Displays - Siemens
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1. Downloading Synchronizing the Standby Changing Determining Active Standby Role on Reading HBU Displays Interfacing with the DiagnosliCS iiu ee ee User initiated Diagnostics Checking Status of Standby Unit SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Bac kup 1 1 1 Manual Contents and References 2 Hot Backup This publication is designed to provide you with an overview of hot backup with the SIMATIC TI560 T 565 Programmable Controller PLC and to give you installation information Additional information on the TI 560 TI565 is found in the following manuals Manual Number Description PPX 560 65 8101 x SIMATIC TI560 TI 565 User Manual This manual includes TI 560 and T1565 Hardware Manuals and Programming Instructions PPX 560 65 8102 x VPU 200 TI560 TI 565 Program Devdopment Manual This manual includes SIMATIC VPU 200 v TI 560 and VPU 200 TI 565 Programming Manuals and PPX VPU 22. connected to the corresponding port marked receive e Thelength of the cable connecting the active and standby units cannot exceed 20 feet SIMATIC TI560 TI565 Hot Backup Installation Manual 1 6 Connecting the Units with the I O System Developing the Power Budget with Hot Bac kup After the two units are connected through the HBU boards as described above both units must be linked with the 1 O system This is accomplished by using cables to connect the RCC boards and CATV splitters to connect the RCC cables to the 1 0 cabling Connect each RCC board by running a cable between the units for each RCC channel used Then use a 3 way splitter arrangement three two way splitters as illustrated in Figure 4 to connect both RCC channels to the cable running to the 1 0 bases on that channel CATV grounding blocks at each RCC channel and base are recommended also The SIMATIC TI560 Hardware Manual PPX 560 8102 contains a detailed description of installing remote I O and developing a power budget for the remote I O system You should consult this section of the manual for installing your overall I O system However additional considerations are necessary with an HBU unit The following paragraphs discuss installation of I O in terms of dB loss from the cable required for connection of the HBU unit Each 1 0 channel of the active unit must be connected to the corresponding I O channel of the standby unit For instance Channel 11 O cabl
3. download time may last for as long as five seconds dependent upon size of program Special Function modules the I O bases may time out during the Standby synchronization period If any of the following modules are present in the 1 0 bases they will function as described below PEERLINK Will drop off the network but will come back online and restart transmission when the download is complete e ASCII Messages in progress will finish printing but no further printing will be initiated until synchronization is complete e NIM Will time out but normal operation will return when synchronization is complete BASIC TheON ERROR statement should be used to avoid having the BASIC module exit the program that is running If the BASIC module is attempting to communicate with the PLC for example PCREAD IOWRITE statements a time out error will occur during synchronization Synchronization is maintained by the execution of identical ladder logic programs and functions as stored in the user memory transferred to the standby unit Both units receive inputs from the I O but only the active unit writes to the I O modules If the standby unit misses 1 communication it will request a retransmission from the active unit Excessive I O errors at the standby will cause it to drop offline You may usethe SSI Scan Synchronization Inhibit instruction to control when the standby unit is brought into synchronization with th
4. 00 3104 x Hardware Manual SIMATIC TI560 TI565 Hot Backup Installation Manual 1 2 Hot Backup Overview Use of the Hot Backup option allows two PLCs to operate in synchronization One unit is designated as active the other standby If the active unit fails the standby assumes control of the process The active unit provides the standby with timing and update information which enables the standby to assume the active role Both active and standby units execute the Relay Ladder Logic Program During the I O both the active and standby units receive the same inputs however only the active unit controls the outputs Timing information is provided to the standby unit from the active unit in order to keep the time bases in synchronization Status Word 01 and Status Words 145 160 are unit dependent and may not contain identical information in both the active and standby units Since image register differences could result use caution if the data from these status words are incorporated in Relay Ladder Logic programs When TI 565 is in hot backup configuration the Special Function SF Programs and Loops are executed only by the active unit The results of calculations and positioning in programs are provided to the standby as executed If the standby assumes control of the process SF programs begin from the last completed statement and loops begin from the last completed calculation in the current loop that is executing SI
5. MATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 3 1 3 11560 11565 in Redundant Configuration Hot backup configuration for the TI 560 TI565 is achieved through connection of two PLCs with identical hardware The second PLC is also connected with the I O through a splitter attached to the cable running between the two PLCs Figure 1 illustrates the connectivity of the two units CIEL u ni rrr rre np mm en CHANNEL tp 22 5 147 gt SE LL ic Ko 22 6 GI 1 y fmm E SE a ao 5 1 v iv 5 UL 278 DISCRETE CPU CARO WITH 96K BYTES MEMORY EXPANSION CARD REMOTE CHANNEL T PARA PECIA fee Y SPECIE t CONTROLLER OPTIONAL HO BACK UP CARD CAROS Figure 1 HBU Connectivity Hot Backup SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Bac kup Board The hot backup board PPX 560 2128 enables a standby PLC to be configured and to operate in conjunction with the active controller The two units are synchronized through the communication port on the HBU board Control is transferred to the standby unit if a fatal error is logged in the active unit Figure2 is a block diagram illustrating an HBU configuration NOTE When the active unit fails the standby unit must bein ONLINE mode in
6. SIEMENS SIMATIC TI560 TI565 Hot Backup Installation Manual Order Number PPX 560 65 8103 2 Manual Assembly Number 2597773 0003 Second Edition Copyright 1994 by Siemens Industrial Automation Inc All Rights Reserved Printed in USA Reproduction transmission or use of this document or contents is not permitted without express consent of Siemens Industrial Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Industrial Automation Inc does not possess full access to data concerning all of the uses and applications of customer s products we do not assume responsibility either for customer product design or for any infringements of patents or rights of others which may result from our assistance Technical data is subject to change We check the contents of every manual for accuracy at the time it is approved for printing however there may be undetected errors Any errors found will be corrected in subsequent editions Any suggestions for improvement are welcomed MANUAL PUBLICATION HISTORY SIMATIC 1560 1565 Hot Backup Installation Manual Order Manual Number PPX 560 65 8103 2 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 10 86 Original Issue 2597772 0001 Second Edition 05 94 Second Edition 2597772 0002 LIST OF EFFECTIVE PAGES Pages Des
7. STDBY will restart only the Standby e Restart to ONLINE STDBY will not be executed rejected SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 17 19 18 Hot Backup Reading HBU Displays You may determine the status of several items by reading the LEDs on the face of the HBU board When the LED is on status is indicated as shown below HBU Good Status of Board Good Standby Indicates this is a Standby unit By observing the PROG RUN LED on the CPU board in conjunction with the Standby LED on the HBU board you can determine when the Standby is Online If the Standby LED and the PROG RUN are both ON the Standby is Online SIMATIC TI560 TI565 Hot Backup Installation Manual 1 10 Interfacing with the Standby Operator interfaces 51 CVU 5000 and PPX VPU 200 3104 be connected to the active and or standby controllers The interfaces connected to the standby unit are for status information only and cannot make program changes however changes in memory made through an operator interface connected to the active unit are passed from the active unit to the standby You may usethe VPU 200 to remove the standby unit from backup ser vice SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 19 1 11 Diagnostics Diagnostics are provided to help you in determining if there is a problem with the HBU board At power up the HBU board runs self tests to determine if memory and communication a
8. cription Cover Copyright Second History Effective Pages Second 1 20 Second Registration Second Pages Description 1 1 12 13 14 1 5 1 6 1 7 1 8 19 1 10 1 11 Hot Backup Manual Contents and References Hot Backup Overview cece cece eee EE eee nnne nena rr ar n 11560 11565 in Redundant Configuration Hot Board e EE be Ee dada dice b ea cas Specificationsfor Hot Backup Board Installing the Hot Backup Selecting Startup Handling Boards eee emendet ePi eR RR iad Ek CER ences Inserting Boards i cs sia Y pmo ener A ete e EAR Cea I RR ECT CR Removing BoardS Packet ARRA kk cic ee Powerup After Board Changes Connecting the Active and Standby Units OJIN GIGI ul NJ Kko 951165 Connecting the Units with the I O System Developing a Power Budget with Hot HBW I O BxaMple pcc crum DUI Setting the Download Select Switch lt lt
9. dive This PLC is the controlling unit Standby Online This PLC is a backup unit in step with the active unit and can assume control continue running if the active unit fails e _ Standby Offline This PLC is a backup unit but is not in step with the active unit Neither memory nor program is guaranteed to match the active unit If the active fails this unit becomes the active in the program mode Designating Active or Standby Status For initial startup with a hot backup configuration the designation of the status of the units being used in the hot backup configuration may be made with the dipswitches on the HBU boards See Figure 3 The positions for the dipswitches are labeled DOWN Active and UP Standby e _ Set the top switch in the position that indicates the status desired for the unit before installing the board To access the switch after installation the board must be removed See Board Removal Instructions Figure 3 Dipswitch Location SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 7 Installing the Hot Bac kup Unit continued Handling Boards A WARNING Inserting Boards 8 Hot Backup When handling inserting or removing boards follow the guidelines given in the paragraphs below All MOS and EPROM devices are susceptible to damage by the discharge of static electricity The following practices will help minimize the possibili
10. e active unit This instruction is treated as an internal coil by the TI 560 and sets the most significant bit MSB of Status Word 01 when power flow to the coil is present While the SSI is active if the standby unit powers up and attempts to automatically come online the active unit inhibits the synchronization steps SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 15 Startup continued While the standby unit remains online the SSI instruction has no further effect The synchronization inhibit will remain active until e _ Power flow to the coil is off at which time the synchronization steps will be initiated or e _ Theuser overrides the inhibit by command from an operator interface The SSI instruction programming format and operation are discussed in detail in the SIMATIC TI560 Program Design Manual 16 Hot Backup SIMATIC TI560 TI565 Hot Backup Installation Manual 1 8 Changing Status After Startup Determining Active Standby Role on Restarts To change status after startup use the VPU 200 Support Function designated for this operation Function 82 Function 82 allows you to set the Standby unit stateto either ONLINE or OFFLINE Early releases of HBU do not support commanded role swaps This is indicated by the error message Illegal Task Code Request on the VPU screen when role swap is requested from Function 82 To make the standby unit become active power cyde the Active unit this in effect
11. e of the active unit and Channel 1 1 0 cable of the standby need to be connected to the same trunk line Connect the corresponding channels to the trunk line through a three way splitter The cables connecting the splitters with the active and standby units may be any length that maintains a loss no greater than 40 dB between the active and standby units Figure 4 illustrates the configuration of the cables with the CATV splitters SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 11 Connecting the Units with the I O System continued ACTIVE STANDBY UNIT UNIT mul 7 DB INSERTION LOSS TO ACTIVE E 5 CHANNEL CHANNEL HLL 7 DB INSERTION LOSS Figure 4 Splitter Configuration Connecting Active and Standby The splitter configuration has a 7 dB loss between any two ports assuming the losses in the three pieces of short cable to be negligible 12 Hot Backup SIMATIC TI560 TI565 Hot Backup Installation Manual HBU I O System Assume the following requirements for a system layout for Channel 1 of an Example O system Active and standby units are connected at the RCC cards by cable having a total run of 100 Keep in mind the 20 maximum on the fiber optic cable between the HBU boards e remote bases on one channel Base locations First base at 4000 then 400 apart except the last base which must be at 10 000 e O base positions are 100 from the t
12. executes a role swap The paragraphs following explain the modes assumed on a restart after initial power up in a hot backup configuration If a unit is Active upon power up of the second unit the second assumes a Standby role If the second unit was not Offline when it powered down it requests to be brought Online with the Active unit If Offline at power down the second unit remains Offline If a unit does not detect another unit and was either Active in RUN or Standby Online at power down it will assume the Active rolein the RUN mode Otherwise it assumes the Active role a modified Program mode To place the unit in the regular Program mode usethe VPU to execute Support Function 10 11 or 12 Restart When two units power up together they arbitrate for the Active role e fthebattery is good and the prior states were a valid complimentary pair then the prior states are resumed e ftheprior states constitute an invalid configuration or the battery is low in both units one unit will be Activein the Program mode and the other Standby Offline Under these conditions the Active unit is determined by the switches on the HBU board provided that the switches are set differently If the switches on the HBU board are set to the same position the unit that assumes the active role is indeterminate Restart commands are treated as follows e Restart to Active will cause Restart of both Active and Standby e Restart to OFFLINE
13. of eight dipswitches is accessible through the front bezel of the Discrete CPU board Switch 4 selects whether or not presets will be downloaded and initialized on restart The switch functions as shown below Presets TCP DCP etc are loaded and Presets TCP DCP etc are not initialized on restart initialized on restart The ON OFF positions of the download select switch are illustrated in Figure 6 Figure 6 On Off Positions of Download Select Switch Before startup be sure the Download Select Switch on the Discrete CPU board is set to the same position in both units On or Off Different settings at power up will result in different actions being performed on the Presets Download of Presets during restarts will follow the Download Select Switch position on the active unit SIMATIC TI560 TI565 Hot Backup Installation Manual Downloading Memory Synchronizing the Standby Unit Download of the program from the active to the standby unit is automatic when the standby unit is brought online If the Active unit is in the RUN mode the standby unit requests to be brought online at power up The active unit responds to the request by copying its memory to the standby unit unless an SSI instruction is active Note that this copy of memory must occur between scans in order to freeze variables until the copy is complete During the copy scans are not executing and the I O are frozen at their last values The
14. order to assume control If the standby is OFFLINE when the active unit fails the standby will become functional in the PROGRAM mode gt lt j Active Standby PLC Hot Backup PLC Communication 18 VPU and or CVU5000 limited function due to standby status CVU5000 l Input and Output Standby is listen only Standard I O channels 8 channels max corresponding I O channels are tied together through a splitter arrangement Figure 2 HBU Block Diagram SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 5 11560 11565 in Redundant Configuration continued Specifications for Microprocessor 68000 Hot Backup Board Communications Fiber Optics Displays ACTIVE HBU GOOD STANDBY and COMM GOOD LEDs Performance Degrades PLC performance less than 10 msec per scan Dimensions Given in the following illustration 6 Hot Backup SIMATIC TI560 TI565 Hot Backup Installation Manual 1 4 Installing the Hot Backup Unit Selecting Startup Modes The hot backup board contains the HBU microprocessor its local RAM and ROM and the hot backup communication link Upon power up the CPU operating system executes self diagnostics and determines the status of all other boards in the PLC If a unit checks out as functional with an HBU board installed it attempts to establish an operational HBU mode with another TI560 TI565 PLC TheHBU Modes are e A
15. re 7 Function 82 Display 20 Hot Backup SIMATIC TI560 TI565 Hot Backup Installation Manual SIMATIC is a trademark of Siemens AG TI560 TI565 are trademarks of Texas Instruments Incorporated VPU200 Peerlink and CVU 5000 are trademarks of Siemens Industrial Automation Inc Customer Registration We would like to know what you think about our user manuals so that we can serve you better How would you rate the quality of our manuals Excellent Good Fair Poor Accuracy Organization Clarity Completeness Overall design Size Index Would you be interested in giving us more detailed comments about our manuals Yes Please send me a questionnaire No Thanks anyway Your Name Title Telephone Number Company Name Company Address Manual Name SIMATIC TI560 TI565 Hot Backup Installation Manual Edition Second Manual Assembly Number 2597773 0003 Date 05 94 Order Number 560 65 8103 2 FOLD NO POSIAGE NEC ESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRSTCLASS PERMITNO 3 JOHNSON CMY TN POSIAGE WILL BE PAID BY ADDRESSEE ATTN Technical Communications M S 3519 SIEMENS INDUSTRIAL AUTOMATION INC 3000 BILL GARLAND RD P O BOX 1255 JOHNSON CITY TN 37605 1255 FOLD
16. re good The LEDs on the front of the HBU board come on if the board and communications check out as good during the tests User Initiated User initiated diagnostics are executed only by the Standby unit in Program Diagnostics mode To run diagnostics on both units use the VPU torun the diagnostics Functions 20 29 on the current Standby power cycle the Active to make it become Standby and execute the diagnostic functions again Checking Status of Support F unctions are accessible at two locations in the menu hierarchy of Standby Unit the programming device Accessing the Support F unctions is detailed in Section 6 of the SIMATIC VPU 200 T1565 Programming M anual If the standby unit does not appear to be in the mode you selected use the VPU 200 to call Function 82 A display as shown in Figure 7 indicates the status of each unit and gives one of the following messages to indicate the reason for the status of the standby e State entered at power up e Off line due to Hardware Mismatch e Off line due to User Command e Off line due to Active unit in Program Mode e Off line requesting online but inhibited by user program in active unit e Off line due to failure in Standby e Off line due to loss of HBU Communications Current Hot Backup Status Connected Unit Standby Off line Alternate Unit Active Off line due to User Command EXIT F1 ONLINE F2 SWITCH F3 See Paragraph on Changing Status after Startup Figu
17. runk lines Figure 5 shows the calculations to determine the power budget for the layout described above Trunk Tap Drop Cable Tap Output Tap to Trunk Loss Cable Terminal Signal Cable Loss Splitter Insertion Signal 100ft Loss Loss Level Length 100 ft Loss Loss Level Destination ft dB dB dB ft dB dB dB dBmV 3 Way Splitter 50 1 4 56 2 Trunk 00 1 7 47 6 Base 1 i 30 6 00 2 28 7 00 Base 3 26 8 00 Base 4 24 8 00 Base 5 22 8 00 Base 6 20 8 00 Base 7 18 4 00 Base 8 17 0 00 Base 9 14 6 00 Base 10 3 0 o o o 00 Figure 5 Worksheet for 500 Cable SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 13 1 7 Startup Setting the Download Select Switc h for Presets NCAUTION 14 Hot Backup The general start up procedure as given in the SIMATIC TI560 Hardware Manual should be followed for all start ups Several additional items should be checked to insure their completion before attempting a start up in a hot backup configuration 1 Theselection of active standby status should be made on the HBU boards before initial startup 2 Settings for download of presets should be made on the CPU board for each unit before the units are powered up in a hot backup configuration 3 Thefiber optic cable between the two units should be connected before powering up the standby unit A panel
18. the top and bottom of the board 3 Grasp the handles and remove the board with a firm steady force When a CPU or Memory Expansion board is replaced or removed the battery should be OFF before start up of the TI 560 TI 565 Before powering down or turning OFF battery save the user program to a disk After power up use the programming device to download the program from disk to the TI 560 TI565 NOTE If the PLC is powered down with battery OFF wait 20 seconds before restoring power to the PLC to insure proper initialization SIMATIC TI560 TI565 Hot Backup Installation Manual Hot Backup 9 1 5 10 Connecting the Active and Standby Units Hot Backup Follow the guidelines given below to connect the fiber optic cables enclosed with this manual between the active and standby units e fthecableis pulled through conduit take care not to strip or nick the plastic insulation e The cable should be pulled with no more than 34 pounds 15 kg of force e Pull force on the connectors should not exceed 5 pounds 2 3 kg e The cable should be strain and abrasion relieved around sharp corners The minimum bend radius should be no less than 1 5 inches 38 mm If excess cable is to be rolled up for storage the diameter of the roll should be at least 6 inches 150 mm e The cable ends are marked transmit and receive The transmit end is connected to the HBU board port marked transmit and the receive end is
19. ty of damage to MOS and EPROM devices on the HBU boards e Both the board and the person handling the board must be at the same ground potential To accomplish this ensure that The work area has a conductive pad with a lead connecting it to a common ground The board is transported in an antistatic container of antistatic material The person is grounded by making contact with the conductive pad and or wearing a grounded wrist strap Do not insert or remove boards while the PLC is powered up The board may be damaged if inserted while power is on and memory may be lost if the board is removed with power to the PLC NOTE Boards must be installed contiguously beginning with Slot 1 i e no open slots between boards are allowed Slot 1 is reserved for the TI 560 Discrete CPU board Procedure for inserting boards 1 Makesurethe power supply is off before inserting boards 2 Position the board in the upper and lower metal channel guides 3 Push the board in until it touches the card connector slot 4 Pushthe board firmly until it is plugged into the connector slot The bezel on the front of the board should be tight against the chassis 5 Insert and tighten the screws at the top and bottom of the board SIMATIC TI560 TI565 Hot Backup Installation Manual Removing Boards Power Up After Board Changes Procedure for removing boards 1 Make sure the power supply is off before removing boards 2 Loosen the screws at
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