navigator window double click on MxnCons1 This
36. 2409A D D Updating an Existing Application D 5 P Go to the nspector window and edit Local Producer ID so that the IP address corresponds to the IP address that was set for the Primary LAN Ethernet module in PLC A E repeto O O O OOOO Eene Gibba Dais NE EfereiBkbiDas O 5 5 5 55 5 05 teaPoacero uri Local Producer I Nus D Local Producer ID Hur 2355515 Use Configueation Serve Falte Use Conhgurslion Serve Falte Primary LAN EGD Consumed Exchange In the Navigator window expand Ethernet Global Data to reveal the Consumed and Produced exchanges T T A F fee Mec OH AXA LD Progect v3 13 4 RC A Hw Data Watch Liste Ae Corrente Exchanges BE Produced Exchanges E Hadese Configuration D Leagi Feference Yee Tables Sake ed Fils Right click on Consumed Exchanges The following pop up menu will be displayed bed ne D 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Click on New to create the first Consumed Exhange The default name for the exchange is ConsExch1 In the nspector window set these properties as follows Name Set to MxnCons1 Producer ID Set to the IP address of the Primary Ethernet module in PLC B Group ID Defaults to 0 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM normally Rack 0 Slot 4 Consumed Period 200 not configurable Update Timeout Defaults to O no Timeout Run Mod
37. 3i LD Project vx yy zip file alzi Look in E Redundancy LD do t E be File name MaxON Rai LD Project v3 04 zip Files of type zip Files zip Cancel E When you click on Open a new project will be added to the Proficy Navigator window Now you may give this new Project a descriptive project name You may also use this project to create a Machine Edition project template that can me used as a starting point for future Max ON RX3i projects Launching the Max ON RX3i Configuration Utility The Max ON RX3i Configuration Utility is launched from the Machine Edition project Open the project that you restored in the previous section There are three targets in the project Navigator Ex E EHESI Max ON Rx3i LD Project v3 D4 B ge PLC A Hw e PLC B HW f et PLC COMMON CODE e PLC A HW This target contains the hardware configuration for PLC A It must be edited to reflect the hardware settings and components in your system Then it must be downloaded to PLC A only e PLC B HW This target contains the hardware configuration for PLC B It must be edited to reflect the hardware settings and components in your system It will be very similar to PLC A hardware configuration except for certain items such IP addresses Genius bus controller settings etc In a similar fashion this configuration must be downloaded to PLC B only GFK 2409A Chapter 1 Introduction 1 7 e PLC COMMON CODE This target contain
38. 4 Controller C3 Documentation Files 3 RX3I MaxoM Files Update EP 13 Select the Max ON Project directory Ev ar N Propect mie Ed Vm Favorites Took Hip Baek o nb o a Geah Troens 1 0 OS X a Ei Address WORXITemplMyMacON ApplicabonlzVaddibonl Files Documentation FleslfMas ON Project T n d Mpa free File Sape 1 74 KE 1 74 KB lel Py Computer d C 4 PACSystems RX3iMax On Hot Standby Redundancy February 2009 GFK 2409A 14 Double click on the config mx3 file This will launch the Max ON RX3i Configuration Utility that can used to define the parameters of the Redundant System n brea dae Prijact Heme B Bie PRS we m Flim 3 ione Humber at Eyre DAHs z Tam bm il etek B Humber aT Beem Lu Jyrin Getting DasthuLr Pii Peri 50 ded Audit Trail Da eek Led an LEH Tupuilog Fd urina r Failcerer Parimi me Ear Tg A mer ALam Humber of AIAERE Ln a Pam nno wm Pra 15 When the parameters of the Redundant Systems are entered or modified using the Configuration Utility the cfg dat C block is updated in the Max ON Project directory This block then must be used to update the C Block in the PLC COMMON CODE of the Project n HM El PLC COMMON CODE 2 EA Data Watch Lists flit Hardware Configuration Aji Rack a ICK9SCHSO12 A Logic EES Program Blocks ET MAIN xd Droponents FPP hbr mon ET hbr aoi
39. 985 for M5S and M5L drop folders Status Reference Type In the Global Data Tab At the GBC s Address Input 1 Address Input 1 Address 90100001 Input 1 Length always 0 Input 2 Address 9oAI0000 1 Input 2 Length always 0 Output 1 Address 20100001 Output 1 Length 16 plus the number of Discrete Inputs installed Output 2 Address 9o AI10000 1 Output 2 Length The number of Analog Inputs installed At SBA 30 oee Buffer Registers Input 1 Length 62 Input 2 Address 9oAI0000 1 Input 2 Length always 0 Output 1 Address 90 Q00001 Output 1 Length always 0 Output 2 Address 90A Q00001 Output 2 Length always 0 At SBA 31 Input 1 see Buffer Registers Input 1 Length 62 Input 2 90100001 Input 2 Length always 0 Output 1 Q00001 Output 1 Length always 0 Output 2 AQ00001 Output 2 Length always 0 The table shown below should be used to configure the Genius bus controller s in a remote drop The table lists the register references that must be entered into the Logic Developer PLC hardware configuration based upon the template folder that was used to create the remote drop 7 10 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Remote 90 30 Genius Drop Project Name RemDrop RemDrop RemDrop RemDrop RemDrop Description M23dxyy zip M31dxyy zip M4xdxyy zip M5sdxyy zip M5ldxyy zip Receive Buffer R00705 R01729 R09680 R09680 R16065 Primary Bus CPU A SBA 31 Receive Buffer R00833 R01857 R09808 R09808 R16193 Secon
40. D Flag for CPU A IDB Mo1018 ID Flag for CPU B CPU_RUN M01019 CPU is in RUN Mode MASTER M01020 Master Flag SYNC_OK M01021 All Data has been Synchronized M01022 Reserved M01024 M01017 ID Flag for CPU A ID A This flag is ON in the CPU identified as PLC A Setting the CPU Identity M01018 ID Flag for CPU B ID B This flag is ON in the CPU identified as PLC B Setting the CPU Identity M01019 CPU is in RUN Mode CPU RUN This flag is ON if the CPU is in RUN Mode It is OFF if the CPU is in STOP Disabled or STOP Enabled M01020 Master Flag MASTER This flag is ON in whichever CPU is the current Master M01021 All Data has been Synchronized SYNC_OK This flag is always ON in the CPU identified as the current Master It is ON in the Backup CPU at the moment when all Synchronized Data items have been updated 5 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Indicating Mastership Using the System Status Flag M01020 Master and the System Status Flags M01017 and M01018 the CPU Identity flags you may determine which PLC is the current Master By combining these flags it is possible to link discrete outputs to indicator lamps link to internal coils to provide status points to an HMI or even link discrete outputs to data switches to route communications lines from a peripheral to the CPU serial ports In the example below the Flags are used to control discrete outpu
41. D Updating an Existing Application D 19 2 riable Lonlfict Resolakion r For veins whch caus s Nan and Sepa coit Fiepiaer al eso vaaabier For vanebles whch caves Ref Adde and Data Type B3 os d J J i i WEHE 7 i ab I oc ce He 6 AMaxON RX3i MAIN Block is also available in the Toolchest Drawer This Block has a comment in the first rung that details the revision history 7 Validate your Max ON RX3i application to verify that all Max ON Driver blocks are properly located in the Project 8 You can also verify the version of each hbr Block by checking the description in the Block Properties Inspector Block Properties Mame her LL Language Block Type Block Scheduling Parameters Lack Settings Extra Local Words 128 Herion Settings Inspector D 20 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A GFK 2409A A Adding a Secondary Bus to an Existing Bus 4 15 Adding an I O Device 4 17 BSM Controller 7 4 BSM Present 7 3 C CIMPLICITY ME backup folders C 1 Configuring Analog Inputs 4 22 Configuring the Analog Output Range 7 13 Configuring the Drop s GBC 7 9 Configuring The Hot Standby GBCs 7 14 Configuring the I O Devices 7 1 7 3 Creating a Connection to a PLC 8 3 Creating a New Project 4 2 Creating Connections to the PLCs 8 3 Creating the Drop Folder 7 6 D Diagnostics 8 1 Ethernet Ha
42. GE Intelligent Platforms Programmable Control Products PACSystems RX3I Max On Hot Standby Redundancy User s Manual GFK 2409A January 2010 GFL 002 Warnings Cautions and Notes as Used in this Publication Warning notices are used in this publication to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in this equipment or may be associated with its use In situations where inattention could cause either personal injury or damage to equipment a Warning notice is used Caution Caution notices are used where equipment might be damaged if care is not taken Note Notes merely call attention to information that is especially significant to understanding and operating the equipment This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software nor to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Intelligent Platforms assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Intelligent Platforms makes no representation or warranty expressed implied or statutory With respect to and assumes no
43. GFK 2409A Chapter Introduction l Welcome Thank you for choosing Max ON RX3i Hot Standby Redundancy software and GE PACSystems RX3i controllers to implement your critical control project Max ON RX3i Software consists of several software components some of which execute in a pair of Hot Standby PACSystems Max ON RX3i Controllers and some of which execute upon your programming workstation The PACSystems controller based software consists of a set of application blocks that perform the Redundancy portion of the Hot Standby application These application blocks are provided as part of a Proficy Machine Edition Project that is the starting point of your redundant automation application Using GE s Proficy Logic Developer PLC programming software you add your application logic to this project and then store the overall project to each of the Hot Standby controllers The Max ON RX3i Configuration Utility which is launched from the Logic Developer PLC Project provides a utility to allow the control system designer to customize the functionality of the redundant system A Proficy View Max ON RX3i Project is also provided to monitor the status of the Redundant oystem and to display diagnostic information GFK 2409A 1 1 With the Max ON RX3i LD Project you can e Create a Hot Standby system that operates using a combination of GE Genius O Field Control V Series 90 30 remote Genius drops and Genius VersaMax I O as
44. Hardware Configuration for PLC B HW Target to match the parameters of PLC B in your system 6 18 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring the I O Devices Configuring the Ethernet I O Devices Before you may use your system you must configure the Ethernet I O devices that are to be installed on the Ethernet I O bus For Max ON RX3i the Ethernet devices may consist of PACSystems RX3i ENIUs and or Series 90 30 ENIUs For a complete description of how to configure and use the PACSystems RX3i ENIUs please see GFK 2434 titled PACSystems RX3i Ethernet Network Interface Unit A summary of the process to configure this ENIU is as follows 1 Determine the IP Addresses for the Primary PLC A and Secondary PLC B Controllers and the Ethernet NIU 2 Add the PACSystems ENIU target s to your Machine Edition Project by selecting the Add Target gt GE Remote I O gt OS he ED Propel v3 Ud Frog ea hiar lies doer B Pe Ek Sexo Bened Taper rishi ook Andes Help Ko m hwo C amp 4b dt o r Phu GFK 2409A 7 1 8 9 the I O Station A LD logic block named Local User Logic is provided for this purpose Repeat steps 2 through 7 for each ENIU Store this information to each ENIU 10 Add the Ethernet Global Data component to the Primary PLC A HW target and 11 13 14 15 16 17 Secondary PLC B HW target Controllers Fir Fc LO Preeect o_O Probity H
45. Internet Explorer and HMI software that might be running in the background You may need to check the task manager to determine if other applications are running As a further precaution it is also recommended that you re boot the PC to make sure components that Max ON RX3i Configuration Utility needs to update are not running during the installation process Put the Max ON RX3i Software CD in CD ROM Drive Select the CD drive from Windows Explorer Double click Setup exe Follow the user prompts to complete the installation GFK 2409A Chapter 1 Introduction 1 3 Uninstalling Max ON RX3i Software Max ON RX3i Software can be uninstalled only from the computer upon which it is installed It cannot be uninstalled over a network You can uninstall Max ON RX3i Software from the Add Remove Programs option on the Windows Control Panel or from the Windows Start Menu If the computer has other GE software products installed Max ON RX3i Software can be uninstalled without removing any files needed by those applications To uninstall Max ON RX3i Software do the following 1 Choose Uninstall from the Start Menu or the Control Panel 9 A dialog box appears asking if you are sure you want to uninstall 3 Confirm the Uninstall All files relating to Max ON RX3i Software will be removed from the hard drive Any files used by both Max ON RX3i Configuration Utility and another application will be left on the system All registry entri
46. LI 35s 36x 374 small amp t I li lB zip mI E RembDrap Mas File name RemDrop M5106 zip Files of type Zip Files zip Cancel E When you click on Open a new project will be added to the Proficy Navigator window 4 Give your project a descriptive name in the Machine Edition Navigator GFK 2409A Chapter 7 Configuring the I O Devices 1 1 Remote Drop Status Word A remote drop always places important status information into its local references at 96100001 through 96100016 inclusive The definition of these inputs is shown in the table below 7 9 System Fault Present 10 11 12 13 Bit Offset Description 4 15 16 To ensure proper operation of the remote drop you must not configure any local module such that it overlaps these discrete input addresses Make certain that addressing for your modules begins at 100017 or above 7 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring the Drop s GBC The Genius bus controller in the remote drop must be configured to transmit the input data to the Hot Standby PLCs and also to receive global data from the Hot Standby PLCs In the Remote Drop global data contains the discrete and analog output data Primary Bus The Genius bus controller should be configured as follows In the Settings Tab Serial Bus Address SBA Status Reference Type In the Global Data Tab At the GBC s Address Inp
47. Max ON Hot Standby Redundancy February 2009 GFK 2409A If a corresponding user defined alarm has been entered during the Max ON RX3i Configuration Utility configuration session then the fault time stamps along with appropriate descriptors will be displayed in the Max ON RX3i Alarm Table in the Proficy View Diagnostics application Max ON RX3i variables used by subroutine HBHR 005 to log a user defined alarm 96R09761 Fault Parameter Circuit Number 96R09762 Fault Parameter Fault Code PLC E Amr Piola 153i 8 Pinging ar Halide i HANT Gpet FFadare EERE i Afire a ae ai Z Afire sx alae 15361218 i PAG fgat FF ade EE RETE bana Fakie te er IEEE RETI Ar cx ae EE FEHI J CP Tipp GFK 2409A Chapter 5 Programming Considerations 5 21 Alarm Table Organization The Alarm Table begins at R9030 and ends at R9190 The Alarm Table organization is shown below Number of Faults in Table 0 empty 33 full o d NUM FLT 156 R9186 Record 32 Fault Type The value in NUM FLT 96R09030 indicates the number of active faults alarms in the table A value of zero indicates that the fault table is empty A value of 33 indicates that the table is full When the table is full no further faults may be added to the table The first fault table entry is located in NUM FLT 001 005 R9031 9035 The second fault entry is in NUM FLT 006 010 R9036 9040 This pattern is repeated for a total of 32 fault
48. Properties menu item The Edit Genius Device dialog is displayed EI Dee Defienison 0 Fami Genus 10 Tyne pn z 4 Editthe device properties 5 Click Apply and Ok to complete the changes or Cancel to leave without making any changes Deleting Genius I O Devices 1 To delete a Genius device select the Genius I O bus from the Project tree for the item to be deleted 2 n the device table select the Genius device by clicking on the gray button to the left of its SBA number A will be placed on the leftmost column and row to indicate that the device has been selected 3 Select the Bus Devices Delete Device menu item The device will be deleted GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 21 Configuring Genius Discrete Inputs The Genius Device dialog allows you to configure Genius discrete inputs If the bus to which this device is attached has been configured to have a Secondary bus controller then both the Primary Bus and Secondary Bus information will be displayed If this is a single non redundant bus then only the Primary Bus information will be displayed Add New Genius Device l VO Device Discrete in j Discrete Inputs Primary Bus Discrete Inputs Secondary Bus Reference anm Reference I BOLT Length i b Lenath wards b Selected Reference Type C xp Discrete Inputs C xm Global Bits f ZA Registers TE Cancel Apply Discrete Inputs
49. Redundancy February 2009 GFK 2409A Selecting the I O Max ON RX3i systems may be implemented using any combination of the following I O Ethernet NIUs Ethernet NIUs are remote I O drops that as based on standard 90 30 or PACSystems RX3i hardware These remote drops communicate to the redundant controllers using Ethernet Global Data These NIUs are configured using Logic Developer PLC Genius Block Genius blocks are intelligent self contained configurable I O modules The blocks are available as discrete analog and special purpose types such as the high speed counter Many of the blocks offer advanced diagnostic capabilities such as open circuit short circuit and overload detection Each block is configured using a hand held monitor Genius Field Control Genius Field Control is a family of versatile modular I O devices The I O modules are small and rugged and are available in both discrete and analog versions I O Terminal Blocks provide universal field wiring terminals for the I O modules allowing I O module types to be mixed on the same I O Terminal Block The I O Terminal block is mounted on a DIN rail As many as eight Field Control I O modules four I O terminal blocks can be connected to one Bus Interface Unit Together they make up a Field Control station The bus interface unit provides either a single or a dual redundant LAN connection to the Hot Standby PLCs Each station is configured using a hand held mo
50. Simplify the System Here are a few suggestions from other system developers that have worked well 3 8 Turn OFF one PLC and troubleshoot the system using the remaining one Disable Max ON RX3i drivers by placing an ZALW OFF contact prior to the call to HBR 000 Now determine if input output devices operate properly This will require that you modify the hardware configuration for the Genius bus controllers Place them in Enable at Start Don t forget to change the configuration to Disable at Start when it is time to place the system into its final redundant operation Disable your application code and troubleshoot the Max ON functionality Check to make certain that synchronized data items transfer properly Check to make certain that the Hot Standby CPUS will exchange mastership properly PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter The Max ON RX3i Configuration Utility Jj The Max ON RX3i Configuration Utility is used to create or edit the operating parameters used by the Max ON RX3i redundancy drivers These parameters specify such things as bus topologies I O addresses and definitions for the ranges of synchronized data transfers Max ON RX3i Projects A Max ON RX3i Project is a collection of items needed to define the elements of a redundant system If you inspected a Max ON RX3i Project using Logic Developer PLC you would see that it consists of a Machine Edition Project with
51. arm Table display page This page lists any alarms that have been archived within the PLCs that have active connections Alarms may be cleared from this display page Project Info Clicking on this tab will display the Project Information page Catalog number version number program checksum and other items are displayed Authorization Clicking on this tab will display the Authorization page that indicates if the system is operating in Demo mode or not Please note that if the Diagnostic Tool is not communicating with the PLCs a ES will be displayed for the items The C symbol indicates a Latched Alarm condition where a symbol indicates a current Alarm condition 8 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A System Status You may view items that relate to the current operating characteristics of your system on the oystem Status page An example is shown in the picture above PLC A and PLC B Status Local Scan Time Remote Scan Time R Update Time AQ Q M Update Time Failover Mode PLC A and PLC C Identity Program Restart Power Up Remote CPU Offline Data Sync OK Authorization GFK 2409A Indicates the operating status of the corresponding PLC either Running or Stopped The scan time in milliseconds for the Local PLC The scan time in milliseconds for the Remote PLC This is the time required to update synchronized data of type R The time is reported in seconds
52. ary Dehnation Type Linicast 100 300 100 2 Produced Parad 1 100 300 10012 Produced Penad 1 vari T pp Fun Hode Stone Ensbie Fake Fun Hode Store Enshi Fake Benton 1001001082 Producer IC 100100 100 2 o i o 1 che d 4 me D Commend Period tad Run Mode Store Enshi Fate Run Mode Store Enable Fale Note All Ethernet modules within a PLC that produce and consume Ethernet Global Data must use the same Producer ID i e IP address For instance all the modules in PLC A that are configured for EGD exchanges might be addressed at IP 100 100 100 1 while all those in PLC B are configured for 100 100 100 2 This applies to Ethernet modules used for I O networking as well GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 7 Exchange References The tables that follow contain the references that are associated with the exchanges You may configure these parameters by double clicking on the Produced or Consumed exchanges and then edit the values within the nfoViewer pane Note These parameters must be set exactly as shown MxnProd1t Primary LAN MxnCons1 Primary LAN oomen qe 199 MxnProd2 Secondary LAN MxnCons2 Secondary LAN 6 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A L Configure Ethernet Interface for Ethernet I O LANS for PLC A if used Configure the Ethernet Interfaces used in conjunction with the Ethernet NIUs Add the Ethernet
53. ays in Demo mode 0009 Authorization Not used Corruption 000A Program Changed The application program in the identified CPU has changed either due to a program store or due to online Bosal Mismatch This implies that the programs in the two CPUs are not equivalent 014 000E Remote is Online The companion CPU has transitioned to an Online mode 015 OOOF Local Switches to The CPU identified in the Source Column has become a Master Master Z2 Switches to The CPU identified in the Source Column has become a Backup acae 3 019 0013 Genius Sync PLRC Not used Error 020 0014 Genius Sync SLRC Not used Error 021 0015 Q Configuration FaultA defective configuration has been entered There are either too many Q groups or the reference range exceeds the capacity of the system 022 A defective configuration has been entered There are either too many AQ groups or the reference range exceeds the capacity of the system 023 0017 M Configuration A defective configuration has been entered There are either too many Fault M groups or the reference range exceeds the capacity of the system 024 R Configuration Fault A defective configuration has been entered There are either too many R groups or the reference range exceeds the capacity of the system 5 24 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Decimal Hex Description Code Code 025 0019 Corrupted Config A defective configuration has
54. changes to EGD exchanges 2 Revise the Application with new Max ON Drivers 3 Download both Hardware Configurations e Select the hardware target that is associated with the Backup PLC Set it as the Active Target e Go online and place the Backup PLC into STOP mode e Download Hardware only the appropriate hardware target to the Backup PLC e Place the Backup PLC in RUN Mode e Go offline e Switch Mastership so that the current Backup becomes the Master e Select the hardware target that is associated with the new Backup PLC Set it as the Active Target GFK 2409A D 1 e Go online and place the Backup PLC into STOP mode e Download Hardware only the appropriate hardware target to the Backup PLC while it is in STOP mode e Place the Backup PLC in RUN Mode e Go offline 4 Download the Application Logic e Set PLC COMMON CODE as the Active Target e Adjust the target s Ethernet I P address to match the address of the Backup PLC Or if using a serial connection connect to the programming port on the Backup PLC e Download Logic only the target named PLC COMMON CODE into the Backup PLC e Place the Backup PLC in RUN Mode e Go offline e Switch Mastership so that the current Backup becomes the Master e Adjust the target s Ethernet I P address to match the address of the Backup PLC Or if using a serial connection connect to the programming port on the Backup PLC e Download Logic only the targ
55. cuit addressed at AI00001 will have a Secondary address at AI01025 Discrete Inputs For discrete inputs the addressing is more flexible If the Primary address is on a word multiple i e 1 17 33 etc AND the length is a word multiple i e 16 32 48 etc then the Secondary address will be mapped into R space If the primary address does not meet the criteria above then the user may select an alternate address at either a G reference or a l reference Secondary Bus References The configuration utility will display the configuration options for the Secondary bus references automatically Please use the configuration information displayed in the text window to obtain the information that is needed to configure the Secondary bus controllers for discrete and analog inputs 4 28 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Project Information Configuration Summary The configuration summary provides information about your project You determine the content of this report by the item that is selected in the project tree Each time an item is selected in the project tree the configuration summary will update automatically ss PS Esk I r A cm iit Frajeri all sd Projet eista Mabenekz Bims riis feted Recon Bio Hep El End Lire a F Sorc Habsah TID neris an Host PLC siran x I I hu M Geen Eun Man Humber of Byrne GAMA aai Higbee GE Mebeworks
56. d the entry along with a date time stamp to indicate when the event occurred Typical events include change of Hot Standby mastership loss of PLC power program restart and loss of I O devices y wwe Ld Project PLC A Alarms 21 41 45 2 21 41 45 21 41 45 21 41 45 g 2141345 21 41 45 PLC BH Alarms Lacation B AD A A B CODD A OOO mt H A UA Description fm rene Circuit Offline Circuit iline Circuit Offline Cimeulir Offline Remote Rack Oime Note User defined alarms are not available in the current version of Max ON RX3i Diagnostic Tools 8 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Project Information You may view certain items that relate to the general nature of your system Select the Project Info tab View Aurime Max ON RX3i Diagnostics Projectinfo d Authorization gt PLC B PLC Catalog Number PLO Catalog Number ow Version SW Version User Version Humber User Version Humber Liter Version Date Leer Version Date Program Siz Program Siz Program Checksum Program Checksum PLC Catalog Number The catalog number of the GE controller that is running the Max ON RX3i project SW Version The current version number of the Max ON RX3i PLC drivers User Version Number If Audit trail has been enabled then this represents the number of times the application logic has been changed If Audit trail has not been enabled then the Max ON RX3i drivers will
57. d within application logic and in some instances by an HMI 9oMO 1009 MO01010 MO0101 1 70M01012 M01013 M01014 M01015 M01016 Variable Reference Description Name SEL A 9oMO 1009 Select A as Preferred SEL B M01010 Select B as Preferred SW_MSTR M01011 Switch Master self resetting 9M01003 Notused o M01044 Clear Remote Alarms self resetting Clear Local Alarms self resetting Clear All Alarms self resetting The definitions of the flags are as follows Select A as Preferred SEL A Used in conjunction with SEL B 96M01010 to determine the manner in which Mastership operates See Selecting the Master Select B as Preferred SEL B Used in conjunction with SEL A M01009 to determine the manner in which Mastership operates See Selecting the Master Switch Master self resetting SW MSTR Used to exchange Mastership See Selecting the Master If it is set ON the Max ON driver will reset it to OFF automatically See Switching the Master Auto Sweep Mode When this is set to ON the Backup CPU will be set to Constant Sweep mode automatically and the Master will be set to Normal oweep mode automatically See PLC Sweep Mode Not used Clear Remote Alarms self resetting When issued to the Master CLEARS the alarms in the Backup CPU only If it is set ON the Max ON driver will reset it to OFF automatically Clear Local Alarms self resetting Clears the alarms in
58. dary Bus CPU A SBA 31 Receive Buffer R00769 R01793 R09744 R09744 R16129 Primary Bus CPU B SBA 30 Receive Buffer R00897 R01921 R09872 R09872 R16257 Secondary Bus CPU B SBA 30 Configuring the Discrete Output Range Discrete output states are broadcast as global data from the Hot Standby PLCs The global data is intercepted by the Remote Drop and then mapped to local output states The mapping process allows output references from the Hot Standby PLCs to be translated to a different set of output references in the remote drop For example assume that your Remote Drop is implemented using a model IC693CPU323 This CPU supports a maximum of 512 discrete output addresses Your Hot Standby CPUs are each a model IC695CMU310 This CPU supports 32640 output addresses The mapping process allows a portion of the output addresses in the range Q00001 02048 to be mapped into the range 99Q00001 00512 at the remote drop GFK 2409A Chapter 7 Configuring the I O Devices 11 Configuring the Range 1 2 3 12 In Logic Developer PLC open the Remote Drop project Using the navigator open the Block named mxn cfg Edit the first rung of data moves In the first MOVE function a constant is moved into the reference named M Q ST Master CPU Starting Q Ref Enter the starting reference for the outputs that are to be received from the Hot Standby PLCs In the second MOVE function a constant is moved into the reference na
59. ddress 9 IU0L1B563 IP Address 5 222522 2555 LO0 100 100 1 PLO m 4 b m P Lb d B b d B b d P E d bL S d amp B Rack 2 52 22524222222 22325 Main Rack Blot saasaa Crete C cR alot 4 Etatus Address 21015953 IP AGP ERR LOO 100 100 2 Add the Ethernet Interface module s to the appropriate slot s in the Hardware Configuration for PLC A and configure its parameters to match the Max ON RX3i Configuration Summary amp 4 ICEASETIHAOT PLE A Hw Tl HE j PLC A W JE etna 5 232 Port Station Manager Poser Consumption Data Walch Lt amiers Andee t Cond igorsion Di ia E El e o cesse Ba Sot 0 CicessrsaDac Sob 1 lined With Shot D B Sot 20ce09cHoun Sick 31 Lined With Slot 2 J TFET Ja S CET Sick 6 CEES B iiit 1o B man TaN i Shot 7 OCR D xau n a fie Pe ed l 6 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A a Configure EGD Exchanges for Sync LANS for PLC A Critical system data is transferred between the PLCs by way of Ethernet Global Data Exchanges A Max ON project contains two preconfigured sets of exchanges for each PLC one for the Primary LAN and one for the Secondary LAN Single Sync LAN If you are not using a Secondary LAN then delete
60. de The valid range is 0000 4095 Alarm Class Alarm Circuit Reference Alarm Class Description Subclass Range Integer Offset 8 Offset 6 7 00 00 FF Always 0 System level faults 00 FF 0001 2048 Discrete input circuit Offset 9 L 85 9 FF 00 02k Areo moase 04 00 FF 001 0256 Analog output circuit ee 9 Not defined GFK 2409A Chapter 5 Programming Considerations 5 23 Alarm Class 00h System Level Alarms Decimal Hex Description Code Code 001 0001 CPU Stopped The CPU identified in the Source Column has transitioned from Run to Stop M p Program Restart The CPU identified in the Source Column has transitioned from Stop to Run 003 10003 PowerUp Power has been restored to the CPU identified in the Source Column 004 0004 Invalid CPU ID The CPU identified in the Source Column does not have a valid ID Open the hardware configuration Zoom into the CPU module and set the Checksum Length to 11 for CPU A or 12 for CPU B 005 0005 Duplicate IDs The CPUS have identical IDs Verify that the hardware configuration has been stored to the proper CPUs Verify the identities in the project have been set so that the Checksum Length for CPU A is 11 and 12 for CPU B 006 0006 New Authorization 007 0007 Authorization Alarm This occurs after operating for a total of approximately 22 days in Demo mode 008 0008 Authorization Fault This occurs after operating for a total of approximately 22 d
61. dler See Max ON RX3i Advanced Programming topic User Defined Alarms 4 32 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter Programming Considerations a This chapter provides additional information on programming considerations and system resources for the Max ON RX3i product In many cases Max ON RX3i System Variables have been predefined to use in application logic in order to interact with the Max ON RX3i redundancy driver Reserved References Max ON RX3i redundancy drivers make use of a small number of variable references Some of these references are used for the internal operation of the drivers to hold system state information Many are available to your application logic to provide both information on the system and to control the operation of the redundancy drivers I O References 6100001 to 2048 Q00001 to 2048 AI00001 to configured limit AQ00001 to configured limit Available to all applications G00001 to 1024 G01025 to 1280 M00001 to 0928 M00929 to 1024 M01025 to 4096 5 al T00001 to 256 R00001 to 8000 GFK 2409A 5 1 System Status Flags The System Status Flags indicate key operating characteristics of a Max ON RX3i system These flags may be monitored by an HMI to display such things as current Master Optionally the system designer may use the status flags to control the operation of the application Variable Reference Description Name ID A 96M01017 I
62. e BSM is connected to the first output circuit In the case of Field Control connecting to the BIU setting the parameter to be a BSM Controller directs the BIU to activate its internal bus switching circuitry If the device is connected to a stub downstream of another device that controls the switching then set BSM Controller to NO Genius VersaMax I O 1 Add the PACSystems VersaMax target s to your Machine Edition Project by selecting the Add Target gt GE Remote I O gt VersaMax Genius menu Add Target GE Controller R GE Remote Ilo Series 90 30 Ethernet ave Motion Series 90 70 Genius Save As Close QuickPanel Yiews Contral versaMax Ethernet Windows CE Validate All Windows MT ZODO XP Windows NTP 2000 Mirror Close without saving H Ld Ld GuickPanel d PACSvsEems Resi Ethernet Ld H H Versahlax S s E Clean All Build Folders Properties 2 Click on the Target and rename it to match your application conventions 3 Expand the Hardware Configuration and then click on the Genius NIU component IC2Z00GBI001 4 Set the following parameters Serial Bus Address Set this in accordance with the addressing scheme for your project Baud Rate Normally this is set to 153 6 kbps Standard however it may require adjustment depending upon cable selections distances and the presence of electrical noise BSM Present Set this to Yes 4 PACSystems RX3i Max ON Hot Standby Redundancy
63. e Redundant LD directory Make certain that the selection for Files of Type in the Restore dialog has been set to Proficy Machine Edition zip E m Max ON Rx3i Tools SE Documents B xL jre EL ta Proficy Components c tuc LL EU B Cj LD 4 When you click on Open a new project will be added to the Proficy Navigator window Restore Look ar CO Redundancs LD Ma UH FS LD Propet v3 148p Fit apa F e ap 5 Give your project a descriptive name in the Machine Edition Navigator GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 3 Launching the Max ON RX3i Configuration Utility The Max ON RX3i Configuration Utility is launched from the Max ON RX3i Machine Edition Project For example open the project that you created in the previous section Navigate to the Max ON RX3i Configuration Utility by following these steps 1 Select the target PLC COMMON CODE node in the Navigator Max OM Rx3i LD Project v3 14 H e PLC A HW HR PLC B Hw PLC COMMON CODE Mm eoo ona te 2 Expand the tree structure so that the Supplemental Files folder named Documentation Files is visible Lug fod Using H ES Program Blacks Flog Reference View Tables FH p Default Tables aA 3 Hfy Supplemental Files iin SS AUP Files ML Update 24 3 Controller P C3 Documentation Files 3 RX3I MaxoN Files ESI P 3 Double click on Documentation Files This will lau
64. e Store Defaults to False Hil 100 100 10 D Adapter Marre Lorumed Pence Ligfaibar T irea 0 i Fun Mode Sion Ens Faks Fan Mode Sine Erle Faks In the Navigator window double click on MxnCons1 This will create a new tab in the InfoViewer window so that you can configure the properties of the consumed exchange The new tab is shown below r p ies IunEonzal PLC A Hw P x Add per lelet Length Bes ll Ofset Rete Hu Varahln GFK 2409A D D Updating an Existing Application D 7 P In the InfoViewer window click on the Add button to add a new item to the table The window will appear as shown below Li Dreher MunConed PLC A HY X Add Insert Delete Length Eyes 1 nrw Mpt Da Wansble Met Accesses Lorne Length Tape Che screens 23 OO CH Faire WOT USED Foodie 3100017 F site Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows MxnCons1 Primary LAN Produced Exchange In the Navigator window right click on Produced Exchanges The following pop up menu will be displayed Hei res Click on New to create the first Produced Exhange The default name for the exchange is ProdExch1 n the nspector window set these properties as follows Name Set to MxnProd1 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM normally Rack 0 Slot 4 Destination Type Defaults to Unicast D
65. elect I O devices based upon functionality cost physical design items carried in spare parts inventory or personnel expertise GFK 2409A Chapter 2 System Overview 2 7 Demo Mode Operation A Max ON RX3i application will operate in demo mode for 22 days on standard PACSystems RX3i CPU hardware IC695CPU310 In this mode all of the system s capabilities are fully operational At the end of the demo period PLC A will either stop immediately if it is the backup or begin an orderly transfer of Mastership to PLC B If the transfer is successful then PLC A will shut down automatically At this point the system will be operating in a non redundant manner A Max ON RX3i system that is installed in a production environment MUST be running on a Max ON RX3i CPU IC695CMU310 in order to allow PLC A to run indefinitely Running Max ON RX3i on a standard RX3i CPU is helpful for short times in case of a hardware failure or for non production demonstration purposes 2 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter Building a Max ON RX3i Hot Standby Application 3 Max ON RX3i Project Max ON RX3i encapsulates your entire application within a single Machine Edition Project Using a generic Max ON RX3i Project you can create a new Max ON RX3i Redundancy project The generic project contains all of the base Max ON RX3i redundancy application components needed to perform the redundant application You
66. eme wem gp F ag tee me gamme me PR Wax ON REH Configuration Fite V Er Ha When a Max ON RX3i project is created a hardware configuration Target is provided for PLC A and one is provided for PLC B In most aspects these targets are very similar to each other The significant differences between the two hardware configurations are e Identity settings for the CPUs via logic checksum words e Serial communication port settings and SNP ID e Ethernet interface IP addresses e Ethernet Global Data configuration for the Ethernet Sync LANs e Ethernet Global Data configuration for the Ethernet I O LANs e Genius bus controllers configuration Many of the configuration items are completed during the process of developing the Project The following sections provide details on the configuration of these elements GFK 2409A 6 1 K Configuring PLC A Open the Hardware Configuration for PLC A HW In the Max ON RX3i Project select and expand the Hardware Configuration node of the PLC A HW target mmu ig VaccH bor Lia lard 4A mca ne 8 Dog fec h Leni Eae Chea eo Set the Max ON RX3i Identity for PLC A The identity for CPU A is determined by the value set in the Logic Checksum Words CPU parameter located in the CPU s Hardware Configuration for CPU A Open the CPU module s Hardware Configuration by double clicking on the IC695CMU310 module Click on the Scan tab to display the Logic Checksum Words parameter Veri
67. en the Secondary analog input addresses will be at the Primary address plus an offset of 1024 For example AI00001 will have an associated Secondary address at AI01025 4 26 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring Genius Analog Outputs The Genius Device dialog allows you to configure Genius analog outputs The main purpose of this configuration is to identify the device and the circuit reference so that online status may be monitored Any offline online activity will be reported in the Max ON RX3i Alarm Table Add New Genius Device GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 27 Configuring the Secondary Address On dual bus systems discrete and analog inputs are mapped from the Primary bus controller s buffers into the normal input reference tables Inputs from the Secondary bus controller are placed into an alternate area and then the Max ON RX3i redundancy driver remaps the alternate states into the table area used by the Primary Remapping occurs whenever the device is detected as being present on the Secondary bus but not present on the Primary In most instances the data will be available on one of the busses but not both The exception is for Remote 90 30 Genius drops in which case there are bus controllers on each bus Analog Inputs For analog inputs the Secondary addressing is fixed at the primary s address reference plus 1024 Thus an analog input cir
68. enius bus controllers to the appropriate slot s in the Hardware Configuration for PLC A and configure its parameters to match the Max ON RX3i Configuration Summary Meet eee B x TAF EHD Mas ANLO Projet v3 DR gt J PLC Hw Ed aa Mach Lak Perdis Con eer atn B iai occisa a 3x 00e uh xor j Oued ath Sor UT ok rA Ti 3 oed Ehe Sod Fj ok 4 DCESSE TP T ok E S2ESSETPAILI ok E Ce u B x 7 cee deed D 3090 mo6iumc T EEMBEMIH O F Cs eran Bur Console GB Relesemce ddis 00077 Serial Bus Address SBA All Genius bus controllers in PLC A must be configured to have their serial bus addresses set at 31 Inputs Default Inputs should be set to Force OFF Status Reference Type The recommended practice is set the device status address at the high end of the discrete input status references For instance the first GBC might start at 96102017 length 32 Output at Start Outputs must be set to Disabled at Start 06 ICGd BESE3E FPLC A HW 6 10 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configure I O Devices on the Primary Bus for PLC A Use the Bus I O configuration summary from the Max ON RX3i Configuration Utility as a guide for configuring the Genius devices that reside on the Genius bus Add Genius devices to the GBC s configuration and configure the Genius device
69. ent Preferred Master In this mode if the corresponding CPU fails or is placed in STOP then the companion CPU will assume Mastership As soon as the Preferred Master resumes operating normally and its Synchronized Data has been updated then the Mastership will transfer The example shown below sets PLC A as the preferred master m next two rungs set the Mastership Mode for Preferred A ALW_ON SEL_A j 26800007 MO1009 Always ON Select A Pref d SALW OFF SELB S00008 MO01010 Always OFF Select B Prefd Setting the System for Floating Master oet the system to Floating Master by including the logic shown below in your application Include this logic in any system that must change mastership based upon a command initiated by either momentary pushbutton or HMI Te next two rungs set the Mastership Mode for Float m ALW OFF SEL A E 94800008 94M 07009 Always OFF Select A Pref d ALW OFF SEL B JARa mmm ir 94800008 YMODD Always OFF Select B Pref d GFK 2409A Chapter 5 Programming Considerations 5 13 Switching Mastership Using a Momentary Pushbutton You may switch Mastership using a momentary pushbutton switch that is wired to a discrete input shared by the Hot Standby CPUs In the example that follows the switch is wired to discrete input Sw Mstr Pb 96101011 When this input transitions from Off to On the System Command Flag SW MSTR 96M01011 will be set The system will reset SW MSTR
70. ere is no project open at this time Pri y FLachinge edion nie M Be pR Search poet Tanger Vanables Took winder Help EEG C FR a Tra Bingo wa m m d 8i Inka Vereer ee Proficy Machine Edition AE A PACDESO CST aedis Blacks JE SOME ochre HR ose Fe Lab UE 2005 Lab 1 Motorctk Logic Developer PLC Bt kay Concepts 2 Using the File menu click on Restore Project Peaticy Machine Edition Inlo iewer O Bj rie Edt Search Project Target arisbles Took Window Help BE nan Project a NI E i Kp Opara the Pastore daly bes OA O e MEME id of ee Gee peer Propet F m T RemwePmjet l EE Proficy Machine Edition 3 2 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 3 Navigate to the Proficy Components directory then to the Redundant LD directory Make certain that the selection for Files of Type has been set to Proficy Machine Edition zip T x ae Drope L LD When you click on Open a new project will be added to the Proficy Navigator window Restore Mae ON Foci LIP Project v3 14 cop Fier of type Zip Files 2s Canoe 4 Give your project a descriptive name in the Machine Edition Navigator 5 Enter Project Setting information by launching the Project Settings dialog in the Max ON RX3i Configuration Utility Refer to Chapter 4 for more
71. es for PLC B The I O devices in CPU B are configured exactly the same as for CPU A Please refer to the instructions earlier in this chapter to complete their configuration Copying PLC A Configuration to PLC B Configuration A productivity tool that can also be used to speed the duplication of the Hardware Configuration between PLC A and PLC B is to Export the Hardware Configuration from PLC A and Import it into PLC B This will accelerate the configuration of the hardware configuration and you only need to modify the slight differences in PLC B To export the Hardware Configuration from the PLC A HW target and import it into the PLC B HW target Select the Hardware Configuration node for PLC A HW target oelect the Export to File right mouse menu item T MSS B Maxon Pas Lb Propet v H d RC A Hw a Dota Walch Las Be ELCHE Fie name admae Conbgurstion hec Lano Sivi lick lpp GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 17 K Select the Hardware Configuration node for PLC B HW target Select the Import from File right mouse menu item nA Tn T 5y Documenistion Fles E Lj FT Mero Piles RC BH a Data ateh Lists CTUDRNTCT Har Dese te Rest rero lee PL sic 0 cesse Sk Lied 9 AEk B uc cer Skt 3 Lise B axis Cem P h8 ses B x s cHSE Pyopartin Files of type Hance Configuration heic Canos Now modify the
72. es relating to Max ON RX3i Software will be removed from the systems registry Icons for Max ON RX3i Software will be removed from the Start Menu Any data you created for example Project that you have created will be left on the system Note You may also uninstall Max ON RX3i Software by choosing Add Remove Programs from the Control Panel then selecting Max ON RX3i Tools 1 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Max ON RX3i Component Installation The default settings for the Max ON RX3i software installation places the Max ON RX3i ooftware and the associated project components in the GE directory The Max ON RX3i components are installed in the tree structure as shown below EH ire EH Proficy Components Diagnostics VIEW L Redundancy LD EL Remote Drops LD LL RemoteDrop CPUS13 and 323 L RemoteDrop CPU331 x RemaoteDrop CPUS RemoteDrop CPUSSx 36x 374 large ef J RemoteDrop CPUSSx 36x 374 small The Max ON RX3i Configuration Utility is located in Max ON RX3i Tools directory It is launched by double clicking on the Max ON RX3i configuration file config mx3 located in the Proficy Logic Developer PLC project The default Max ON RX3i Hot Standby Redundancy application project named Max ON RX3i LD Project vx yy zip is located in the Redundancy LD directory This project must be brought into your Proficy Machine Edition development environment using Pr
73. es the main items that the application developer should keep in mind when planning and developing such a system 1 Ethernet Synchronization LAN should use dedicated Ethernet Interface Modules If other devices such as I O or HMIs are placed on the Sync LAN they can have a negative impact on the performance of the system in terms of Failover and Synchronization time Therefore it is recommended that the Sync LAN be isolated Adding a single device like the Logic Developer PLC programmer or the Max ON RX3i Diagnostic tool should be acceptable and also useful when diagnosing the system 2 Ethernet I O LANs should use dedicated Ethernet Interface Modules and be isolated from a main Ethernet network Again if other devices are placed on the I O LAN they can have a negative impact on the performance of the I O system in terms of IO update time Therefore it is recommended that the I O LAN be isolated Improving Ethernet Sync Efficiency Using PLC Sweep Mode For the Ethernet Synchronization interfaces to work efficiently it is necessary to extend the ocan Time in one or both of the PLCs The extra time is used to transfer Synchronized Variables through the CPU Communications Window There are two approaches Each has its own advantage Automatic Mode Selection In this approach the system detects which CPU is the Backup and then sets the Backup to Constant Sweep f there is a transfer in Mastership then the Max ON RX3i driver will set the ne
74. estination Set to the IP address of the Primary ETM in PLC B Produced Period Set to 10 Reply Rate 0 not configurable Send Type Always not configurable Run Mode Store Defaults to False D 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Fun Mode Store Enable Fake In the Navigator window double click on MxnProd1 This will create a new tab in the nfoViewer window so that you can configure the properties of the produced exchange The new tab is shown below Jdfceeer MerSonsh PLC A Hw MtenProdd PLE A HW Add Ins ert Delete Length Hytes 0 In the nfoViewer window click on the Add button to add a new item to the table The window will appear as shown below Intoviewer Mwnconsl PiC A HW MwnProdl PLC A HW Add insert Delete Length Bytes 1 ps Jem 0v i ae ae IRUNC D 9 GFK 2409A D D Updating an Existing Application n Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows MxnProd1t Primary LAN Secondary LAN EGD optional LAN IP Address In this release of Max ON the Secondary LAN must use the same IP address settings as used for the Primary LAN Consumed Exchange These exchanges are similar to the Primary exchanges except for the Reference addresses that are set in the properties table Refer to the procedure used for the Primary exchange and then set
75. et named PLC COMMON CODE into the Backup PLC e Place the Backup PLC in RUN Mode Additional information on how to revise the three Max ON targets follows D 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 2 Updating an Existing Max ON RX3i Application If you have a Max ON RX3i application that was created using an earlier version of Max ON RX3i software such as version 3 04 you must update the Max ON Drivers in your application to take advantage of issue resolutions in later versions A Machine Edition Toolchest drawer is provided on the Max ON RX3i Software Release CD to aid in the upgrade process To upgrade an existing Max ON RX3i application perform the following steps Backup the Application Back up your Max ON RX3i application using the Backup feature in Machine Edition 1 Make certain that all projects are closed so that only the current projects are displayed in the Navigator window 2 Select the project that is to be backed up In this example it is O06Feb17 DPCS Navigator dg Projects My Computer E Shared Projects JR O6Febi7_DPCS JE b amp Febi7 ZEF B Max ON Rx3i LD Project v3 14 AR NH3 ME B u3scr JR UACSAU B UACUIL JR UNIT1 ME unit3 With MaxON 3 Right click on the project and the following menu list will be displayed Open Creste Tempe md To Shared Froris yor ate Eros Dasiops Propect Panama Properties 4 Select Back UP and the fo
76. ex or 4 dual Genius I O busses and up to 3 Ethernet I O busses Ethene HIU VO Station with M GFK 2409A 2 1 The example below shows the Max ON RX3i controllers connected to a single Genius I O LAN This example includes dual Ethernet synchronization LANs CPU A CPUB Mitel Genius Io LANs 1L L B VersaMax 0 Genius 1 0 Blocks Series 90 30 UO Up to 29 Genius IO Device Max ON RX3i provides the following functionality Discrete Inputs 961 2048 Discrete Outputs Q 2048 Analog Inputs Al 1024 Analog Outputs AQ 256 Synchronized Internal Coils M 4096 Synchronized Registers R 8000 I O Busses Up to eight simplex Genius busses or Up to four dual Genius busses Up to 29 devices per simplex or dual bus Up to 3 simplex Ethernet busses or one dual Ethernet bus Synchronizing LANs One or two Ethernet LANs CPU Model IC695CMU310 I O Families Ethernet Series 90 30 Ethernet NIU or PACSystems RX3i Ethernet NIU Genius Genius Block Field Control VersaMax Remote 90 30 Drop 2 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Software Components Max ON RX3i software consists of several components some of which execute in the Hot Standby Controllers and some of which execute in your programming workstation A base Logic Developer PLC Project provides the basic template for the Logic of the Redundant oys
77. for Files of Type has been set to Proficy Machine Edition zip EM IC646MsNDDI Ee 3 Quick Start mm File name Max ON RX3i QuickStart 3ENIUs zip Files of type Zip Files zip Cancel E C 2 PACSystems RX3iMax On Hot Standby Redundancy February 2009 GFK 2409A When you click on Open a new project will be added to the Proficy Navigator window 5 Give your project a descriptive name in the Machine Edition Navigator 6 The Quick Start project is set up with controller targets named Primary Controller PLC A and Secondary Controller PLC B and 3 ENIUs named ENIU11 ENIU12 ENIU13 You can rename the Targets as appropriate If you need fewer ENIUs delete the ones you don t need If you need more ENIUS select hardware configuration of a ENIU right click and export the configuration Create a new ENIU target select hardware configuration right click and import the hardware configuration You will need to adjust the IP address before proceeding to the next step 7 Using the list you created in step 1 change the hardware configuration for the controllers and ENIU to match the I O in your project Make sure the I O reference addresses are correct 8 Adjust the Produced exchange of the ENIUs and the Consumed exchange of the Controller s to match the l and AI in the hardware configuration of the ENIUs 9 f you are changing the IP addresses of the devices you need to change the following items
78. fy that the Logic Checksum Words parameter value is 32 If it is not 32 change the parameter to this value Verify that the Number of Last Scans is set to 1 If it is not 1 change the parameter to this value 0 2 IC 595C am Hw 6 2 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Set Memory Limits for PLC A The Max ON RX3i drivers have memory requirements as defined below 26 W R AI AQ Registers Registers Analog In Analog Out 50000 16384 2048 512 minimum minimum minimum minimum Select the Memory tab of the CPU configuration and verify that these values have been configured Please note the memory limits may be larger than these values for use in your application 0 2 IC695CMU310 PLC_A HW Settings Scan Memory Faults Fort 1 Port 2 Scan Sets Power Consumption Parameters V alues zaB System aaa Reference Words ZAL Analog Input 240 Analog Output 4H Register Memory zw Bulk Memory Total Reference words GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 3 Configure Ethernet Sync Network for PLC A Use the Sync LAN Interface Module configuration summary from the Max ON RX3i Configuration Utility as a guide for configuring the Ethernet synchronization interfaces in the system R amp ck 5 enh area eee a Main Rack BENE 2ovuudaex os oe ee RE OR alot 4 Status A
79. gested practice is to address Genius bus controllers at high addresses This leaves the low addresses available for Input devices such as field sensors Note The input address must be set to less than 96102017 Genius Bus Controller Location Hack Main Hack Slot Slot b Status Address 5g Lancel PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Adding Genius I O Devices To add Genius devices to a Genius Bus select the Genius I O item in the Project tree Now the I O Assignments table is displayed which lists the Genius Devices that are assigned to the various SBAs Serial Bus Addresses SIL C884 UO Feri M Tye T Liria TI E triu i ae lium Sur Her B 7 30 lh Ea Bus Topology 1 1 Wimbser af Devices 2 sconcar Dur Lonirallat Lom ciae To add a Genius I O device to this Genius Bus 1 Select an SBA for the new Genius device by clicking on the gray button to the left of the SBA number A will be placed on the button to indicate it s selection 2 Select the Bus Devices Add Device menu item The Add New Genius Device dialog is displayed GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 17 Adi Pies Denis Device Ok anced 3 Click in the cell labeled O Family A dropdown list will appear En Aew Derius ERE Discrete in Discrete Cul 4 Ifthe I O
80. hecksum word lengths are incorrect CPU A should be configured to have a checksum word length of 32 CPU B should Duplicate IDs i be configured to have a checksum word length of 16 Q Configuration Fault One or more of the Synchronized Data types that you have AQ Configuration Fault configured is greater than the maximum quantity allowed for the product on which the project is based M Configuration Fault R Configuration Fault GFK 2409A B 1 My system indicates that both PLCs are Masters What is wrong The two PLCs are not exchanging Ethernet Sync LAN data properly If the system is being started up for the first time then there may be a problem with the hardware configuration for the Ethenet Interface modules Or there may be a problem with the LAN cabling stopped one of my CPUs and then disabled the Max ON RX3i PLC drivers in the remaining CPU Now my Genius output devices aren t working What has happened You will need to change the configuration in the Genius bus controllers In the Logic Developer PLC Hardware Configuration open your Max ON RX3i Project zoom into the bus controller and set Output at Start to Enabled Store the new configuration into the CPU Make certain that you do this for both CPUs Redundant operation is affected adversely by these settings Don t forget to change the configuration to Disabled when you are ready to run the Max ON RX3i drivers again CPU A has stopped know that the demo
81. information 6 Enter Developer and End User Information by launching the Biographical Information dialog in the Max ON RX3i Configuration Utility Refer to Chapter 4 for more information GFK 2409A Chapter 3 Building a Max ON RX3i Hot Standby Application 3 3 Step 3 Configure the Controller Hardware In Logic Developer PLC For CPU A Open the Hardware Configuration for PLC A HW target in the Max ON RX3i Project 2 Configure the PLC hardware for PLC A CPU Memory CPU SNP ID Genius Bus Controllers O Devices on the Genius Bus or Busses Ethernet Modules o Ethernet IP Address and Subnet Mask o Device Status Address Ethernet Global Data EGD Exchanges for Ethernet NIUs 3 otore the new hardware configuration into CPU A 4 oet the time and date for CPU A For CPU B Open the Hardware Configuration for PLC B HW target in the Max ON RX3i Project 2 Configure the PLC hardware for PLC B CPU Memory CPU SNP ID Genius Bus Controllers O Devices on the Genius Bus or Busses Ethernet Modules o Ethernet IP Address and Subnet Mask o Device Status Address o Ethernet Global Data EGD Exchanges for Ethernet NIUs 3 Store the new hardware configuration into CPU B 4 oet the time and date for CPU B 3 4 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Step 4 Add Your Application Logic Using Logic Developer PLC open the PLC COMMON CODE Target folder and add your applica
82. ing the Remote 90 30 Genius Drop Project Follow these steps to create a Remote 90 30 Genius Drop Project in Proficy Logic Developer PLC 1 Create a new project based on the appropriate Remote 90 30 Genius Drop template The Remote 90 30 Genius Drop project is added to the Machine Edition project Navigator by using the File Restore Project menu item Select the Project Navigator window making certain that there is no project open at this time niis Slachine Pichi bL d M ris pd earch powt Toget vanabler Jode inie Help ns sx Oda 3 Ind oie r Proficy Machine Edition E Logic Developer PLC E ak 2805 Lab i Motori Key Concepts 2 Using the File menu click on Restore Project Proficy Pirrihine Editha MNT ud MG pe fede Search Project Target variables Took window Help aF Open Projert LEL EL 2on 7 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 3 Navigate to the Proficy Components directory then to the Remote Drops LD directory Open the desired Remote Drop directory RemoteDrop CPU35x 36x 374 small for example Make certain that the selection for Files of Type has been set to Proficy Machine Edition zip Select the Remote Drop project backup file JE Froficy Components tu Diagnostics VIEW if Redundancy LO B Ga Remote Drops LD e L RemoteDrop CPUS13 and 323 e A RemoteDrop CPUS31 axl o E Look in E RemoteDrop CP
83. iscrete output data is being broadcast in the global data exchange and thus no other discrete output data is available for the remote drops Synchronized Data Groups 7 14 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter Diagnostic Tools S Max ON RX3i Diagnostic Tools software provides diagnostic functions that may be used to obtain both real time and historical operating information from your Hot Standby system The Diagnostic Tools are provided by a Proficy View project that is used to monitor the redundant system Step 1 Create a Max ON RX3i Diagnostic Tool View Project In Proficy Logic Developer PLC 1 Create a new project based on the generic Max ON RX3i Diagnostic Tool project This project is added to the Machine Edition project Navigator by using the File gt Restore Project menu item Select the Project Navigator window making certain that there is no project open at this time Prohicy Hahira EdRien EE E B De Gt Search prec lpg Vajab ooh mido pee FB mL a tt m e AGT aNg 3 j al 844 minii erT T A F a i 4 Proficy Machine Edition Ba PAL DEPAO 5 Tad PSBIbbocks 2 na Cot Stan Logic Developer PLC Ear 2005 Lab 1 Mobertkt Key Comempe 2 Using the File menu click on Restore Project Pretice arhin ESiien Inira M re Edt Sead Projet Target imde Took nie Help ij tH mel Bur ges he peie dis bene uA E Hoa Oo
84. it this information double click on the LAN Interface Modules item in the project tree or select the Module Properties menu item The Ethernet Modules configuration dialog is now displayed and the information about them can be entered Ethernet 5 Tedule re pe p T Te To E 4 10 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring Dual Sync Networks If you want to use a dual Ethernet Sync Networks then you must use two ETMOO1 modules in each PLC for the Sync Network In this case you need to define the Secondary Sync network To add a Secondary Sync Network to the Max ON RX3i system select the Sync Networks node in the project tree Then select the Networks Redundancy Add Secondary Network menu item Now the Secondary Network will be added to the system and parameters may be configured Mi Feb iapa aim Le an um Hamid IF diiss FICA DE diei FLL I h E BOR IUE ER B aot fru ins Zink 1 SE A LIP bee eee To edit the Secondary LAN information double click on the LAN Interface Modules item in the project tree or select the Module gt Properties menu item Note The Ethernet LAN information that is placed in the Max ON RX3i Configuration must match the configuration information that is placed in PLC A HW and PLC B HW hardware configurations in order for the system to operate properly GFK 2409A Chapter 4 The Max ON RX3i Configura
85. larms mul PIDE Dsschusege High Fresco a e Ide Tuc Piatt Creche ah Pra Shka sar Datzned Alarms Huxber cf Alarms Alarm Hurbrt Alira Description m m rum mm MES DEM EM NEC REM DEM EM EMO NEZ DEM XMO REC RES DEMO EM E E DEM EM XHC NES DEM COEM ONE e ZEE CEN cXE ERU NES GEM CERO GS aan Punp L402 Start Beguence Failed maal Pl402 Discharge High Pressure Alarm Tags Bl4OZ Discharge High Frassure Shutdown jf 12a Maa 5 Save your Max ON RX3i Configuration update the cfg_dat C Block in the Max ON Project 6 Download the new Max ON RX3i Configuration to the CPUs GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 31 Deleting a User Alarm 1 Select the User Alarms item in the Max ON RX3i Configuration Utility Project tree 2 Select a User Alarm by clicking on the gray button to the left of the User Alarm number A will be placed on the button to indicate it s selection 3 Select the User Defined Alarms Delete Alarm menu item The alarm has now been removed 4 Repeat steps 2 and 3 for any additional user defined alarms 5 Save your Max ON RX3i Configuration update the cfg dat C Block in the Max ON Project 6 Download the new Max ON RX3i Configuration to the CPUs Note In order for User Defined Alarms to be active ladder logic must be added to the application The logic passes the user specified alarm number to the Alarm han
86. llowing dialog box will be displayed GFK 2409A D D Updating an Existing Application D 3 Bark Up Seren irc C Hae Project for GEKZALS rr EE Guai 3D Febl7 zEF LUNITI ME IC3Haz ON Rad LO Project v3 14 OGUMA With Mat NHS ME user mme a Save at pp Zi Files zip 00 Cancel 5 Navigate to the directory in which you wish to save the backup copy of the project 6 Make certain that the file is saved as a Zip File zip and then click on Save D 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Updating from Releases Prior to 3 14 In release 3 14 the system state values are transferred by way of Ethernet Global Data Exchanges EGD Add EGD Exchanges to PLC A Select the target named PLC A HW Right click on the target to display the pop up menu Click on Add Component Ethernet Global Data A new component named Ethernet Global Data will be added to the target ALU Prepi vi_11 Frc ey ru ditan Ep rn B De gp pr posa Target Vejbir ole Window hip Bebev ie CARTONE TIT Aem Gs el ag f TakLa wo o DE uuu de Tae El Ma n Fein PLC AR Hu Tee eh Bul Fodien s E Trademarks Dei Decet nnum oe Fa Prat a Lanier Tae Flee hi IH Leyeed zn with no Pree sey Des fered Frome ibe Set the Producer ID Go to the Navigator window and click on Ethernet Global Data so that you may edit the properties GFK
87. lues Because many bus devices are able to perform their own scaling this option may be enabled for devices that do not provide scaling inherently Please be aware that enabling this option adds to overall scan time and consumes additional configuration memory The circuit configuration parameters are as follows Address The analog circuit reference This item is read only Scaling Enables scaling from raw units RU to engineering units EU for the corresponding analog input circuit RU Lower The lowest raw count value RU that the analog circuit will produce RU Upper The highest raw count value RU that the analog circuit will produce EU Lower The desired lowest value expressed in the sensor s measurement unit EU EU Upper The desired highest value expressed in the sensor s measurement unit EU The acceptable range of values for any of the units is 32768 to 3276 If the raw value produced by the analog circuit is less than the RU Lower value OR if the value is greater than the RU Upper value then an alarm will be generated for the analog circuit Notes Many of the GE analog input devices are capable of performing scaling independently It is better to use the built in capabilities of the devices This will reduce the CPU scan time by eliminating the extra processing associated with the scaling function Also it reduces the amount of configuration memory consumed If the device is configured to be on a dual bus th
88. med L Q ST Local Rack Starting Q Ref Enter the starting reference for the outputs in the Remote Drop in that you wish to place the Hot Standby values In the third MOVE function a constant is moved into the reference named L Q LN Local Rack Q Length bits Enter the number of outputs that are to be mapped into the Remote Drop Save the Project Store the Project to the Remote Drop MOVE MOVE MOVE INT INT INT 1 1 1 1 4l N Qr M QST 174I N QI L Q ST 256 JIN Qr L Q LN 94809288 94809289 94809290 Master CPU Local Rack Local Rack Q Startng Q Ref Startng Q Ref Length bits PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring the Analog Output Range Analog output values from the Hot Standby PLCs are intercepted by the Remote Drop and then mapped i e the output reference may be modified to local output references For example assume that your Remote Drop is implemented using a model IC693CPU323 This CPU supports a maximum of 512 analog output addresses Your Hot Standby CPUs are each a model IC695CMU310 This CPU supports up to 32640 analog output addresses The mapping process allows a portion of the output addresses in the range AQ00001 32640 to be mapped into the range AQ00001 00032 at the remote drop Configuring the Range 1 In Logic Developer PLC open the Remote Drop project 2 Using the navigator open the Block named mxn cfg 3 Edit the second rung of data moves 4 In the fi
89. nch Windows Explorer for this directory 4 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 4 Click on the Max ON Project directory to display contents The Explorer window will be similar to what is shown below E an A Propert File Edk view Favortes Took Help sea Back p ua seach Froes QC OS 0X 3 E n E C Documentation Fies j LL Types mx3 File Siga 1 74 KE 1 74 kB lel My Computer F 5 Double click on the Max ON RX3i Configuration file named config mx3 This launches the Max ON RX3i Configuration Utility You may now examine and edit the parameters of the Max ON RX3i redundant system Note The cfg_dat gefelf file in the Max ON Project directory is the C Block that is modified by the Max ON RX3i Configuration Utility After the utility has updated this file you must update the cfg dat C Block that is located in the PLC COMMON CODE target in the Max ON RX3i Project GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 5 Working with the Max ON RX5i Configuration Utility Now that you have created a Max ON RX3i Project and launched the Max ON RX3i Configuration Utility you can set the parameters of the redundant system When the Max ON RX3i Configuration Utility is launched it will display the following Fumherz ot Purser yo tam HetbiTgp i Daf ult Moe Fariad 10 maac kudlit Fraill
90. nd edit the parameters of the Max ON RX3i redundant system 1 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Chapter System Overview d Architecture A Max ON RX3i Hot Standby Redundancy system consists of two PACSystems Max ON RX3i Controllers at least one dedicated Ethernet Synchronization link and an I O system comprised of at least one I O LAN The Ethernet Synchronization link is used to exchange status and synchronization data between the two Max ON RX3i Controllers For higher system availability dual redundant LANs may be employed The I O LAN is used to communicate with the I O devices that are attached to it The I O system may be implemented using a combination of Ethernet drops Series 90 30 ENIU or PACSystems RX3i ENIU or Genius drops Genius I O Field Control I O VersaMax I O or Remote I O drops based upon Series 90 30 I O The example below shows the Max ON RX3i controllers connected to a single Ethernet I O LAN Frarareiber Tranxzmittar CFL Modules Ried ule r cR RC Niaa On Hol Standby Ra Max On Het Standbry Controller with Modules Controller with Modules mRxx REN Gthernce iex 3i RXx3i Ethernel Elharrwil Tanim ar Elsen ot Traecamifier PELI Boduls HILI Hadduta a Eher NIU I O Stason with Modules WW Max ON RX3i has been designed to satisfy applications that have high performance requirements It has support for up to 8 simpl
91. ned next GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 11 Configure I O Devices on the Secondary Bus for PLC A Use the Bus I O configuration summary from the Max ON RX3i Configuration Utility as a guide for configuring the Genius devices that reside on the Secondary Genius bus You can use the Copy Genius Bus function in the hardware configuration to facilitate the speedy duplication of Genius bus configurations peragat 7 i EA Masc OR Doi LD Praiect v3 4 mc A Hw da on ad rn Lathe MB Hondar Configuration 2 EM hack 0 Ceo a uo acer zirt D Lisad With Slot D BM StI Elo X Len Ah Sole 2 Sek 4 CER TIO Select the location for the duplicate Genius Bus and an exact copy will be made to the destination slot location Destination GEC Hack 5 Slot LE Mate The destination BBC s Genius Bus Sistem will be overwritten with the sources Benus Bus Sustem Cancel 6 12 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring PLC B Open the Hardware Configuration for PLC B HW In the Max ON RX3i Project select and expand the Hardware Configuration node of the PLC B HW target T m Hardware Configuration zl Pack o cces5cHs012 M Sot o c osesesadgen Slat 1 Used with Shot 0 B sir z icesong Slot 3 Used with Slot 2 B stot 4 arcesseTHoOL B shot 5 acesseTHoOL Sot 6 i Sr 0 Shot 8 n Shot 9 siet
92. nitor Genius Remote 90 30 Genius Remote 90 30 drops consist of a Series 90 30 CPU power supply base Drop plate and one Genius bus controller for a single LAN connection or two bus controllers for a dual redundant LAN connection Normally input and output modules are installed in the base A Scanner routine executes in the drop s CPU This routine scans all input devices and transmits the input states to the Hot Standby PLCs The routine also monitors outputs Q and AQ in the Synchronized Data stream from the Hot Standby PLCs Any output data that is configured to be active in the remote drop is captured from the data stream and then is mapped into the Drop s output reference tables Configuration of the remote drop is accomplished using the Logic Developer PLC software package Also a few rungs of ladder logic must be edited in order to characterize the outputs in the drop Genius VersaMax Genius VersaMax I O products feature DIN rail mounted modules with up to eight I O and option modules per rack and up to 8 racks per VersaMax I O Station system Expansion racks can be located up to 750 meters from the main VersaMax I O Station rack Expansion racks can include any VersaMax I O option or communications module Genius Third Party In some cases third party devices may be used on the LAN as well These devices must comply with the Genius I O specification relating to Controller Redundancy With a Max ON RX3i system you may s
93. not update any value here User Version Date If Audit trail has been enabled then the current date and time will be posted here each time the application logic is changed If Audit trail has not been enabled then the Max ON RX3i drivers will not update any value here Program Size An approximate program size There will be a slight difference between the value displayed in Logic Developer PLC and the value displayed here The Max ON RX3i value includes the memory overhead associated with subroutines Program Checksum The additive checksum for the Program GFK 2409A Chapter 8 Diagnostic Tools 8 7 Authorization You may view the information related to the authorization of your system by selecting the Authorization tab yw Le Max ON RX3i Diagnostics PLC A Stat Runtime Remaining Status Runtime Remaining N oo Authorization PLC B EE UL Eur Remaining The Status field indicates whether the system is running on a Max ON RX3i CPU IC695CMU310 or running in Demo mode on a standard RX3i CPU IC695CPU310 The Runtime Remaining field indicates how much demo time remains when the system is in Demo mode 8 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Appendix System Considerations A General Max ON RX3i Considerations There are a number of considerations and recommendations that should be taken into account when defining a Max ON RX3i system This appendix summariz
94. o ge com Japan support in io ge com remaining Asia customers Customer Care Email customercare apo ip ge com customercare cn ip ge com China Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 GFK 2409A Contents HUF OCUCU OM PE AA AE A E T E T A 1 1 NCU ON O MTM E E E dome alesse eomalseccna 1 1 Installing Max ON RX39i Software sssssssssssssssseseese nennen nnne nennen nnn nna nnns 1 3 System Redguirertiel lis c iiec exime n idt Ee o Pede Ue peed desta Doe ded 1 3 To Install Max ON RAG SOMWANLEC iore eked piste iu ta LO e Remertedu terete 1 3 Uninstalling Max ON RX3i Software seeessessssesseseneee nennen nnns 1 4 Max ON RX3i Component Installation ccc ccecccceeceseeeeeeeeeeeeeseeeeeeeeeseeeeseueeseees 1 5 System OVGRWICW b 2 1 ARCHIBCIUIB e cce EAE E E IL iL ML S E RM i E 2 1 SOnware COMpPONGM Siac cael oc acetate edis Cue De aon ieee pU sc dist c c emu ees eei 2 3 Hot Standby dancy Operation cccccccscccssccceececseeeceeeceuceceucessueesueeseaeessueessueesaees 2 4 FAllOV GR TM Or ae E cc tO EEA 2 5 Synchronized Data Transfers cccccsscccescccseeeceeescececeueecaeeceuceseueesseeseaeessaeessueess 2 5 VO BUS LODOlOGIC mtm 2 6 Genius Dual Bus O C 3DaCclU iss iie dintusta eset si ead cw epe Sup uio Putas esbta oda epu oe tob seduce d prns 2 6 SELECIONE O sun ad aed cal eases renin ete cretus ta
95. od Sand T We Abas Fun Mode Store Enable Fake In the Navigator window double click on MxnProd1 This will create a new tab in the InfoViewer window so that you can configure the properties of the produced exchange The new tab is shown below O oiee MsnCoWi RC B HW MeProdi PL B HW OOOO FOX Inzierni lbeletr Length Bytes mmus e eno In the nfoViewer window click on the Add button to add a new item to the table The window will appear as shown below GFK 2409A D D Updating an Existing Application D 15 n Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows MxnProd1t Primary LAN Secondary LAN EGD optional LAN IP Address In this release of Max ON the Secondary LAN must use the same IP address settings as used for the Primary LAN Consumed Exchange These exchanges are similar to the Primary exchanges except for the Reference addresses that are set in the properties table Refer to the procedure used for the Primary exchange and then set the table properties as shown below MxnCons2 Secondary LAN Produced Exchange Refer to the procedure used for the Primary exchange and then set the table properties as shown below MxnProd2 Secondary LAN D 16 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Update the Max ON Drivers 1 Import the latest Max ON RX3i Driver Toolchest drawe
96. od This value is the default time period used to advance the oynchronized Data multiplexer This is used when there are Remote 90 30 Drops present on a Genius I O LAN Sync Data synchronization data from the 96M Q AQ and R reference tables may be transferred from the Master CPU to the Backup CPU in order for the redundant system to be synchronized By selecting the Sync Data item in the Project tree the Max ON RX3i Sync Data settings may be displayed and modified e c rri of Pray Lehi irtatace Meck Byes Data Groups Dis crzetgs Outputs FOI 11 D greups g encor Analog Cutputs AZ O grcupa Internal Coils SR D grcups LAB Hoe ace bones Raegimztscz eR gropa 7 D cai n aa b n oynchronized data may be transferred in up to 6 groups for each of the reference tables listed above This allows transfer of non contiguous data areas The general format uses a Start Reference and a Length To add a new address range to a data group select the Data Group tab in the table and then select the Sync Data gt Add Data ltem menu Now enter the new range for the new data group for this reference table Add New Sync Data Item for Yo Start Hef Length k 4 Cancel 4 8 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A EN Ered La o TTE C UL TT je Pup M eT Wap Laconia a LAH larvae nca cca
97. oficy Machine Edition s File gt Restore Project menu A Proficy View Diagnostic project is located in the Diagnostics VIEW directory When it is active this diagnostic utility displays key information regarding the operation and state of the redundant CPU pair This project must also be brought into your Proficy Machine Edition development environment using Proficy Machine Edition s File Restore Project menu GFK 2409A Chapter 1 Introduction 1 5 Adding the Max ON RX3i Hot Standby Redundancy Application Project to Proficy Machine Edition The default Max ON RX3i LD project is added to the Machine Edition project Navigator by using the File Restore Project menu item Select the Project Navigator window making certain that there is no project open at this time Fr licy Lachine Edition Tn ewes Me UR ech bue Tae var Lek ery ee Gere Re Bo ke TAE g EE es BH awh T A i gp 1o m 4 Proficy Machine Edition AJ APAC DEMO ST andSBbiocks B Logic Developer PLC kay Toncepes Navigate to the Proficy Components directory then to the Redundant LD directory Make certain that the selection for Files of Type has been set to Proficy Machine Edition zip E 0 Max ON Rx3i Tools L Documents B jre EL ta Proficy Components x Diagnostics VIEW cH Redunda ancy LD B 1 Remote em LD 1 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Select the Max ON RX
98. ogram Restart The Local CPU has been switched from STOP mode to RUN mode Max ON Fault Present There is at least one fault entry in the Local CPU s Max ON Alarm Table Max ON Fault Table Full The Local CPU s Max ON Alarm Table is full Config Fault The Max ON configuration has exceeded one or more limits for the allowable size of Synchronized Data transfers Reserved Chapter 5 Programming Considerations 5 7 Remote Status Flags Latched The following flags indicate the status as received from the companion remote CPU For instance if you are attached to CPU A in Logic Developer PLC then these bits in CPU A will depict system status received from CPU B The flags below are latched They may be cleared by resetting the alarms see Command Flags If the alarm condition persists then the flag s will be set again M00929 Remote is Offline M00930 Remote Forces Overrides Present M00931 Remote PLC Low Battery M00929 Remote is Offline CPU is offline or there has been a bus failure on a system that uses a single Ethernet Sync bus or on a system using dual Sync busses both have failed MO00930 Remote Forces Overrides Present There is at least one force override present in the remote same as ZOVR PRE S0011 in the remote M00931 Remote PLC Low Battery Same as PLC_BAT S0014 in the remote MO00932 Remote Config Mismatch Same as CFG_MM SA0O009 in the remote M00933 Remo
99. ored to service the current Mastership does not change While the system is in Float Mode Mastership may be changed by setting the System Command Flag SW MSTR M01011 Float Mode is required if you intend to switch Mastership using an HMI GFK 2409A Chapter 5 Programming Considerations 5 11 Setting the Master Using a Selector Switch A three position center OFF selector switch may be connected to a pair of discrete inputs shared by the two CPUs This allows a system operator to chose either of the CPUs to be the Preferred Master or the Mastership may float between the two controllers In the example that follows the switch contacts are wired to discrete inputs SEL A 96101009 and SEL B 96101010 When the switch is in the A position only SEL A 96101009 is ON When the switch is in the B position only SEL B 96101010 is ON When the switch is in the center Float position SEL A 99101009 and SEL B 96101010 are both OFF Selector Switch 24 Vdc A Float B Input Device 26101009 70101010 mi s next two rungs choose the preferred Master SSw 101A SEL A M My Lu 9 d 01009 94M 01009 Selector Select A Switch Select Pref d A Sw 0B SEL B ir 90 00D YMODD Selector Select B Switch Select Pref d B 5 12 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Setting a Preferred Master You may set a perman
100. parameters to match A sample is shown below Hun UU Dereon nm nan Eur Bik BMG coeur tien IO Bus Eus Topalogy E Fua o o om Rs Ta Hambeer af Dawvicam 2 t i 49 Bere Ba Ba erial Bus AddressB OG I Pi Bus Crin Primary Gas Hattings Tit Famniw 2 i i x sad ru J Sere mweigp i g Les Typs Ii EEEE E jcti TRG Diacrets Inputs ZzrartEBT Ln Earn 0002 E Dena LU Dizcrats Cutputz HtartkEst YOUN Lan Ug Analey znpuka z e ster Analey Gubputa DBs zandary Dus Settings Dyp ee ee ee 22 Gamera Diserete Inputa oie Jrtartkef tRLIZDOI ben O02 Discrete Cutputza ZtartkEsef to000L Lar 0002 Analcq Inputs Analog cutputas Repeat this process for each Genius device in the Max ON RX3i configuration niver 0 7 0 GEMERIE 60 PLE A HW Hw E B suerncesxsEEMiSI A B Sot cessseM331 B 32s i GENERIC 13 B sea GENERIC 13 B sea s GENERIC 13 lg sea so eee Bg 354 x1 Ycessegn FI rwn 1 ped Gute 2 Referee Publienn e TI keg i DU aiig Repeat the above process until there are no more bus controllers to be configured Note VersaMax I O is no longer configured automatically by the PLC Max ON drivers Please make certain that you use the Remote I O Manager in Machine Edition to set and download the configurations If there are no Secondary busses in the system then store the configuration into CPU A Otherwise configure the secondary bus as explai
101. period has expired but can t get the CPU running again What can I do Make certain that you turn ON M1016 while the CPU is in STOP Then restart the CPU This will re initialize the CPU to run in Demo Mode for an additional 22 days Can I use my existing Max ON RX3i Configuration Tools to create new projects or do need to re install the software each time You may use the Max ON RX3i Configuration Tools as often as you like However you will need to purchase a copy for each PC that you want to run the Configuration Tool on The software license for C646MXNO01 is a single user license When view the EGD Status word for the System Data Transfers it often contains a value of 5 Stale Data Is this a problem No you may ignore this value The Produced data rate is set at 10 milliseconds which is less than one half the period of the PLC Scantime This has been done to make certain that at least one exchange will be produced in every scan In many scans there will be two or more exchanges In these extra exchanges the same data is being transferred multiple times hence the message Stale Data B 2 PACSystems RX3i Max ON Hot Standby Redundancy User s Manual February 2009 GFK 2409A would like to transfer some information from the Backup to the Master PLC Is this possible Yes There are five word references available for Reverse Data Transfers T Buff R BuffP RBufS CommBuff W40070 W40146 W40222 W49612 W40071
102. r into Machine Edition a Open your Max ON RX3i Project in Machine Edition b Open the Toolchest by pressing the Toolchest button on the Toolbar or by pressing Shift F9 C Select a node in the Toolchest d Using the right mouse button select mport Drawer Toolchest nx I Local i E 3 If at t pf Bas Collapse All ES a New Drawer ur c Rename Drawer ES i Delete Drawer Del Ep Ma m Ma Export Drawer Ep Ma NN Import Drawer c P Het a PC Scan Far new abjecEs mE PC Mew Folder p PC nstructions ff PLC FBD Instructions RS P 7 1 inetroctions e Navigate to the Max ON RX3i Driver Toolchest drawer located on the Max ON RX3i Software Release CD The file is named Max ON RX3i Drivers v3 nn ZDRW where nn indicates the release number GFK 2409A D D Updating an Existing Application D 17 Import laalchest Ovens Lenk rr E T acdeheci Diss Fra Upi Havs CI Fc vera v 14 Z DET Toolchest Dra f Press the Open button This will add the drawer to your Toolchest 2 Expand the MaxON Components folder in the PLC COMMON CODE Target in your project to display the current set of Max ON Drivers If you examine the Block Properties of each Block you can see your current Block revision such as v3 04 3 Delete the Max ON Driver blocks that start with hbr from the MaxON Components folder 3 PLC ODN D DE E Data Watch Lote CER Vic ON Control Dis C Mex ON se Fils Dt Lxx
103. rdware A 1 Fr Fault Record Structure 5 22 Fault Table 5 22 Frequently Asked Questions B 1 G Genius and Field Control I O 7 3 Genius and Field Control I O Config I O 7 3 Genius Bus Controllers 6 4 6 9 6 10 6 16 Genius Bus Controllers CPU A 6 10 Genius Bus Controllers CPU B 6 16 I O devices 6 11 6 12 6 17 adding 4 17 Identity CPU A 6 2 Identity CPU B 6 14 If You Have a Question or Problem 1 10 Indicating Mastership 5 3 Index M Mastership Modes 5 11 Memory 6 3 6 14 O Online Project Information 8 5 8 7 8 8 P PID Function Blocks 5 16 PLC Sweep Mode A 1 Programming 5 1 Project information 8 5 8 7 8 8 Project workflow 3 2 Q Quick Start project C 3 R Redundant Controllers 7 3 Remote 90 30 Drops 7 6 Remote Drop Status Word 7 8 Remote Status Flags 5 8 S Secondary bus adding 4 15 Selecting a Master 5 11 Setting a Preferred Master 5 13 Simplex Genius Bus 4 12 system Command Flags 5 10 System Data Registers 5 15 System Level Alarms 5 26 System Status Flags 5 2 T Time Stamp Record Structure 5 22 Troubleshooting diagnostic tools 8 1 frequently asked questions B 1 U Uninstalling Max ON Tools 1 4 W Welcome 1 1 Working with Projects 4 1 Index 1
104. responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply indicates a trademark of GE Intelligent Platforms Inc and or its affiliates All other trademarks are the property of their respective owners Copyright 2009 GE Intelligent Platforms Inc All Rights Reserved Contact Information If you purchased this product through an Authorized Channel Partner please contact the seller directly General Contact Information Online technical support and http www ge ip com support GlobalCare Additional information http www ge ip com Solution Provider solutionprovider ip ge com Technical Support If you have technical problems that cannot be resolved with the information in this guide please contact us by telephone or email or on the web at www ge ip com support Americas International Americas Direct Dial Europe the Middle East and Africa Online Technical Support www ge ip com support Phone 80 0 1 433 2682 EMEA Direct Dial 352 26 722 780 if toll free 800 option is unavailable or if dialing from a mobile telephone Primary languages of support English French German Italian Czech Spanish Asia Pacific Online Technical Support www ge ip com support 86 400 820 8208 86 21 3217 4826 India Indonesia and Pakistan Technical Support Email support cn ip ge com China support jp i
105. rimary Bus These are the same references that will be used throughout the user application logic AI Reference The first reference address used within the discrete input group AI Length The number of discrete references that are to be included on this device Analog Inputs Secondary Bus When a dual bus is employed there must be an alternate location for the analog inputs to report their values The alternate location is the reference area in which the inputs will appear while they are connected to the Secondary Genius I O bus Max ON RX3i redundancy drivers detect when the Primary inputs are unavailable If the Secondary inputs are reporting into the Secondary reference area the drivers will map the data automatically from the Secondary area into the Primary address locations This permits the user application to be written with references to the Primary addresses only GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 25 AI Reference The first reference address used in the secondary alternate reference table This value is read only The reference will always be equal to the Primary reference plus an offset of 1024 AI Length The number of discrete references that are to be included on this device This is a read only value that is generated from the number that was entered for the Primary Bus Circuit Configurations Analog input scaling may be used to convert raw values received from the input device into scaled va
106. rops then configure the Genius bus controller s and edit the configuration rungs in the remote s I O driver Make certain that Synchronized Data has been configured for the range of outputs used by the Remote Drop Step 6 Start the System Divide the system into manageable subsystems that may be verified as independent entities I O Bus Make certain that the Ethernet LAN s have been installed and configured correctly Make certain that the Genius LAN s have been installed correctly LAN polarity and shield IN OUT are connected consistently and correctly Also make certain that terminating resistors are installed at each end of the LAN s Genius and Field Control Using a Handheld Monitor verify that output devices may be turned ON or OFF from the LAN Use the Handheld Monitor check the LAN for any Bus Error activity 3 6 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A I O Devices When Interfacing to CPU A With the I O operating place CPU A in RUN mode and CPU B in STOP mode Verify that the system input devices return real time values properly Verify that system output devices may be controlled from the Output Reference Tables Note This might require that you place a temporary JUMP in your application The JUMP should be placed immediately after the CALL to HBR 000 The companion label should be placed at the end of MAIN When Interfacing to CPU B With the I O operating
107. rst MOVE function a constant is moved into the reference named M AQ ST Master CPU Starting AQ Ref Enter the starting reference for the outputs that are to be received from the Hot Standby PLCs 5 In the second MOVE function a constant is moved into the reference named L AQ ST Local Rack Starting Q Ref Enter the starting reference for the outputs in the Remote Drop in that you wish to place the Hot Standby values 6 In the third MOVE function a constant is moved into the reference named L AQ LN Local Rack Q Length words Enter the number of outputs that are to be mapped into the Remote Drop 7 Save the Project 8 Store the Project to the Remote Drop 94809291 R09292 R09293 M aster CPU Local Rack Local Rack Startng AQ Startng AQ AQ Length Ref Ref words GFK 2409A Chapter 7 Configuring the I O Devices 7 13 Configuring the Hot Standby GBCs The bus controllers should be configured in the same fashion as other I O devices Configuring the Synchronized Output Variables Discrete and analog outputs in a Remote Drop receive values from the Hot Standby CPUs by way of the Synchronized Variables data exchange In order for outputs to update properly there must be a corresponding range of Synchronized Variables that has been configured in Max ON RX3i Configuration Utility For example in the configuration shown below remote drops would be able to access discrete outputs only within the range Q00001 00064 No other d
108. s the core logic for the Max ON RX3i redundancy application You must add your application logic starting in the rung that follows the call to the core Max ON RX3i logic hbr 000 The logic from this target will be downloaded to both PLC A and PLC B Note that the download consists of the PLC Logic only the Hardware Configuration option must be unchecked You navigate to the Max ON RX3i Configuration Utility by following these steps 1 Select the target PLC COMMON CODE 2 Expand the tree structure so that the Supplemental Files folder named Documentation Files is visible Le i od Using H ES Program Blacks i E A Reference View Tables p Default Tables Hab 3 Hfy Supplemental Files ip SS AUP Files hs nee Update 24 3 Controller in rigid C3 Documentation Files 03 RX3I MaxoM Files 3 Double click on Documentation Files This will launch Windows Explorer for this directory 4 Click on the Max ON Project directory to display its contents The Explorer window will be similar to what is shown below deBak e i erch Faden Qm UL X oo EH Address C Program Files CIMPLICIT Machine Edicion Secun WORN Temp Max ON 231 Protectiz Addons Fiesp i36 a dy da geEm oiim Folders x 2 Dic gend tion File 5 Double click on the Max ON RX3i Configuration file named config mx3 This launches the Max ON RX3i Configuration Utility 6 You may now examine a
109. sing the latest internal states from the ex Master These states may represent such things as latched coils timer counter values PID values system set points and perhaps user calculated values Enforce an Orderly PLC Startup When a failed PLC is returned to service it must not attempt to assume control of the system prior to being synchronized to the current Master If both PLCs startup simultaneously then whichever one was the last valid Master assumes the Mastership Process Genius Dual Bus I O Devices When the system uses dual Genius I O busses input devices are mapped automatically from the active I O LAN into the PLC s input reference tables Execute Diagnostic Tests Automatically post time stamped fault messages into the Max ON RX3i Alarm Table Identify system problems such as bus faults loss of devices change of Mastership program restart and power up event PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Failover Time The Mastership Time of the Max ON RX3i system determines the Failover Time The Failover Time is the time required for control of the system to transfer from the Master Controller to the Backup Controller Mastership Time This is the time interval for the Backup Controller to recognize that the Master Controller has failed It takes one or two CPU scans plus one Synchronized Data Transfer period to determine that the Master has failed Then it takes an additional scan
110. t A 2 Demo Mode Operation tT 2 8 Building a Max ON RX3i Hot Standby Application 3 1 WiaX OIN M e SLEPO CC bias HE 3 1 I XTOIS CE VVOF KNOW oceana Seales oediohs a E TL Ern anne soneamanucies 3 2 The Max ON RX3i Configuration Utility 4 1 MaX ON RX SN rectc T D 4 1 Working with the Max ON RX3i Configuration Utility eeeeeeessseesseessss 4 6 Adding Genius O D 6 VvlCGS oko oix o Dos er ince clone EO ER bebo tcv Lu I voc REUS 4 17 Proje c MORMON E DL EL 4 29 UserDeined Alamis assar E ceste mutui Lud rut teas cate m EAD M teer cate eae 4 30 Programming Considerations 1 eee ceeee eere rere nnne nnn 5 1 PROVENCE GO GS e RHET Rm 5 16 Configuring the Hot Standby Redundancy CPUS 6 1 CONTOUR sib Dur RAE 6 2 Sie giilo le Male Wh ad oci RC E 6 13 V Contents Chapter 7 Chapter 8 Appendix A Appendix B Appendix C Appendix D Configuring the VO DEVICES ioi aedi ce ede diente rra dedecore diss 7 1 Configuring the Ethernet I O Devices eeeeeeeeeeeeeeeeeeennnnn nnn 7 1 Configuring the Genius I O Devices ccccseccceeeeceeeeceeeseeseceueeseueeseeeseeeseasessaeens 7 3 Diagnoslie FOOLS uu 235 05 c25020952 5030000252 9 000109122 iso E SEP Oeo DU OPI EOS 8 1 Step 2 Configure Ethernet Connections to the PLOs
111. talled in an active system there is a possibility that the bus may be disrupted with a subsequent impact on the corresponding I O devices For systems that require online maintainability it is recommended that dual redundant Genius busses be used GFK 2409A Appendix A System Considerations A 3 A 4 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Appendix Frequently Asked Questions b Does Max ON RX3i Configuration Tools generate my Logic Developer PLC hardware configuration No You must create the Hardware Configuration in the Logic Developer PLC project to match the parameters defined in the Max ON RX3i Configuration Tool Is the hardware configuration in the Max ON RX3i Project used in any fashion Yes The memory limits on the CPU must be set to be compatible with your application requirements Note that you may have to adjust these in the PLC A HW and PLC B HW targets as well Can Max ON Configuration Tools append the drivers onto one of my existing application folders No You must start by creating a Max ON RX3i Project and then add your application to it Or you can add the Max ON RX3i driver blocks to an existing Project using the Toolchest drawer supplied with the Max ON RX3i software My two CPUs will not start What is wrong There are several possibilities You should use Max ON RX3i Diagnostic Proficy View Project to display the Fault Tables in the PLCs Invalid CPU ID The c
112. te Loss of I O Module Same as LOS_IOM SA0014 in the remote M00934 Remote Loss of Option Module Same as LOS SIO SA0015 in the remote MO00935 Remote Option Module Hard Fault Same as HRD_SIO SA0027 in the remote 90M00936 Remote Option Module Soft Fault Same as SFT_SIO SA0031 in the remote 5 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Remote Status Flags Latched cont MO00946 Reserved MO0960 90M00937 Remote System Fault Present Same as SY_PRES SC0012 in the remote MO00938 Remote I O Fault Present Same as IO_ PRES S0013 in the remote MO00939 Remote HBR Fault Present there is at least one fault in the Max ON fault table MO00940 Remote HBR Fault Table Full The Max ON fault table is full MO0094 1 Remote Program Changed The user application in the remote has changed MO00942 Remote HW Config Changed The hardware configuration in the remote has changed MO00943 Remote Power Up The remote has undergone a power up event MO00944 Remote Program Restart The remote has undergone a Program Stop to Run event MO00945 Remote Authorization Alarm The Remote CPU is operating in DEMO mode M00946 Reserved MO0960 GFK 2409A Chapter 5 Programming Considerations 5 9 System Command Flags Operation of the system may be influenced by interfacing to the Max ON RX3i command flags They may be accesse
113. tem This project is modified by the system designer to add the other necessary Logic to perform the user application and then the final application is stored in the Controllers using Proficy Logic Developer PLC You may think of the software provided in the Project template for the Controllers as drivers that handle the complex tasks associated with Hot Standby redundancy These drivers allow the two Controllers to behave as a single Controller from the perspective of your application The Max ON RX3i Configuration Utility allows the system designer to customize the parameters of the Max ON RX3i drivers and to specify the hardware that is contained within the system The Max ON Configuration Utility software operates in Windows XP Professional Windows NT4 0 and Windows 2000 Professional The Max ON RX3i Configuration Utility software allows you to define the way your system is constructed and how you want the system to operate It provides additional information that is not included in the Hardware Configuration files produced by Logic Developer PLC The Max ON RX3i software includes a Proficy View Diagnostic Project that allows you to observe the way your system is operating and helps you to diagnose problems This Project displays the operational status of the redundant system in real time The Max ON RX3i software also includes a set of projects to configure Series 90 30 Remote Genius Drops The Max ON RX3i software components are organi
114. the project tree or select the Edit Properties menu item The Biographical Information dialog is now displayed and the detailed information may be entered and saved Empra nhe al Infor i e irm Fast hara Jobs Tie Project Manage Cicer Hase ACME Akhi Line T Akhi Line Z Cee ir Prenet Fita Cicer Sat bo Ded ult Drees County Eira Akiai P iran F r Hurrian Po reed A ps Settings By selecting the Settings item in the Project tree the Max ON RX3i System Parameters settings may be displayed and modified These parameters are defined as follows Ga Ach Cont zinj a Project E indem Hip Tome Fogectss SS fo ni gram Peeri ZW Maci M Fari Cina Daiackon E Piagasm Chega Jur Tied Gmg RE siue Dm Mupi wid 3 Fast Offline Detection Enabling this option directs the CPUs to detect an offline condition within one CPU scan If the option is not enabled then it will require two consecutive scans to produce an offline condition Program Change Audit Trail Checking this box instructs the Max ON RX3i redundancy system to monitor the program for changes to logic If there is a change the value in the change counter UR N1 R9003 9004 DINT will be incremented by one and a date time PDAT 01 R9005 9007 packed BCD will be posted for the moment at which the change was detected GFK 2409A Chapter 4 The Max ON RX3i Configuration Utility 4 7 Default Multiplexer Peri
115. the CPU to which it is directed Is reset automatically Clear All Alarms self resetting When issued to the Master CLEARS the alarms in the Master and Backup CPUs Is reset automatically PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Mastership Modes You may specify the Mastership mode of operation for the Hot Standby CPUs This may be accomplished by setting the states of the System Command Flags SEL A 99M01009 and SEL B 99MO1010 Both CPUs must have the states set identically in order to function properly The truth table shown below illustrates the operation of the Mastership Command Flags 26M01009 MO01010 oOo oat O 1 Jo Preferred 0 1 B Preferred A Preferred In this mode SEL A M01009 is ON and SEL B M01010 is OFF Assume that CPU A is currently the Master If CPU A fails or is placed in STOP then CPU B will become the new Master CPU B will remain the Master until CPU A is repaired or is restored to RUN mode As soon as the all of the Synchronized Data has been updated in CPU A the Mastership will return to CPU A B Preferred In this mode SEL A M01009 is OFF and SEL B 99M01010 is ON The description is similar to A Preferred except that the roles are transposed Float Either CPU may be the Master Mastership will not change unless the current Master fails or is placed into STOP or RUN Outputs Disabled mode When the failed stopped CPU is rest
116. the Consumed Exchange named MxnCons2 and also the Produced Exchange named MxnProd2 T PE im PN 3 RC a Hw 2 b PLC A HW mel Clete abch Lits Cate nach Ln E Consumed Exchanges E Consumed Exchanges B minces E oreo WE Procuced Exchanges B Mercian B MenProadd menProdz RB Hardie Config ation Dr Loge qu Reference vire Tables GFK 2409A Chapter 6 Configuring the Hot Backup CPUs 6 5 Producer ID Modifications It might be necessary to revise the EGD configurations to match your unique system requirements such as the IP addresses used The local producer ID may be configured by clicking on Ethernet Global Data and then setting the appropriate properties within the Inspector window Navigator PLC A HW EA Data Watch Lists Se Ae Ethernet Global Data a Consumed Exchanges ai Menlons 1 ai MenCons2 BE Praduced Exchanges Inspector Ethernet Global Data Local Producer ID 100 100 100 1 Local Producer IO Hur 23356516 Use Configuration Serve False g PTxnPradti E MxnProd Blin Hardware Configuration Logic p Reference View Tables lf Supplemental Files PLC B Hw P NALE gd GT URS GER oe GE ee am lili Inspector 6 6 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A If the IP address needs to be changed then you must also change the IP addresses in the Produced and Consumed Exchanges that follow PLC A Primary PLC A Second
117. the table properties as shown below MxnCons2 Secondary LAN Produced Exchange Refer to the procedure used for the Primary exchange and then set the table properties as shown below MxnProd2 Secondary LAN D 10 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Add EGD Exchanges to PLC B Select the target named PLC B HW Right click on the target to display the pop up menu Click on Add Component Ethernet Global Data A new component named Ethernet Global Data will be added to the target dgpm Marine biren Lg d MB me pk seach Deed Typi Vanib ns Teoh Sanches bein iai k NNITiBNXwN Fe oU E ITE aa Proficy Mac g i MH Fie LD e 3 13 Fic de Ty i j AH Components Motion i Hia rome e E Lay Concer d Hi E sirasnrmar FH ael Fe Lo Deinin Dal O amp ara Nag DO Tomia Tangel i n Wie Bi dla ig Fa ack u Moi B pals a Iren M RAEDT Set the Producer ID Go to the Navigator window and click on Ethernet Global Data so that you may edit the properties GFK 2409A D D Updating an Existing Application D 11 P Go to the nspector window and edit Local Producer ID so that the IP address corresponds to the IP address that was set for the Primary LAN Ethernet module in PLC B E repeto 0000000 LIII Eene Gibba Data NE EfereiBkbiDas 5 5 5 5 5 5 5 05 teaPoacero 010000
118. ther PID function blocks as well GFK 2409A Chapter 5 Programming Considerations 5 17 User Defined Alarms The user may post self defined faults from within the application by performing the following steps In Max ON RX3i Configuration Utility 1 Select the User Alarms item in the Max ON RX3i Configuration Utility Project tree End iie o t pre Data Spe frre Hen Umaer Dafimmed Alarmm Humber pf Alarms 2 Select the User Defined Alarms Add Alarm menu item 3 Enter an Alarm Number and then the corresponding Alarm Description Note The Alarm Number must be within the numerical range 3840 4095 The descriptor may be up to 60 characters in length Add sew NET Alarm 5 18 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 4 Enter any additional alarms Lez Conde ation Lib s jun i pel Pree ee See Dee Bek Ere co eer Ih Ba a z Pi p 7 J p in Mam arbe EHI Purgl42 zus Segaence F aad TH Plil et Pieire aa JH PIT Deckmge High Prepare hhadonn Usser Dmefinmi Alarmz Himbeer pf Boe 5 I arr Huber Alarm Damcripticr iau Ramp Lad tart Saquanca Failed 3341 FL402 Pblaschkarge High Pressure Alam 1842 Tl4d2 DLiz charga High Prasggura Shutdeen g o Gm aD 5 Save your Max ON RX3i Configuration update the cfg dat C Block in the Max ON Project 6 Download the ne
119. thernet Synchronization Link Secondary uv ME cc ete ee pe IP 10 10 10 2 IP 10 10 10 3 11 32 11 32 O1 32 Q1 32 Al1 16 Al1 16 AQ1 16 AQ1 16 ENIU 11 ENIU 12 ENIU 13 IP 10 10 10 11 IP 10 10 10 12 IP 10 10 10 13 133 64 0165 128 701129 256 Q33 64 Q65 96 70Q97 128 JoAI17 32 AI none Al 33 56 AQ17 32 AQ none JoAQ none A Machine Edition backup folder to start from is provided with the Max ON RX3i Software Max ON RX3i Quick Start 3 ENIUs GFK 2409A C 1 2 n Proficy Logic Developer PLC create a new project based on the Project named above This project is added to the Machine Edition project Navigator by using the File gt Restore Project menu item Select the Project Navigator window making certain that there is no project open at this time Petes leche Ecler Ine wer E Die Ld manh pot Tgp Variation Doch Windows Chi Baek Th hocks msmegsesa 4 6 3g ud llc 4 Proficy Machine Edition i A PAL DEHO S Tandil bik Perr Sam 8 Logic Developer PLC Cams D AE 2005 Lab i Mawit 3 Using the File menu click on Restore Project Prolicy Machine Edition InfoViewes M De Lit Jerch Promet anges variables Jodi jinde Delo OM EB few raket gn EE ren Poit T ATTEN ga 4 Proficy Machine Edition 4 Place the Max ON RX3i Installation CD in your CD drive and navigate to the Quick Start directory Make certain that the selection
120. tion Utility 4 11 Genius Busses By selecting the Genius Busses item in the Project tree the Max ON RX3i Genius busses may be displayed and their settings may be modified By default no Genius busses are defined so you must configure the bus definitions to match your hardware configuration Genius busses can be defined as a Simplex or a Duplex bus Simplex Genius Bus A simplex Genius Bus is a non redundant I O bus that connects to one or more Genius I O devices To Add a Genius Bus 1 To add a new Genius Bus select the Genius Busses item in the Project tree then select the Busses gt Add Genius Bus menu item Prost Ed emp ee tss um mp nc Here Pravin Genium Bumsaesm Humber of B smsem D B Linsen iae A encor LAM rimate hin i 4 12 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A 2 Give the Genius bus a descriptive name such as Main and change the Baudrate setting if necessary Add new Genius Bus 3 After the Genius bus has been created it is added to the Project tree and now Genius devices may be added to this bus Ce re Hanni Et d Piy Humber o Bussusm B ee m 4 eem Humhar of I O Devices B onim oie TEE ED 4b Germ Gee m B eias cades Gy imn Fg um um GFK 2409A Chapter 4 The Max ON RXS3Si Configuration Utility 4 13 4 Double click on the Primary Bus Controller item in order
121. tion logic after the call to the subroutine named HBR 000 F m T 88 x Ta CALL hbr ODO MU If you are using an Existing Project If you have developed the application previously then you may copy and paste the Max ON RX3I logic into the existing Project A Machine Edition Toolchest drawer is also provided that may be used to copy the Max ON Blocks into the Project If this is a New Application Add your application logic into the project folder directly after the CALL to the hbr 000 Block in MAIN Rung 3 Step 5 Configure the I O Devices Ethernet NIUs If you are using Ethernet NIUs then you will need to create Ethernet NIU targets configure the I O in the remote drop and then download the ENIU information to the remote drop using Logic Developer PLC Genius or Field Control If you are using Genius or Field Control then set the appropriate parameters for Serial Bus Address O Settings I O Quantities Redundant Controllers BSM present always set to yes BSM Controller set to yes when a dual I O bus is used etc GFK 2409A Chapter 3 Building a Max ON RX3i Hot Standby Application 3 5 Genius VersaMax I O In Logic Developer PLC add a Target for each VersaMax I O Drop Add the appropriate modules to the drop and then configure the parameters for each module Connect to each drop with a serial cable and then store the configuration data Remote Genius 90 30 Drops If you are using Remote Genius 90 30 D
122. to activate the output data stream in the Backup Controller For the Ethernet I O LAN the Remote Ethernet drop will start using the data from the Backup Controller as soon as it detects that 1 The Backup is now the Master 2 he Master is no longer sending data For the Genius IO LAN Lacking output data from the current Master s GBC each output circuit on each device on the Genius I O LANs will hold its last state for up to 2 5 seconds before it assumes the Default State unless there is output data from the Backup GBC This assumes that each device has been configured for either BSM present or for long timeout Then the output device will begin using output data from the other GBC Synchronized Data Transfers Data may be synchronized from the Master to the Backup on a continuous basis in order to assure that the Backup controller s data is always in sync with the Master s Max ON RX3i supports up to 6 groups of synchronization data for each data type listed below The groups do not have to be contiguous Each group is specified by a starting reference address and a length For each data type the lengths are added together and the sum must not exceed the value in the corresponding column below Registers Discrete Internal Analog R Outputs Coils Outputs 6Q M AQ Max Length 8000 2048 4096 1 8000 1 2048 1 4096 1 256 GFK 2409A Chapter 2 System Overview 2 5 I O Bus Topologies The Max ON RX3i application supports the
123. to configure parameters or select the Busses gt Properties or Module gt Properties menus Enter the module s location in the RX3i main rack and it s status address A suggested practice is to address devices such as Genius bus controllers and Ethernet modules at high addresses This leaves the low addresses available for Input devices such as field 4 14 Sensors Genius Bus Controller Location Hack Main Hack Slot Slot z Status Address 0297 PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Adding a Secondary Genius Bus To add a Secondary Genius Bus to an Existing Genius Bus 1 Select the Genius Bus in the Project tree and then select the Busses Redundancy gt Add Secondary Bus menu item to add a Secondary Genius Bus ni bpr in Lp Pepe nius Fas Details for Hair BuudratHB fe a LEJ S Btd Bum Tap Wolle s dinrgls umber o7 I5 Deviass 2 A Secondary Genius Bus Controller is added to the Project tree zenius Eus Details for Main Buaudrats Bum Topology mumbey of TS bewiokB GFK 2409A Chapter 4 The Max ON RXS3Si Configuration Utility 3 Double click on the Secondary Bus Controller in order to configure it s parameters or 4 16 select the Busses gt Properties or Module gt Properties menus Enter the module s location in the RX3i main rack and it s status address A sug
124. ts that are attached to indicator lamps im next two rungs will indicate which CPU is Master ID A MASTER 90M 01017 90M 01020 ThisisCPUA This CPUis Master ID B MASTER I 3 94M 01018 90M 01020 ThisisCPUB This CPUis CPUB isth Master Master GFK 2409A Chapter 5 Programming Considerations 5 3 Local Status Flags Instantaneous The following status flags represent the instantaneous not latched state corresponding to the associated descriptors M0096 1 MO00962 MO00963 MO00964 5 4 Variable Reference Description Name AUTH_ALM MO00961 Authorization Alarm REM OFF MO00962 Remote CPU Offline PROG CHG MO00963 Program Changed HWC_CHG MO00964 HW Configuration Changed MO0965 Reserved MO00968 Authorization Alarm AUTH ALM This alarm bit indicates that the corresponding PLC is operating in DEMO mode on a standard PACSystems RX3i CPU IC695CPU310 In a system that has been properly authorized this flag will be OFF Remote CPU Offline REM OFF The companion PLC is offline This may be due to the CPU being in STOP Fault or Power OFF Also it may be due to a cable problem or Ethernet Interface failure Program Changed PROG CHOG The program in the Local CPU has changed HW Configuration Changed HWC_CHG The hardware configuration in the Local CPU has changed PACSystems amp RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Local Status Flags
125. uch ne Editizn 1nfaWieserr BER De dE ew Boek Peet Vabbe Took Meke Hein Bake DORKA D 8 DUE SS aW ad ip ab xu He hw it oC f h L e ac n d ua ndis aA mmu z Il Fac o8 Fi LDP Project 3 04 Proficy Machine Edition T MM M Cry Potion Set the EGD Local Producer ID in the controllers 12 Create EGD Exchanges in the Primary controller PLC A to match the EGD exchanges in each ENIU Create EGD Exchanges in the Secondary controller PLC B to match the EGD exchanges in each ENIU If Remote COMMREQ Calls will be used with the ENIUs add the RCC Parameterized C Block to the PLC COMMON CODE target s application and add any logic needed to execute these commands otore the Hardware Configurations PLC A HW and PLC B HW targets to PLC A and PLC B otore the Application Logic PLC COMMON CODE target to PLC A and PLC B Verify that the EGD Exchanges are working 18 19 Verify that any RCC commands are working Verify that any Local Logic is working PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Configuring the Genius I O Devices Before you may use your system you must configure the Genius I O devices that are to be installed on the Genius I O bus You must configure each device for e Serial Bus Address SBA Type of I O Input Output Combination e Scaling e Defaults Additionally you must set the I O to operate properly for redundancy e Dual I O
126. urrent Scan Instantaneous PLC Scan time in msec time LOC MUX jo R9027 Average Mux Packet Interval Average time interval for advancing to the next multiplexer packet msec IOM UPD 969028 joo YM Q WAQ Update Time to update all S M Q AQ and time of Interval day in the backup PLC sec X 0 01 REG UPD R9029 R Update Interval Time to update registers in the backup PLC sec X 0 01 NUM_FLT R9030 Number of Faults in Fault 0 empty 33 full Table NUM FLT 001 R9031 Fault Record 01 R9036 NUM FLT 007 R9037 Fault Record 02 R9041 NUM FLT 156 R9186 Fault Record 32 R9190 GFK 2409A Chapter 5 Programming Considerations 5 15 Advanced Topics PID Function Blocks The PID function block uses a data structure consisting of 40 registers These registers contain not only configuration parameters but also intermediate and final terms used in the internal calculations Some of the internal calculations are based upon values from the PLC s system clock Because the internal clocks in the two CPUs are not synchronized precisely to each other it is necessary to include a small amount of logic to compensate for the difference Also it will be necessary to include the PID registers in one or more of the R Synchronized Data Groups This ensures that the PID in the Backup CPU tracks the Master The ladder logic is straightforward following rungs control the operation of the PID This first Rung allows the PID to
127. use of single non redundant and or dual redundant busses interfacing to the I O devices A Max ON RX3i controller supports up to four Ethernet LANs At least one Ethernet Interface must be dedicated to the Synchronization Link This allows up to 3 additional Ethernet Interfaces that may be used as dedicated Ethernet I O LANs Support is also available for a single duplex Ethernet I O LAN Simplex Ethernet I O Busses Dual Ethernet I O Busses NOTE Redundant IP on the Primary and Secondary Synchronization LANs is not available Max ON RX3i supports up to four redundant Genius LANs or up to eight non redundant Genius LANs or a mixture of the two However the system may not have more than eight Genius bus controllers in a Controller Simplex Genius I O Busses Dual Genius I O Busses Up to 8 Up to 4 Redundant busses are superior to non redundant busses when there is a requirement to protect against cable failures or Genius bus controller failures When the primary consideration is to protect against cable failures then the system designer should consider separating the cables so that a single mechanical failure does not damage both cables Genius Dual Bus I O Capacity The maximum allowable I O capacity for Max ON RX3i redundant system that is configured for Genius Dual busses is as follows Discrete Discrete Analog Analog Inputs Outputs Inputs Outputs 2048 2048 1024 256 2 6 PACSystems RX3i Max ON Hot Standby
128. ut 1 Address Input 1 Length Input 2 Address Input 2 Length Output 1 Address Output 1 Length Output 2 Address Output 2 Length At SBA 30 Input 1 Address Input 1 Length Input 2 Address Input 2 Length Output 1 Address Output 1 Length Output 2 Address Output 2 Length At SBA 31 Input 1 Address Input 1 Length Input 2 Address Input 2 Length Output 1 Address Output 1 Length Output 2 Address Output 2 Length GFK 2409A Any address from 0 to 29 is acceptable Note Normally a Genius Handheld Monitor normally is set for SBA 0 It is standard practice to avoid O when using Field Control or Genius I O 90100481 for M23 M31 and M40 drop folders 70102017 for M5S and M5L drop folders 90100001 always 0 9oAI00001 always 0 90100001 16 plus the number of Discrete Inputs installed 90100001 The number of Analog Inputs installed oee Buffer Registers 62 90100001 always 0 Q00001 always 0 AQO00001 always 0 oee Buffer Registers 62 90100001 always 0 Q00001 always 0 joAQO00001 always 0 Chapter 7 Configuring the I O Devices 9 Secondary Bus optional The Genius bus controller should be configured as follows In the Settings Tab Serial Bus Address SBA Any address from 0 to 29 is acceptable Note Normally a Genius Handheld Monitor normally is set for SBA 0 It is standard practice to avoid O when using Field Control or Genius I O 90100449 for M23 M31 and M40 drop folders 90101
129. w Master CPU into Normal Sweep and the new Backup to Constant Sweep Why you should consider this approach The Master always operates with the fastest Scan Time possible GFK 2409A A 1 The Backup will adjust its timing regularly to meet current system requirements The period for Constant Sweep is determined automatically once per second The value is calculated by adding 75 milliseconds to the Master s Scan Time and then rounding downward to the nearest multiple of 5 milliseconds To enable this mode of operation 1 Using Logic Developer PLC open your Max ON RX3i Project 2 Select the PLC COMMON CODE Target as the Active Target 3 Prior to the call to HBR 000 in the MAIN Block enter a rung that sets AUTSWP M1012 to ON Store the Logic into CPU A 5 Store the Logic into CPU B Manual Mode The second method is to configure the CPUs to execute in Constant Sweep mode The configuration is entered via the Logic Developer PLC Hardware Configuration Both of the hardware configurations for targets PLC A HW and PLC B HW must be set and then stored into the corresponding CPUs Why you should consider this approach By having the Master in Constant Sweep mode Ethernet communications with HMIs may be improved dramatically Prerequisite The system has been commissioned and is operating in its normal fashion All application logic has been completed and is being executed in the hot standby CPUs HMls are attached and
130. w Max ON RX3i Configuration to the CPUs GFK 2409A Chapter 5 Programming Considerations 5 19 In Your Application Folder 5 20 1 Move a user specified fault value into FLT COD 96R9762 The fault value must be in the range 3840 4095 decimal inclusive and should correspond to the equivalent user defined fault created in Max ON RX3i Configuration Utility In most cases move a value 0 into FLT CKT R9 61 However you may define your own identifier that may be MOVed into this register The diagnostic tool will display this as a decimal value in the Circuit Reference position Call the subroutine named HBHR 005 This must be done for only once otherwise each subsequent call will post an additional alarm into the alarm table In the sample logic shown below ua 0002 99M02050 has been used as an alarm latch The user defined alarm will be posted only if the coil is not already set Note that a setcoil is used so that the alarm state will be retained through a loss of power Also a rung has been provided that resets the coil if the alarm clear flags are invoked m a User Alarm PSH 402 ua_0002 jf MOVE MOVE CALL un 0002 4 ii INT fee INT Ihr 0051 Lcd E 9400259 90M02050 M 02050 Pump User 0002P1 User 0002 Discharge 402 High 402 High Pressure High Pressure Pressure Alarm Alarm 1 1 0 N QF FLT_CKT 3841 IN QF FLT_COD 90M 01015 Reset Local Alarms os PACSystems RX3i
131. will create a new tab in the InfoViewer window so that you can configure the properties of the consumed exchange The new tab is shown below r rien Fiunicoemsl PLc B Mw x Add insert Delete Length Bytes t DOsat Byte fa Viable GFK 2409A D D Updating an Existing Application D 13 P In the nfoViewer window click on the Add button to add a new item to the table The window will appear as shown below r c e Manon PLE E He T x Add inseri Delete Length Byes 1 Dieet fete Ha HOT USED Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows MxnCons1 Primary LAN Produced Exchange In the Navigator window right click on Produced Exchanges The following pop up menu will be displayed Hes Ires Click on New to create the first Produced Exhange The default name for the exchange is ProdExch1 n the nspector window set these properties as follows Name Set to MxnProd1 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM normally Rack 0 Slot 4 Destination Type Defaults to Unicast Destination Set to the IP address of the Primary ETM in PLC A Produced Period Set to 10 Reply Rate 0 not configurable Send Type Always not configurable Run Mode Store Defaults to False D 14 PACSystems RX3i Max ON Hot Standby Redundancy February 2009 GFK 2409A Produced Peri
132. zed as follows ECC Max ON Rx3i Tools Max ON Rast Configuration Tool installation af J Documents Getting Started Document J ire HG Praficy Components 7 Diagnostics VIEW Proficy View Diagnostics Project oof Redundancy LD Default Max ON Rasi LD Project El Remote Drops LD cernes 90 30 Genius Remote Drop Projects RemoteDrop CPUS13 and 323 2 RemoteDrap CPU331 gd RemoteDrap CPUS Lu RemoteDrop CPUSSx 36x 374 large B L RemoteDrop CPU35x 36x 374 small A Max ON RX3i Quick Start Project is also included on the Max ON RX3i Software CD This Quick Start Project also includes 3 RX3i ENIU targets GFK 2409A Chapter 2 System Overview 2 3 Hot Standby Redundancy Operation During each controller scan the Max ON RX3i redundancy drivers are solved first and then your application logic is solved The Max ON RX3i redundancy drivers handle the following functions 2 4 Determine Mastership One CPU operates as the Master The other operates as the Backup Output devices use the output states from the Master only In a Max ON RX3i system the user may specify either PLC to be the preferred Master If no preference is specified then Mastership floats between the PLCs The current Master retains its status until it fails or until the user switches Mastership at which time the Master and Backup exchange their roles Transfer Synchronization Data If the Master fails the Backup must be prepared to control the process u

PACSystems Max-On Hot Standby Redundancy Manual

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