cost-effective unity premium hot standby solution

Cost-effective Unity Premium Hot Standby Solution

Presenter – Tom RoyalAmericas Business SupportEnd User Domain – Automation BU

Call-in number 1-866-758-0236Passcode 3306817

Schneider Electric 2Automation BU – End User Domain - Americas Business Support

● Overview

● Typical architectures

● Competition

● Sales Arguments and Value Proposition

● Migration from Standalone

● Targeted applications and opportunities

● Operation and Rollover

● Positioning with Quantum

Contents


●Automation system keeps running despite a controller failure

●Primary PLC with a Standby PLC as backup

●Running guaranteed only for the first failure

●No guarantee for a second failure in the system (unless the first one is repaired)

Introduction What is HSBY?


● The UNITY Premium Hot Standby System is designed foruse where downtime cannot be tolerated.

● Two backplanes are configured with identical hardware, firmware** and application program.

● One of the PLCs acts as the Primary. The Primary Controller updates the Standby Controller at the beginning of each scan.

● Primary and Standby States are switchable. Either controller can be put in the primary state.

● The remote I/O (STB,OTB… ) is never aware of the existence of two PLCs.

● The CPU-sync link is a point-to-point connection dedicated to application data exchange and hot standby system diagnostics.

Introduction HSBY overview


Typical Architecture with Redundant I/O & SCADA Network

ETG1000

Ethernet I/O Scanner RING

CPU-syncLink

Primary Premium

Standby Premium

Ethernet TCP/IP network #2

ET

YE

TY

ET

YE

TY

ET

Y

ET

Y

Tesys

U

Modbus

XBT-

GT

Mom

entu

m

IO

STB

OTB

Ethernet TCP/IP network #1

VIJEO CITECT

ATV61


o Easy to Program● Design and commission as quickly as a standalone application● No specific user programming.● Access to all Unity Pro and IEC1131-3 features

o Easy to Operate● Hot Swap and auto-reconfiguration ability for selected I/O modules● Bumpless rollover for selected I/O modules● Transparent rollover for SCADA & HMI (IP swapping)

o Efficient● Uses our experience in HSBY systems● Efficient data context exchange (no application programming)● Uses the very powerful Unity Premium hardware● Execution performances

Value Propositions Easy to program and operate


Typical Premium HSBY Architecture STB I/O islands over Ethernet

Premium PRIMARY

Premium STANDBY

Ethernet I/O ring 10/100 Mbps

Advantys STB

Modicon M340 Momentum

SCADABriefly:•Specific Hot Standby CPUs required.•Hardware redundancy – not software.•CPUs are linked with Ethernet crossover cable.•I/O located remotely through Ethernet

network (ring topology).•Local rack I/O can also be used (redundant)

Briefly:•Specific Hot Standby CPUs required.•Hardware redundancy – not software.•CPUs are linked with Ethernet crossover cable.•I/O located remotely through Ethernet

network (ring topology).•Local rack I/O can also be used (redundant)

Premium HSBY positioningPerformance

Availability Rate

Easy usage

Cost effective


Typical Rockwell ControlLogix ArchitectureFlex I/O islands over ControlNet

Briefly :•Hardware redundancy with a dedicated redundancy module•Dual attachment topology

Briefly :•Hardware redundancy with a dedicated redundancy module•Dual attachment topology

Premium HSBY vs ControlLogix

Performance

Availability Rate

Easy usage

Cost effective

Premium HSBY EthI/O

ControlLogix Flex I/O


Typical Siemens architectureET200 I/O islands over Profibus

Briefly :•Software redundancy solution•Dual attachment topology

Briefly :•Software redundancy solution•Dual attachment topology

Premium HSBY vs SoftRed

Performance

Availability Rate

Easy usage

Cost effective

Premium HSBY EthI/O

SoftRed ET200 I/O


IM 153-2 with ET200M

IM 157 with PA bus

Y-Link with DP bus

Rack 0 Rack 1

Briefly :•Hardware redundancy solution•Dual attachment topology

Briefly :•Hardware redundancy solution•Dual attachment topology

Premium HSBY vs S7-400HPerformance

Availability Rate

Easy usage

Cost effective

Premium HSBY EthI/O

S7-400H ET200 I/O

Typical Siemens S7 400H architectureET200 I/O islands over Profibus


Market segmentation Performance

SCANTime

SoftwareSoftware redundancyredundancy

HardwareHardwareRedundancyRedundancy

Slow

Performance

Slow S/O onRemote I/O

Fast S/O onRemote I/O

Premium WSBY

ET

Y

ET

Y

Premium Hot Standby

Fast S/Oon CPU &Rack I/O

Slow S/Oon CPU &Rack I/O

Very FastFast except Small App Fast

Quantum Hot StandbyAB ControlLogix

Omron CS1D

SiemensSoftRed

Siemens S7400H


Pricing policy

●Comparison of:●Premium HSBY with STB I/O over Ethernet●Siemens SoftRed with ET200 I/O over Profibus●Siemens S7400H with ET200 I/O over Profibus●Rockwell Contrologix with Flex I/O over ControlNet

Small HSBy configuration - Country

PLCPLC

PLCPLC

I/OsI/Os

I/OsI/Os

0

5000

10000

15000

20000

25000

30000

Premium + STB S7-300 S7-400 + ET200M ControlLogix

Net Price in LC

Medium HSBy configuration - Country

PLCPLCPLC

PLC

I/OsI/Os

I/OsI/Os

05000

1000015000

2000025000

3000035000

4000045000


Net Price in LC

Large HSBy configuration - Country

PLCPLCPLCPLC

I/OsI/Os

I/OsI/Os

010000

2000030000

4000050000

6000070000

8000090000


Net Price in LC


oStrong points of the offer:● High Performance in terms of scan time, CPU & rack I/O performance

while keeping “bumpless” warranty (Rockwell / Siemens SoftRed)● Just enough global functionalities for targeted markets (SI)● Flexibility in terms of rollover performances and availability rate● Non-specific HSBY programming (SI – Siemens SoftRed)● IP address swapping and Ethernet choice (SI - Everybody)● Long lasting investment (EU)● Ring topology gives higher redundancy (better than Siemens/Rockwell).

Sales arguments


oWeak points of the offer (and how to address them):● Fieldbus compatibility with instrumentation (SI). Go through gateways,

push architectures with Ethernet compatible devices, move to Quantum● Process stopped while doing heavy process modifications (EU). Address

applications where process can be stopped sometimes or where application updates are not requested

● No Remote I/O double attachment. Propose in-rack I/O - put I/O island in a cabinet with switch or use remote M340 or move to Q HSBY

● No Power Supply redundancy. Duplicate the STB islands or move to Q.● No Automatic Download from Primary to Standby (EU)

Sales arguments


oGlobal saleso ~100 unit -

equally split between the two part numbers.

Worldwide Sales Figures

Number of CPUs

0

10

20

30

40

50

60

70

80

Telecom

Power

Water

F&B

Marine

Mining

Chem/PharmaO&G

Infra

Chem /Pharma

o By market segment

No quality issues so far!


oFault Tolerant Solution for Non Time-critical Applications where:

● Production downtime is expensive● Valuable material is processed● Production restart costs are high● Skilled monitoring, maintenance personnel are rare

Targeted Applications

Infrastructure

Power TunnelAirportWater


Power production ● Hydroelectric dams

Road infrastructure● Tunnel Lighting,

Ventilation and Signaling

● Road Signaling

●River infrastructure● Locks

●Airport infrastructure● Runway lighting

and signaling

Targeted Application Examples

Water ● Water treatment● Desalination


HSBY Operation and Rollover Premium Hot Standby System Overview

It is not possible to have non-ambiguous diagnostics of the Premium Hot Standby system with only one link between the two PLCs (CPU-sync link). Therefore an Ethernet module in each PLC is configured, then they’re linked with an Ethernet cable (with or without switches).

CPU SYNCCPU SYNCCPU SYNCCPU SYNC

ETY SYNC ( Monitored )ETY SYNC ( Monitored )ETY SYNC ( Monitored )ETY SYNC ( Monitored )


HSBY Operation and Rollover Interpreting LED blink patterns

Display Block Indicators: ERR: faults relating to the Processor Module RUN: Program Execution States and Hot Standby Mode I/O: faults on another Station Module or Configuration fault TER: activity on the Terminal port ACT: Blinking: indicates communication between Primary and Standby Controllers STS: Blinking: the System is Redundant and Data are exchanged from Primary to Standby Steady On: the System is not Redundant or Copro is booting from Power-on to end of self-tests Steady Off: Copro Auto Tests Failed

State of RUN LED dependson the HSBY Mode: PRIMARY STANDBY OFFLINE STOP


In accordance with IEC Standards, Unity uses global objects called System Bits and System Words:

oSystem Words:● %SW60 - Read / Write the Premium Hot Standby Command Register.● %SW61 – Read the Premium Hot Standby Status Register.● %SW62/63/64/65 - Reverse Registers reserved by the Reverse

Transfer process. Written by the Application program Controlled and transferred at each scan to the Primary controller.

● %MW0 to %MW99 – Non-Transfer Area

HSBY Operation and Rollover System Words & Bits


HSBY Operation and Rollover Database Transfer Diagram

Located Variables (maximum 128 kilobytes)

All Unlocated variables up to 300 kb (depending on the CPU** )

The Database is built automatically by the Primary PLC Operating System and sentat each Primary PLC cycle to the Standby PLC. This exchange is performed via the

embedded Ethernet coprocessor of the two HSBY PLCs.

**CPU Max data sizeTSX H57 24 M 193 kbytesTSX H57 44 M 440 kbytes

PrimaryPrimary RedundantRedundant

Database

Reverse registers


HSBY Operation and Rollover Database Transfer Timing - 1

1 – Time required to copy the application data to the communication link layer.

2 – The Hot Standby system is thus able to transfer a data zone from the “Primary” PLC to the “Standby” PLC

At the start of each scan cycle, the contents of the data memory in the “Primary” PLC are transferred to the “Standby” PLC.

The Standby PLC refreshes its own OUTPUTs managed in the first section



1 We use a CYCLIC or a PERIODIC mode and the time to transfer the data is less than the scan time of the PRIMARY.

INPUTINPUT

WAITWAIT ++

HSBY CoproHSBY Copro

1 section1 section

OUTPUTOUTPUT

INPUTINPUT

WAIT WAIT ++


INPUTINPUT


ProgramProgram

OUTPUTOUTPUT

INPUTINPUT


OUTPUTOUTPUT OUTPUTOUTPUT

Data exchangeData exchange


No impact on the PRIMARY cycle time



2 We use a CYCLIC or a PERIODIC mode and the time to transfer the data is greater than the scan time of the PRIMARY.

INPUTINPUT

WAITWAIT++


1 section1 section

OUTPUTOUTPUT

INPUTINPUT

INPUTINPUT


ProgramProgram

OUTPUTOUTPUT

INPUTINPUT

HSBY CoproHSBY Copro+ WAIT+ WAIT


Effect: Output flickers on in-rack I/O (not I/O Scanning) because the outputs are managed in parallel

Data exchangeData exchange WAITWAIT++


PRIMARY cycle time is affected


HSBY Operation and Rollover X-Bus (local) I/O Rollover Time

The rollover time is the time between the last update of an output by the old Primary and the first update of that same output by the new Primary.

********

** ** Worst case for the rollover performanceWorst case for the rollover performance


Unity Pro Configuration Information Tab

In this screen Hot Standby status is clearly displayed.


Unity Pro Configuration Hot Standby Tab

“Topological address (slot #) of the monitored Ethernet module”: This dropdown is populated by the addresses of the existing ETY modules.


HSBY Operation and Rollover Selection of Primary PLC

A & B designations:• PLC with lowest MAC address in Ethernet copro becomes “A”

MAC1 = 00.80.F4.01.6E.E1 MAC2 = 00.80.B4.01.6E.E1Which becomes Primary:• First one powered up with valid application becomes Primary • If powered up simultaneously and both have valid applications – A becomes Primary• If only one has valid application – it becomes Primary

How to power down?• Stop Standby first to avoid needless rollover


HSBY Operation and Rollover Common Rollover Events

• Power supply failure on the CPU rack (slowest rollover because of wait for watchdog to time out)

• Application program fault that generates a HALT state

• Hardware or firmware fault on the CPU module

• Hardware or firmware fault on the monitored ETY module

• Cable disconnected between the monitored ETY and the first hub/switch

• A CPU-sync link failure - (only when PLC is Standby, no rollover if Primary)


Aspects to consider during a migration:o Hardware

● ETY4103/ETY5103 (firmware must be upgraded when migrating)● Non-extendable racks : TSXRKY6 / TSXRKY8 / TSXRKY12

o Application program● 100 first memory words (%MW) are not exchanged between Primary and

Standby● First section in Standby not scanned● No event tasks, rising edges, SAVE_PARAM commands

o Ethernet ● Do not use consecutive Ethernet addresses in your standalone configuration● Do not use Global Data service/FDR/DHCP service

o Testing ● Do not use consecutive Ethernet addresses in your standalone configuration● PLC will always be designated “A” in standalone -> this must be considered

if used in application● CPU-sync link NOK -> since the standby PLC is not present.● Allow for longer CPU scan time (because HSBY CPU takes some time to

exchange data between processor and coprocessor):

Migrating from a standalone application


HSBY Operation and Rollover Online Modifications

Reminder: Logic mismatch is not allowed in a Premium Hot Standby system.

PRIMARY is PRIMARY is AA and STANDBY is and STANDBY is BB

AA BB

Modify the application online in the PRIMARY Modify the application online in the PRIMARY

- The Primary is still active- The Primary is still active- Standby goes OFFLINE - Standby goes OFFLINE

Save application in the PC Save application in the PC

Transfer modified application to CPU Transfer modified application to CPU B B

- The Primary is still active - The Primary is still active - After transfer, the CPU- After transfer, the CPU B B is in STOP/OFFLINE is in STOP/OFFLINE RUN command on the RUN command on the BB

- The Primary is still active - The Primary is still active - After RUN the CPU - After RUN the CPU BB is in RUN/STANDBY is in RUN/STANDBY

RUNRUN


HSBY Operation and Rollover OS Upgrade Procedure

PRIMARY is PRIMARY is AA and STANDBY is and STANDBY is BB

AA BB

Through Unity or the application, set bit 4 of %SW60 Through Unity or the application, set bit 4 of %SW60 on the PRIMARY on the PRIMARY

STOP the PRIMARY STOP the PRIMARY AA STANDBYSTANDBY B B becomes the PRIMARY becomes the PRIMARY

Download the new OS with UNITY LOADER and Download the new OS with UNITY LOADER and the application to the application to A A

Connect unity on Connect unity on BB and STOP the PLC and STOP the PLC PLC PLC AA becomes PRIMARY / becomes PRIMARY / BB STANDBY STANDBY

Put PLC A in RUNPut PLC A in RUN PLC PLC A A becomes the STANDBYbecomes the STANDBY

Download the new OS with UNITY LOADER and Download the new OS with UNITY LOADER and the application to the application to B B

Put the PLC in RUNPut the PLC in RUN PLC PLC B B becomes the STANDBYbecomes the STANDBY

Through Unity or the application, reset bit 4 of %SW60 Through Unity or the application, reset bit 4 of %SW60 on the PRIMARY on the PRIMARY

RUNRUN RUNRUN

Reminder : OS mismatch is supported by a Premium Hot Standby system.

r


HSBY Operation and Rollover Verifying the Health of a Standby System

•Hot Standby Diagnostics are displayed in the Status Registerof each Hot Standby PLC (%SW61).

•More Diagnostic information can be obtained by monitoring PLC States, Module Bits and Words (%S ,%SW).

•Diagnostic information can be stored in non-transfer %MW area (%MW0-99).

•This Diagnostic information can be sent from Standby to Primary PLC, using the Reverse Transfer Registers (%SW62 - %SW65).

•Health Messages are exchanged between the Primary and Standby.

•If there is a fault in the Primary, Standby is notified and assumes Primary role.

•If there is a fault in the Standby, Primary continues to operate as Standalone.

•Monitored ETY Modules periodically verify communication with each other.


Functional positioning with Quantum

Monitored Ethernet S/O Yes Through DFBRedundant in-rack I/O Yes Yes in mandatory 3rd Rack

through applicationMulti Modbus Master

CommunicationYes No

Number of Available CPUs 2 1 non SIL, 1 SIL2System Words 4 Reverse Registers 2 Reverse and less Status Info

Consequence of Logic Mismatch

Standby goes offline user choice

Dual PS for CPU No YesSIL rating No SIL2

CPU Sync Link without transceivers

100 meters copper 2 km fiber optic

Remote I/O Only on Ethernet Ethernet or Local Shared in Double Attachment 4.5 km

Front Panel Status LEDs LCD keypadProfibus Communication No YesApp Transfer Prim -> Stby No Yes

Internal Memory Size 192 / 440 kb 1 MbApplication Size 768 kb / 2 Mb 7 Mb

Network connections 2 /4 6Remote I/O Racks No 31 (RIO)

Remote I/O Ethernet Islands 64 per Network 128 per Network


Technical characteristics lead to Market positioningoPremium is optimized for:

● very high availability and high switching performance over short distances

● high availability and non time-critical switching performance over long distances

oQuantum is ideal for:● High availability in big applications with good switching time performance ● High availability with long distance architecture● High availability in continuous process control● Quantum has options not always mandatory in water or infrastructures

Market segmentation Premium or Quantum HSBY?


Final Comments Launch Site and DMDI

• Much information on launch site – go to Planet, search on “Premium”, select “launch site”.

• Checklist in DMDI

• Marc Lafont will visit from France for a full 2-day training session. Details tbd depending on interest

• Survey

Any questions?

Thanks for joining us!

cost-effective unity premium hot standby solution

Documents

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standby controller

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remote io stb

local rack io