Modicon Quantum 35010533 04/2014 Modicon Quantum Hot Standby System User Manual 04/2014 35010533.11 www.schneider-electric.com The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage. © 2014 Schneider Electric. All rights reserved. 2 35010533 04/2014 Table of Contents Safety Information . 7 About the Book. 9 Part I Introducing the Modicon Quantum Hot Standby System. 13 Chapter 1 Modicon Quantum Hot Standby System . 15 1.1 Quantum Hot Standby Introduction . 16 Terminology. 17 Purpose and Features . 18 Overview . 19 Redundant Hardware . 20 Quantum Hot StandBy CPU Front Panel . 25 Hot Standby Sync-Link . 26 S908 Hot Standby Hardware and Topology . 28 Quantum Ethernet I/O Hot Standby Hardware and Topology . 35 Mixed Ethernet and S908 RIO Network . 45 Configuration Requirements . 47 Hot Standby Restricted Functions . 49 Establishing Redundancy . 50 Quantum Hot Standby Operation Modes . 53 Remote I/O Management . 55 Hot Standby Programming Differences . 57 1.2 Hot Standby Safety CPUs . 61 Hot Standby Safety CPU Specifics . 62 Operating Modes of the Safety PLC . 65 Part II Configuring and Maintaining a Quantum Hot Standby System . 67 Chapter 2 Configuring with Unity Pro . 69 2.1 Unity Pro Tabs and Dialogs. 70 Introducing Unity Pro . 71 Using the Summary Tab . 72 Using the Overview Tab . 73 Using the Configuration Tab . 74 Using the Modbus Port Tab. 80 Using the Animation Tab and PLC Screen Dialogs. 82 35010533 04/2014 3 Using the Hot Standby Tab . 86 Configuring the PCMCIA Cards . 88 Configuring the Modbus Plus Communication Type . 89 Non-Transfer Area and Reverse Transfer Words . 90 Setting Up the Quantum Hot Standby System. 91 2.2 Reading and Configuring Registers . 93 Hot Standby Command Register . 94 Hot Standby Status Register . 98 Hot Standby Firmware Mismatch Register. 101 Using Initialized Data . 102 Synchronizing System Timers . 103 2.3 140 NOE 771 x1 and 140 NOC 78• 00 Modules . 104 Quantum Hot Standby and 140 NOE 771 •1 / 140 NOC 78• 00 Modules . 105 140 NOE 771 x1 / 140 NOC 78• 00 Operating Modes in Quantum Hot Standby System . 107 140 NOE 771 x1 / 140 NOC 78• 00 IP Address Assignment . 111 140 NOE 771 x1 / 140 NOC 78• 00 Modules in Hot Standby System 113 Chapter 3 Maintaining a Quantum Hot Standby System . 115 3.1 Hot Standby Module Replacement . 116 Replacing a Module . 116 3.2 Hot Standby Health Messages. 117 Verifying the Health of a Quantum Hot Standby System . 117 3.3 Single Point of Detected Failure. 119 Detecting and Diagnosing Inoperative Components through Health Messages. 120 Detected Inoperative Conditions on Rack, CPU, Copro and RIO Head 121 Detecting High Speed Sync-Link Interruptions . 124 Troubleshooting Primary PLC . 126 Chapter 4 Programming and Debugging. 129 4.1 Operating Modes and Switchover Information . 130 Operating States and Modes . 131 System Performances . 136 Conditions for Switchover . 137 Switchover Behavior during Application Mismatch . 139 Handling Network Addresses at Switchover . 141 Testing Switchover of a Quantum Hot Standby System . 146 Connection Health Bits and Switchover . 149 4 35010533 04/2014 4.2 EFBs for Quantum Hot Standby . 150 HSBY_RD . 151 HSBY_ST . 154 HSBY_WR. 157 REV_XFER . 160 4.3 Equipment Restrictions . 163 Local and Distributed I/O Restrictions . 164 Module Restrictions . 166 Application Restrictions . 167 4.4 PLC Communications . 168 Data Transfer. 169 Application Program Transfer . 170 Scan Time . 174 4.5 Developing a Hot Standby Application . 176 Adjusting MAST Task Properties. 177 How to Program a Quantum Hot Standby Application . 180 Transferring Your Program to the Primary and Standby PLCs . 181 4.6 Debugging a Hot Standby Application. 182 Debugging . 182 Part III Modifying and Upgrading . 185 Chapter 5 Application Modifications . 187 Quantum Hot Standby Application Mismatches . 188 Online or Offline Modifications and Application Mismatch. 192 Standby CPU Online Application Modifications with Application Mismatch . 193 Primary CPU Online Application Modifications with Allowed Application Mismatch . 194 Offline Application Modification with Allowed Application Mismatch . 195 Switchover Methods with Application Mismatch . 196 Manual Application Program Transfer Method and Application Mismatch . 198 Recommendations for Using Application Mismatch . 199 Chapter 6 Firmware . 201 Firmware Levels . ..